Decorative panel

Abstract

A panel, in particular wall, ceiling, furniture or floor panel, wherein the panel comprises: a support panel, such as a medium density fiber (MDF) panel, a high density fiber panel (HDF) or a particle panel; wherein the panel has at least one chamfer at least one edge; and a decorative printing layer applied to the panel and to the at least one chamfer.

Description

1. TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a panel, in particular a laminate, wall, ceiling, furniture or floor panel. The present invention further relates to a correspondingly manufactured panel.2. STATE OF THE ART

[0002] Currently, a wide range of materials exists which can be used in the manufacture of panels, such as wall, ceiling, furniture and floor panels. Furthermore, a wide range of manufacturing methods for panels exists.

[0003] There is a continuing need to improve the properties of the panels and / or the corresponding manufacturing methods. In particular, it is of interest to improve a variety of different panel properties. These properties include, for example, environmental friendliness, such as recyclability, haptics, appearance and / or durability, such as fire, moisture and / or scratch resistance.

[0004] In particular in the technical field of manufacturing panels for visible surfaces which comprise contact surfaces, it is essential that the panels have a visually attractive surface. Thus, the manufacturing methods should provide for visually attractive panels, panels with improved haptic appearance and panels which are also durable at the same time.

[0005] Known panels in such a technical field for visible surfaces comprise laminate panels which are relatively inexpensive and easy to handle. Typically, they comprise a support panel made of a medium density fiber (MDF) or high density fiber (HDF) material which allows thermal recyclability. Known methods in such a technical field for visible surfaces comprise applying decorative layers to the support panel during the manufacturing process to provide visually attractive panels.

[0006] In the state of the art, attempts have been made to provide decorative panels by applying a decorative layer to the panel (e.g. by printing), coating the panel (e.g. painting and / or painting), which is then followed by formatting the panel (e.g. separating the panel into smaller pieces). Subsequently, the panel can be profiled which comprises providing a specific shape on front and / or side surfaces of the panel such that a connection of two or more panels is facilitated. Subsequently, one or more edges of the panels can be provided with a beveled edge which is typically done by milling a chamfer (or bevel) on the edge. The chamfer is subsequently coated, i.e. provided with a painted layer in a single color. The provision of the beveled edge together with its coating can be performed by separate devices.

[0007] The approaches in the state of the art have several disadvantages. For example, the chamfer does not have the decorative layer thereover but is coated in a single color. Thus, such common practices must always provide a compromise to align the chamfer with the decorative layer of the panel. The aligning of the decorative layer by post-processing the chamfer is very expensive and thus is not carried out. In addition, the coating of the chamfer is an additional step which is not very effective. A further disadvantage of known approaches in the state of the art is that structural properties of the chamfer always differ from the remaining panel by the separate and / or additional coating step. Thus, such chamfers can be more susceptible to mechanical failure and can break more easily.

[0008] Furthermore, there are pressed chamfers in the state of the art. The manufacturing of a pressed chamfer is enabled by pressing an edge into the panel. This has the disadvantage that the mechanical integrity of the overall panel is negatively influenced. Furthermore, a continuous layer along the overall panel is difficult to achieve since the pressing interferes with the layers at the edge / chamfer.

[0009] In view of the above disadvantages, there is an increased need to provide improved panels and improved manufacturing methods for panels.

[0010] Thus, it is an object of the present invention to at least partially overcome the above-mentioned disadvantages. In particular, it is an object of the present invention to provide an improved, overall attractive and resistant panel which feels haptically pleasant. In addition, a corresponding manufacturing method for the panel is to be enabled. The manufacturing method should be simplified and inexpensive.

[0011] Furthermore, it is an object to provide a manufacturing method and panel in which the variation of the appearance of the panel is simplified.3. SUMMARY OF THE INVENTIONPanel

[0012] The objects are at least partially achieved by a panel and a method for manufacturing a panel as defined in the independent claims. Further aspects of the present disclosure are defined in the dependent claims. Since the panel and the method for manufacturing a panel both relate to panels, it is to be understood that advantages and / or features of the panel can also apply to the method and vice versa.

[0013] In particular, the object is achieved by a panel, in particular wall, ceiling, furniture or floor panel, wherein the panel comprises: a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel; wherein the panel has at least one chamfer at at least one edge; and a decorative printing layer applied to the panel and to the at least one chamfer.

[0014] This has the advantage that the decorative printing layer is applied to both, i.e. to the panel and to the at least one chamfer. Thus, the decorative effect is improved since there is essentially no variation of the decorative printing layer seen from above. This is advantageous since it contributes to the aligning of a more natural appearance.

[0015] A further advantage is that essentially no additional manufacturing steps are required to provide the chamfer with a color and / or a layer since the decorative printing layer also covers the chamfer.

[0016] In addition, the panel has the advantage that its quality is improved since there is essentially no difference between a material applied to the panel and a material applied to the chamfer. Thereby, a haptic advantage is also achieved since there is a smooth transition of the same material on the panel seen from a center of the panel to the chamfer. Accordingly, structural properties of the panel are improved.

[0017] The at least one chamfer is provided in such a way, e.g. processed, that layers can be easily applied to the panel and / or to the decorative printing layer. Such a processing (e.g. by milling) is advantageous since it does not negatively influence the structural integrity of the panel (which would be the case if the chamfer is pressed).

[0018] The support panel (also referred to herein as “panel” for brevity) may be a panel made of a wood-based material, such as a medium density fiber panel or a high density fiber panel, a particle panel, an oriented strand panel or the like. However, it may also be made of a plastic material, such as luxury vinyl tile (LVT), a rigid polymer core or an expanded polymer core as well as mixed constructions that are widely used in the flooring industry. High density fiber (HDF) panels have proven to be good recyclability.

[0019] The decorative printing layer is applied to the support panel and to the at least one chamfer, which is to be understood such that the printing layer can be seen from e.g. the top side when the panel is in a typical position, e.g. on a floor, a wall, a ceiling or the like. This is to be understood such that the printing layer is applied to a top surface of the panel. The top surface may face a back surface. Thereby, the printing layer and the decorative aspect of the printing layer can be recognized.

[0020] The back surface may be configured to be attached to a base surface, e.g. a wall, ceiling or floor surface. In an example, the back surface may be provided with adhesives and / or mechanical attachment means.

[0021] The chamfer as used herein may also be understood as a bevel. The chamfer could mean that the edge of the panel is inclined seen in a cross-section perpendicular to a longitudinal extension of the panel. In an example, at the location where the edge of the panel was located, the chamfer may represent an empty space. The chamfer may have a constant inclination and / or be at least partially rounded and / or be composed of a combination thereof.

[0022] The panel typically has a longitudinal extension (length) and a width perpendicular to the longitudinal extension. The edge of the panel is substantially parallel to the longitudinal extension. The chamfer is preferably applied along the overall length of the panel. Thereby, the chamfer is substantially parallel to the longitudinal extension of the panel. The width of the panel is typically small compared to the length.

[0023] It is to be understood that the panel is already formatted prior to providing the chamfer and prior to applying the decorative printing layer. Thus, the panel can already be provided with a width which is suitable for a specific application.

[0024] Preferably, the decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer.

[0025] This has the advantage that there is essentially no difference between the decorative printing layer on the panel, which improves the product quality of the panel. Furthermore, it contributes to the decorative value of the panel.

[0026] The transition is to be understood such that it extends over a part of a top surface of the panel at which no inclination is provided by means of the chamfer, and also extends over a part of the chamfer along a width direction of the panel. Furthermore, the transition can also extend along the longitudinal extension / direction of the panel (length). Thus, in one example, the transition can comprise a substantially rectangular region (e.g. seen from above).

[0027] In a preferred embodiment, the decorative printing layer comprises a decorative pattern which is substantially continuous at a transition of the panel and the at least one chamfer.

[0028] The decorative pattern can imitate any desired surface, which is appreciated by a user. In one example, the decorative pattern can imitate a natural surface. It is advantageous that the pattern is continuous at the transition of the panel and the at least one chamfer. Thereby, essentially no surface / material variations and / or no variations of the pattern can distract a user. Furthermore, a continuous material quality is achieved on the overall panel. In this regard, the “overall” panel means the panel (e.g. a top surface of the panel) and the chamfer of the panel.

[0029] In a preferred embodiment, the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel and a depth (d) perpendicular to the top side of the panel, wherein the ratio w / d of the at least one chamfer is at least 0.5, preferably at least 0.8, more preferably at least 1.2, more preferably at least 1.4, most preferably at least 1.6, and / or wherein the ratio w / d of the at least one chamfer is at most 30, preferably at most 25, more preferably at most 20, more preferably at most 15, more preferably at most 10, more preferably at most 8, most preferably at most 6.

[0030] The width and the depth of the chamfer may be understood as geometric properties of the chamfer. The geometric properties as specified herein have the advantage that the decorative printing layer can be easily applied to the panel and the at least one chamfer. Thereby, the adhesion of in particular a layer (e.g. the decorative printing layer) to the chamfer is improved. In conventional panels, the chamfer is typically constructed in such a way that it is difficult to reliably apply a layer.

[0031] It should also be noted that one or more of the geometric properties of the chamfer described herein comprise lower and upper limits which can be combined into a region of a lower limit and an upper limit. In some configurations, a lower limit may be larger than an upper limit. In this regard, it is noted that the lower and upper limits are to be combined into a region in a technically meaningful way. When thereby a lower and upper limit are to be combined to specify a region, the lower limit should be at least lower than the upper limit. Thereby, the specified region comprises technically meaningful values between the lower limit and the upper limit.

[0032] Tests have shown that the geometric properties as specified herein in particular facilitate and improve the application of the decorative printing layer (and also of the further layers, such as the varnish layer).

[0033] In an example, the ratio w / d is at least 2, preferably at least 3, more preferably at least 3.5, more preferably at least 4, most preferably at least 4.5.

[0034] In a further example, the ratio w / d is at most 4, preferably at most 3, more preferably at most 2.5, more preferably at most 2, most preferably at most 1.8.

[0035] Tests have shown that the specific combinations of upper and lower limits of the ratio w / d facilitate the provision of the chamfer. They also facilitate that layers can be reliably applied to the panel.

[0036] In a preferred embodiment, the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, more preferably at least 0.6 mm, most preferably at least 0.7 mm, and / or of at most 10 mm, preferably at most 8 mm, more preferably at most 6 mm, more preferably at most 5 mm, most preferably at most 4 mm.

[0037] In an example, the width (w) is at least 1.0 mm, preferably at least 1.4 mm, more preferably at least 1.8 mm, more preferably at least 2.2 mm, most preferably at least 2.6 mm.

[0038] In a further example, the width (w) is at most 1.2 mm, preferably at most 1.1 mm, more preferably at most 1.0 mm, more preferably at most 0.95 mm, most preferably at most 0.9 mm.

[0039] In a preferred embodiment, the at least one chamfer has a depth (d) perpendicular to the top side of the panel of at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.15 mm, more preferably at least 0.2 mm, more preferably at least 0.3 mm, more preferably at least 0.35 mm, more preferably at least 0.4 mm, most preferably at least 0.45 mm, and / or the at least one chamfer has a depth (d) perpendicular to the top side of the panel of at most 2.0 mm, preferably at most 1.6 mm, more preferably at most 1.2 mm, more preferably at most 0.8 mm, more preferably at most 0.6 mm, most preferably at most 0.55 mm.

