Patent Description:
More particularly, the invention relates to floor panels of the type which is at least composed of a substrate and a decorative top layer forming a decorative surface, wherein said top layer comprises a motif. Above said motif a transparent or translucent synthetic material layer may be provided, which layer then forms part of said top layer.

In particular, the present invention relates to floor panels of the type which, at two or more opposite edges, comprises coupling means or coupling parts, with which two of such floor panels can be coupled at the respective edges, such that they are locked together in a horizontal direction perpendicular to the respective edge and in the plane of the floor panels, as well as in a vertical direction perpendicular to the plane of the floor panels. Such floor panels can be applied for composing a so-called floating floor covering, wherein the floor panels are interconnected at their edges, however, are lying freely on the underlying floor.

From <CIT>, <CIT> and <CIT>, laminate floor panels are known for forming a floating floor covering. However, laminate floor panels show the disadvantage that they mostly are provided with a moisture-sensitive substrate, namely MDF or HDF (Medium Density Fiberboard or High Density Fiberboard), and that the top layer provided on said substrate, when the floor covering is in use, leads to the development of ticking noises. From <CIT>, it is known to provide laminate floor panels with a bevelled edge portion that is formed by removing a material portion from the edge of the floor panel, to thereby expose a portion of the core material. From <CIT> it is known to form bevelled edge portions by compressing the core material, such that the top layer extends uninterruptedly from the global surface of the panel to and over the bevelled edge portion.

From <CIT>, vinyl-based floor panels are known for forming such floating floor covering. Such vinyl-based floor panels mostly have a thickness of <NUM> to <NUM> millimeters and have a high material density. <CIT> and <CIT> disclose decorative panels having a foamed core. <CIT> discloses that vinyl-based floor panels may be provided with a bevelled edge portion as well, either by machining away a material portion and exposing a layer underlaying the motif, or by deforming the surface of the panel such that the motif extends also over the bevelled edge portion.

<CIT> discloses a method for manufacturing a resilient floor tile, wherein said tile comprises a substrate and a decorative top layer, wherein said substrate is a thermoplastic material containing substrate. The method of US'<NUM> comprises a step of providing a larger material comprising said substrate and said decorative top layer by means of a continuous operation including an extrusion operation and a lamination operation. The larger material is divided and provided with lower edge areas at both upper edges of a pair of opposite side edges by means of a press die.

The present invention relates to an alternative method of manufacturing a decorative panel, which in particular is intended as a floor panel for forming a floating floor covering. According to various preferred embodiments of the invention, also a solution is offered for one or more problems with the floor panels and their method of manufacture of the state of the art.

To this aim, the invention is defined in the appended claims and relates to a method for manufacturing a decorative panel, wherein said panel comprises a substrate and a decorative top layer, wherein said substrate is a thermoplastic material containing substrate, wherein said substrate and decorative top layer is obtained from a larger material by means of a dividing operation, wherein said panel comprises at at least one and preferably at both upper edges of a pair of opposite side edges a lower edge area, wherein said lower edge area is obtained prior to said dividing operation. Obtaining the lower edge area while the decorative panel material still forms part of a larger material allows for a more fluent production process. For example any bulging out or unwanted deformation of the larger material due to the forming of the lowered edge area can be concentrated in a part of the larger material which is destined to be removed in subsequent steps, for example in said dividing operation or afterwards. Further the method of the invention allows to position the dividing operation with respect to said upper edges having said lower edge area, e.g. such that opposite side edges have a lower edge area of predetermined size or shape. Further, in the cases where such larger material contains two or more decorative panels, lower edge areas at two or more upper edges of said two or more decorative panels can be formed in the same operation. In such case the lower edge areas can be made to resemble closely with limited effort. In light of the invention, and throughout the description, the term "cut edge" indicates the edge along which a slab of substrate material is physically cut from a larger material, e.g. a larger slab of substrate material, by means of a dividing operation. The term "upper edge" relates to the edge that is formed on the upper side of the panel, and along which the lower edge area is adjacently formed.

Said dividing operation comprises performing a cutting operation releasing at least said substrate from said larger material at at least two opposite side edges.

Preferably, said cutting operation forms opposite cut edges for releasing said at least two opposite side edges, wherein said opposite cut edges are positioned at a mutually different distance from said upper edges of said panel. The different distances allow for formation of profiled edges horizontally extending differently beyond the respective upper edge, with a minimized material loss.

Said dividing operation comprises a cutting operation, more particularly a punching operation, namely an operation in which a stationary, i.e. non-rotating, cutting blade or knife is pressed down to, into and through the material to be cut.

The lower edge area can be formed using one or more of a variety of different methods, of which here below some important possibilities are described without desiring to be exhaustive.

