Floor panel with joint, floor panel arrangement and method for producing

Abstract

The invention relates to a floor panel (1), wherein the floor panel comprises: - a plate-shaped core (20) with a visible printed layer (40); - an overlay (50) on the visible printed layer (40), such that the visible printed layer (40) is protected by the overlay (50); and - at least one chamfer (24) which is pressed into the plate-shaped core (20) by the overlay (50), wherein the visible printed layer (40) has an effect on a surface of the at least one chamfer (24) to enhance an optical depth effect of the chamfer (24).

Description

[0001] The invention relates to a floor panel with at least one bevel, a floor panel arrangement, and a method for producing such a floor panel.

[0002] Floor panels, such as laminate flooring, are a popular flooring option. They are made from individual panels, each made from multiple layers. Typically, fiberboard is used, with additional layers on the top and bottom surfaces. These layers can be made from paper, for example, which is often soaked and impregnated with special resins. These layers typically include an overlay on the top surface for added durability, a decorative paper for visual impact, and a top layer to withstand wear and tear. A counterbalance and, if necessary, an underlay for impact sound insulation are usually added to the bottom surface.

[0003] EP 3 578 383 B1 discloses a method for finishing a prepared board. A decorative paper is applied to the top side, followed by an overlay paper as an abrasion-resistant layer. A countercoat is applied to the underside. When the layers are pressed together, a relief is pressed in, which can correspond to a bevel.

[0004] A bevel is a chamfer that is usually arranged at the edge of a floor panel, so that when two floor panels are placed together, a complete joint is created by two bevels arranged at the edge of the floor panels.

[0005] EP2774770B1 discloses methods for printing a wood-based panel with a decorative layer by means of a digital printing process using various layers of lacquer and / or resin as well as a protective layer.

[0006] PCT / EP2017 / 060710 describes a process for producing an abrasion-resistant wood-based panel with a decorative layer and an overlay comprising several resin layers with abrasion-resistant particles, as well as the pressing of the layer structure.

[0007] For the production of floor panels, the decors are printed digitally or analogously onto paper webs or board-shaped cores. The paper webs are typically impregnated, and the impregnated materials are pressed with an AC4 / AC5 paper overlay in short-cycle presses. After printing with a liquid overlay, board cores are also pressed in short-cycle presses. Some press plates contain elements that become visible as joints between the floor panel joints after further processing. The joint edges are milled in a process. The milled bevels are then painted over. Various colors are selected to match the decors.

[0008] The disadvantages of this technique are that the depth effect is often weak with pressed bevels, and panel transitions appear flat or barely visible in the final product. Furthermore, with milled bevels, the otherwise abrasion-resistant and protected surface at the panel edges is destroyed in order to apply paint for a visual effect. This compromises the quality of the panels in the joint area. There is also a risk of the paint peeling off due to abrasion, as it is not protected by an overlay.

[0009] The invention is based on the technical problem of visually designing the bevel on a floor panel in such a way that it appears deeper while simultaneously remaining protected by an overlay. At the same time, in an arrangement of multiple floor panels, the joints resulting from two adjacent bevels at the edges of the floor panels should appear deeper.

[0010] The problem is solved by the subject matter of the independent patent claims. Advantageous developments of the invention are specified by the dependent patent claims, the following description, as well as the figures and the associated description.

[0011] One aspect of the invention relates to a floor panel with at least part of a bevel, wherein the floor panel comprises a plate-shaped core with a visible print layer, an overlay on the visible print layer such that the visible print layer is protected by the overlay and at least one bevel which is pressed into the plate-shaped core by the overlay, wherein the visible print layer on a surface of the at least one bevel has an effect for enhancing an optical depth effect of the bevel.

[0012] The floor panel can be a floor slab, a panel, a ceiling panel, or a wall panel. The bevel can be any portion of a joint if it is divided along its width. In particular, the bevel can, for example, comprise half of the joint along its width. The width is the side along which the bevel has a chamfer in cross-section. The bevel can be a straight bevel, e.g., corresponding to half of a V. The bevel can have any angle, e.g., an angle between 30° and 60° to the ground plumb line. The bevel can be a bevel with a shape such as a half U or a quarter circle, or have other shapes. The bevel can comprise portions other than half of the complete joint, e.g., one-third or two-thirds of a V, U, semicircle, etc.

[0013] The slab core is shaped like a slab and is, for example, cuboid or approximately cuboid. The corners of the cuboid shape can be rounded. The slab core has a length, width, and height. The length of the slab core is greater than the width and height. The slab core is suitable for forming a floor panel with additional layers.

[0014] The visible print layer is applied to the top side of the panel-shaped core. The print layer is visible in the floor panel when viewed from above. The top side is the side that is visible when the floor panel is used as a floor covering and on which furniture can be placed and walked on.

[0015] The floor panel also features an overlay that is applied to the print layer and at least partially covers it. This makes the print layer less susceptible to damage from mechanical impact, such as walking on the floor panel or placing objects on it, and thus more durable and resistant. The overlay can be applied directly to the print layer. The overlay can be transparent. The print layer is visible through the overlay. The overlay can be a paper layer impregnated with resin and provided with abrasion-resistant particles. Alternatively, the overlay can be a liquid overlay.

[0016] The printed layer has an effect for enhancing the optical depth of the chamfer on one surface of the chamfer. The chamfer surface is the area of ​​the upper surface of the printed layer that has a bevel in cross-section. In other words, the effect is printed where the chamfer is pressed in. The effect is designed to make the chamfer appear deeper. The effect can, for example, be a 3D effect. The effect for enhancing the optical depth of the chamfer is designed to create a three-dimensional effect that is visually perceptible to humans.

[0017] The bevel is pressed into the floor panel with a certain offset.

[0018] The floor panel designed in this way offers the advantage that the depth-enhancing effect of the bevel makes it appear deeper than if the bevel were simply pressed. A further advantage is that the surface quality as well as the durability and longevity of the bevel are improved by the overlay placed over the printed layer, compared to the conventional process, which would require milling out the edge of the bevel to apply paint.