[0040] As described herein, the width and the depth of the chamfer may be understood as geometric properties of the chamfer. The specific values and regions described herein contribute to the mechanical integrity of the panel. In contrast, conventional panels may be susceptible to abrasion in the vicinity of a chamfer due to the geometric properties of conventional chamfers. Accordingly, the chamfer, as described herein, simplifies the application of layers such as the decorative printing layer to the panel and the at least one chamfer. Further, a varnish layer can be more easily applied to the panel by means of the geometric properties specified according to the present disclosure.

[0041] In a preferred embodiment, the at least one chamfer has a rounded curvature.

[0042] This means that such a rounded curvature can be seen in a cross-section of the chamfer perpendicular to a longitudinal extension of the panel. Here, the rounded curvature may be understood in one example as a path, a spline and / or an arc. The rounded curvature is not to be understood such that the chamfer will be described along the longitudinal extension (e.g. in a three-dimensional region).

[0043] Preferably, the rounded curvature has a radius (r) of at least 0.5 mm, preferably at least 0.8 mm, more preferably at least 1 mm, more preferably at least 1.2 mm, most preferably at least 1.4 mm, and / or the rounded curvature has a radius (r) of at most 80 mm, preferably at most 60 mm, more preferably at most 40 mm, more preferably at most 35 mm, more preferably at most 30 mm, most preferably at most 29 mm.

[0044] In an example, the radius (r) is at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, more preferably at least 25 mm, most preferably at least 28 mm.

[0045] In a further example, the radius (r) is at most 4 mm, preferably at most 2.5 mm, more preferably at most 2 mm, more preferably at most 1.8 mm, most preferably at most 1.6 mm.

[0046] Preferably, the radius (r) is constant along the rounded curvature.

[0047] The rounded curvature of the chamfer has the advantage that the application of a layer to the panel and to the at least one chamfer is improved. In particular, the layer can be reliably applied. Compared to chamfers with a constant inclination (or inclination angle), the rounded curvature facilitates that a larger amount, e.g. a paint layer, settles at the transition (of the panel and the at least one chamfer). The transition is thereby improved and can withstand larger mechanical impacts. The transition is typically subjected to mechanical impacts, such as impacts resulting from objects / devices falling on the panel and / or depending on the application of the panel by feet of a user.

[0048] The radius (r) as used herein is understood as the radius of curvature of the rounded curvature. As an example, the radius of an approximate circle at a particular point of the rounded curvature is the radius (r) as used herein. The radius may not necessarily be constant along the rounded curvature. This is understood in such a way that, when following the path of the rounded curvature, the radius (r) may vary. As an example, this may be the case if the rounded curvature is similar to an involute. A constant radius of the rounded curvature means that the rounded curvature is a circular segment, wherein the segment angle is between 0° and 90°.

[0049] In a preferred embodiment, the rounded curvature has an acute angle (α) formed between two tangents of substantially opposite ends of the rounded curvature of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at least 45°, more preferably at most 40°, most preferably at most 37°.

[0050] In a preferred embodiment, the rounded curvature has an acute angle (β) formed between a tangent at substantially an outer end of the rounded curvature and the top surface of the panel of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at least 45°, more preferably at most 40°, most preferably at most 37°.

[0051] In an example, the acute angle (α and / or β) is at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.

[0052] In a further example, the acute angle (α and / or β) is at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°.

[0053] The acute angle (α and β) and the radius (r) may be comprised by the geometric properties of the chamfer as described herein. Thereby, the advantages described with respect to the geometric properties also apply to the acute angle (α and β) and the radius (r).

[0054] The two tangents of substantially opposite ends are to be understood such that a tangent on the rounded curvature is at an outer end of the rounded curvature. The outer end of the rounded curvature may be understood as the deepest location of the chamfer, e.g. the location with the largest depth (d) of the chamfer. However, usually manufacturing tolerances have to be taken into account, which is expressed by the term “substantially”. Thus, the tangents described herein to form acute angles may vary slightly at their location along the rounded curvature.

[0055] The other tangent of the two tangents of substantially opposite ends is on the rounded curvature at an inner end of the rounded curvature. The inner end of the rounded curvature may be understood as the location of the chamfer with the lowest value of the depth (d).

[0056] The “outer end” and “inner end” are described with reference to the plate such that the outer end faces away from the plate and the inner end faces the plate. It is understood that the outer end is arranged on the side surface of the plate.

[0057] The rounded curvature is typically arranged such that the inner end of the rounded curvature is oriented parallel to the top surface of the plate. This helps in providing a smooth transition from the top surface to the chamfer. In one example, the rounded curvature may be arranged such that the tangent of the outer end of the rounded curvature is oriented parallel to the side surface of the plate. In another example, the rounded curvature may be arranged such that the tangent of the outer end of the rounded curvature forms an angle with the side surface of the plate.

[0058] The acute angle formed between the tangent at an outer end of the rounded curvature and the top surface of the plate is understood as the acute angle between this tangent and an imaginary plane in extension of the top surface. It may be possible that the tangent at the inner end of the rounded curvature is oriented parallel to the top surface of the plate.

[0059] It should be understood that the geometric properties of the chamfer described herein can also be determined / measured / derived from the panel to which one or more, in particular all, layers as described herein are applied. Thereby, e.g., the width (w), depth (d), ratio w / d, radius (r) and the acute angle (α and / or β) of the chamfer can be determined / measured / derived from the chamfer with the primer layer, the decorative printing layer, the varnish layer and / or the wear layer applied to the panel and to the chamfer. This may be the case since the layers typically have a small thickness.

[0060] In a preferred embodiment, the panel further comprises a primer layer applied to the panel and to the at least one chamfer, preferably directly below the decorative printing layer as seen from the panel.

[0061] The primer layer enables the decorative printing layer to be applied with sufficient quality. Thereby, the application of the decorative printing layer is improved. It is to be understood that the primer layer is applied directly before (in the case of the manufacturing method) and / or directly below (structurally speaking and seen in the end product, i.e. the panel) the decorative printing layer and also covers the chamfer. This improves in particular the application in the transition and the chamfer.

[0062] In a further preferred embodiment, the panel further comprises a varnish layer applied to the panel and to the at least one chamfer, preferably directly above the decorative printing layer as seen from the panel.

[0063] The varnish layer provides sufficient elasticity to compensate for a deformation of the panel. It may also be possible to apply a varnish layer based on a harder, i.e. less elastic, material. A higher resistance to impacts, scratches and / or chemicals can thereby be achieved. Suitable varnish layers which can be used herein comprise in a non-exhaustive list corundum particles, acrylate, polymers, oligomers, additives and / or the like. Further, the varnish layer can be applied by means of flexography or any other type of application technique.

[0064] In a preferred embodiment, the panel further comprises a wear layer applied to the panel and to the at least one chamfer, preferably directly above the varnish layer as seen from the panel; optionally the wear layer is applied by means of melt lamination or adhesive lamination, wherein the wear layer is optionally based on cast polypropylene.

[0065] The wear layer has the advantage that the protection of the panel is further improved. In particular, the wear layer protects the decorative printing layer.

[0066] The varnish layer and the wear layer applied to the panel and to the at least one chamfer have the advantage that the product quality is improved in particular in the transition as described herein. Thereby, substantially no deviations occur in the layers seen in a cross-section perpendicular to the longitudinal extension of the panel from the center of the panel to an outer end of the panel. This is advantageous compared to conventional panels and methods in which the chamfer is processed after applying substantially all layers to a support panel.

[0067] In particular, the varnish layer and the wear layer are applied to the top of the decorative printing layer, which means that the varnish layer and the wear layer do not substantially directly contact the panel and / or the at least one chamfer. For example, if the varnish layer applied “to” the panel and “to” the at least one chamfer is mentioned, it is to be understood that a layer (such as the decorative layer) can be arranged between the varnish layer and the panel and / or the chamfer.

[0068] Preferably, the decorative printing layer contacts the primer layer and / or the panel and the chamfer. The varnish layer preferably contacts the decorative printing layer. The wear layer preferably contacts the varnish layer. Thereby, the layers can be applied to the panel and the at least one chamfer in the following order as seen from the panel: optionally the primer layer, decorative printing layer, optionally the varnish layer, optionally the wear layer.

[0069] Preferably, the decorative printing layer and / or the decorative pattern imitates a wood pattern.

[0070] This has the advantage that a more natural appearance is provided.

[0071] Preferably, the panel has a thickness (t) of at least 4 mm, preferably at least 5 mm, more preferably at least 6 mm, more preferably at least 7 mm, most preferably at least 7.5 mm, and / or at most 12 mm, preferably at most 11 mm, more preferably at most 10 mm, more preferably at most 9 mm, most preferably at most 8 mm.

[0072] These thicknesses have proven to be sufficient on the one hand to provide sufficient rigidity (to provide a high wear resistance) while on the other hand the material use is kept at a moderate level.

[0073] Preferably, the panel has a width (wp) of at least 4 cm, preferably at least 5 cm, more preferably at least 6 cm, more preferably at least 7 cm, most preferably at least 8 cm, and / or at most 200 cm, preferably at most 150 cm, more preferably at most 120 cm, more preferably at most 100 cm, more preferably at most 80 cm, more preferably at most 60 cm, more preferably at most 40 cm, more preferably at most 30 cm, more preferably at most 20 cm, most preferably at most 18 cm.

[0074] These widths of the panel have proven to be small enough on the one hand so that the panel can be used directly in a respective field of application without requiring further formatting into smaller widths. On the other hand, the widths of the panel have proven to be large enough to facilitate the processing of the chamfer on the panel and the performance of manufacturing steps (e.g. application of the layer(s)).

[0075] The decorative printing layer can be applied by means of rotogravure printing, flexography and / or digital printing. By using these printing technologies, prints of higher quality can be achieved. In particular, the digital printing facilitates the application of the layer substantially contactlessly.

[0076] In an example, the panel in the panel as described herein has two chamfers, namely on both edges parallel to the longitudinal extension of the panel (e.g. on the edges on both side surfaces of the panel), wherein the ratio w / d is between 2 and 30, preferably between 6 and 20, most preferably between 7.5 and 15. This is particularly advantageous for panels which require water-tightness. Such a water-tightness can be achieved since the width (w) of the chamfer is substantially larger compared to the depth (d) of the chamfer. This ensures that a layer thickness is advantageously distributed in particular in the transition as described herein, thereby promoting the water-tightness. Thus, in particular the requirements of the NALFA test can be achieved.

[0077] The NALFA test is a standardized test method of the North American Laminate Flooring Association (NALFA). In this test, it is measured how a laminate floor behaves when its surface is exposed to standing water for about 24 hours. Before and after this time, the surface is measured at e.g. four different positions and the visual and tactile changes of the panel are recorded and evaluated.Method

[0078] The objects are further at least partially achieved by a method for manufacturing a panel, in particular wall, ceiling, furniture or floor panel, comprising the following steps: providing a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel; processing the panel to provide the panel with at least one chamfer at at least one edge; applying a decorative printing layer to the panel and to the at least one chamfer.