According to a first possibility not pertaining to the invention as claimed, said lower edge area is formed simultaneously with, i.e. during said dividing operation, or practically simultaneously with said dividing operation. In this manner, a very accurate positioning of the cut edge relative to the upper edge of the panel can be obtained. With the forming tools being engaged with the larger material at least during part of said dividing operation, the respective lowered edge area is considered to be formed simultaneously with or during the dividing operation, and the lowered edge area is considered to be obtained during said dividing operation. With the forming tools engaging with the larger material while the larger material is within the dividing apparatus and/or aligned with the operational position of the cutting tools, and disengaging prior to the engagement of the cutting tools with said larger material, the respective lowered edge area is considered to be formed, at least in part, prior to, but practically simultaneously with said dividing operation. In light of the invention, and throughout the description, the terms "simultaneously with" and "during" in relation to forming the lower edge area and the dividing operation are to be interpreted in that said forming the lower edge area and the dividing operation are performed preferably at the same time and/or are at least partially overlapping. The term "practically simultaneously with" herein indicates that a slight time gap between the dividing operation and the forming of the lower edge area is allowed, however while still obtaining a very accurate positioning of the cut edge relative to the upper edge of the panel. Such a slight time gap may constitute a gap of less than <NUM>,<NUM> second, preferably of less than <NUM>,<NUM> seconds, of less than <NUM>,<NUM> seconds, of less than <NUM>,<NUM> seconds, of less than <NUM>,<NUM> seconds, or of less than <NUM>,<NUM> seconds. Such a slight time gap may also constitute a gap of less than <NUM>% of the duration of the forming the lower edge area and/or of the dividing operation, preferably of less than <NUM>%, less than <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or less than <NUM>%.

According to a practical embodiment, for example of said first possibility, said dividing operation comprises:.

Preferably, said indenting is executed by means of a mold or mold portions that press down on said substrate and/or said decorative top layer. Said mold or mold portions may be engaged with said substrate and/or said decorative layer at the start of said cutting operation, and are preferably still engaged at the end of said cutting operation. With the mold or mold portions being engaged with the larger material at least during part of said cutting operation, the respective lowered edge area is formed, at least in part, simultaneously with or during the dividing operation. In this manner the material to be cut may be kept stationary, and an accurate positioning of the cut edge may be obtained. Preferably, said mold or mold portions are movable with respect to said cutting tool. Preferably, said mold or mold portions are substantially at standstill during the cutting operation, i.e. while the cutting tool is moved into and through said substrate and/or decorative layer.

According to a second possibility and in accordance with the invention, said lower edge area is formed in line with and prior to said cutting operation releasing at least said substrate from said larger material at at least two opposite edges. The inline operation allows for an accurate positioning of the cutting operation with relation to the lower edge areas or the final upper edges of the decorative panels to be obtained.

In accordance with said second possibility and in accordance with the invention, the formation of the lower edge area is formed using a continuous forming or deforming operation. Said lower edge area is formed by means of one or more structured rollers indenting said larger material. Such operation can fluently be arranged in-line with a continuous operation, for example with an extrusion and lamination operation for forming the larger material. The rollers form the lower edge area while the larger material is fed passed the respective equipment.

In accordance with said second possibility, said cutting operation is preferably performed by means of a plurality of, preferably rotating, cutting tools. The cutting tools may be saw blades or rotating knives. Preferably, said cutting tools are positioned to form opposite cut edges at predefined distances from said upper edges of said decorative panel.

The position of said cutting tools maybe controllable and/or controlled on the basis of an upstream portion of said larger material. The cutting tools may for example be controlled to attain said predefined distances between a cut edge and a respective upper edge. The upstream portion of said larger material may be recorded by means of optical or tactile sensors, such as by means of one or more camera's or feeling gauges. The upstream portion preferably comprises a portion within or at a fixed distance of an available lower edge area and/or upper edge to be obtained. The upstream portion may be detectable because of its relief, in the case of a lower edge area for example because it extends beneath the global surface of the larger material, or because of its decoration or marking.

As already mentioned above, the method of the invention further comprises a step of providing a larger material comprising said substrate and decorative top layer by means of a continuous operation including one or more extrusion operations and/or lamination operations.

Iin accordance with said second possibility and in accordance with the invention, said lowered edge area and said cutting operation is performed in line with said step of providing said larger material.

According to a special embodiment of said first or second possibility, said lowered edge area is formed by indenting material at an edge of a pre-machined portion of said larger material. By means of pre-machining a portion of material can be taken away at the location where the lower edge area is to be formed. In this manner less material must be displaced to form the lower edge area, and a more accurate result may be obtained with less power needed for the deformation. Preferably, said pre-machined portion is performed from the top of said larger material at least into said substrate. Preferably, said pre-machined portion comprises an undercut, i.e. a portion available vertically beneath a remaining top surface portion of said larger material.

According to said second possibility, said method may further comprise a step of providing a larger material comprising at least said substrate, wherein said substrate is provided with lowered substrate areas at the location of said lower edge area, prior to application of said decorative top layer to said substrate. According to a variant not pertaining to the invention, said method may further comprise a step of providing a larger material comprising at least said substrate, wherein a decorative top layer is applied to said substrate, wherein said decorative top layer or a portion thereof comprises a structure prior to application thereof to said substrate. Preferably, said structure of said top layer or the respective portion thereof includes said lowered edge area. Preferably, at least in case of said variant, said decorative top layer comprises a plurality of layers and comprises a motif. A layer underlaying said motif may comprise thinned portions or openings basically corresponding to the structure of said lowered edge area. Such thinned portions or openings may limit the needed deformation and power to obtained the lowered edge area or areas. Preferably, at least two, and preferably all of said plurality of layers are laminated to each other, prior to their application to said substrate.

According to a third possibility, not pertaining to the invention, said method further comprises a step of providing a larger material comprising said substrate and/or decorative top layer by means of a continuous or discontinuous pressing operation wherein a plurality of prefabricated layers are adhered to each other. Preferably, said lower edge area is formed simultaneously with said pressing operation. Preferably said pressing operation is a discontinuous pressing operation, for example by means of a single daylight or multiple daylight press. Such press may comprise at least one pressing element associated to each larger material to be pressed, in the case of a single daylight press, at least a pressing element for coming into contact with the decorative top layer, and potentially a pressing element for coming into contact with the bottom of the larger material to be pressed. Such press element, especially the press elements coming into contact with the decorative top layer, may be structured, for example it may concern a structured press plate or a structured foil. The pressing operation may be a heated press operation, potentially followed by a cooling operation under pressure, preferably in the same or in a separate, but similar press.

