ES2401153T3 - Cladding panel with beveled edges of cross section that vary visibly with respect to the end edge, and method of manufacturing thereof - Google Patents

Abstract

Panel (1) intended to be used in an assembly of panels (1) fixed together to form a lining, comprising an upper surface (2) and a lower surface (3), each extending in a different main plane, and to the minus one edge (4) between these surfaces comprising coupling means (5, 6) for coupling the panel (1) to the coupling means (5, 6) of another panel (1), where the upper surface (2) includes a low part (7) on said edge (4) of the panel (1), the cross section of the low part (7), perpendicular to the edge (4) of the panel (1), varies along the edge (4) , where the lower part (7) has an end edge (9) that is intended to be positioned against an end edge (9) of an adjacent panel (1), said end edge (9) has a constant position in each cross section , where the lower part (7) has an inclined extension to form a V groove between the panels (1), which V groove has an in section upper (10) and an upper section (11) having a variable cross section, and where the acute angle of the lower section (10) with respect to the upper surface (2) is greater than the acute angle of the upper section (11 ) with respect to the upper surface (2), characterized in that a line along which the lower section (10) cuts the upper section (11) varies visibly with respect to the extreme edge (9) to improve the natural appearance of the panel.

Description

Cladding panel with bevelled edges of cross section that vary visibly with respect to the extreme edge, and method of manufacturing thereof.

[0001] The invention relates to a panel intended to be used in an assembly of panels fixed together to form a coating, according to the preamble of claim 1.

[0002] The invention also relates to a method of realizing these panels.

[0003] Such panels are known in various embodiments, for example in the form of laminated floor panels. Such panels were manufactured on a wooden base and have a decorative layer essentially provided to mimic natural panels made of wood or other natural materials.

[0004] WO 2006/066776 refers to a laminated floor panel comprising a decoration representing a wooden structure. The panel comprises an inclined flange part whose shape and / or angle can be altered depending on the longitudinal direction of the flange.

[0005] WO 2006/031169 refers to a decorative laminated board with edges, a top decorative layer and a back layer. Default parts of the upper decorative layer are provided with a raised surface by means of a laser beam.

[0006] WO 03/078761 refers to floor boards that consist of a center and a surface layer and are provided with decorative joint edges that are formed by removing the surface layer.

[0007] An object of the present invention is to provide a panel that mimics an even better natural panel.

[0008] To achieve this object the invention provides a panel having the characteristic corresponding to the characterization part of claim 1.

[0009] The lower part of the panel according to claim 1 has a non-planar structure along the edge, which improves the natural appearance of a panel. The advantage is that the panels according to the invention provide a better imitation of natural panels than those with a flat bottom.

[0010] The cross section of the lower part may vary along the edge length irregularly, preferably randomly, for example a rustic design. This further improves the natural appearance of a panel.

[0011] The lower part may have an end edge that is intended to be positioned against an end edge of an adjacent panel, which end edge has a constant position in each cross section. The result of this feature is that the end edge of each of the panels in a panel assembly can be coupled together to form the coating such that the coating is sealed between panels adjacent to the end edge. This prevents a water leak or the like between the panels. On the other hand, this feature has the advantage of avoiding the exposure of a part of the

[0012] panel edge if the end edge of adjacent panels have varying positions in different places with respect to each other along the edge.

[0013] The upper surface of the panel can be provided with a surface decoration, while the lower part can be provided with a surface finish. In this way, the production method can be applied to apply the surface decoration to the panel as is known in the art, while the lower part can be finished by a separate process.

[0014] Alternatively, a panel intended to be used in an assembly of panels fixed to each other to form a liner, comprises an upper surface and a lower surface that extend each within a different main plane, and at least an edge between these surfaces comprising coupling means for coupling the panel to the coupling means of another panel, where the upper surface includes a lower part on said panel edge, where the lower part crosses the main plane of the upper surface to the along a second line and crosses an end edge of the panel that is intended to be positioned against an end edge of an adjacent panel along a third line, where the extension of the second line deviates from the extension of the third line . In this embodiment the second line between the upper surface and the lower part can be used to improve the natural appearance of a panel.

[0015] The invention also provides a method of realizing a panel for use in a coating, as defined in claim 7.

[0016] This method can provide panels whose advantages are as mentioned above.

[0017] The lower part can be provided with a cover, such as a sheet or paint, which is helpful as it protects the panels from dirt, water and the like. For aesthetic reasons, this can be for example a rustic design.