[0079] While the description of the panel relates to “a . . . layer applied to . . . ”, the description of the method for manufacturing a panel relates to “applying a . . . layer”. This is the case since the panel comprises layers already applied / attached to the panel and to the at least one chamfer, preferably systematically. On the other hand, the method comprises a step of applying layers which are not necessarily connected during the application. Also, during the application of the layers in the method for manufacturing a panel, the layers may be at least partially viscous / liquid. However, it is to be understood that substantially the same advantages and features mentioned with respect to the panel apply equally to the method for manufacturing a panel. Furthermore, the features can thus also be applied in combination and / or interchangeably to embodiments of the panel or the method, respectively.

[0080] The processing of the panel can be carried out by milling which is appreciated since it does not negatively influence the structural integrity of the panel, which would be the case if the chamfer is pressed.

[0081] Preferably, the method and / or the processing does not comprise pressing the chamfer. This has the advantage that the mechanical integrity and resistance of the panel is improved.

[0082] Preferably, the applied decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer. Respective advantages are described herein with respect to the panel.

[0083] Preferably, the decorative printing layer comprises a decorative pattern and the decorative pattern is substantially continuous at a transition of the panel and the at least one chamfer. Respective advantages are described herein with respect to the panel.

[0084] Preferably, the applying of the decorative printing layer to the panel and to the at least one chamfer is carried out substantially at the same time and / or no other method step is carried out in between.

[0085] This has the advantage that no separate coating step of the chamfer is required. Such a separate coating step is typically cumbersome since it increases the manufacturing time. By using the phrase “substantially at the same time” herein, it cannot be excluded that the applying of the decorative printing layer to the panel takes some time before the layer is applied to the chamfer. This time span may depend on the width of the panel in one example. However, it is important that no other dedicated method step is carried out in between. Further advantages are described herein with respect to the panel.

[0086] The decorative printing layer can be applied by means of rotogravure printing, flexography and / or digital printing. Respective advantages are described herein with respect to the panel.

[0087] In a preferred embodiment, the method comprises applying a primer layer to the panel and to the at least one chamfer, preferably prior to the step of applying the decorative printing layer and after the step of processing the panel.

[0088] In a further preferred embodiment, the method comprises applying a varnish layer to the panel and to the at least one chamfer, preferably after the step of applying the decorative printing layer.

[0089] In a preferred embodiment, the method comprises applying a wear layer to the panel and to the at least one chamfer, preferably after the step of applying the varnish layer; optionally applying the wear layer by means of melt lamination or adhesive lamination, wherein the wear layer is optionally based on cast polypropylene.

[0090] In a further preferred embodiment, the providing of the support panel comprises formatting an initial support panel into one or more support panel(s).

[0091] It should be noted that in the method, as described herein, an initial (large) panel is formatted into the panel. Thus, the panel is suitable to be used directly in a respective field of application. As a result, no formatting is required, e.g. after processing and / or applying any layers to the panel. Further advantages are described herein with respect to the panel.

[0092] In another preferred embodiment, the method further comprises profiling the panel to provide a connecting structure on at least one side surface of the panel, wherein the side surface is substantially parallel to a thickness of the panel, preferably prior to the step of applying the decorative printing layer.

[0093] The side surface of the panel is substantially perpendicular to the top side of the panel. Profiling facilitates that the panel can be connected to another panel, e.g. by form-fitting, or the like. The connecting structure enables that the side surface is configured to be engaged with a side surface of another panel. Profiling can also comprise providing a connecting structure on both side surfaces. It is to be understood that profiling is carried out prior to applying the decorative printing layer, and preferably also prior to applying the optional primer layer. This facilitates that after applying the decorative printing layer the number of manufacturing steps is reduced which ensures that the chamfer is not negatively influenced. Thus, the quality of the chamfer is improved.

[0094] Preferably, the decorative printing layer and / or the decorative pattern imitates a wood pattern.

[0095] Preferably, the panel has a thickness (t) of at least 4 mm, preferably at least 5 mm, more preferably at least 6 mm, more preferably at least 7 mm, most preferably at least 7.5 mm, and / or at most 12 mm, preferably at most 11 mm, more preferably at most 10 mm, more preferably at most 9 mm, most preferably at most 8 mm.

[0096] Preferably, the panel has a width (wp) of at least 4 cm, preferably at least 5 cm, more preferably at least 6 cm, more preferably at least 7 cm, most preferably at least 8 mm, and / or at most 30 mm, preferably at most 25 mm, more preferably at most 22 mm, more preferably at most 20 mm, most preferably at most 18 mm.FURTHER EMBODIMENTS

[0097] A first embodiment is directed to the panel as described herein, wherein the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel and a depth (d) perpendicular to the top side of the panel, wherein the ratio w / d of the at least one chamfer is at least 0.5, preferably at least 0.8, more preferably at least 1.2, more preferably at least 1.4, most preferably at least 1.6 (or 1.65), and / or

[0098] at least 2, preferably at least 3, more preferably at least 3.5, more preferably at least 4, most preferably at least 4.5, and / or

[0099] at most 30, preferably at most 25, more preferably at most 20, more preferably at most 15, more preferably at most 10, more preferably at most 8, most preferably at most 6, and / or

[0100] at most 4, preferably at most 3, more preferably at most 2.5, more preferably at most 2, most preferably at most 1.8.

[0101] A second embodiment is directed to the panel as described herein, wherein the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, more preferably at least 0.6 mm, most preferably at least 0.7 mm, and / or

[0102] at least 1.0 mm, preferably at least 1.4 mm, more preferably at least 1.8 mm, more preferably at least 2.2 mm, most preferably at least 2.6 mm, and / or

[0103] at most 10 mm, preferably at most 8 mm, more preferably at most 6 mm, more preferably at most 5 mm, most preferably at most 4 mm, and / or

[0104] at most 1.2 mm, preferably at most 1.1 mm, more preferably at most 1.0 mm, more preferably at most 0.95 mm, most preferably at most 0.9 mm.

[0105] A third embodiment is directed to the panel as described herein, wherein the rounded curvature has a radius (r) of at least 0.5 mm, preferably at least 0.8 mm, more preferably at least 1 mm, more preferably at least 1.2 mm, most preferably at least 1.4 mm, and / or

[0106] at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, more preferably at least 25 mm, most preferably at least 28 mm, and / or

[0107] at most 80 mm, preferably at most 60 mm, more preferably at most 40 mm, more preferably at most 35 mm, most preferably at most 29 mm, and / or

[0108] at most 4 mm, preferably at most 2.5 mm, more preferably at most 2 mm, more preferably at most 1.8 mm, most preferably at most 1.6 mm.

[0109] A fourth embodiment is directed to the panel as described herein, wherein the rounded curvature has an acute angle (α) formed between two tangents of substantially opposite ends of the rounded curvature of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or

[0110] at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°, and / or

[0111] at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at most 45°, more preferably at most 40°, most preferably at most 37°, and / or

[0112] at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.

[0113] A fifth embodiment is directed to the panel as described herein, wherein the rounded curvature has an acute angle (β) formed between a tangent at substantially an outer end of the rounded curvature and the top surface of the panel of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or

[0114] at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°, and / or

[0115] at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at most 45°, more preferably at most 40°, most preferably at most 37°, and / or

[0116] at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.4. BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

[0117] In the following, preferred embodiments are described only by way of example. Reference is made to the following accompanying Figures:

[0118] FIG. 1 shows a schematic cross section of a panel according to an embodiment of the present disclosure;

[0119] FIG. 2 shows the embodiment of FIG. 1 in a top view;

[0120] FIG. 3 shows a top view of an exemplary panel according to the state of the art;

[0121] FIG. 4 shows a more detailed cross section of a support panel and the chamfer according to an embodiment of the present disclosure, wherein dimensions of the panel and the chamfer are highlighted;

[0122] FIG. 5 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein further dimensions of the panel and the chamfer are highlighted;

[0123] FIG. 6 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein still further dimensions of the panel and the chamfer are highlighted;

[0124] FIG. 7 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein different dimensions of the panel and the chamfer are highlighted;

[0125] FIG. 8 shows a more detailed cross section of a support panel and the chamfer according to another embodiment compared to FIG. 7, wherein the dimensions of FIG. 7 are highlighted;

[0126] FIG. 9 shows a schematic cross section of a panel comprising further layers according to an embodiment of the present disclosure; and

[0127] FIG. 10 shows a diagram of an exemplary method according to the present disclosure.5. DETAILED DESCRIPTION OF THE FIGURES

[0128] Subsequently, presently preferred embodiments are outlined, mainly with reference to the above Figures. It is pointed out that further embodiments are certainly possible and the following explanations are provided only by way of example and without limitation. Further, the present invention may also be used in other embodiments which are not explicitly disclosed below. Furthermore, as described in detail below, the embodiments are compatible with each other and individual features of one embodiment can also be applied to another embodiment.

[0129] Throughout the present Figures and specification, the same reference numbers refer to the same elements. It is pointed out that the reference numbers 4XX, 8XX and 9XX refer to the same elements as the reference numbers XX. However, some parts / elements have been varied, which is the reason why a first digit is introduced in these embodiments. The Figures may not be to scale and the relative size, proportions and representation of elements in the Figures may be exaggerated for clarity, illustration and convenience.

[0130] FIG. 1 shows a schematic cross section of a panel according to an embodiment of the present disclosure.

[0131] The panel 1 may be a wall, ceiling, furniture or floor panel. The panel 1 comprises a support panel 10, such as a medium density fiber (MDF) support panel, a high density fiber (HDF) support panel or a particle panel. The panel 10 comprises at least one chamfer 12 on at least one edge 11 of the panel 10. The panel 1 further comprises a decorative printing layer 20 applied to the panel 10 and to the at least one chamfer 12. The panel 10 has a back surface 17. The back surface 17 typically faces a floor, a wall, a ceiling or the like, depending on the field of application of the panel 1.

[0132] The decorative printing layer 20 is substantially continuous at a transition 13 of the panel 10 (e.g. the top surface 15 of the panel) and the at least one chamfer 12.

[0133] FIG. 2 shows the embodiment of FIG. 1 in a top view. It can be seen that the decorative printing layer 20 comprises a decorative pattern 21 which is substantially continuous at the transition 13 of the panel 10 and the at least one chamfer 12. In this Figure, the width wp of the panel 10 is also indicated. It is to be understood that the transition 13 comprises a region along the longitudinal extension L of the panel 10 and along the width wp of the panel 10.

[0134] In addition to the decorative advantage, it is also to be understood that the quality of the panel 1 is improved since there is essentially no difference between a material applied to the panel 10 and a material applied to the chamfer 12. Thereby, a haptic advantage is also provided due to the smooth transition of the same material on the panel 10 seen from a center of the panel 10 to an outer side of the chamfer 12, e.g. along the direction of the width wp.

[0135] FIG. 3 shows a top view of an exemplary panel 1p according to the state of the art. The panel 1p of the state of the art comprises a support panel 10p. There is also a chamfer 12p. The support panel 10p has a decorative printing layer 20p with a decorative pattern 21p applied to the panel 10p. The chamfer 12p is provided with uniform varnish and / or coloring. Regarding the manufacturing process, the chamfer 12p is processed for example after applying the decorative printing layer 20p. It can be seen that the decorative printing layer 20p and the decorative pattern 21p are not continuous at the transition 13p of the panel 1op and the at least one chamfer 12p.