According to the method of said third possibility, preferably at least one of said prefabricated layers may comprise thinned sections and/or removed sections, preferably at least at the location where said lower edge area is obtained or to be obtained. Such thinned portions or removed sections may limit the needed deformation and power to obtained the lowered edge area or areas. Preferably, said at least one of said prefabricated layers is a thermoplastic layers from which sections have been removed by means of a cutting operation, more particularly a punching operation. Preferably, said at least one of said prefabricated layers is a one-piece layer.

In general, independent from the fact whether one of the above possibilities are used, said larger material is preferably provided with a reference portion prior to said dividing operation. Such reference portion may aid in positioning the larger material with respect to further operations. Preferably, said reference portion is used to align the larger material to the dividing operation or part thereof, more particularly to one or more cuts performed therein, or vice-versa, namely wherein said reference portion is used to align one or more cutting tools performing said cuts to the larger material, or both. For example, said aligning may be such that the lower edge area is parallel to one or more of the cuts performed in said dividing operation.

Said reference portion may comprises an indentation or excavation provided in the bottom of said larger material. According to a variant or in combination with the aforesaid, said reference portion may comprise an edge of said larger material. According to another variant, said reference portion comprises a visual or tactile marking available at the side of said larger material that comprises said lower edge area.

Preferably, said reference portion is provided at a predefined distance from an upper edge of said panel.

Preferably, said reference portion cooperates with a stop or guiding tool in said dividing operation. The reference portion may therefore be performed as an excavation for engagement with a portion of a stop or guiding tool, be it in said dividing operation or in another operation.

In accordance with the invention, said decorative top layer continues uninterruptedly from on the global upper surface of said panel to and over said lower edge area.

Preferably, said lower edge areas are formed as straight or curved chamfers. According to a variant the lower edge areas may be formed with an L- shape, i.e. with a horizontal, or substantially horizontal bottom adjoining the upper edge and an upwardly extending wall portion at the proximal side of the lower edge area.

Preferably, said lower edge areas are available at both edges of a pair of opposite upper edges, wherein said lower edge areas at opposite upper edges mutually extend to a same depth and/or over a same horizontal distance, as measured perpendicularly to said upper edge. In the case of lower edge areas formed as straight or curved chamfers, a so-called V-groove may be formed when two lower edge areas of similar panels are adjacent in a covering formed from such decorative panels.

For example in the case of L-shaped lower edge areas, they may be available at one or both edges of a pair of opposite upper edges. With an L-shaped lower edge area an imitation of a grout line, rubber or asphalt joint may be achieved.

Preferably, at least two substrates and top layers for respective panels are obtained or obtainable from said larger material. Preferably the larger material has a practically endless web-shape or a limited length slab-shape, wherein at least in one direction, for example the width direction of the web or slab, four or more rectangular panels can be obtained, wherein the width of the panels is preferably oriented in the same direction as the width of the web or slab.

As is clear from the above, said substrate at the location of said lower edge area is compressed or deformed.

In general, the substrate and/or decorative top layer of the decorative panel of the invention, preferably show one or a combination of two or more of the following properties:.

Said substrate may comprise at least one of an Magnesiumoxychloride or Magnesiumoxysulphate containing board or layer.

In accordance with the invention, said substrate is a thermoplastic material containing board or layer, preferably a filled synthetic composite comprising thermoplastic material and filler material, preferably mineral filler materials, such as sand, talcum, chalk or other forms of CaCO3.

Preferably, said decorative top layer comprises a motif preferably formed by a printed pattern or a wood veneer. Said decorative top layer may comprise a carrier layer upon which said printed pattern is provided and a transparent wear layer applied on top of said printed pattern. Said carrier layer may be a thermoplastic foil, preferably a PVC foil, a paper layer or a wood veneer. Preferably, said wear layer is a thermoplastic foil.

In accordance with a special embodiment, said decorative top layer comprises from bottom to top at least a backing layer, a printed carrier layer and a transparent wear layer. Preferably said backing layer forms the majority of the thickness T of said decorative top layer, or at least <NUM> percent thereof. Said decorative top layer is preferably assembled from said backing layer, printed carrier layer and wear layer by means of thermal lamination, i.e. preferably in the absence of separate glue layers in between said layers. Preferably said decorative top layer, or at least the bottom layer thereof, is connected to said substrate by means of thermal lamination as well, i.e. in the absence of a separate glue layer. However it is not excluded that said decorative top layer, or at least the bottom layer thereof, is glued to said substrate.

In the cases where said decorative layer comprises a backing layer, said backing layer is preferably a thermoplastic layer, preferably of soft PVC, namely PVC with more than <NUM> phr plasticizer, and/or of a thermoplastic foamed material, e.g. foamed PVC.

In accordance with the invention, said lower edge area is formed by means of one or more structured rollers indenting said larger material.

As already mentioned above, the methods of the invention comprise a step of providing a larger material comprising said substrate and/or decorative top layer by means of a continuous operation including one or more extrusion operations and lamination operations. Preferably the step of providing a larger material at least comprises one or more extrusion operations and a lamination operation. During the lamination operation multiple layers may be laminated, at once, subsequently or in any other sequence.