[0019] The panel-shaped core can, for example, consist of a fiberboard, plastic, solid wood, stone, concrete, metal, or other materials. In one possible embodiment, the panel-shaped core can consist of a high-density fiberboard (HDF). For example, the panel-shaped core can have a height of 6 mm - 12 mm. Possible values ​​for the length and width can be, for example, 2800 mm x 2070 mm. The size is not to be understood as limiting. An exemplary floor panel comprises a fiberboard, on the upper side of which a carrier material, such as a paper web, is arranged; the printing layer is arranged on top of the carrier material and can be printed in an area, for example,at the edge of the panel or in the middle of the panel, it has an effect that enhances the optical depth of the bevel; an overlay is arranged on the top side of the printed layer to protect the printed layer; the floor panel has a second area in which the bevel is pressed in. The layers mentioned above can, for example, be glued and / or pressed together. On the underside of the floor panel, which is different from the top side, one or more additional layers can be applied, e.g. a counter-layer or a layer for impact sound absorption.

[0020] One embodiment relates to a floor panel, wherein the visible print layer is applied to a carrier material different from the plate-shaped core.

[0021] One embodiment relates to a floor panel in which the carrier material is a paper web.

[0022] The paper web can be applied to the plate-shaped core. The printing layer is applied to the paper web. Thus, the bevel is pressed through both the paper web and the plate-shaped core.

[0023] This has the advantage that printing on paper allows for great technical freedom in terms of which exact colors, patterns, etc. can be printed.

[0024] The overlay can be a liquid overlay. Liquid overlays are typically used for directly decorated substrates. In the case of directly decorated substrates, the substrate itself has a decoration. The liquid overlay can comprise one or more liquid resin layers. Advantageously, at least one resin layer comprises abrasion-resistant particles.

[0025] Possible examples of paper webs can have widths of 2070 mm. Possible examples of decorative paper webs can have a basis weight of 50-65 g / m². The paper web can be impregnated, for example, to make the colors more vibrant and / or less sensitive to liquids. The paper web can be pressed and / or glued to the sheet-like core, for example.

[0026] One embodiment relates to a floor panel, wherein at least one of the at least one bevel is arranged such that it forms at least one edge of the floor panel.

[0027] The bevel has a long and a shorter side, as well as an offset. The long side forms one edge of the floor panel. The shorter side corresponds to the width of the bevel, along which the bevel has a bevel in cross-section.

[0028] For example, the edge preferably extends along the width of the floor panel. Alternatively, the edge can be arranged along the length of the floor panel.

[0029] One embodiment relates to a floor panel, wherein an edge opposite the edge further comprises at least one bevel. The floor panel has at least two bevels, each located on a different edge of the floor panel. This has the advantage that several of these floor panels can then be placed next to one another, so that two bevels of the adjacent floor panels abut one another, thus forming a complete joint between each two adjacent floor panels.

[0030] One embodiment relates to a floor panel, wherein the offset of the joint is between 0.2 mm and 0.6 mm.

[0031] The offset refers to the difference between the surface of the panel in the area where no bevel is pressed to the deepest pressed point of the bevel.

[0032] One embodiment relates to a floor panel, wherein the effect comprises a color gradient. The color gradient comprises various colors, hues, and / or brightnesses, wherein in particular the color, hue, and / or brightness is darkest in the center of the width and / or increases along the width with distance from the center.

[0033] In this embodiment, the optical effect for enhancing the optical depth effect of the bevel comprises a color gradient from one color to another. In particular, the color gradient can be formed from a darker color at the most deeply pressed point of the bevel to a lighter color at a non-pressed area.

[0034] The color gradient creates the visual impression that the darker areas are deeper than the lighter areas. If a darker shade is used at the deepest point of the bevel and a gradient to a lighter shade is used, with the brightness increasing with distance from the deepest point of the bevel, the optical effect is that the bevel's offset is increased.

[0035] For example, in a panel that is essentially brown, the bevel may have a color gradient from the same shade of brown as the panel to a darker shade of brown or to black at the most deeply pressed point of the bevel.

[0036] Specific examples of a color gradient include, for example, a color gradient from black to deep brown for printing the bevel. The gradient can be structured so that black is printed at the deepest pressed point of the bevel and brown fades to the surface level. Additionally, markings can be inserted into the print data, for example, at positions that are omitted during the further processing step of sawing and profiling. These can be used to align the impregnated paper sheets in the short-cycle press systems and the pressed panels during sawing using cameras and a control unit. This ensures that the printed bevel is positioned precisely at the circumferential edges of the finished panel or at the positions of the pressed bevel.

[0037] One embodiment relates to a floor panel, wherein the floor panel has a second bevel and a third bevel, such that the second bevel and third bevel form a joint, wherein the joint is arranged within the floor panel.

[0038] This creates a complete joint within the floor panel. For example, herringbone patterns with a three-dimensional effect are possible, so that each herringbone appears deeper due to the optical effect of the bevels, which enhances the depth effect. The bevels and thus the resulting complete joint can have various cross-sectional shapes, offsets, and widths. The complete joint can have a V-shaped, U-shaped, semicircular, or other cross-sectional shapes.

[0039] One embodiment relates to a floor panel, wherein the printed layer, in addition to the effect, has a decoration different from the effect, which is arranged outside the at least one bevel.

[0040] The advantage is that the floor panel can be given almost any look desired by the customer thanks to the decor.

[0041] The decoration is arranged in an area on top of the printed layer, with the decoration area being distinct from the wider area in which the effect is arranged to enhance the optical depth of the bevel. Possible examples of decorations can include imitations of wood, stone, concrete, cork, or other materials, as well as combinations and variations thereof, as well as fantasy patterns.

[0042] For example, a walnut decor in a dark brown tone can be used to create a particularly deep bevel as a combination of printed and pressed bevel. The pressed structure for the decor can contain areas where the bevel(s) are embossed. The bevel(s) can be visible on the edges of the finished panel. A gradient from dark gray to black is used for the bevel area when printing the bevel. When creating the print data, an anthracite / black color gradient can be created at the positions that correspond to the bevel edge after further processing. The gradient can, for example, be structured so that black is printed at the deepest point of the pressed bevel and fades to dark gray down to the surface level. In addition, markings can optionally be inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling.These can be used, on the one hand, to align the impregnated paper sheets in the cutting and sawing process using cameras and a control unit, as well as the pressed panels during sawing. This enables the printed bevel(s) to be positioned precisely on the peripheral edges of the finished panel or at the positions of the pressed bevel. The printed color gradient at the positions of the pressed bevel gives it a visually significantly deeper appearance. The contrast with the mid-gray tone is high and stands out clearly from the rest of the installed flooring surface. Without the visual enhancement provided by the printing in the area of ​​the pressed joint, the visual effect of a deep bevel would not be possible.