[0136] FIGS. 4 to 8 show a more detailed cross section of a support panel 10 and the chamfer 12 according to one or more embodiments of the present disclosure, wherein dimensions of the panel 10 and the chamfer 12 are highlighted.

[0137] In these embodiments, the chamfer 12 has a rounded curvature, i.e. seen in a cross-section of the chamfer 12 perpendicular to the longitudinal extension L of the panel 10. Here, the rounded curvature is understood as a path, a spline and / or an arc. The rounded curvature is not to be understood such that it has an extension in the longitudinal extension L of the panel 10.

[0138] FIG. 4 shows the width w of the at least one chamfer 412 and the depth d of the at least one chamfer. As can be seen, the width w is perpendicular to the longitudinal extension L of the panel. It can also be said that the width w is perpendicular to the longitudinal extension L of an edge of the panel 410. The depth d is perpendicular to the top side 415 of the panel 410.

[0139] The ratio w / d of the at least one chamfer 412 is at least 0.5 and / or at most 30.

[0140] The panel 410 has a side surface 416 which is substantially parallel to the direction of the thickness t of the panel 410. The thickness t of the panel 410 may be at least 4 mm and / or at most 12 mm.

[0141] FIG. 5 shows the embodiment of FIG. 4, wherein further dimensions of the panel 10 and the chamfer 412 are highlighted. The rounded curvature of the chamfer 412 has an acute angle α formed between two tangents t1, t2 of substantially opposite ends 412a, 412b of the rounded curvature of the chamfer 412.

[0142] The outer end 412b faces away from the panel 410 and the inner end 412a faces the panel 410. It is understood that the outer end 412b is arranged on the side surface 416 of the panel 410.

[0143] FIG. 6 shows the embodiment of FIG. 4, wherein further dimensions of the panel 410 and the chamfer 412 are highlighted. The rounded curvature has an acute angle β formed between a tangent t2 at substantially an outer end 412b of the rounded curvature of the chamfer 412 and the top surface 415 of the panel 410.

[0144] The acute angle β formed between the tangent t2 at an outer end 412b of the rounded curvature and the top surface 415 of the panel 410 is understood as the acute angle between this tangent t2 and an imaginary plane 415i in extension of the top surface 415. As described herein, manufacturing tolerances have to be taken into account when determining the geometric properties. Furthermore, the imaginary plane 415i may aid in determining the acute angle β, as the imaginary plane 415i can be established by placing a large auxiliary panel on the top side of the panel (e.g. including any layers) for determining the acute angle β. Thus, this may enable the angle to be determined more easily compared to determining the tangent t1.

[0145] FIG. 7 shows the embodiment of FIG. 4, wherein further dimensions of the panel 410 and the chamfer 412 are highlighted. The rounded curvature of the chamfer 412 has a radius r, which may also be referred to as radius of curvature. The radius r may be determined by the radius of an approximate circle at a particular point of the rounded curvature.

[0146] The radius r of the rounded curvature is not constant along the rounded curvature. This means that, when following the path of the rounded curvature, the radius r varies. It can be seen that the radius r1 at the inner end 412a of the rounded curvature of the chamfer 412 is larger compared to the radius r2 at the outer end 412b of the rounded curvature of the chamfer 412. In some cases, however, it may be advantageous to keep the radius constant since a simplified manufacturing could thus result.

[0147] FIG. 8 shows a more detailed cross section of a support panel 810 and the chamfer 812 according to another embodiment compared to FIG. 7. The radius r of the rounded curvature is constant along the rounded curvature.

[0148] In all embodiments described herein, the rounded curvature of the chamfer 812 is preferably arranged such that the inner end 812a of the rounded curvature should be oriented parallel to the top surface 815 of the panel 810. Furthermore, the rounded curvature is arranged such that the tangent t2 of the outer end 12b of the rounded curvature forms an angle with the side surface 816 of the panel 810. Although not shown here, the rounded curvature may be arranged such that the tangent t2 of the outer end 12b of the rounded curvature is oriented parallel to the side surface 816 of the panel 810.

[0149] FIG. 9 shows a schematic cross section of a panel 1 comprising further layers according to an embodiment of the present disclosure.

[0150] The panel 901 is similar to the embodiment of FIG. 1 and only the differences are described. The panel 901 further comprises a primer layer 19 applied to the panel 910 and to the at least one chamfer 12, directly below the decorative printing layer 20 as seen from the panel 910. The panel 901 further comprises a varnish layer 22 applied to the panel 910 and to the at least one chamfer 12, directly above the decorative printing layer 20 as seen from the panel 910. The panel 901 further comprises a wear layer 23 applied to the panel 910 and to the at least one chamfer 12, preferably directly above the varnish layer 22 as seen from the panel 910.

[0151] The layers above the decorative printing layer 20 are configured such that the decorative printing layer 20 and the decorative pattern 21 can be seen from above (e.g. in the Figure in a vertical direction from top to bottom). In particular, the decorative printing layer 20 and the decorative pattern 21 can be seen when the panel 910 is in a typical position, e.g. on a floor, a wall, a ceiling or the like, depending on the field of application of the panel 901 with its back surface 17.

[0152] The panel 1 also comprises a connecting structure 30 on at least one side surface 16 of the panel 910.

[0153] The panel 1 of all embodiments described herein can advantageously be used not only as a floor, ceiling or wall panel, but also as a worktop or as a vertical surface, such as in furniture fronts or doors.

[0154] FIG. 10 shows a diagram of an exemplary method 100 according to the present disclosure.

[0155] The method 100 for manufacturing a panel, in particular wall, ceiling, furniture or floor panel, comprises the following steps:

[0156] providing 110 a support panel 10, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel;

[0157] processing 120 the panel 10 to provide the panel 10 with at least one chamfer 12 on at least one edge;

[0158] applying 130 a decorative printing layer 20 to the panel 10 and to the at least one chamfer 12.

[0159] Optionally, the providing 110 of the support panel 10 comprises formatting an initial support panel into one or more support panel(s) 10.

[0160] Optionally, the method 10 further comprises profiling the panel to provide a connecting structure 30 on at least one side surface 16 of the panel 10, wherein the side surface 16 is substantially parallel to a thickness t of the panel 10, optionally the profiling step is carried out prior to the step of applying 130 the decorative printing layer 20.

[0161] It is noted that the above examples can be combined with further aspects as described herein and details of the examples can also be omitted, as will be understood by those skilled in the art. The scope is determined by the claims and is not limited by the embodiments disclosed in the above Figures.

[0162] It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teachings. The disclosed examples and embodiments are presented for illustrative purposes only. Other embodiments may comprise some or all of the features disclosed herein. Therefore, it is intended to cover all such modifications and alternative embodiments which may fall within the true scope of this invention.6. List of Reference Signs 1pState of the art: Panel 10pState of the art: Support panel 11pState of the art: Edge of the support panel 12pState of the art: Chamfer 13pState of the art: Transition 20pState of the art: Decorative printing layer 21pState of the art: Decorative pattern 1Panel10Support panel11Edge of the support panel12Chamfer 12aInner end 12bOuter end13Transition15Top surface 15iImaginary plane in extension of the top surface16Side surface17Back surface19Primer layer20Decorative printing layer21Decorative pattern22Varnish layer23Wear layer30Connecting structure  4XXParts / elements of a further embodiment  8XXParts / elements of a further embodiment  9XXParts / elements of a further embodimentdDepth of the chamferLLongitudinal extension of the panel / edgewWidth of the chamferwpWidth of the panelrRadius of the rounded curvature of the chamfer(radius of curvature)αAcute angle between two tangents at opposite endsof the rounded curvatureβAcute angle between a tangent at an outer end ofthe rounded curvature and the top surfacet1First tangent of the rounded curvaturet2Second tangent of the rounded curvaturet2Tangent at an outer end of the rounded curvature100 Method for manufacturing a panel110 providing a support panel120 processing the panel130 applying a decorative printing layer

Examples

Embodiment Construction

[0128]Subsequently, presently preferred embodiments are outlined, mainly with reference to the above Figures. It is pointed out that further embodiments are certainly possible and the following explanations are provided only by way of example and without limitation. Further, the present invention may also be used in other embodiments which are not explicitly disclosed below. Furthermore, as described in detail below, the embodiments are compatible with each other and individual features of one embodiment can also be applied to another embodiment.

[0129]Throughout the present Figures and specification, the same reference numbers refer to the same elements. It is pointed out that the reference numbers 4XX, 8XX and 9XX refer to the same elements as the reference numbers XX. However, some parts / elements have been varied, which is the reason why a first digit is introduced in these embodiments. The Figures may not be to scale and the relative size, proportions and representation of elemen...

1. TECHNICAL FIELD

[0001] The present invention relates to a method for manufacturing a panel, in particular a laminate, wall, ceiling, furniture or floor panel. The present invention further relates to a correspondingly manufactured panel.2. STATE OF THE ART

[0002] Currently, a wide range of materials exists which can be used in the manufacture of panels, such as wall, ceiling, furniture and floor panels. Furthermore, a wide range of manufacturing methods for panels exists.

[0003] There is a continuing need to improve the properties of the panels and / or the corresponding manufacturing methods. In particular, it is of interest to improve a variety of different panel properties. These properties include, for example, environmental friendliness, such as recyclability, haptics, appearance and / or durability, such as fire, moisture and / or scratch resistance.

[0004] In particular in the technical field of manufacturing panels for visible surfaces which comprise contact surfaces, it is essential that the panels have a visually attractive surface. Thus, the manufacturing methods should provide for visually attractive panels, panels with improved haptic appearance and panels which are also durable at the same time.

[0005] Known panels in such a technical field for visible surfaces comprise laminate panels which are relatively inexpensive and easy to handle. Typically, they comprise a support panel made of a medium density fiber (MDF) or high density fiber (HDF) material which allows thermal recyclability. Known methods in such a technical field for visible surfaces comprise applying decorative layers to the support panel during the manufacturing process to provide visually attractive panels.

[0006] In the state of the art, attempts have been made to provide decorative panels by applying a decorative layer to the panel (e.g. by printing), coating the panel (e.g. painting and / or painting), which is then followed by formatting the panel (e.g. separating the panel into smaller pieces). Subsequently, the panel can be profiled which comprises providing a specific shape on front and / or side surfaces of the panel such that a connection of two or more panels is facilitated. Subsequently, one or more edges of the panels can be provided with a beveled edge which is typically done by milling a chamfer (or bevel) on the edge. The chamfer is subsequently coated, i.e. provided with a painted layer in a single color. The provision of the beveled edge together with its coating can be performed by separate devices.

[0007] The approaches in the state of the art have several disadvantages. For example, the chamfer does not have the decorative layer thereover but is coated in a single color. Thus, such common practices must always provide a compromise to align the chamfer with the decorative layer of the panel. The aligning of the decorative layer by post-processing the chamfer is very expensive and thus is not carried out. In addition, the coating of the chamfer is an additional step which is not very effective. A further disadvantage of known approaches in the state of the art is that structural properties of the chamfer always differ from the remaining panel by the separate and / or additional coating step. Thus, such chamfers can be more susceptible to mechanical failure and can break more easily.