Preferably, the larger material comprises a printed pattern of adjacent rectangular and oblong panels or tiles. For example, a printed pattern applied to a carrier layer, such as a thermoplastic foil. Preferably said lower edge areas are at least available in between adjacent longitudinal edges of said panels or tiles. The longitudinal edges of said panels or tiles may be directed in the feed direction of said continuous operation. According to a variant, the longitudinal edges of said panels are directed transversely to said feed direction. In the latter case the possible stretching of the printed pattern can be controlled in an enhanced manner and the forming operation for said lower edge areas can be executed more accurately, as well as the dividing operation. In the cases where a printed thermoplastic foil is used, for example a printed PVC foil may be used. Such PVC foil may be of the soft type, or of the semi-rigid or rigid type. A rigid type PVC foil, i.e. a PVC foil comprising <NUM> to <NUM> phr of plasticized is preferred in order to minimize possible elongation of the PVC foil during processing, e.g. the lamination.

Preferably, the larger material is a flat web shaped substrate material, for example having a width W of <NUM> to <NUM> meter, preferably about <NUM> meter, and, preferably, a thickness T2 of <NUM> to <NUM>, by preference of <NUM> to <NUM>, more by preference of <NUM> to <NUM>, even more by preference of <NUM>,<NUM> to <NUM>,<NUM>, for example about <NUM>. The flat web shaped substrate material is preferably provided in continuous length, by means of an extrusion operation.

In some embodiments, said dividing operation comprises a stationary cutting operation, more particularly a punching operation, namely an operation in which a stationary, i.e. non-rotating, cutting blade or knife is pressed down to, into and through the material to be cut, and which is transversely oriented with respect to the feeding direction of said larger material. In some embodiments, said dividing operation comprises a non-stationary cutting operation, namely an operation in which a non-stationary, i.e. a rotating, roller is operated, said roller comprising a knife-shaped protrusion, which protrusion is brought intermittently into engagement with the material to be cut through the rotation of the roller, and which is transversely oriented with respect to the feeding direction of said larger material.

In some embodiments, the cutting blade or knife, or the knife-shaped protrusion, may comprise a cutting edge which is substantially parallel to the plane of the larger material to be divided. In some embodiments, the cutting blade or knife, or the knife-shaped protrusion, may have a cutting edge which is not parallel to the plane of the larger material to be divided. Preferably, the cutting blade or knife, or the knife-shaped protrusion, may have a cutting edge which is slightly angled with respect to the plane of the larger material. In particular, the cutting edge may be angled over at least <NUM>,<NUM>° with respect to the plane of the larger material. More in particular, the cutting edge may be angled over at least <NUM>,<NUM>° with respect to the plane of the larger material, over at least <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, <NUM>,<NUM>°, or over at least <NUM>,<NUM>° with respect to the plane of the larger material.

With the intention of better showing the characteristics according to the invention, in the following, as an example without limitative character, several embodiments are described, with reference to the accompanying drawings, wherein.

<FIG> illustrates some steps in a method for manufacturing a decorative panel <NUM>.

As shown in <FIG>, said panel <NUM> comprises a substrate <NUM> and a decorative top layer <NUM>, wherein said substrate is a thermoplastic material containing substrate, wherein said substrate and decorative top layer is obtained from a larger material <NUM> by means of a dividing operation S1, with as a characteristic that said panel <NUM> comprises at both upper edges <NUM> of a pair of opposite side edges a lower edge area <NUM>, wherein said lower edge area <NUM> is obtained prior to or during said dividing operation S1.

Said dividing operation S1 comprises performing a cutting operation releasing at least said substrate <NUM> of said panel <NUM> from said larger material <NUM> at at least two opposite edges.

The cutting operation forms opposite cut edges <NUM> for releasing said at least two opposite edges, wherein said opposite cut edges <NUM> are positioned at a mutually different distance D1-D2 from said upper edges <NUM> of said panel <NUM>. The distance D2 at the upper edge <NUM> where the panel will be provided with a groove <NUM> is larger than the distance D1 at the upper edge <NUM> where the panel will be provided with a tongue <NUM>. The tongue <NUM> and groove <NUM> form part of coupling means with which two of such panels can be coupled at the respective edges, such that they are locked together in a horizontal direction H perpendicular to the respective edge and in the plane of the panels <NUM>, as well as in a vertical direction V perpendicular to the plane of the panels.

The decorative top layer <NUM>, preferably at least the printed pattern <NUM> thereof, continues uninterruptedly from on the global upper surface of said panel <NUM> to and over said lower edge area <NUM>.

Said lower edge areas <NUM> at opposite upper edges <NUM> mutually extend to a same or substantially same depth and/or over a same or substantially a same horizontal distance, as measured perpendicularly to said upper edge <NUM>. Said lower edge areas <NUM> are formed as chamfers, in this case somewhat bent chamfers.

Said lower edge areas <NUM> at opposite upper edges <NUM> may mutually extend to a same or substantially same depth, said depth being between <NUM>,<NUM> and <NUM>,<NUM> below the global upper surface of said panel <NUM>. By preference, said depth may be about <NUM>,<NUM> or <NUM>,<NUM>.

In the example, at least two substrates and/or top layers for respective panels <NUM> are obtained from said larger material <NUM>.

Said substrate <NUM> at the location of said lower edge area <NUM> is compressed or deformed. The bottom of the substrate <NUM> remains undeformed. In this case the bottom of the substrate <NUM> is supported by supporting means <NUM> to this aim.