[0043] Another example of a color gradient could be a concrete decor in a medium gray tone with a particularly deep bevel, which is created using a combination of printed and pressed bevel. A gradient from dark anthracite to black is used for the bevel to bevel. When creating the print data, an anthracite / black color gradient is created at the positions that correspond to the joint edge after further processing. The gradient is structured so that black is printed at the deepest pressed point of the bevel and then fades to brown down to the surface level. In addition, markings can be inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling. These markings can be used to align the impregnated paper sheets in the short-cycle press and also the pressed panels during sawing using cameras and a control unit.This ensures that the printed bevels are positioned precisely along the perimeter of the finished panel or at the positions of the pressed bevel. The printed color gradient at the positions of the pressed bevel gives it a much deeper visual appearance, as the contrast with the mid-gray tone is high and stands out clearly from the rest of the installed flooring.

[0044] In another possible embodiment, the bevels can also be located additionally or solely in the middle of the floor panel and not just at panel transitions. This could be the case, for example, with a panel that imitates a herringbone pattern. The individual slat transitions can be printed for visual enhancement and additionally pressed as a bevel. Any color variation within the printable color space is possible to achieve the best possible depth or the desired effect. This can include, for example, solid colors, straight gradients, or even structured / speckled variants. Grids or line combinations are also conceivable to achieve specific effects. There are hardly any restrictions in this regard, especially in digital printing.

[0045] The printed color gradient at the positions of the pressed bevel gives it a much deeper visual appearance. The contrast with the natural oak color is high and stands out clearly from the rest of the installed flooring. Without the visual enhancement provided by the print in the area of ​​the pressed bevel, this goal would not be achievable. The surface quality of the bevel is significantly better protected with the pressed bevel over the printed gradient than if the edge had to be milled out to be painted, as is the case with other common processes.

[0046] Optionally, the printed layer also includes markings or control characters, allowing the effect to be positioned precisely at the pressed bevel using an optical alignment system. This has the advantage that the positioning of the pressing equipment is simple and precise using the control characters, ensuring that the pressed joint precisely matches the optical effect of the bevel. Contrasting colors are preferably used for the control characters. The control characters can include lines, dots, or combinations thereof. The control characters are preferably located in areas that are not visible on the finished panel, e.g. because they are cut away in a processing step.

[0047] The area in which the bevel is printed can correspond to the area in which the bevel is pressed. In one possible embodiment, the area in which the bevel is printed can protrude beyond the area in which the bevel is pressed. This protrusion can have various dimensions. Preferably, the area of ​​the printed bevel protrudes beyond the area of ​​the pressed joint by the value of the tolerances of the machines used. The tolerances can be 1 mm, for example. This ensures that even small deviations in the positioning of the pressed bevel compared to the printed bevel, e.g. due to inaccurate adjustment, do not result in defects. This serves quality assurance and, at the same time, low consumption of printing ink. Printing well beyond the tolerance range would also be conceivable, but would be associated with disadvantages in terms of printing ink consumption.

[0048] A further aspect of the invention relates to a floor panel arrangement, wherein the floor panel arrangement comprises at least two floor panels with the aforementioned features, wherein when the floor panels are joined together, the at least one bevel of a first floor panel forms a complete joint with the at least one bevel of a further floor panel.

[0049] The at least two floor panels can be placed next to each other, either directly or with a slight gap.

[0050] Together, the two bevels of the at least two floor panels form a complete joint when the bevels are joined together along a length of the floor panel. A panel floor covering comprises a plurality of floor panels that are placed against one another. A boundary is located between adjacent panels. At the boundary, there can be a direct transition without a visible boundary, or a visible boundary, e.g., by two bevels placed against one another. The floor panel arrangement according to the invention comprises at least two floor panels. In particular, the floor panels can be the same floor panels. The panels each have a bevel on at least one edge. In an arrangement of two floor panels, a complete joint is created when the panels are placed against one another with the bevels.In an arrangement of more than two floor panels, the panels can be joined at the bevels or along the length of the panel in addition to being joined at the bevels. A bevel is not necessarily present along the length of the panel. In particular, an arrangement of a large number of panels can form a continuous floor covering. This floor covering has joints formed by two adjacent bevels at multiple boundaries between the individual panels, and has no joints at a further multiple boundaries between the individual panels.

[0051] The arrangement of at least two floor panels results in a complete joint being formed at the interface between each two panels when they are placed beveled against each other. The depth of the complete joint appears significantly deeper due to the optical depth enhancement effect of the bevel, which is arranged at the edges of the adjacent panels.

[0052] For example, the bevels can be printed onto the print layer and pressed into the floor panel so that the bevel is formed so that half of the joint is located on one panel and the other half on the adjacent panel. Other divisions are also conceivable, e.g., 1 / 3 and 2 / 3, or the joint is completely or almost completely (e.g., > 90%) located on one of the two panels, while the adjacent panel has no or almost no joint (e.g., < 10%).

[0053] An arrangement of a plurality of floor panels can, for example, be designed such that there are bevels along the width direction of the individual panels, each of which is formed by placing the bevels together at the edges of the individual panels. Preferably, for example, two opposite edges of a panel each have a bevel, so that when they are placed together, a complete joint is created at the boundary between two panels. If, for example, the joint has a V-shape, the bevel of one panel at one edge can have the right half of a V if the V is split in the middle with a vertical cut, for example, the opposite edge of the panel has a bevel corresponding to the left half of a V, wherein the deepest point of the bevel's inset is preferably located at the boundary between the two panels.Preferably, the darkest shade of the effect is located at the point of the panel that is pressed in the most deeply to enhance the optical depth effect of a bevel.