[0018] In a preferred method, the top surface of the panel is provided with a surface finish before applying the coating on the bottom, where the top end surface is provided with a non-adhesive before coating the bottom, and any surface finish. surface applied on the adhesive is removed, for example by brushing. The advantage of these stages is that they simplify the method of manufacturing the panels according to the invention. As the cross section of the lower part along the edge varies, the width of the lower part as can be seen in one direction along the edge of the panel may vary. Consequently, the width of the sheet or the amount of paint may vary along the edge of the panel. Due to the application of the adhesive, the width of the sprayed sheet or paint can be locally greater than the width of the lower part as mentioned above, since an excess of sheet or paint can easily be removed from the next upper surface to the lower part, for example by brushing. Of course, if there is no problem with respect to the adhesion between the cover and the lower part, other methods can be devised for the application of a cover in the lower part preferably to the use of a non-adhesive.

[0019] Preferably, the edge is manufactured by means of a milling tool, which moves either in a direction towards and away from the edge during milling of the edge, or the milling is carried out by means of a rotary milling tool with teeth around its circumference that have a variable distance from the rotary center of the tool. The advantage of applying this technique is that a rapid manufacturing process is provided to obtain the desired structure of the lower part as mentioned above, thus minimizing production costs.

[0020] The invention will be explained below in reference to the very schematic annexed drawings.

Fig. 1 is a very schematic perspective plan view of two adjacent panels according to the invention.

Fig. 2 is a cross-section in perspective of larger scale along line II-II of Fig. 1.

Fig. 3a is a very schematic side view of a panel, illustrating an alternative machining phase, showing the inverted panel.

Fig. 3b is a lower scale view as shown in Fig. 2, illustrating adjacent panels that are manufactured according to an alternative single machining phase as illustrated in Fig. 3a. The panels are not part of the present invention.

Fig. 3c is a view as shown in Fig. 2, illustrating adjacent panels manufactured according to another alternative machining phase as described in Fig. 3a.

Figures 4a-4c are very schematic sectional views of two panels in different manufacturing phases, in which the inverted panels are shown.

Figures 5a-5b are very schematic sectional views of a panel and a pressing tool, illustrating the process of fixing a sheet in the lower part.

Fig. 6a is a very schematic side view of an apparatus used to apply and glue the sheets on a low part of a panel.

Fig. 6b is a view partially similar to Fig. 6a, in which the way in which two different parts of a panel are pressed is illustrated.

Fig. 6c is a very schematic side view of an apparatus almost similar to that of Fig. 6b, but including a simple belt.

Fig. 6d is a very schematic side view of an apparatus almost similar to that of Fig. 6c, but including a shorter single strap as can be seen in a direction of movement, illustrating the way in which they are pressed Two different parts of a panel synchronously.

Fig. 7 is a very schematic side view of an embodiment of a milling tool for machining the edge of a panel to form the lower part.

[0021] Fig. 1 illustrates two adjacent panels 1 of an embodiment of the panel according to the invention. The panels 1 as shown in Fig. 1 are fixed to each other and can be part of a coating when a plurality of panels are thus fixed to each other. Generally, the panels will be rectangular, square or elongated or an intermediate point between them. However, other forms can be conceived.

[0022] Fig. 2 illustrates a cross section of the assembly of panels 1 as shown in Fig. 2 on a larger scale in more detail. Each panel 1 comprises an upper surface 2 and a lower surface 3. These surfaces 2, 3 each extend in different main planes. In the embodiment shown in Fig. 2, the main parts of the upper surface 2 and lower surface 3 are parallel to each other and separated in the direction

Y. The upper and lower surfaces 2, 3 are substantially flat surfaces. The panel comprises an edge 4 between both surfaces. The edge 4 has coupling means for coupling the panel 1 to coupling means of the adjacent panel 1, as shown in Fig. 2. The coupling means are well known in the art, for example formed by a tongue 5 and a slot 6 and are not part of the present invention. Of course, panel 1 can be provided with various types of coupling means and locking means for joining panels 1 together.

[0023] The upper surface 2 includes a lower part 7 in at least one, but preferably in all the edges 4 of the panel. Fig. 2 shows that the upper surface 2 comprises a substantially flat surface part 8 and the lower part 7. The lower part 7 is located below the flat surface part 8 of the upper surface 7 as can be seen in the direction Y.

[0024] The upper surface 2 of panel 1 has a surface decoration that mimics natural materials, such as wood. This surface decoration may include a laminate of layers of paper impregnated with resin. The remaining part of panel 1 below the upper surface 2 may include a core comprising one or more layers of MDF, HDF, HTSP, PVC, compounds or the like, and possibly an equilibrium layer.