Said substrate <NUM> and/or decorative top layer <NUM> show the following properties:.

As shown, said lower edge areas <NUM> are formed simultaneously with, or during said dividing operation S1, such in accordance with the first possibility for forming lower edge areas mentioned in the introduction.

Preferably, as shown here, said dividing operation S1 comprises:.

Said indenting is executed by means of a mold or mold portions <NUM> that press down on said substrate <NUM> and said decorative top layer <NUM>. Said mold or mold portions <NUM> are engaged with said substrate <NUM> and said decorative layer <NUM> at the start of said cutting operation, and are preferably still engaged at the end of said cutting operation. For this purpose said mold or mold portions <NUM> are movable with respect to said cutting tool <NUM>. Preferably said mold or mold portions <NUM> are substantially at standstill during the cutting operation, i.e. while the cutting tool <NUM> is moved into and through said substrate <NUM> and decorative layer <NUM>.

As illustrated here said dividing operation comprises a cutting operation, more particularly a punching operation, namely an operation in which a stationary, i.e. non-rotating, cutting blade or knife is pressed down to, into and through the larger material <NUM> to be cut.

In the example of <FIG>, said substrate <NUM> comprises at least a thermoplastic material containing board or layer, preferably a filled synthetic composite comprising thermoplastic material and filler material, preferably mineral filler materials, such as sand, talcum, chalk or other forms of CaCO3. Said decorative top layer <NUM> comprises a motif formed by said printed pattern <NUM>. According to an alternative a wood veneer may be used to form the motif. The printed pattern <NUM> is provided on a carrier layer <NUM> and a transparent wear layer <NUM> is applied on top of said printed pattern <NUM>.

Preferably, the wear layer <NUM> comprises a relief <NUM> applied thereto or realized prior to said dividing operation S1. Said relief <NUM> preferably remains available in the lower edge areas <NUM>, after the molding portions <NUM> are disengaged.

In the example, said decorative top layer <NUM> comprises from bottom to top at least a backing layer <NUM>, a printed carrier layer <NUM> and a transparent wear layer <NUM>, preferably said backing layer <NUM> forms the majority of the thickness T of said decorative top layer <NUM>, or, as is the case here, at least <NUM> percent thereof. The substrate <NUM> is preferably a one piece substrate, i.e. without internal glue layers, and preferably forms the majority of the thickness T1 of the panel <NUM>.

In the example, said backing layer <NUM> is a thermoplastic layer of soft PVC, namely PVC with more than <NUM> phr plasticizer, that also comprises filler materials.

One or more of the cutting tools <NUM> and/or molds or molding portions <NUM> may be heated, but are preferably not heated.

It is further remarked that, in the represented case of <FIG>, the deformation of the substrate <NUM> and decorative layer <NUM>, and the positioning of the coupling means in the decorative panel <NUM> is such that the contact surfaces <NUM>-<NUM> between the top of the tongue <NUM> and the bottom of the upper groove lip <NUM> is formed in the backing layer <NUM>, while the horizonally locking surfaces <NUM>-24A on the lower groove lip <NUM> and the bottom of the tongue <NUM> are formed in the substrate <NUM>.

<FIG> represent an embodiment in accordance with the invention, more particularly in accordance with the second possibility mentioned in the introduction for forming lower edge areas <NUM>. Herein the lower edge area <NUM> is formed in line with, and prior to said cutting operation S1 that releases at least said substrate <NUM> from said larger material <NUM> at at least two opposite edges. The lower edge area <NUM> is formed using a continuous forming operation by means of a structured roller <NUM>. The roller <NUM> comprises mold portions <NUM> at its circumference that press down or deform the larger material <NUM> to create said lower edge areas <NUM>. The roller <NUM> forms the lower edge area <NUM> while the larger material <NUM> is fed passed it in the feeding direction F. The forming operation S2 is arranged in line with an extrusion operation S3 and a lamination operation S4 for forming the larger material <NUM>.

The extrusion operation S3 comprises a feed <NUM> for feeding raw material for the substrate <NUM> to the extruder <NUM>. The raw material is extruded through a so-called flat die or slot die <NUM> into a flat web shaped substrate material, for example having a width W of <NUM> to <NUM> meter, preferably about <NUM> meter, and a thickness T2 of <NUM> to <NUM>, by preference of <NUM> to <NUM>, more by preference of <NUM> to <NUM>, even more by preference <NUM>,<NUM> to <NUM>,<NUM>, preferably about <NUM>. In the lamination operation S4 one or more of a carrier layer <NUM> having a printed pattern <NUM>, a transparent wear layer <NUM> and a backing layer <NUM> may be laminated to the web shaped substrate material to form the larger material <NUM>.

In the example, an optional thickness calibration S5 by means of one or more rollers and/or calibration plates and/or heaters and/or coolers may be performed on the extruded material.

In the example, prior to said forming operation S2, a relief <NUM> is formed at least in said transparent wear layer <NUM> in an embossing operation S6. As illustrated here, the printed pattern <NUM> represents a wood pattern and the relief <NUM> comprises indentations representing wood pores and/or wood grain lines. The indentations may be performed in accordance with the printed pattern <NUM>, to create a so-called embossing-in-register, and a true to nature look of the panels <NUM>. It is of course not excluded that other printed patterns <NUM> are used, such as stone or fantasy patterns, wherein, in such case, also corresponding indentations can be applied, whether or not in register with the printed pattern <NUM>.