[0008] Furthermore, there are pressed chamfers in the state of the art. The manufacturing of a pressed chamfer is enabled by pressing an edge into the panel. This has the disadvantage that the mechanical integrity of the overall panel is negatively influenced. Furthermore, a continuous layer along the overall panel is difficult to achieve since the pressing interferes with the layers at the edge / chamfer.

[0009] In view of the above disadvantages, there is an increased need to provide improved panels and improved manufacturing methods for panels.

[0010] Thus, it is an object of the present invention to at least partially overcome the above-mentioned disadvantages. In particular, it is an object of the present invention to provide an improved, overall attractive and resistant panel which feels haptically pleasant. In addition, a corresponding manufacturing method for the panel is to be enabled. The manufacturing method should be simplified and inexpensive.

[0011] Furthermore, it is an object to provide a manufacturing method and panel in which the variation of the appearance of the panel is simplified.3. SUMMARY OF THE INVENTIONPanel

[0012] The objects are at least partially achieved by a panel and a method for manufacturing a panel as defined in the independent claims. Further aspects of the present disclosure are defined in the dependent claims. Since the panel and the method for manufacturing a panel both relate to panels, it is to be understood that advantages and / or features of the panel can also apply to the method and vice versa.

[0013] In particular, the object is achieved by a panel, in particular wall, ceiling, furniture or floor panel, wherein the panel comprises: a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel; wherein the panel has at least one chamfer at at least one edge; and a decorative printing layer applied to the panel and to the at least one chamfer.

[0014] This has the advantage that the decorative printing layer is applied to both, i.e. to the panel and to the at least one chamfer. Thus, the decorative effect is improved since there is essentially no variation of the decorative printing layer seen from above. This is advantageous since it contributes to the aligning of a more natural appearance.

[0015] A further advantage is that essentially no additional manufacturing steps are required to provide the chamfer with a color and / or a layer since the decorative printing layer also covers the chamfer.

[0016] In addition, the panel has the advantage that its quality is improved since there is essentially no difference between a material applied to the panel and a material applied to the chamfer. Thereby, a haptic advantage is also achieved since there is a smooth transition of the same material on the panel seen from a center of the panel to the chamfer. Accordingly, structural properties of the panel are improved.

[0017] The at least one chamfer is provided in such a way, e.g. processed, that layers can be easily applied to the panel and / or to the decorative printing layer. Such a processing (e.g. by milling) is advantageous since it does not negatively influence the structural integrity of the panel (which would be the case if the chamfer is pressed).

[0018] The support panel (also referred to herein as “panel” for brevity) may be a panel made of a wood-based material, such as a medium density fiber panel or a high density fiber panel, a particle panel, an oriented strand panel or the like. However, it may also be made of a plastic material, such as luxury vinyl tile (LVT), a rigid polymer core or an expanded polymer core as well as mixed constructions that are widely used in the flooring industry. High density fiber (HDF) panels have proven to be good recyclability.

[0019] The decorative printing layer is applied to the support panel and to the at least one chamfer, which is to be understood such that the printing layer can be seen from e.g. the top side when the panel is in a typical position, e.g. on a floor, a wall, a ceiling or the like. This is to be understood such that the printing layer is applied to a top surface of the panel. The top surface may face a back surface. Thereby, the printing layer and the decorative aspect of the printing layer can be recognized.

[0020] The back surface may be configured to be attached to a base surface, e.g. a wall, ceiling or floor surface. In an example, the back surface may be provided with adhesives and / or mechanical attachment means.

[0021] The chamfer as used herein may also be understood as a bevel. The chamfer could mean that the edge of the panel is inclined seen in a cross-section perpendicular to a longitudinal extension of the panel. In an example, at the location where the edge of the panel was located, the chamfer may represent an empty space. The chamfer may have a constant inclination and / or be at least partially rounded and / or be composed of a combination thereof.

[0022] The panel typically has a longitudinal extension (length) and a width perpendicular to the longitudinal extension. The edge of the panel is substantially parallel to the longitudinal extension. The chamfer is preferably applied along the overall length of the panel. Thereby, the chamfer is substantially parallel to the longitudinal extension of the panel. The width of the panel is typically small compared to the length.

[0023] It is to be understood that the panel is already formatted prior to providing the chamfer and prior to applying the decorative printing layer. Thus, the panel can already be provided with a width which is suitable for a specific application.

[0024] Preferably, the decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer.

[0025] This has the advantage that there is essentially no difference between the decorative printing layer on the panel, which improves the product quality of the panel. Furthermore, it contributes to the decorative value of the panel.

[0026] The transition is to be understood such that it extends over a part of a top surface of the panel at which no inclination is provided by means of the chamfer, and also extends over a part of the chamfer along a width direction of the panel. Furthermore, the transition can also extend along the longitudinal extension / direction of the panel (length). Thus, in one example, the transition can comprise a substantially rectangular region (e.g. seen from above).

[0027] In a preferred embodiment, the decorative printing layer comprises a decorative pattern which is substantially continuous at a transition of the panel and the at least one chamfer.

[0028] The decorative pattern can imitate any desired surface, which is appreciated by a user. In one example, the decorative pattern can imitate a natural surface. It is advantageous that the pattern is continuous at the transition of the panel and the at least one chamfer. Thereby, essentially no surface / material variations and / or no variations of the pattern can distract a user. Furthermore, a continuous material quality is achieved on the overall panel. In this regard, the “overall” panel means the panel (e.g. a top surface of the panel) and the chamfer of the panel.

[0029] In a preferred embodiment, the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel and a depth (d) perpendicular to the top side of the panel, wherein the ratio w / d of the at least one chamfer is at least 0.5, preferably at least 0.8, more preferably at least 1.2, more preferably at least 1.4, most preferably at least 1.6, and / or wherein the ratio w / d of the at least one chamfer is at most 30, preferably at most 25, more preferably at most 20, more preferably at most 15, more preferably at most 10, more preferably at most 8, most preferably at most 6.

[0030] The width and the depth of the chamfer may be understood as geometric properties of the chamfer. The geometric properties as specified herein have the advantage that the decorative printing layer can be easily applied to the panel and the at least one chamfer. Thereby, the adhesion of in particular a layer (e.g. the decorative printing layer) to the chamfer is improved. In conventional panels, the chamfer is typically constructed in such a way that it is difficult to reliably apply a layer.

[0031] It should also be noted that one or more of the geometric properties of the chamfer described herein comprise lower and upper limits which can be combined into a region of a lower limit and an upper limit. In some configurations, a lower limit may be larger than an upper limit. In this regard, it is noted that the lower and upper limits are to be combined into a region in a technically meaningful way. When thereby a lower and upper limit are to be combined to specify a region, the lower limit should be at least lower than the upper limit. Thereby, the specified region comprises technically meaningful values between the lower limit and the upper limit.

[0032] Tests have shown that the geometric properties as specified herein in particular facilitate and improve the application of the decorative printing layer (and also of the further layers, such as the varnish layer).

[0033] In an example, the ratio w / d is at least 2, preferably at least 3, more preferably at least 3.5, more preferably at least 4, most preferably at least 4.5.

[0034] In a further example, the ratio w / d is at most 4, preferably at most 3, more preferably at most 2.5, more preferably at most 2, most preferably at most 1.8.

[0035] Tests have shown that the specific combinations of upper and lower limits of the ratio w / d facilitate the provision of the chamfer. They also facilitate that layers can be reliably applied to the panel.

[0036] In a preferred embodiment, the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, more preferably at least 0.6 mm, most preferably at least 0.7 mm, and / or of at most 10 mm, preferably at most 8 mm, more preferably at most 6 mm, more preferably at most 5 mm, most preferably at most 4 mm.

[0037] In an example, the width (w) is at least 1.0 mm, preferably at least 1.4 mm, more preferably at least 1.8 mm, more preferably at least 2.2 mm, most preferably at least 2.6 mm.

[0038] In a further example, the width (w) is at most 1.2 mm, preferably at most 1.1 mm, more preferably at most 1.0 mm, more preferably at most 0.95 mm, most preferably at most 0.9 mm.

[0039] In a preferred embodiment, the at least one chamfer has a depth (d) perpendicular to the top side of the panel of at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.15 mm, more preferably at least 0.2 mm, more preferably at least 0.3 mm, more preferably at least 0.35 mm, more preferably at least 0.4 mm, most preferably at least 0.45 mm, and / or the at least one chamfer has a depth (d) perpendicular to the top side of the panel of at most 2.0 mm, preferably at most 1.6 mm, more preferably at most 1.2 mm, more preferably at most 0.8 mm, more preferably at most 0.6 mm, most preferably at most 0.55 mm.

[0040] As described herein, the width and the depth of the chamfer may be understood as geometric properties of the chamfer. The specific values and regions described herein contribute to the mechanical integrity of the panel. In contrast, conventional panels may be susceptible to abrasion in the vicinity of a chamfer due to the geometric properties of conventional chamfers. Accordingly, the chamfer, as described herein, simplifies the application of layers such as the decorative printing layer to the panel and the at least one chamfer. Further, a varnish layer can be more easily applied to the panel by means of the geometric properties specified according to the present disclosure.

[0041] In a preferred embodiment, the at least one chamfer has a rounded curvature.

[0042] This means that such a rounded curvature can be seen in a cross-section of the chamfer perpendicular to a longitudinal extension of the panel. Here, the rounded curvature may be understood in one example as a path, a spline and / or an arc. The rounded curvature is not to be understood such that the chamfer will be described along the longitudinal extension (e.g. in a three-dimensional region).

[0043] Preferably, the rounded curvature has a radius (r) of at least 0.5 mm, preferably at least 0.8 mm, more preferably at least 1 mm, more preferably at least 1.2 mm, most preferably at least 1.4 mm, and / or the rounded curvature has a radius (r) of at most 80 mm, preferably at most 60 mm, more preferably at most 40 mm, more preferably at most 35 mm, more preferably at most 30 mm, most preferably at most 29 mm.

[0044] In an example, the radius (r) is at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, more preferably at least 25 mm, most preferably at least 28 mm.

[0045] In a further example, the radius (r) is at most 4 mm, preferably at most 2.5 mm, more preferably at most 2 mm, more preferably at most 1.8 mm, most preferably at most 1.6 mm.

[0046] Preferably, the radius (r) is constant along the rounded curvature.

[0047] The rounded curvature of the chamfer has the advantage that the application of a layer to the panel and to the at least one chamfer is improved. In particular, the layer can be reliably applied. Compared to chamfers with a constant inclination (or inclination angle), the rounded curvature facilitates that a larger amount, e.g. a paint layer, settles at the transition (of the panel and the at least one chamfer). The transition is thereby improved and can withstand larger mechanical impacts. The transition is typically subjected to mechanical impacts, such as impacts resulting from objects / devices falling on the panel and / or depending on the application of the panel by feet of a user.

[0048] The radius (r) as used herein is understood as the radius of curvature of the rounded curvature. As an example, the radius of an approximate circle at a particular point of the rounded curvature is the radius (r) as used herein. The radius may not necessarily be constant along the rounded curvature. This is understood in such a way that, when following the path of the rounded curvature, the radius (r) may vary. As an example, this may be the case if the rounded curvature is similar to an involute. A constant radius of the rounded curvature means that the rounded curvature is a circular segment, wherein the segment angle is between 0° and 90°.