[0054] A further aspect of the invention relates to a method for producing a floor panel with at least one bevel, wherein the method comprises providing a plate-shaped core with a visible printed layer and an overlay on the visible printed layer, such that the visible printed layer is protected by the overlay. Furthermore, the method comprises pressing at least one bevel, wherein the printed layer on a surface of the at least one bevel has an effect for enhancing an optical depth effect of the bevel.

[0055] The overlay is applied to the print layer so that the overlay at least partially covers the print layer. The overlay can be a paper layer impregnated with resin and provided with abrasion-resistant particles. The overlay can be applied by pulling the overlay from a pallet onto a stack of countersheet, decorative paper and overlay in front of the short-cycle press, placing it on top and pressing the stack into a laminate. The overlay can be a liquid overlay. The liquid overlay can comprise one or more liquid resin layers. Advantageously, abrasion-resistant particles are sprinkled onto at least one resin layer. If there are multiple resin layers, intermediate drying can take place. During intermediate drying, the resin layer is only dried and thus retains a large part of its reactivity, which is utilized under the influence of pressure and temperature in the short-cycle press.

[0056] This protects the printed layer from damage caused by mechanical impacts such as walking on it, placing objects on it, or similar impacts, making the floor panel more durable and resistant. This advantage is particularly evident compared to the conventional prior art method of milling the bevel and coating it with paint. Milling destroys the overlay in the bevel area, and the subsequently applied paint is therefore not protected by the overlay. Therefore, the bevel area is particularly sensitive to abrasion and damage. This problem is solved by the method according to the invention.

[0057] The method may further comprise providing a carrier material. The carrier material may be a paper web. The carrier material may have a decoration. The carrier material may be arranged between the plate-shaped core and the printing layer.

[0058] Possible printing methods can be digital or analogue. For example, a digital printing system can print the decorations and the optical effect to enhance the depth of the bevel in the same step. In the case of an analogue printing method, one or more printing rollers can be used, e.g., using the indirect gravure printing method on a plate.

[0059] An exemplary system for producing the floor panels according to the invention includes, for example, an automated panel loading system, priming and drying units, inline primers, an analog printing system with printing rollers or a digital printing system, a cooling device, and a stacking system. The creation and preparation of the print data can be carried out, for example, in prepress using an image processing program.

[0060] In analog printing, information for the bevels for engraving the printing rollers is incorporated into the separation data. The effects, colors, contrast levels, and gradients can be created in image editing programs. Precise positioning is required here to ensure that the pressed joints are precisely aligned with the print during further processing. In digital printing, such joint reinforcement can be easily implemented even for existing designs, as only the data is changed. With analog printing, new rollers must also be engraved, incorporating the joints as a printing element.

[0061] The layers can be bonded together, for example, by gluing and / or pressing. If pressing is used, the pressing of the joint part into the panel can be done in a separate step from the pressing of the layers, or in the same step.

[0062] The process steps can be integrated into common floor panel manufacturing processes without having to completely rebuild the entire production line. This makes it possible to produce floor panels with visually deeper bevels cost-effectively and thus competitively.

[0063] An example relates to a method for producing a floor panel, wherein the step of applying also comprises applying a decoration which is different from the effect and is arranged outside the surface of the at least one bevel.

[0064] The bevel can be printed simultaneously with the decorative printing step, allowing it to be cost-effectively integrated into existing production processes. This makes the process ideal for large-scale producers. Floor panel manufacturers are generally geared toward mass production, and additional processing steps or modifications to large-scale systems are always associated with significant effort and expense. In industrial digital printing, the effect of the bevel can be incorporated into digital print data to enhance the optical depth effect.

[0065] Another example relates to a method for producing a floor panel, wherein the step of applying the effect occurs before the step of applying the overlay and wherein the step of pressing occurs after the step of applying the overlay.

[0066] This results in the advantage that the floor panel is manufactured from the lower layers to the upper layers, so the next step always takes place on the upper side. This makes production particularly simple, as the panel does not have to be turned over and all machines work on the panel from the upper side.

[0067] Another example relates to a method for producing a floor panel, wherein the step of applying the printing layer, when a carrier material in the form of a paper web is used, comprises applying the printing layer beyond the plate-shaped core, wherein the paper web is pressed to the plate-shaped core.

[0068] The print layer is applied in an area that extends beyond the area where the print layer will be visible in the finished panel. For example, the protruding part of the print layer is cut or sawn away in a later process step. The advantage is that even minor deviations from the planned dimensions and positioning of the print layer or the other layers of the panel do not result in defects. This allows for a margin of tolerance. For example, the print layer can be printed 1 mm beyond the area of ​​the planned panel dimensions, and if the area actually protrudes in the finished panel, this excess area is then cut away.

[0069] The exemplary embodiments explained below represent a preferred embodiment of the invention. In the exemplary embodiment, the described components of the embodiment each represent individual, independently considered features of the invention, which also further develop the invention independently of one another and are thus also to be considered as components of the invention, either individually or in a combination other than that shown. Furthermore, the described embodiment can also be supplemented by further features of the invention already described.

[0070] In the figures, the same reference symbols designate elements with the same function. Fig. 1 shows an exemplary cross-section of a floor panel as a possible embodiment of the invention, in which a bevel is located in the panel; Fig. 2 shows an exemplary cross-section of a floor panel as a possible embodiment of the invention; Fig. 3 shows an exemplary cross-section of a floor panel in which a complete joint is located in the panel; Fig. 4 shows an exemplary cross-section of two adjacent floor panels, each having a bevel; Fig. 5 shows an exemplary cross-section of a floor panel that has a complete joint in the middle of the panel width and bevels at the panel edge; Fig. 6 shows a top view of two exemplary adjacent floor panels, each with a bevel; and

[0071] Fig. 1 shows a floor panel 1 in cross-section. The floor panel 1 has, among other things, a plate-shaped core 20. The plate-shaped core 20 can consist of wood, stone, plastic, concrete, metal or other materials, in particular it can consist of a fiberboard, for example. A printing layer 40 is arranged on the upper side 22 of the plate-shaped core 20. An overlay 50 is arranged on the printing layer 40. The printing layer 40 contains an effect for enhancing the optical depth effect of a bevel 24. The printing layer 40 can additionally have a decoration 70 and / or control characters for positioning for pressing. Further layers are optionally possible. The layer thickness, which runs along the y-axis, can be freely selected within the limits specified by the material.