As shown in <FIG> and <FIG> the relief <NUM> is formed by means of an embossing roller <NUM>.

Prior to said embossing operation S6 and/or prior to said deforming operation S2 the larger material <NUM>, in particular the decorative top layer <NUM> may be heated, for example by means of infrared or near-infrared radiators <NUM>. In some embodiments, the larger material <NUM> may be heated to a temperature of between <NUM> and <NUM>, by preference of between <NUM> and <NUM>, more by preference of between <NUM> and <NUM>. In a particular embodiment, the larger material <NUM> may be heated to a temperature of about <NUM>.

Whether or not in combination with such heating, the rollers <NUM> and/or <NUM> may be cooled, or at least not heated by any other means than the possibly still hot larger material <NUM> and/or decorative top layer <NUM>.

It is however also possible that the roller <NUM> and/or <NUM> are heated by other means than the possibly still hot larger material <NUM> and/or decorative top layer <NUM>, for example by means of thermic oil at a temperature above <NUM>, or above <NUM>. In such case, a prior heating of the larger material <NUM>, or in particular the decorative top layer <NUM>, may be unnecessary.

Especially in the case of using a heated roller <NUM> and/or a heated roller <NUM> it is preferred that the larger material <NUM> follows a bent path around the respective roller <NUM>-<NUM> for an arc length L corresponding to at least <NUM>°. Such is illustrated here in case of the embossing roller <NUM>, where the larger material <NUM> follows a bent path around the embossing roller for an arc length L corresponding to about <NUM>°.

It is to be noted that at least the embossing roller <NUM> and/or the structured roller <NUM> that forms the lowered edge areas <NUM> is preferably paired with at least one counter roller <NUM>-<NUM>'. Preferably, said at least one counter roller <NUM>-<NUM>' has a rubber surface or mantle and/or has a surface or mantle with a shore hardness A lower than <NUM> at <NUM> degrees Celsius, and even better between <NUM> and <NUM> at <NUM> degrees Celsius. According to a preferred embodiment, said at least one counter roller has a rubber surface and/or has a surface with a shore hardness A of about <NUM> at <NUM> degrees Celsius.

The cutting operation S1 is performed by means of a plurality of rotating cutting tools <NUM>. In this case the cutting tools <NUM> are comprised on a cutting roller <NUM>. It is clear that the cutting operation S1 shown here released the substrate <NUM> from the larger material only at one pair of opposite edges. The cutting operation S1 is more particularly configured to form one or more cut edges <NUM> in the feeding direction F of the larger material <NUM>.

The cutting tools <NUM> are positioned to form opposite cut edges <NUM> at fixed distances D1-D2 from the upper edges <NUM> of said decorative panel <NUM>. The position of the cutting tools <NUM> may be controllable or controlled on the basis of an upstream portion of said larger material as illustrated by means of the arrows <NUM> and the sensor <NUM>. The sensor may be a tactile and/or optical sensor.

A supporting means <NUM> is provided for the cutting tools <NUM> by means of the counter roller <NUM>. The counter roller may be provided with indentations that match the position of the cutting tools <NUM>.

As illustrated in <FIG> with the dashed line <NUM> the larger material <NUM> may be provided with reference portions <NUM>, preferably prior to said dividing operation S1. In the example the reference portions <NUM> are formed as indentations in the bottom of said larger material <NUM>. For the forming the counter roller <NUM>' may be provided with protrusions <NUM> for indenting the bottom of the larger material <NUM>, or a separate means may be provided for realizing excavations, e.g. indentations, in the bottom of the larger material <NUM>.

The reference portions <NUM> are provided at a fixed distance D3 from an upper edge <NUM>, and may be used in the cutting operation S1 to align one or more cutting tools <NUM> such that the lower edge area <NUM> is parallel, and preferably at predefined distance, to one or more of the cut edges <NUM>.

As illustrated here, the reference portions <NUM> are provided in a part of the larger material <NUM> that is maintained in the finally obtained decorative panels <NUM>. According to a variant, the reference portions <NUM> may be provided in the so-called technical zone <NUM>, i.e. a part of the larger material <NUM> that is to be removed in subsequent operations, for example in a milling operation that forms the coupling means at the respective edges.

<FIG> illustrate a variant wherein the lowered edge area <NUM> is formed by indenting material at an edge of a pre-machined portion <NUM> of said larger material <NUM>. The pre-machined portion <NUM> is performed from the top of said larger material <NUM>, through said decorative top layer <NUM>, into said substrate <NUM>. In the example, the pre-machined portion <NUM> comprises lateral undercuts <NUM> vertically beneath a remaining decorative top layer portion of said larger material <NUM>.

As shown in <FIG> the walls <NUM> of the undercuts <NUM> are brought closer to each other in the forming operation S2, and are potentially brought into contact. The walls <NUM> may adhere to each other by thermal fusion or by means of a separate glue, such as tetrahydrofuran glue, or by means of additional, e.g. powdery, substrate material added to the pre-machined portions <NUM>. The latter is an interesting embodiment, since the substrate material comprises a thermoplastic material, such as polyvinyl chloride (PVC), polyethylene (PE), polyethylene terephthalate (PET) or polypropylene (PP), and since such material can fluently be brought to create adherence between the walls <NUM> by means of heating and subsequent cooling, be it forced cooling or cooling at thermic conditions.