[0049] In a preferred embodiment, the rounded curvature has an acute angle (α) formed between two tangents of substantially opposite ends of the rounded curvature of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at least 45°, more preferably at most 40°, most preferably at most 37°.

[0050] In a preferred embodiment, the rounded curvature has an acute angle (β) formed between a tangent at substantially an outer end of the rounded curvature and the top surface of the panel of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at least 45°, more preferably at most 40°, most preferably at most 37°.

[0051] In an example, the acute angle (α and / or β) is at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.

[0052] In a further example, the acute angle (α and / or β) is at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°.

[0053] The acute angle (α and β) and the radius (r) may be comprised by the geometric properties of the chamfer as described herein. Thereby, the advantages described with respect to the geometric properties also apply to the acute angle (α and β) and the radius (r).

[0054] The two tangents of substantially opposite ends are to be understood such that a tangent on the rounded curvature is at an outer end of the rounded curvature. The outer end of the rounded curvature may be understood as the deepest location of the chamfer, e.g. the location with the largest depth (d) of the chamfer. However, usually manufacturing tolerances have to be taken into account, which is expressed by the term “substantially”. Thus, the tangents described herein to form acute angles may vary slightly at their location along the rounded curvature.

[0055] The other tangent of the two tangents of substantially opposite ends is on the rounded curvature at an inner end of the rounded curvature. The inner end of the rounded curvature may be understood as the location of the chamfer with the lowest value of the depth (d).

[0056] The “outer end” and “inner end” are described with reference to the plate such that the outer end faces away from the plate and the inner end faces the plate. It is understood that the outer end is arranged on the side surface of the plate.

[0057] The rounded curvature is typically arranged such that the inner end of the rounded curvature is oriented parallel to the top surface of the plate. This helps in providing a smooth transition from the top surface to the chamfer. In one example, the rounded curvature may be arranged such that the tangent of the outer end of the rounded curvature is oriented parallel to the side surface of the plate. In another example, the rounded curvature may be arranged such that the tangent of the outer end of the rounded curvature forms an angle with the side surface of the plate.

[0058] The acute angle formed between the tangent at an outer end of the rounded curvature and the top surface of the plate is understood as the acute angle between this tangent and an imaginary plane in extension of the top surface. It may be possible that the tangent at the inner end of the rounded curvature is oriented parallel to the top surface of the plate.

[0059] It should be understood that the geometric properties of the chamfer described herein can also be determined / measured / derived from the panel to which one or more, in particular all, layers as described herein are applied. Thereby, e.g., the width (w), depth (d), ratio w / d, radius (r) and the acute angle (α and / or β) of the chamfer can be determined / measured / derived from the chamfer with the primer layer, the decorative printing layer, the varnish layer and / or the wear layer applied to the panel and to the chamfer. This may be the case since the layers typically have a small thickness.

[0060] In a preferred embodiment, the panel further comprises a primer layer applied to the panel and to the at least one chamfer, preferably directly below the decorative printing layer as seen from the panel.

[0061] The primer layer enables the decorative printing layer to be applied with sufficient quality. Thereby, the application of the decorative printing layer is improved. It is to be understood that the primer layer is applied directly before (in the case of the manufacturing method) and / or directly below (structurally speaking and seen in the end product, i.e. the panel) the decorative printing layer and also covers the chamfer. This improves in particular the application in the transition and the chamfer.

[0062] In a further preferred embodiment, the panel further comprises a varnish layer applied to the panel and to the at least one chamfer, preferably directly above the decorative printing layer as seen from the panel.

[0063] The varnish layer provides sufficient elasticity to compensate for a deformation of the panel. It may also be possible to apply a varnish layer based on a harder, i.e. less elastic, material. A higher resistance to impacts, scratches and / or chemicals can thereby be achieved. Suitable varnish layers which can be used herein comprise in a non-exhaustive list corundum particles, acrylate, polymers, oligomers, additives and / or the like. Further, the varnish layer can be applied by means of flexography or any other type of application technique.

[0064] In a preferred embodiment, the panel further comprises a wear layer applied to the panel and to the at least one chamfer, preferably directly above the varnish layer as seen from the panel; optionally the wear layer is applied by means of melt lamination or adhesive lamination, wherein the wear layer is optionally based on cast polypropylene.

[0065] The wear layer has the advantage that the protection of the panel is further improved. In particular, the wear layer protects the decorative printing layer.

[0066] The varnish layer and the wear layer applied to the panel and to the at least one chamfer have the advantage that the product quality is improved in particular in the transition as described herein. Thereby, substantially no deviations occur in the layers seen in a cross-section perpendicular to the longitudinal extension of the panel from the center of the panel to an outer end of the panel. This is advantageous compared to conventional panels and methods in which the chamfer is processed after applying substantially all layers to a support panel.

[0067] In particular, the varnish layer and the wear layer are applied to the top of the decorative printing layer, which means that the varnish layer and the wear layer do not substantially directly contact the panel and / or the at least one chamfer. For example, if the varnish layer applied “to” the panel and “to” the at least one chamfer is mentioned, it is to be understood that a layer (such as the decorative layer) can be arranged between the varnish layer and the panel and / or the chamfer.

[0068] Preferably, the decorative printing layer contacts the primer layer and / or the panel and the chamfer. The varnish layer preferably contacts the decorative printing layer. The wear layer preferably contacts the varnish layer. Thereby, the layers can be applied to the panel and the at least one chamfer in the following order as seen from the panel: optionally the primer layer, decorative printing layer, optionally the varnish layer, optionally the wear layer.

[0069] Preferably, the decorative printing layer and / or the decorative pattern imitates a wood pattern.

[0070] This has the advantage that a more natural appearance is provided.

[0071] Preferably, the panel has a thickness (t) of at least 4 mm, preferably at least 5 mm, more preferably at least 6 mm, more preferably at least 7 mm, most preferably at least 7.5 mm, and / or at most 12 mm, preferably at most 11 mm, more preferably at most 10 mm, more preferably at most 9 mm, most preferably at most 8 mm.

[0072] These thicknesses have proven to be sufficient on the one hand to provide sufficient rigidity (to provide a high wear resistance) while on the other hand the material use is kept at a moderate level.

[0073] Preferably, the panel has a width (wp) of at least 4 cm, preferably at least 5 cm, more preferably at least 6 cm, more preferably at least 7 cm, most preferably at least 8 cm, and / or at most 200 cm, preferably at most 150 cm, more preferably at most 120 cm, more preferably at most 100 cm, more preferably at most 80 cm, more preferably at most 60 cm, more preferably at most 40 cm, more preferably at most 30 cm, more preferably at most 20 cm, most preferably at most 18 cm.

[0074] These widths of the panel have proven to be small enough on the one hand so that the panel can be used directly in a respective field of application without requiring further formatting into smaller widths. On the other hand, the widths of the panel have proven to be large enough to facilitate the processing of the chamfer on the panel and the performance of manufacturing steps (e.g. application of the layer(s)).

[0075] The decorative printing layer can be applied by means of rotogravure printing, flexography and / or digital printing. By using these printing technologies, prints of higher quality can be achieved. In particular, the digital printing facilitates the application of the layer substantially contactlessly.

[0076] In an example, the panel in the panel as described herein has two chamfers, namely on both edges parallel to the longitudinal extension of the panel (e.g. on the edges on both side surfaces of the panel), wherein the ratio w / d is between 2 and 30, preferably between 6 and 20, most preferably between 7.5 and 15. This is particularly advantageous for panels which require water-tightness. Such a water-tightness can be achieved since the width (w) of the chamfer is substantially larger compared to the depth (d) of the chamfer. This ensures that a layer thickness is advantageously distributed in particular in the transition as described herein, thereby promoting the water-tightness. Thus, in particular the requirements of the NALFA test can be achieved.

[0077] The NALFA test is a standardized test method of the North American Laminate Flooring Association (NALFA). In this test, it is measured how a laminate floor behaves when its surface is exposed to standing water for about 24 hours. Before and after this time, the surface is measured at e.g. four different positions and the visual and tactile changes of the panel are recorded and evaluated.Method

[0078] The objects are further at least partially achieved by a method for manufacturing a panel, in particular wall, ceiling, furniture or floor panel, comprising the following steps: providing a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel; processing the panel to provide the panel with at least one chamfer at at least one edge; applying a decorative printing layer to the panel and to the at least one chamfer.

[0079] While the description of the panel relates to “a . . . layer applied to . . . ”, the description of the method for manufacturing a panel relates to “applying a . . . layer”. This is the case since the panel comprises layers already applied / attached to the panel and to the at least one chamfer, preferably systematically. On the other hand, the method comprises a step of applying layers which are not necessarily connected during the application. Also, during the application of the layers in the method for manufacturing a panel, the layers may be at least partially viscous / liquid. However, it is to be understood that substantially the same advantages and features mentioned with respect to the panel apply equally to the method for manufacturing a panel. Furthermore, the features can thus also be applied in combination and / or interchangeably to embodiments of the panel or the method, respectively.

[0080] The processing of the panel can be carried out by milling which is appreciated since it does not negatively influence the structural integrity of the panel, which would be the case if the chamfer is pressed.

[0081] Preferably, the method and / or the processing does not comprise pressing the chamfer. This has the advantage that the mechanical integrity and resistance of the panel is improved.

[0082] Preferably, the applied decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer. Respective advantages are described herein with respect to the panel.

[0083] Preferably, the decorative printing layer comprises a decorative pattern and the decorative pattern is substantially continuous at a transition of the panel and the at least one chamfer. Respective advantages are described herein with respect to the panel.

[0084] Preferably, the applying of the decorative printing layer to the panel and to the at least one chamfer is carried out substantially at the same time and / or no other method step is carried out in between.

[0085] This has the advantage that no separate coating step of the chamfer is required. Such a separate coating step is typically cumbersome since it increases the manufacturing time. By using the phrase “substantially at the same time” herein, it cannot be excluded that the applying of the decorative printing layer to the panel takes some time before the layer is applied to the chamfer. This time span may depend on the width of the panel in one example. However, it is important that no other dedicated method step is carried out in between. Further advantages are described herein with respect to the panel.

[0086] The decorative printing layer can be applied by means of rotogravure printing, flexography and / or digital printing. Respective advantages are described herein with respect to the panel.

[0087] In a preferred embodiment, the method comprises applying a primer layer to the panel and to the at least one chamfer, preferably prior to the step of applying the decorative printing layer and after the step of processing the panel.

[0088] In a further preferred embodiment, the method comprises applying a varnish layer to the panel and to the at least one chamfer, preferably after the step of applying the decorative printing layer.

[0089] In a preferred embodiment, the method comprises applying a wear layer to the panel and to the at least one chamfer, preferably after the step of applying the varnish layer; optionally applying the wear layer by means of melt lamination or adhesive lamination, wherein the wear layer is optionally based on cast polypropylene.

[0090] In a further preferred embodiment, the providing of the support panel comprises formatting an initial support panel into one or more support panel(s).

[0091] It should be noted that in the method, as described herein, an initial (large) panel is formatted into the panel. Thus, the panel is suitable to be used directly in a respective field of application. As a result, no formatting is required, e.g. after processing and / or applying any layers to the panel. Further advantages are described herein with respect to the panel.