[0025] According to the invention the cross section of the lower part 7, perpendicular to the edge of the panel, varies along the edge 4. In Fig. 2, the edge 4 extends in the Z direction. It can be seen that the lower part 7 has a non-planar structure seen along the edge 4. This provides a natural appearance to the panels 1. The embodiment of the panel 1 as shown in Fig. 2 has a low part 7 whose cross section varies irregularly. Preferably, it varies randomly to provide a more natural look to panel 1.

[0026] In the embodiment as shown in Fig. 2 the lower part 7 has an end edge 9, which is placed against an end edge 9 of the adjacent panel 1. The end edge 9 is straight and therefore has the same position in each cross section to obtain an appropriate seal between adjacent panels 1. It can be seen in Fig. 2 that the end edge 9 has a fixed position with respect to the bottom surface 3 since the end edge 9 extends parallel to the lower surface 3 and the upper surface 2, while the rest of the lower part 7 varies randomly.

[0027] In the embodiment of Figure 2, the lower part 7 has an inclined extension as can be seen from the end edge 9 to the upper surface 2. A V-groove is thus obtained between the panels 1 when they are joined each. In addition, a lower section 10 of the V-groove that is adjacent to the end edge 9 has a flat shape and a constant cross section along the edge 4. An upper section 11 of the lower part 7, which is located between the section lower 10 and the flat surface portion 8 of the upper surface 2, has a variable cross section along the edge 4. The angle of the lower section 10 with respect to the upper surface 2 is greater than the angle of the upper section 11 with respect to the upper surface 2, for example 35-85 ° and 15-40 °, respectively, but obviously, other angles are also possible. The width of the lower part 7 in the plane X, Y along the edge 4 can vary from about 2 mm, for example, but obviously other dimensions are conceivable.

[0028] Fig. 2 also shows that the lower part 7 crosses the upper surface 2 in a second line 12. The end edge 9 forms a third line. It can be seen that the extension of the second line 12 deviates from that of the end edge 9 to form the desired non-flat structure of the lower part 7.

[0029] According to the invention, the panel 1 as described above can be carried out by the following phases consisting of: machining the edge 4 to form coupling means 5, 6: providing on the upper surface 2 a lower part 7 in the edge 4; and machining of edge 4 to provide a variable cross section perpendicular to edge 4 of panel 1 in the lower part 7. The structure of the lower part 7 in Fig. 2 can be obtained by performing the following phases: first the machining of the flat bottom section 10 through the panel 1 along a milling tool that has a fixed position with respect to the step panel 1, then passing through the panel along a milling tool that moves in a direction to and from panel 1 in order to form the upper section 11.

[0030] Alternatively, the lower part 7 can be carried out in a single machining phase that is not part of the claimed invention. This is illustrated in Fig. 3a. The lower part 7 is formed by a milling tool 21, which has a fixed position with respect to the position of the end edge 9 of the panel 1. The milling tool 21 can rotate around the end edge 9 as shown by the arrow of double head in Fig. 3a. This alternative machining method produces panels whose lower part 7 having a non-flat structure between the second line 12 and the end edge 9 that has maintained its original shape, in this case a straight line. This machining method produces a panel 1 as illustrated in Fig. 3b.

[0031] Referring to Fig. 3a, the milling tool 21 can also be rotated on a line extending parallel to the end edge 9 between the end edge 9 and the top surface 2. This produces a panel 1 as illustrated. in Fig. 3c. In this case the inclined lower section 10 is machined in a previous machining phase.

[0032] Normally, the upper surface 2 of a large sheet whose panels 1 will be sawn later, is initially provided with a surface decoration 13 before sawing said panels 1. After machining the edge 4 to form the lower part 7, the lower part 7 is preferably provided with a surface finish, such as a cover 14 comprising a sheet 14a or paint. This protects the material of the panel 1 against dirt and liquids or the like that can penetrate the panel 1. A color or decoration is also provided in the lower part 7 which adapts to the decoration of the upper surface of the panel.