<FIG> illustrate variants where the substrate <NUM> comprises voids <NUM> at a position vertically underneath the to be formed lowered edge area <NUM> or in the technical zone <NUM>. In the case of <FIG>, said voids are formed by the cells of a foamed material portion <NUM> within the substrate <NUM>. In the case of <FIG>, said voids are formed by chambers <NUM> comprised in said substrate <NUM>. Such chambers <NUM> may have a maximum size D4 being at least <NUM> percent of the undeformed thickness T2 of the substrate <NUM>. Both in the case of <FIG>, as in the case of <FIG>, the substrate <NUM> is otherwise formed as one or more solid material layers, in this case as a single solid material layer.

<FIG> illustrates another variant. In this case the substrate <NUM> comprises foamed material portions <NUM> at the location of the to be formed lower edge areas <NUM>. More particularly, the foamed material portions <NUM> are in this case available at the surface of the substrate <NUM>.

<FIG> illustrates another variant. In this case, the substrate <NUM> comprises excavations <NUM> at the location of the to be formed lower edge areas <NUM>. The excavations <NUM> comprises powder material <NUM>. The powder material <NUM> may conform to the shape of the lower edge areas <NUM> during the forming operation S2, for example by melting or otherwise flowing to conform to the mold portions <NUM>. Preferably, said powder material <NUM> subsequently solidifies to maintain said shape. As an alternative to the powder material a material may be used that shows liquid or paste like behavior upon forming the lower edge areas. Preferably the filling material, be it a powder material <NUM> or another material, is of thermoplastic nature. Preferably for the filling material the same or similar material as the substrate <NUM> is used. In the case of a PVC containing substrate, PVC containing powder may be used, but any other thermoplastic containing powder material may serve the purpose.

<FIG> illustrates another variant wherein the substrate <NUM> comprises zones <NUM> of different material composition at the location where the lower edge areas <NUM> are to be formed. In this case the zones <NUM> extend from the bottom to the top of the respective material layer. In this case, the substrate <NUM> is formed as a single material layer, and the zones <NUM> extend from the bottom to the top of the substrate <NUM>. Preferably, the material of the zones <NUM> shows one or a combination of two or more of the following properties:.

<FIG> illustrates a variant where the substrate <NUM>, prior to the lamination step S4 has been preformed at least partially in accordance with the lower edge areas <NUM> to be formed. Such preforming may be obtained by using a suitable die instead of said slot die <NUM>, or by suitably machining the extruded web shaped substrate material.

Although the <FIG> have been described in relation to the method illustrated by means of <FIG>, it is clear that pre-machined portions <NUM>, voids, foamed material portions <NUM>, chambers <NUM>, zones <NUM>, preformed substrates <NUM>, or the use of powder material <NUM> may be advantageous in combination with any of the methods of the present invention.

It is further remarked that a substrate <NUM> or substrate material layer that comprises coextruded zones <NUM> of different composition may find broader application than solely for realizing lower edge areas <NUM>. Such zones <NUM> may for example be practiced to create an increased flexibility or mechanical strength at the edges for the benefit of the quality of the coupling means to be machined therein and/or to create an increased water repellency or water resistance at these edges while keeping the material costs manageable.

<FIG> illustrates a further example of said second possibility mentioned in the introduction, though not pertaining to the invention as claimed. Herein the lower edge areas <NUM> are formed prior to said cutting operation S1. In particular the printed carrier layer <NUM>, the transparent wear layer <NUM> and/or the backing layer <NUM> are laminated to form a decorative top layer <NUM> in a lamination operation S4A prior to laminating the obtained decorative top layer <NUM> to said substrate <NUM> in a subsequent lamination operation S4B. In said lamination operation S4A a decorative top layer <NUM>, as shown in <FIG> is obtained, namely comprising lower edge areas <NUM> at the surface thereof having the transparent wear layer <NUM>, while the opposite surface is maintained substantially flat or flat to allow for fluent lamination in said lamination operation S4A. In the example of <FIG>, this is obtained through a forming operation S2 by means of a structured roller <NUM> indenting said decorative top layer <NUM> prior to said lamination operation S4B.

<FIG> illustrates a variant where a pre-structured backing layer <NUM> is used. In such case the availability of the structured roller <NUM> may still be of interest to obtain a good lamination quality onto said pre-structured backing layer <NUM>. The pre-structured backing layer <NUM> comprises thinned sections <NUM> at least at the location where said lower edge areas are to be obtained.

<FIG> and <FIG> show a further variant where a backing layer <NUM> is used that comprises removed sections <NUM> corresponding to the lower edge areas <NUM> to be formed. Such embodiment is of interest to enable the formation of said lower edge areas <NUM> at lower power or deformation. <FIG> clearly illustrate that, despite the removed sections <NUM>, the backing layer <NUM> remains a one-piece layer.

Regarding the variants of <FIG> it is noted that these backing layers <NUM> with thinned sections <NUM> and/or removed sections <NUM> may be provided in a prefabricated manner from a roll, or be provided with said thinned sections <NUM> and/or removed sections <NUM> prior to and in line with said lamination operation S4A, for example immediately prior or practically immediately prior to the lamination operation S4A, or in between the unrolling and the lamination operation S4A.