[0072] In one possible embodiment, the plate-shaped core 20 can have a significantly greater layer thickness than the pressure layer 40 and the overlay 50. A chamfer 24 is arranged on an edge 5 of the floor panel 1. The chamfer 24 is pressed into the panel 1 with a depth t. Possible values ​​for t can be freely selected. Examples of the offset t are 0.2 - 0.6 mm. The shape of the chamfer 24 can be, for example, V-shaped, where the chamfer can be, for example, half of a V or another portion of the entire V. Other possible chamfer shapes can be, for example, a shape similar to a U, a rectangle, a parabola, an arc of a circle, or combinations thereof, whereby the list is not exhaustive. The further edge 5, marked with a wavy line, can optionally have, for example, a chamfer 24, or no chamfer, or a complete joint 25.The floor panel 1 can optionally comprise additional layers, which can be arranged on the top, bottom, and / or between the above-mentioned layers. However, in this exemplary embodiment, the floor panel 1 comprises only a plate-shaped core 20, a print layer 40, and an overlay 50.

[0073] In Fig. 2 The cross section of another embodiment is shown, which is a variant of the Fig. 1 The illustrated embodiment shows Fig. 2 The embodiment shown differs from the variant in Fig. 1 in that the floor panel 1 additionally comprises a carrier material 30. The carrier material 30 is arranged on the upper side 22 of the plate-shaped core. The carrier material 30 can be, for example, a paper web. The printing layer 40 is applied to a first side 32 of the carrier material 30. The first side 32 is the upper side, i.e., the side of the carrier material opposite the plate-shaped core.

[0074] In Fig. 3 The cross section of another embodiment is shown, which is a variant of the Fig. 1 The illustrated embodiment shows Fig. 3 The embodiment shown differs from the variant in Fig. 1 in that a complete joint 25 is arranged at the edge 5 of the panel 1, while in the variant in Fig. 1 a bevel 24 is arranged at the edge 5 of the panel. The complete joint 25 shown has, as an example, the shape of a V. Other shapes of the joint 25, such as a U, a circular arc, a rectangle, and others, are possible.

[0075] The Fig. 4 The embodiment shown in cross section is a variant of the Fig. 1 illustrated embodiment and differs in that a second joint 60 is arranged in the middle of the floor panel 1. Chamfers 24 or even complete joints 25 can also be arranged at the two edges 5 of the floor panel 1. In this example, there is a chamfer 24 in the shape of a halved V at the edge 5 of the panel 1, and a complete V-shaped joint 25 in the middle.

[0076] Fig. 5 shows a floor panel arrangement 100 consisting of two adjacent floor panels 1 in cross section. The floor panels 1 in this example are like the panel 1 in Fig. 1 Alternatively, the panels 1 can be designed as shown in Fig. 2 , 3 or 4 or have other variants. The two panels 1 can be placed next to one another such that the two bevels 24 at the edge 5 of the panels 1 together form a complete joint 25. For example, there can be a narrow gap between the edges 5 of the two panels 1, or the two panels 1 can touch each other directly. The shape of the joint 25 or the bevels 24 can be V-shaped in cross-section. Other possible embodiments can have differently shaped bevels 24 or joints 25.

[0077] In Fig. 6 A plan view of two adjacent floor panels 1 is shown. The floor panels 1 can have cross sections such as those shown in Fig. 1-4 shown floor panels 1. For example, the cross sections of the adjacent floor panels 1 can be as shown in Fig. 5shown. Other cross sections are also possible. A bevel 24 is arranged on the edge 5 of each of the two floor panels 1. The two floor panels 1 are placed against one another in such a way that the two bevels 24 together form a complete joint 25. The surface of the bevel 24 on the edge 5 of the floor panels 1 is printed with an optical effect to enhance the depth effect of the bevel 24. In one possible embodiment, the area of ​​the printed bevel 24 can have the same extent in the x and / or z direction as the area in which the bevel 24 is pressed. In another possible embodiment, the area of ​​the printed bevel 24 can extend beyond the area of ​​the pressed bevel 24 in the x and / or z direction.

[0078] The floor panel 1 can have a decor 70. The decor 70 can be designed, for example, as an imitation of wood, stone, concrete, or other materials, or as any desired pattern. In the example shown, the decors 70 of both panels 1 are identical. In another embodiment, the panels 1 can have different decors 70.

[0079] An exemplary method for producing a floor panel 1 with a bevel 24 comprises providing a plate-shaped core 20 with a visible print layer 40 and an overlay 50 on the visible print layer 40, such that the visible print layer 40 is protected by the overlay 50. The method further comprises pressing the bevel 24 such that a bevel is formed in the cross-section of the floor panel in the region of the bevel 24. The print layer 40 comprises an effect for enhancing the depth effect of a bevel 24. The method may further comprise coating the print layer 40 with an overlay 50.

[0080] The panel-shaped core 20 can, for example, be a fiberboard or consist of solid wood, other composite wood, plastic, concrete, stone or metal, or combinations thereof, the list being not exhaustive. The application of the printing layer 40 can, for example, be carried out using a digital printing process or analog printing. In a further step, the printing data can be processed and / or created. The printing data includes data for printing the effect to enhance the optical impact of the bevel 24. Optionally, the printing data can also contain data for printing a decoration 70. Optionally, the printing data can also contain data for printing control characters or markings. The control characters or markings are designed to serve to align the machines with which the joint is pressed into the panel. If an analog printing process is used, the printing rollers can be produced in a prior step.The printing rollers are manufactured in such a way that they are oriented to print the effect for enhancing the optical effect of the bevel 24 onto the printing layer 40. Optionally, the printing rollers can also be configured to print a decoration 70 and / or control characters or markings.

[0081] The method may include a step of pressing the carrier material 30 to the plate-shaped core 20. The method may include a step of bonding the carrier material 30 to the plate-shaped core 20. The method may include a step of pressing and / or bonding the overlay 50 to the printing layer 40. If a pressing step is used, this can be performed separately from the step of pressing the bevel 24 into the panel 1 or simultaneously therewith.