[0092] In another preferred embodiment, the method further comprises profiling the panel to provide a connecting structure on at least one side surface of the panel, wherein the side surface is substantially parallel to a thickness of the panel, preferably prior to the step of applying the decorative printing layer.

[0093] The side surface of the panel is substantially perpendicular to the top side of the panel. Profiling facilitates that the panel can be connected to another panel, e.g. by form-fitting, or the like. The connecting structure enables that the side surface is configured to be engaged with a side surface of another panel. Profiling can also comprise providing a connecting structure on both side surfaces. It is to be understood that profiling is carried out prior to applying the decorative printing layer, and preferably also prior to applying the optional primer layer. This facilitates that after applying the decorative printing layer the number of manufacturing steps is reduced which ensures that the chamfer is not negatively influenced. Thus, the quality of the chamfer is improved.

[0094] Preferably, the decorative printing layer and / or the decorative pattern imitates a wood pattern.

[0095] Preferably, the panel has a thickness (t) of at least 4 mm, preferably at least 5 mm, more preferably at least 6 mm, more preferably at least 7 mm, most preferably at least 7.5 mm, and / or at most 12 mm, preferably at most 11 mm, more preferably at most 10 mm, more preferably at most 9 mm, most preferably at most 8 mm.

[0096] Preferably, the panel has a width (wp) of at least 4 cm, preferably at least 5 cm, more preferably at least 6 cm, more preferably at least 7 cm, most preferably at least 8 mm, and / or at most 30 mm, preferably at most 25 mm, more preferably at most 22 mm, more preferably at most 20 mm, most preferably at most 18 mm.FURTHER EMBODIMENTS

[0097] A first embodiment is directed to the panel as described herein, wherein the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel and a depth (d) perpendicular to the top side of the panel, wherein the ratio w / d of the at least one chamfer is at least 0.5, preferably at least 0.8, more preferably at least 1.2, more preferably at least 1.4, most preferably at least 1.6 (or 1.65), and / or

[0098] at least 2, preferably at least 3, more preferably at least 3.5, more preferably at least 4, most preferably at least 4.5, and / or

[0099] at most 30, preferably at most 25, more preferably at most 20, more preferably at most 15, more preferably at most 10, more preferably at most 8, most preferably at most 6, and / or

[0100] at most 4, preferably at most 3, more preferably at most 2.5, more preferably at most 2, most preferably at most 1.8.

[0101] A second embodiment is directed to the panel as described herein, wherein the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel of at least 0.2 mm, preferably at least 0.4 mm, more preferably at least 0.5 mm, more preferably at least 0.6 mm, most preferably at least 0.7 mm, and / or

[0102] at least 1.0 mm, preferably at least 1.4 mm, more preferably at least 1.8 mm, more preferably at least 2.2 mm, most preferably at least 2.6 mm, and / or

[0103] at most 10 mm, preferably at most 8 mm, more preferably at most 6 mm, more preferably at most 5 mm, most preferably at most 4 mm, and / or

[0104] at most 1.2 mm, preferably at most 1.1 mm, more preferably at most 1.0 mm, more preferably at most 0.95 mm, most preferably at most 0.9 mm.

[0105] A third embodiment is directed to the panel as described herein, wherein the rounded curvature has a radius (r) of at least 0.5 mm, preferably at least 0.8 mm, more preferably at least 1 mm, more preferably at least 1.2 mm, most preferably at least 1.4 mm, and / or

[0106] at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, more preferably at least 25 mm, most preferably at least 28 mm, and / or

[0107] at most 80 mm, preferably at most 60 mm, more preferably at most 40 mm, more preferably at most 35 mm, most preferably at most 29 mm, and / or

[0108] at most 4 mm, preferably at most 2.5 mm, more preferably at most 2 mm, more preferably at most 1.8 mm, most preferably at most 1.6 mm.

[0109] A fourth embodiment is directed to the panel as described herein, wherein the rounded curvature has an acute angle (α) formed between two tangents of substantially opposite ends of the rounded curvature of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or

[0110] at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°, and / or

[0111] at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at most 45°, more preferably at most 40°, most preferably at most 37°, and / or

[0112] at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.

[0113] A fifth embodiment is directed to the panel as described herein, wherein the rounded curvature has an acute angle (β) formed between a tangent at substantially an outer end of the rounded curvature and the top surface of the panel of at least 1°, preferably at least 2°, more preferably at least 4°, more preferably at least 5°, more preferably at least 6°, more preferably at least 7°, most preferably at least 8°, and / or

[0114] at least 10°, preferably at least 15°, more preferably at least 20°, more preferably at least 25°, more preferably at least 30°, more preferably at least 35°, most preferably at least 37°, and / or

[0115] at most 65°, preferably at most 60°, more preferably at most 55°, more preferably at most 50°, more preferably at most 45°, more preferably at most 40°, most preferably at most 37°, and / or

[0116] at most 25°, preferably at most 22°, more preferably at most 20°, more preferably at most 17°, more preferably at least 15°, more preferably at most 14°, most preferably at most 13°.4. BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES

[0117] In the following, preferred embodiments are described only by way of example. Reference is made to the following accompanying Figures:

[0118] FIG. 1 shows a schematic cross section of a panel according to an embodiment of the present disclosure;

[0119] FIG. 2 shows the embodiment of FIG. 1 in a top view;

[0120] FIG. 3 shows a top view of an exemplary panel according to the state of the art;

[0121] FIG. 4 shows a more detailed cross section of a support panel and the chamfer according to an embodiment of the present disclosure, wherein dimensions of the panel and the chamfer are highlighted;

[0122] FIG. 5 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein further dimensions of the panel and the chamfer are highlighted;

[0123] FIG. 6 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein still further dimensions of the panel and the chamfer are highlighted;

[0124] FIG. 7 shows a more detailed cross section of a support panel and the chamfer according to the embodiment of FIG. 4, wherein different dimensions of the panel and the chamfer are highlighted;

[0125] FIG. 8 shows a more detailed cross section of a support panel and the chamfer according to another embodiment compared to FIG. 7, wherein the dimensions of FIG. 7 are highlighted;

[0126] FIG. 9 shows a schematic cross section of a panel comprising further layers according to an embodiment of the present disclosure; and

[0127] FIG. 10 shows a diagram of an exemplary method according to the present disclosure.5. DETAILED DESCRIPTION OF THE FIGURES

[0128] Subsequently, presently preferred embodiments are outlined, mainly with reference to the above Figures. It is pointed out that further embodiments are certainly possible and the following explanations are provided only by way of example and without limitation. Further, the present invention may also be used in other embodiments which are not explicitly disclosed below. Furthermore, as described in detail below, the embodiments are compatible with each other and individual features of one embodiment can also be applied to another embodiment.

[0129] Throughout the present Figures and specification, the same reference numbers refer to the same elements. It is pointed out that the reference numbers 4XX, 8XX and 9XX refer to the same elements as the reference numbers XX. However, some parts / elements have been varied, which is the reason why a first digit is introduced in these embodiments. The Figures may not be to scale and the relative size, proportions and representation of elements in the Figures may be exaggerated for clarity, illustration and convenience.

[0130] FIG. 1 shows a schematic cross section of a panel according to an embodiment of the present disclosure.

[0131] The panel 1 may be a wall, ceiling, furniture or floor panel. The panel 1 comprises a support panel 10, such as a medium density fiber (MDF) support panel, a high density fiber (HDF) support panel or a particle panel. The panel 10 comprises at least one chamfer 12 on at least one edge 11 of the panel 10. The panel 1 further comprises a decorative printing layer 20 applied to the panel 10 and to the at least one chamfer 12. The panel 10 has a back surface 17. The back surface 17 typically faces a floor, a wall, a ceiling or the like, depending on the field of application of the panel 1.

[0132] The decorative printing layer 20 is substantially continuous at a transition 13 of the panel 10 (e.g. the top surface 15 of the panel) and the at least one chamfer 12.

[0133] FIG. 2 shows the embodiment of FIG. 1 in a top view. It can be seen that the decorative printing layer 20 comprises a decorative pattern 21 which is substantially continuous at the transition 13 of the panel 10 and the at least one chamfer 12. In this Figure, the width wp of the panel 10 is also indicated. It is to be understood that the transition 13 comprises a region along the longitudinal extension L of the panel 10 and along the width wp of the panel 10.

[0134] In addition to the decorative advantage, it is also to be understood that the quality of the panel 1 is improved since there is essentially no difference between a material applied to the panel 10 and a material applied to the chamfer 12. Thereby, a haptic advantage is also provided due to the smooth transition of the same material on the panel 10 seen from a center of the panel 10 to an outer side of the chamfer 12, e.g. along the direction of the width wp.

[0135] FIG. 3 shows a top view of an exemplary panel 1p according to the state of the art. The panel 1p of the state of the art comprises a support panel 10p. There is also a chamfer 12p. The support panel 10p has a decorative printing layer 20p with a decorative pattern 21p applied to the panel 10p. The chamfer 12p is provided with uniform varnish and / or coloring. Regarding the manufacturing process, the chamfer 12p is processed for example after applying the decorative printing layer 20p. It can be seen that the decorative printing layer 20p and the decorative pattern 21p are not continuous at the transition 13p of the panel 1op and the at least one chamfer 12p.

[0136] FIGS. 4 to 8 show a more detailed cross section of a support panel 10 and the chamfer 12 according to one or more embodiments of the present disclosure, wherein dimensions of the panel 10 and the chamfer 12 are highlighted.

[0137] In these embodiments, the chamfer 12 has a rounded curvature, i.e. seen in a cross-section of the chamfer 12 perpendicular to the longitudinal extension L of the panel 10. Here, the rounded curvature is understood as a path, a spline and / or an arc. The rounded curvature is not to be understood such that it has an extension in the longitudinal extension L of the panel 10.

[0138] FIG. 4 shows the width w of the at least one chamfer 412 and the depth d of the at least one chamfer. As can be seen, the width w is perpendicular to the longitudinal extension L of the panel. It can also be said that the width w is perpendicular to the longitudinal extension L of an edge of the panel 410. The depth d is perpendicular to the top side 415 of the panel 410.

[0139] The ratio w / d of the at least one chamfer 412 is at least 0.5 and / or at most 30.

[0140] The panel 410 has a side surface 416 which is substantially parallel to the direction of the thickness t of the panel 410. The thickness t of the panel 410 may be at least 4 mm and / or at most 12 mm.

[0141] FIG. 5 shows the embodiment of FIG. 4, wherein further dimensions of the panel 10 and the chamfer 412 are highlighted. The rounded curvature of the chamfer 412 has an acute angle α formed between two tangents t1, t2 of substantially opposite ends 412a, 412b of the rounded curvature of the chamfer 412.

[0142] The outer end 412b faces away from the panel 410 and the inner end 412a faces the panel 410. It is understood that the outer end 412b is arranged on the side surface 416 of the panel 410.

[0143] FIG. 6 shows the embodiment of FIG. 4, wherein further dimensions of the panel 410 and the chamfer 412 are highlighted. The rounded curvature has an acute angle β formed between a tangent t2 at substantially an outer end 412b of the rounded curvature of the chamfer 412 and the top surface 415 of the panel 410.