[0033] Because the cross section of the lower part 7 of the panel 1 along the edge 4 varies, the required amount of coverage 14 or paint per unit of length along the edge 4 provided in the lower portion 7 a along the edge 4 varies too. According to the invention, the surface finish can be provided on the upper surface 2 before providing the coating 14 on the lower part 7, while the upper final surface 2 is provided with a non-adhesive before applying the coating on the lower part 7 After coating the lower part 7, a part of the cover 14 can be provided on the upper surface 2 close to the lower part 7 - the flat surface part 8 - which was previously coated with the adhesive. The remaining cover 14 on the upper surface 2 can be easily removed from the upper surface 2 next to the adhesive, for example by brushing.

[0034] Preferably, the anti-adhesive is applied on the upper surface 2 before machining the edge to form the lower part 7, since in this case the lower part 7 is performed automatically without anti-adhesive during the machining, while the surface part Flat 8 remains covered with the adhesive. These phases are illustrated in Fig. 4. Fig. 4a shows that the upper surfaces 2 of two panels 1 are covered by the non-stick near the edges before machining the edges 4 and form the lower part 7 that will be note that the panels are shown inverted in Fig. 4�. The adhesive can be applied to the upper surface 2 by the use of a spraying apparatus 15. Fig. 4b illustrates the panels 1 after providing the coupling means 5, 6 and the lower part 7. Fig. 4c illustrates the process of applying a sheet 14a in the form of coverage 14 on the bottom 7.

[0035] Figures 5a and 5b illustrate the process of applying a sheet 14a on the lower surface 7 in more detail. Fig. 5a illustrates the pressing process of the sheet 14a on the panel 1 by two pressing tools separated 15 one behind the other seen in the direction along the edge 4. Each of the pressing tools 15 has surfaces of substantially flat pressing 16, which can be angular with respect to each other to create a pressing surface 16 corresponding to the shape of the bottom 7. Fig. 5b shows the pressing process of the sheet 14a on the panel 1 by a single pressing tool 15 having a deformable pressing surface 16 that adapts to the variable shape of the lower part 7.

[0036] Fig. 6a is a very schematic side view of an apparatus intended for the application of a sheet in a lower part 7 of a panel 1. A sheet 14a is applied from the left side by a roller 17 comprising a sheet 14a . The sheet 14a has a width of 8-10 mm, for example, although other dimensions are conceivable. The panels 1 are also provided from the left side `` not shown '' and move from left to right at the same speed as the speed of the sheet 14a. Fig. 6a also shows that the apparatus comprises pressing belts 18 and pressing rollers 19 that press the belt 18 against the sheet 14a on the lower part 7 of the panel 1. The apparatus also comprises heating elements 20 to support a process of adhesion of the sheet 14a with the panel 1. The heating elements 20 are able to maintain the temperature of the sheet at a constant level during the adhesion process. In addition, Fig. 6a shows two belts for the case in which the lower part 7 is provided with a lower section 10 and an upper section 11, each with different angles with respect to the upper surface 2, as illustrated in the Fig. 5a. A belt 18 may be provided to press the sheet in the lower section 10 and the other belt 18 may be provided to press the sheet 14a in the upper section 11. This is illustrated in Fig. 6b. Alternatively, the apparatus can be provided with only a deformable endless belt 18 and pressure rollers 19 where the axes of rotation of the pressure rollers 19 can be inclined relative to each other to press the belt 18 into a low part 7 whose lower section 10 and upper section 11 have different angles with respect to the upper surface 2, as shown in Fig. 5b. This apparatus is illustrated in Fig. 6c. In this apparatus, the orientation of a part of the belt 18 that presses the sheet 14A changes along its direction of movement between the set of wheels on the left and the set of wheels on the right in Fig. 6c.

[0037] Another alternative embodiment of the apparatus comprises a pressing belt 18, which is capable of pressing the sheet synchronously in the lower section 10 and the upper section 11 whose angles are different with respect to the upper surface 2, as illustrated in Fig. 6d. In this case the pressing belt 18 is made of a more flexible material.

[0038] According to the invention the non-flat structure of the lower part 7 is made by machining the edge 4 by a milling tool 21, which can be moved in a direction towards and away from the edge 4, and along the edge 4 to Same time. This method produces a structure of the lower part 7, as shown in Fig. 2. An alternative method was explained above in reference to Fig. 3a. A rotary milling tool 21 can also be applied, as shown in Fig. 7. This embodiment of the milling tool 21 is provided with teeth 22 around its circumference, which have a variable distance d with respect to a Rotary center 23 of the milling tool 21. The amount of material cut by the milling tool can thus be varied by changing the rotational position of the milling tool 21 during the passage of a panel 1 along the tool of milling 21 while the rotary center remains in the same place.