[0082] An exemplary method for producing a floor panel 1 with a bevel 24 comprises: providing a plate-shaped core 20, e.g., in the form of a fiberboard, and a carrier material 30, e.g., in the form of a paper web; optionally impregnating the paper web, e.g., with a resin; then bonding the carrier material 30 to the plate-shaped core 20; then printing the provided print data onto the carrier material 30 using a digital printing process, wherein the print data includes a decor 70, control characters for positioning the presses, and an optical effect for enhancing the optical depth effect of the bevel 24, which can be, e.g., a color gradient from brown to black. The decor 70 can be, e.g., a wood decor; other examples are imitations of cork, concrete, stone, fantasy decors, or any desired pattern. After the print layer 40 has been applied, an overlay 50 is applied to it, e.g., by bonding.The overlay 50 protects the printed layer 40 from scratching, abrasion, and other mechanical impacts and is preferably liquid-repellent. A bevel 24 is then pressed into the panel 1, the area into which the bevel 24 is pressed at least partially overlapping the area in which the effect for enhancing the optical depth effect of the bevel 24 is printed. For example, the bevel 24 can have a V-shape and be pressed onto a panel 1. Preferably, the deepest point along the press-in depth t of the pressed-in bevel 24 corresponds to the darkest color tone of the printed effect for enhancing the optical depth effect of the bevel 24. Optionally, it is possible to incorporate further layers and steps into this process, e.g., applying a layer to the plate-shaped core 10 on the underside, i.e., on the side opposite the printed layer 40.Additional layers between the other layers are optionally possible.

[0083] The effect of the chamfer appearing deeper can be achieved by printing a three-dimensional effect to enhance the optical depth effect of a chamfer exactly in the area where the pressed chamfer 24 is located.

[0084] The effect of enhancing the optical depth of a bevel 24 can be adjusted in various ways to match the decor 70 or its color scheme to achieve the desired degree of visual depth. For example, the printing of the bevel 24 takes place simultaneously with the decor printing step and can thus be cost-effectively integrated into existing production processes. This makes the process ideal for large-scale producers. Floor panel manufacturers are generally geared towards mass production, and additional work steps or modifications to large-scale systems always involve considerable effort and expense.

[0085] In industrial digital printing, the bevels 24 can be inserted into the digital print data. In analog printing, information for the joints for engraving the printing rollers is included in the separation data. The effects / colors / contrast levels / gradients can be created in image processing programs. Precise positioning is necessary here in order to precisely match the area of ​​the pressed bevel 24 and the area of ​​the effect for enhancing the optical depth effect of the bevel 24 in the print layer 40 during further processing. In digital printing, such an effect for enhancing the optical depth effect of a bevel 24 can be implemented quite easily even for existing decorations 70, since only the data is changed. In analog printing, new rollers must also be engraved in which the effect for enhancing the optical depth effect of a bevel 24 is included as a printing element.

[0086] There are several ways in which the effect can be printed to enhance the optical depth of a bevel 24.

[0087] A first exemplary possibility is that the effect for enhancing the optical depth effect of a bevel 24 is only printed exactly in the area which, after further processing, corresponds to the area of ​​the pressed bevel 24.

[0088] This has the advantage that ink is saved, since the effect to enhance the optical depth of a bevel 24 is only printed where it is actually needed. Another option is for the area in which the effect to enhance the optical depth of a bevel 24 is printed to extend a small amount (e.g. up to 1 mm) beyond the actual panel edge 5 in order to absorb any tolerances or prevent defects. This is the preferred variant due to the good ratio of quality assurance to ink consumption. In another example, the entire areas in the print between the panel transitions are printed with the effect to enhance the optical depth of a bevel 24. This means that the areas that are sawn away or profiled in further processing steps and will therefore not be visible in the final format are also printed.A particularly large amount of ink is consumed here, which could lead to an unfavorable cost situation.

[0089] Control characters in contrasting colors can also be printed to align finishing equipment. These can be lines, dots, or similar. The goal is to position the areas of the printed effects to enhance the optical depth effect of a chamfer 24 with the help of optical alignment equipment so that they correspond exactly to the area in which the chamfer 24 is pressed.

[0090] Furthermore, these control characters can also be used for alignment when sawing the panels. In another embodiment, the joint elements can also be located additionally or solely in the center of the floor panel and not just at panel transitions. This can be the case, for example, with a panel that imitates a herringbone pattern. The individual edges 5 of the panels 1 or the individual areas of the pressed bevel 24 can be printed with an effect to enhance the optical depth effect of a bevel 24, and a bevel 24 can also be pressed.

[0091] Any color variation is possible that is within the possible color space in order to achieve the best possible depth effect in the effect of enhancing the optical depth effect of a bevel 24.

[0092] This can include solid colors, straight gradients, or even textured / speckled variations. Grids or line combinations are also conceivable to achieve specific effects. Especially in digital printing, there are virtually no limits here. Example 1 - Digital printing on paper

[0093] A manufacturer of laminate flooring uses an industrial digital printer to print decorative paper webs with wood, stone, and fantasy designs. The paper web is up to 2070 mm wide and has a basis weight of 50-65 g / m². The paper is primed inline with 3-6 g / m². The printing system can produce 50 million m² and more of decorative paper per year.

[0094] The creation and preparation of the print data takes place in prepress using image editing programs. The manufacturer's sales department / customer requests an oak decor in a natural shade with a particularly strong bevel of 24, or, when placed side by side to form a complete joint, with a particularly strong joint of 25. This is to be achieved using a combination of printed and pressed bevels of 24.