[0144] The acute angle β formed between the tangent t2 at an outer end 412b of the rounded curvature and the top surface 415 of the panel 410 is understood as the acute angle between this tangent t2 and an imaginary plane 415i in extension of the top surface 415. As described herein, manufacturing tolerances have to be taken into account when determining the geometric properties. Furthermore, the imaginary plane 415i may aid in determining the acute angle β, as the imaginary plane 415i can be established by placing a large auxiliary panel on the top side of the panel (e.g. including any layers) for determining the acute angle β. Thus, this may enable the angle to be determined more easily compared to determining the tangent t1.

[0145] FIG. 7 shows the embodiment of FIG. 4, wherein further dimensions of the panel 410 and the chamfer 412 are highlighted. The rounded curvature of the chamfer 412 has a radius r, which may also be referred to as radius of curvature. The radius r may be determined by the radius of an approximate circle at a particular point of the rounded curvature.

[0146] The radius r of the rounded curvature is not constant along the rounded curvature. This means that, when following the path of the rounded curvature, the radius r varies. It can be seen that the radius r1 at the inner end 412a of the rounded curvature of the chamfer 412 is larger compared to the radius r2 at the outer end 412b of the rounded curvature of the chamfer 412. In some cases, however, it may be advantageous to keep the radius constant since a simplified manufacturing could thus result.

[0147] FIG. 8 shows a more detailed cross section of a support panel 810 and the chamfer 812 according to another embodiment compared to FIG. 7. The radius r of the rounded curvature is constant along the rounded curvature.

[0148] In all embodiments described herein, the rounded curvature of the chamfer 812 is preferably arranged such that the inner end 812a of the rounded curvature should be oriented parallel to the top surface 815 of the panel 810. Furthermore, the rounded curvature is arranged such that the tangent t2 of the outer end 12b of the rounded curvature forms an angle with the side surface 816 of the panel 810. Although not shown here, the rounded curvature may be arranged such that the tangent t2 of the outer end 12b of the rounded curvature is oriented parallel to the side surface 816 of the panel 810.

[0149] FIG. 9 shows a schematic cross section of a panel 1 comprising further layers according to an embodiment of the present disclosure.

[0150] The panel 901 is similar to the embodiment of FIG. 1 and only the differences are described. The panel 901 further comprises a primer layer 19 applied to the panel 910 and to the at least one chamfer 12, directly below the decorative printing layer 20 as seen from the panel 910. The panel 901 further comprises a varnish layer 22 applied to the panel 910 and to the at least one chamfer 12, directly above the decorative printing layer 20 as seen from the panel 910. The panel 901 further comprises a wear layer 23 applied to the panel 910 and to the at least one chamfer 12, preferably directly above the varnish layer 22 as seen from the panel 910.

[0151] The layers above the decorative printing layer 20 are configured such that the decorative printing layer 20 and the decorative pattern 21 can be seen from above (e.g. in the Figure in a vertical direction from top to bottom). In particular, the decorative printing layer 20 and the decorative pattern 21 can be seen when the panel 910 is in a typical position, e.g. on a floor, a wall, a ceiling or the like, depending on the field of application of the panel 901 with its back surface 17.

[0152] The panel 1 also comprises a connecting structure 30 on at least one side surface 16 of the panel 910.

[0153] The panel 1 of all embodiments described herein can advantageously be used not only as a floor, ceiling or wall panel, but also as a worktop or as a vertical surface, such as in furniture fronts or doors.

[0154] FIG. 10 shows a diagram of an exemplary method 100 according to the present disclosure.

[0155] The method 100 for manufacturing a panel, in particular wall, ceiling, furniture or floor panel, comprises the following steps:

[0156] providing 110 a support panel 10, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel;

[0157] processing 120 the panel 10 to provide the panel 10 with at least one chamfer 12 on at least one edge;

[0158] applying 130 a decorative printing layer 20 to the panel 10 and to the at least one chamfer 12.

[0159] Optionally, the providing 110 of the support panel 10 comprises formatting an initial support panel into one or more support panel(s) 10.

[0160] Optionally, the method 10 further comprises profiling the panel to provide a connecting structure 30 on at least one side surface 16 of the panel 10, wherein the side surface 16 is substantially parallel to a thickness t of the panel 10, optionally the profiling step is carried out prior to the step of applying 130 the decorative printing layer 20.

[0161] It is noted that the above examples can be combined with further aspects as described herein and details of the examples can also be omitted, as will be understood by those skilled in the art. The scope is determined by the claims and is not limited by the embodiments disclosed in the above Figures.

[0162] It will be apparent to those skilled in the art that numerous modifications and variations of the described examples and embodiments are possible in light of the above teachings. The disclosed examples and embodiments are presented for illustrative purposes only. Other embodiments may comprise some or all of the features disclosed herein. Therefore, it is intended to cover all such modifications and alternative embodiments which may fall within the true scope of this invention.6. List of Reference Signs 1pState of the art: Panel 10pState of the art: Support panel 11pState of the art: Edge of the support panel 12pState of the art: Chamfer 13pState of the art: Transition 20pState of the art: Decorative printing layer 21pState of the art: Decorative pattern 1Panel10Support panel11Edge of the support panel12Chamfer 12aInner end 12bOuter end13Transition15Top surface 15iImaginary plane in extension of the top surface16Side surface17Back surface19Primer layer20Decorative printing layer21Decorative pattern22Varnish layer23Wear layer30Connecting structure  4XXParts / elements of a further embodiment  8XXParts / elements of a further embodiment  9XXParts / elements of a further embodimentdDepth of the chamferLLongitudinal extension of the panel / edgewWidth of the chamferwpWidth of the panelrRadius of the rounded curvature of the chamfer(radius of curvature)αAcute angle between two tangents at opposite endsof the rounded curvatureβAcute angle between a tangent at an outer end ofthe rounded curvature and the top surfacet1First tangent of the rounded curvaturet2Second tangent of the rounded curvaturet2Tangent at an outer end of the rounded curvature100 Method for manufacturing a panel110 providing a support panel120 processing the panel130 applying a decorative printing layer

Examples

Embodiment Construction

[0128]Subsequently, presently preferred embodiments are outlined, mainly with reference to the above Figures. It is pointed out that further embodiments are certainly possible and the following explanations are provided only by way of example and without limitation. Further, the present invention may also be used in other embodiments which are not explicitly disclosed below. Furthermore, as described in detail below, the embodiments are compatible with each other and individual features of one embodiment can also be applied to another embodiment.

[0129]Throughout the present Figures and specification, the same reference numbers refer to the same elements. It is pointed out that the reference numbers 4XX, 8XX and 9XX refer to the same elements as the reference numbers XX. However, some parts / elements have been varied, which is the reason why a first digit is introduced in these embodiments. The Figures may not be to scale and the relative size, proportions and representation of elemen...

Claims

1. A panel, in particular wall, ceiling, furniture or floor panel, wherein the panel comprises:a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel;wherein the panel comprises at least one chamfer on at least one edge; anda decorative printing layer applied to the panel and to the at least one chamfer.

2. The panel according to claim 1, wherein the decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer.

3. The panel according to claim 1, the decorative printing layer comprises a decorative pattern which is substantially continuous at a transition of the panel and the at least one chamfer.

4. The panel according to claim 1, wherein the at least one chamfer has a width perpendicular to the longitudinal extension of the panel and a depth perpendicular to the top side of the panel,wherein the ratio w / d of the at least one chamfer is at least 0.5, and / orat most 30.

5. The panel according to claim 1, wherein the ratio w / d is at least 2.

6. The panel according to claim 4, wherein the ratio w / d is at most 4.

7. The panel according to claim 1, wherein the at least one chamfer has a width (w) perpendicular to the longitudinal extension of the panel of at least 0.2 mm, and / orat most 10 mm.

8. The panel according to claim 1, wherein the width is at least 1.0 mm.

9. The panel according to claim 7, wherein the width (w) is at most 1.2 mm.

10. The panel according to claim 1, wherein the at least one chamfer has a depth (d) perpendicular to the top side of the panel of at least 0.05 mm, and / orat most 2.0.

11. The panel according to claim 1, wherein the at least one chamfer has a rounded curvature.

12. The panel according to claim 1, wherein the rounded curvature has a radius (r) of at least 0.5 mm, and / orat most 80 mm.

13. The panel according to claim 1, wherein the radius (r) is at least 10 mm.

14. The panel according to claim 12, wherein the radius (r) is at most 4 mm.

15. The panel according to claim 12, wherein the radius (r) is constant along the rounded curvature.

16. The panel according to claim 11, wherein the rounded curvature has an acute angle (α) formed between two tangents of substantially opposite ends of the rounded curvature of at least 1°, and / orat most 65°.

17. The panel according to claim 11, wherein the rounded curvature has an acute angle (β) formed between a tangent at substantially an outer end of the rounded curvature and the top surface of the panel of at least 1°, and / orat most 65°.

18. The panel according to claim 16, wherein the acute angle (α and / or β) is at most 25°.

19. The panel according to claim 16, wherein the acute angle (α and / or β) is at least 10°.

20. The panel according to claim 1, further comprising:a primer layer applied to the panel and to the at least one chamfer, preferably directly below the decorative printing layer as seen from the panel.

21. The panel according to claim 1, further comprising:a varnish layer applied to the panel and to the at least one chamfer, preferably directly above the decorative printing layer as seen from the panel.

22. The panel according to claim 1, further comprising:a wear layer applied to the panel and to the at least one chamfer, preferably directly above the varnish layer as seen from the panel;wherein optionally the wear layer is applied by means of melt lamination or adhesive lamination, wherein the wear layer is optionally based on cast polypropylene.

23. A method for manufacturing a panel, in particular wall, ceiling, furniture or floor panel, comprising the following steps:providing a support panel, such as a medium density fiber (MDF) panel, a high density fiber (HDF) panel or a particle panel;processing the panel to provide the panel with at least one chamfer on at least one edge;applying a decorative printing layer to the panel and to the at least one chamfer.

24. The method according to claim 1, wherein the applied decorative printing layer is substantially continuous at a transition of the panel and the at least one chamfer.

25. The method according to claim 23, wherein the decorative printing layer comprises a decorative pattern and the decorative pattern is substantially continuous at a transition of the panel and the at least one chamfer.

26. The method according to claim 23, wherein the applying of the decorative printing layer to the panel and to the at least one chamfer is carried out substantially at the same time and / or no other method step is carried out in between.

27. The method according to claim 23, wherein the decorative printing layer is applied to the panel and to the at least one chamfer by means of rotogravure printing, flexographic printing and / or digital printing, preferably by digital printing.

28. The method according to claim 23, wherein the providing of the support panel comprises:formatting an initial support panel into one or more support panel(s).

29. The method according to claim 23, further comprising:profiling the panel to provide a connecting structure on at least one side surface of the panel, wherein the side surface is substantially parallel to a thickness (t) of the panel, preferably prior to the step of applying the decorative printing layer.

30. The panel or the method according to claim 23, wherein the decorative printing layer and / or the decorative pattern imitates a wood pattern.

31. The panel or the method according to claim 1, wherein the panel has a thickness (t) of at least 4 mm, and / orat most 12 mm.

32. The panel or the method according to claim 1, wherein the panel has a width (wp) of at least 4 cm, and / orat most 200 cm.

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