[0039] In an alternative embodiment, the second line of the panel may be parallel to the end edge, while a part of the lower part between the second line and the end edge has a non-planar structure.

[0040] As seen above, the invention clearly provides a panel that presents an optimal imitation of a panel made of natural materials. In addition, the invention provides an appropriate manufacturing method of this panel.

[0041] The invention is not limited to the embodiments described above, which may vary in many ways included in the field of the claims.

Claims (11)

one.

Panel �1� intended to be used in an assembly of panels �1� fixed together to form a coating, comprising an upper surface �2� and a lower surface �3�, each extending in a different main plane, and at minus one edge �4� between these surfaces comprising coupling means �5, 6� for coupling the panel �1� to the coupling means �5, 6� of another panel �1�, where the upper surface �2� includes a low part �7� on said edge �4� of the panel �1�, the cross section of the lower part �7�, perpendicular to the edge �4� of the panel �1�, varies along the edge �4� , where the lower part �7� has an end edge �9� that is intended to be positioned against an end edge �9� of an adjacent panel �1�, said end edge �9� has a constant position in each cross section , where the lower part �7� has an inclined extension for fo Sign a V groove between the panels �1�, which V groove has a lower section �10� and an upper section �11� that has a variable cross section, and where the acute angle of the lower section �10� with respect to the upper surface �2� is greater than the acute angle of the upper section �11� with respect to the upper surface �2�, characterized by the fact that a line along which the lower section �10� cuts the upper section �11� varies visibly with respect to the extreme edge �9� to improve the natural appearance of the panel.

2.

Panel �1� according to claim 1, wherein the cross section of the lower part �7� varies along the length of the edge �4� irregularly, preferably randomly.

3.

Panel �1� according to claim 1 or 2, wherein the upper surface �2� of the panel �1� is provided with a surface decoration �13�, while the lower part �7� is provided with a surface finish � 14�.

Four.

Panel �1� according to any of the preceding claims, wherein the extension of a second line �12�, along which the upper surface �2� cuts the upper section �11�, deviates from the extension of the end edge �9� to form a non-flat structure of the lower part �7�.

5.

Panel �1� according to any of the preceding claims, wherein the cross section of the upper section �11� varies parallel to itself along the edge �4�.

6.

Panel �1� according to any of claims 1-3, wherein a second line �12�, along which the upper surface �2� cuts the upper section �11�, extends parallel to the extreme edge �9� , while a part of the lower part between the second line and the end edge has a non-flat structure.

7.

Method of manufacturing a panel �1� intended to be used in a coating, comprising the steps consisting of:

provide a panel �1� comprising an upper surface �2� and a lower surface �3� each extending in a different main plane, and at least one edge �4� between these surfaces �2, 3�, machining the edge �4� to form coupling means �5, 6� to couple the panel �1� to the coupling means �5, 6� of another panel �1� and providing the upper surface �2� with a low part �7� to said edge �4� of panel �1�, where the edge �4� is manufactured in such a way that the lower part �7� is provided with a transverse section perpendicular to the edge �4� of the panel �1� which varies along the edge �4� of the panel �1� , where the lower part �7� is formed by firstly machining a lower section �10� of the lower part �7� such that the lower part �7� has an end edge �9� provided to position itself against an end edge �9� of an adjacent panel �1� and where said end edge �9� is straight and has the same position in each cross section, characterized by the fact that an upper section �11� with a Variable cross section along the length of the edge �4� is formed later, so that the line along which the lower section �10� cuts the upper section �11� varies visibly with respect to the extreme edge � 9� to improve the natural appearance of the panel.

8.

Method according to claim 7, wherein the upper section �11� is manufactured by means of a milling tool �21�, which moves in a direction to and away from the edge �4� during milling of the edge �4�, or either it is carried out by means of a rotary milling tool �21� with teeth �22� around its circumference that have a variable distance �d� from the rotary center �23� of the tool.

9.

Method according to claim 7, wherein the upper section �11� is manufactured by means of a milling tool �21� that rotates around a line that extends parallel to the end edge �9� between the end edge �9� and the upper surface �2�.

10.

Method according to one of claims 7-9, wherein the lower part �7� is provided with a �14� coverage, such as a �14a� sheet or paint.

eleven.

Method according to claim 10, wherein the upper surface �2� of the panel �1� is provided with a finish of

surface �13� before the application of coverage �14� in the lower part �7�, the upper final surface �2� being provided with a non-adhesive before coating the lower part �7�, and any coverage � is removed 14� applied to the adhesive, for example by brushing.