[0095] The press structure for the decor contains areas in which the bevels are pressed so that the joints at the edges 5 of the finished panel 1 become visible. For printing the effect to enhance the optical depth of a bevel 24, a gradient from black to strong brown is desired. When creating the print data, a black / brown color gradient is created at the positions that correspond to the panel edge 5 after further processing. The gradient is structured so that black is printed at the deepest point of the pressed bevel 24 along the offset t and brown fades to the surface level. In addition, markings are inserted into the print data at the positions that are omitted in the further processing step of sawing and profiling. These are used on the one hand to align the impregnated paper sheets in the short-cycle press and also the pressed panels during sawing using cameras and a control unit.This ensures that the areas where the effect is printed to enhance the optical depth of a bevel 24 are located precisely on the peripheral edges 5 of the finished panel or in the area of ​​the pressed bevel. The printed color gradient in the area of ​​the pressed bevel makes it appear much deeper visually. The contrast to the natural color of the oak is high and stands out clearly from the rest of the installed flooring surface. Without the optical enhancement created by printing the effect to enhance the optical depth of a bevel 24 in the area of ​​the pressed bevel 24, the sales department's request would not have been feasible.

[0096] The surface quality of the bevel 24 is significantly better protected with the pressed bevel 24 over the printed layer 40, which contains the effect of enhancing the optical depth of the bevel 24, and the overlying overlay 50, than if the edge had to be milled out to be coated with paint, as in other conventional processes. By applying this process, the optical effect could be significantly changed without compromising quality. This gives the manufacturer a significant competitive advantage, enabling them to sell their products more effectively on the market. Example 2 - Digital printing on plate

[0097] A manufacturer of laminate flooring uses digital printing to print wood, stone, and fantasy decors on high-density fiberboard (HDF). The boards are 2800 mm long, 2070 mm wide, and 6-12 mm thick. The entire system has a feed speed of 80 m / min with a board gap of approximately 1500 mm and is fully automated. The system includes automated board loading, priming and drying units, an inline primer and digital printing system, a cooling device, and stacking.

[0098] The creation and preparation of the print data takes place in prepress using image editing programs. A customer of the manufacturer requests a concrete decor in a medium gray tone with a particularly deep bevel (24). This is to be implemented using a combination of printed and pressed bevel (24).

[0099] The press structure for decor 70 contains areas in which the bevels 24 are pressed, which become visible at the edges 5 of the finished panel. To print the effect to enhance the optical depth of a bevel 24, a gradient from dark anthracite to black is used. When creating the print data, an anthracite / black color gradient is created at the positions that correspond to the panel edges 5 after further processing. The gradient is structured so that black is printed at the deepest point of the pressed bevel 24 and fades to brown down to the surface level. In addition, markings are inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling. These markings are used to align the impregnated paper sheets in the short-cycle press and the pressed panels during sawing using cameras and a control unit.This ensures that the printed effects for enhancing the optical depth effect of a bevel 24 are located precisely on the circumferential edges 5 of the finished panel or in the area of ​​the pressed bevel 24. The printed color gradient as an effect for enhancing the optical depth effect of a bevel 24 in the area of ​​the pressed bevel 24 makes it appear much deeper visually. The contrast to the mid-gray tone is high and stands out clearly from the rest of the installed floor covering surface. Without the effect of enhancing the optical depth effect of a bevel 24 through the printing in the area of ​​the pressed bevel 24, the sales department's request would not have been feasible.The surface quality of the bevel 24 is also significantly better protected with the pressed bevel 24 over the printed layer 40, which has the effect of enhancing the optical depth effect of a bevel 24, and the overlying overlay 50, than if the edge had to be milled out in order to coat it with paint as in other conventional processes.

[0100] By applying this process, the optical effect could be significantly changed without compromising quality. This gives the manufacturer a significant competitive advantage, helping them sell their products more effectively on the market. Example 3 - Analogue printing on plate

[0101] A manufacturer of laminate flooring uses digital printing to print wood, stone, and fantasy decors on high-density fiberboard (HDF). The boards are 2800 mm long, 2070 mm wide, and 6-12 mm thick. The entire system has a feed speed of 80 m / min with a board gap of approximately 1500 mm and is fully automated. The system includes automated board loading, priming and drying units, inline primer, and analog printing / printing rollers for indirect gravure printing on boards, a cooling system, and stacking.

[0102] The creation and preparation of the print data takes place in prepress using image editing programs. For the manufacturer's new collection, a walnut decor in a dark brown tone with a particularly deep bevel 24 is desired. This is to be achieved using a combination of printed and pressed bevel 24.

[0103] The press structure for decor 70 contains areas in which the bevels are pressed, which become visible at edges 5 of the finished panel. To print the effect to enhance the optical depth of a bevel 24, a gradient from dark gray to black is used. When creating the print data, an anthracite / black color gradient is created at the positions that correspond to the bevel edge after further processing. The gradient is structured so that black is printed at the deepest point of the pressed bevel 24 and fades to dark gray down to the surface level. In addition, markings are inserted into the print data at the positions that are omitted during the further processing step of sawing and profiling. These markings are used on the one hand to align the impregnated paper sheets in the short-cycle press and also the pressed panels during sawing using cameras and a control unit.This ensures that the printed bevel is located exactly on the peripheral edges 5 of the finished panel or in the area of ​​the pressed bevel 24.

[0104] The printed color gradient in the area of ​​the pressed bevel 24 gives it a much deeper visual appearance. The contrast with the mid-gray tone is high and stands out clearly from the rest of the installed floor covering surface. Without the effect of enhancing the optical depth of a bevel 24 through the printing in the area of ​​the pressed bevel 24, the sales department's request would not have been feasible. The surface quality of the joint is also significantly better protected with the pressed joint over the printed layer 40, which contains the effect of enhancing the optical depth of a bevel, and the overlay 50 above it, than if the edge had to be milled out in order to paint it, as in other conventional processes. By applying this process, the optical effect could be significantly changed without any loss of quality.

[0105] In one example, the floor panel 1 can have at least part of a joint 25, wherein the floor panel 1 comprises the following: a plate-shaped core 20, a carrier material 30, a printing layer 40 which is applied to the carrier material 30 within a first region on a first side 32 of the carrier material 30, wherein the printing layer 40 in the first region has an effect for enhancing an optical depth effect of the joint 25; an overlay 50 on the printing layer 40 such that the printing layer 40 is protected by the overlay 50; and at least part of the at least one joint 25 in a second region, which is pressed from the first side 32 through the carrier material 30 into the plate-shaped core 20, wherein the second region is arranged within the first region, wherein the joint 25 has a width which is different from an offset t and a longer side of the joint 25.

[0106] In a second example, the floor panel 1 may be constructed as in the first example, wherein the plate-shaped core 20 is the carrier material 30.

[0107] In a third example, the floor panel 1 may be designed as in the first example, wherein the carrier material 30 is a paper web.

[0108] In a fourth example, the floor panel 1 may be designed as in the first, second or third example, wherein a part of the at least one joint 25 is arranged such that it forms at least one edge 5 of the floor panel 1.

[0109] In a fifth example, the floor panel 1 may be as in one of the previous examples, wherein the at least part of the at least one joint 25 corresponds to one half of the joint 25 along the width of the joint 25.

[0110] In a sixth example, the floor panel 1 may be designed as in one of the previous examples, wherein the joint has a V-shape along the width in cross-section.

[0111] In a seventh example, the floor panel 1 may be designed as in one of the previous examples, wherein the offset depth t of the joint is between 0.2 mm and 0.6 mm.

[0112] In an eighth example, the floor panel 1 may be as in any of the previous examples, wherein the effect comprises a color gradient along the width, wherein the color gradient changes its color and / or brightness, wherein in particular the color and / or brightness is darkest in a center of the width of the joint 25 and / or increases along the width with distance from the center.

[0113] In a ninth example, the floor panel 1 may be designed as in one of the previous examples, wherein the floor panel 1 has a further second joint 25 which is different from the at least part of the at least one joint 25.

[0114] In a tenth example, the floor panel 1 may be designed as in one of the previous examples, wherein the print layer 40, in addition to the effect, has a decoration 70 which is different from the effect and is arranged outside the at least one joint 25.

[0115] In one example, a floor panel arrangement 100 may comprise at least two floor panels 1 according to one of the previous examples, wherein when a first part of the joint 25 of a first of the at least two floor panels 1 is joined to a part of the joint 25 of another of the at least two floor panels 1, the respective parts of the joint 25 form a complete joint 25.

[0116] In one example, a method for manufacturing a floor panel 1 having at least a portion of a joint 25 may comprise the following steps: Providing a plate-shaped core 20 Providing a carrier material 30 Applying a printing layer 40 to the carrier material 30 within a first region on a first side 32, wherein the printing layer 40 in the first region has an effect for enhancing an optical depth effect of the joint 25; Coating the printing layer 40 with an overlay 50 on the first side 32 such that the printing layer 40 is protected by the overlay 50; and Pressing at least a part of the at least one joint 25 in a second region from the first side 32 through the carrier material 30 into the plate-shaped core 20, wherein the second region is arranged within the first region, wherein the joint 25 has a width which is different from an offset t and a longer side of the joint 25.

[0117] In a further example, a method may be as in the previous example, wherein the step of applying also comprises applying a decoration 70 which is different from the effect and is arranged outside the at least part of the at least one joint 25.

[0118] In a further example, a method may be as in the two previous examples, wherein the step of applying the effect occurs before the step of applying the overlay 50 and wherein the step of pressing occurs after the step of applying the overlay 50.

[0119] In a further example, a method may be as in the previous examples, wherein the step of applying the printing layer 40, when the carrier material 30 is a paper web, comprises applying the printing layer 40 beyond the plate-shaped core 20, wherein the paper web is pressed to the plate-shaped core 20. List of reference symbols

[0120] 1Floor panel 5Edge of the floor panel 20Plate-shaped core 22Top of the plate-shaped core 24Bevel 25Full joint 30Carrier material 32First side of the carrier material 40Print layer 50Overlay tOffset 70Decor 100Floor panel arrangement

Claims

1. Floor panel (1), the floor panel comprising: - a plate-shaped core (20) with a visible print layer (40) - an overlay (50) on the visible print layer (40), such that the visible print layer (40) is protected by the overlay (50); and - at least one bevel (24) which is pressed into the plate-shaped core (20) by the overlay (50), wherein the visible print layer (40) on a surface of the at least one bevel (24) has an effect for enhancing an optical depth effect of the bevel (24).

2. Floor panel (1) according to claim 1, wherein the visible print layer (20) is applied to a carrier material (30) different from the plate-shaped core.

3. Floor panel (1) according to claim 2, wherein the carrier material (30) is a paper web.

4. Floor panel (1) according to one of the preceding claims, wherein at least one of the at least one bevel (24) is arranged such that it forms at least one edge (5) of the floor panel (1).

5. Floor panel (1) according to claim 4, wherein an edge (5) opposite the edge (5) further comprises at least one bevel (24).

6. Floor panel (1) according to one of the preceding claims, wherein an offset (t) of the chamfer (24) is between 0.2 mm and 0.6 mm.

7. Floor panel (1) according to one of the preceding claims, wherein the effect comprises a color gradient.

8. Floor panel (1) according to one of the preceding claims, wherein the floor panel (1) has a second bevel and a third bevel, such that the second bevel and third bevel form a joint (25), wherein the joint (25) is spaced from the edge (5) of the floor panel (1).

9. Floor panel (1) according to one of the preceding claims, wherein the printed layer (40) has, in addition to the effect, a decoration (70) which is different from the effect and which is arranged outside the at least one bevel (24).

10. Floor panel arrangement (100) comprising at least two floor panels (1) according to one of the preceding claims, wherein when the floor panels (1) are joined together, the at least one bevel (24) of a first floor panel forms a complete joint (25) with the at least one bevel (24) of a further floor panel (1).

11. Floor panel assembly (100) according to claim 10, wherein the joint has a V-shaped and / or U-shaped cross-section.

12. A method for producing a floor panel (1) with at least one bevel (24), the method comprising the following steps: - providing a plate-shaped core (20) with a visible printing layer (40) and an overlay (50) on the visible printing layer (40) such that the visible printing layer (40) is protected by the overlay (50); and - pressing at least one bevel (24) from the first side (32) into the plate-shaped core (20), wherein the printing layer (40) on a surface of the at least one bevel (24) has an effect for enhancing an optical depth effect of the bevel (24).

13. The method according to claim 12, wherein the step of applying the printing layer (40) also comprises applying a decoration (70) which is different from the effect and is arranged outside the surface of the at least one bevel (24).

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