<FIG> illustrates a method in accordance with the third possibility for forming a lowered edge area <NUM> mentioned in the introduction. A larger material <NUM> comprising a substrate <NUM> and a decorative top layer <NUM> is formed by means of a pressing operation S4' wherein a plurality of prefabricated layers <NUM>-<NUM>-<NUM> are adhered to each other. In this case the printed carrier layer <NUM>, the transparent wear layer <NUM> and the backing layer <NUM> are adhered to the substrate <NUM> by means of said pressing operation S4'. Lower edge areas <NUM> are formed simultaneously with said pressing operation S4' by means of a structured press element <NUM> coming into contact with said decorative top layer <NUM> to be formed. In the example, the backing layer <NUM> comprises removed sections <NUM>, similar or identical to that described in connection to <FIG> and <FIG>.

As illustrated by the dashed line <NUM> a bottom press plate <NUM> may be shaped to provide reference portions <NUM> in the bottom of the larger material <NUM>. Such reference portions may be similar to those illustrated in connection to <FIG>.

It is clear that the pressing operation S4', as illustrated in <FIG>, makes use of a single daylight press. Of course, as a not represented alternative, a multiple daylight press may be used, wherein then several stacks composed of at least a substrate <NUM> and one or more layers <NUM>-<NUM>-<NUM> of a decorative top layer <NUM>, are positioned on top of each other with one or more intermediate pressing elements <NUM>, and pressed at once.

<FIG> illustrates that the transparent wear layer <NUM> may be provided with thinned sections <NUM> corresponding in position to the lower edge areas <NUM> to be formed. Such transparent wear layer <NUM> may be used in combination with any of the methods described in the preceding and following figures and/or in the introduction and claims. It is clear that such transparent wear layer <NUM> with thinned sections <NUM> will at least partially accommodate a lower edge area <NUM> with minimized deformation. The thinned sections <NUM> may provide for a lower abrasion resistance at the surface of the lower edge areas <NUM>. However, the inventors deem this of no interest, as the lowered edge areas <NUM> are usually so small that they cannot be walked upon, and are hence less subject to wear and abrasion.

<FIG> illustrates that a reference portion <NUM> may be used to align the larger material <NUM> with a dividing operation S1 or dividing apparatus <NUM>. In the example of <FIG>, a single reference portion <NUM> is used for the alignment. Herein a guiding tool 38A engages with said reference portion <NUM>. As is the case here, such reference portion <NUM> is preferably available in the middle <NUM>% of the width of the larger material <NUM>. In so doing a possible misalignment is limited, and is expected to be largest with the outer decorative panels <NUM> to be divided out. It is possible however that, in accordance with a preferred embodiment, the position of the cutting tools <NUM> is controllable or controlled on the basis of a material portion of said larger material <NUM>, in order to minimize potential misalignment in the width direction.

<FIG> illustrates an alternative wherein multiple reference portions <NUM> are used subsequently to divide out one decorative panel at a time and/or to perform one cut at a time. In so doing the larger material may be re-aligned multiple times using a suitable reference portion <NUM>, preferably the reference portion <NUM> closest to the cut to be made. In the view of <FIG> after having performed a cut, the divided out decorative panel <NUM> can be removed, the larger material <NUM> shifted towards the viewer in the direction of the arrow <NUM> and realigned using the reference portion 38A. Afterwards a subsequent cut to divide out the next decorative panel <NUM> is performed.

<FIG> shows an enlargement of the set-up for the embossing roller <NUM>, the structured roller <NUM> and counter roller <NUM>' from <FIG>. According to a not-represented variant, the embossing roller and the structured roller may swap positions, i.e. a method wherein the forming operation S2 is performed prior to and in line with the embossing operation S6.

<FIG> shows an alternative set-up for the forming operation S2 per se. Herein the structured roller <NUM> is paired with a plurality of counter rollers 32A-32B-32C, and optionally with a belt <NUM> provided on said counter rollers 32A-32B-32C. Herein the larger material <NUM> follows a bent path around the roller <NUM> for an arc length L corresponding to at least <NUM>°, in this case even <NUM>°.

Preferably, the pressure exerted on the larger material <NUM> at the location of the counter rollers 32A-32B-32C increases in the feed direction F. The contact at counter roller 32A is hence preferably at lower contact pressure than the contact at counter roller 32B which is in its turn preferably at lower contact pressure than the contact at counter roller 32C. According to a variant, or in combination therewith, the gap 57A-57B-57C between the counter rollers 32A-32B-32C and embossing roller <NUM> diminishes in the feed direction F. Thus the gap 57A at the location of counter roller 32A is preferably larger than the gap 57B at counter roller 32B which is in its turn preferably larger than the gap 57C at counter roller 32C. The pressure exerted on the larger material <NUM> and/or the gaps 57A-57C-57B may be adjustable by changing the position of the respective counter rollers 32A-32B-32C as shown by means of the arrows in <FIG>.

Preferably, at least one of said plurality of counter rollers 32A-32B-32C has a rubber surface. Preferably the first counter roller 32A in feed direction F has a rubber surface. In the case a belt <NUM> is used, this preferably concerns a steel belt, which may be heated or not.

Preferably the structured roller <NUM> of the embodiment of <FIG> is a heated roller, for example heated by means of thermic oil or another fluid at a temperature above <NUM>, or above <NUM>. Other manners of heating the roller <NUM> are of course not excluded, and it is also possible that the larger material <NUM> is heated prior to entering the gap between the first counter roller 32A and the structured roller <NUM>. In such case the structured roller <NUM> may be cooled, or at least not heated by any other means than the possibly still hot larger material <NUM> and/or decorative top layer <NUM>.

The inventors have found that pairing a structured roller <NUM> and/or an embossing roller <NUM> with a plurality, i.e. at least, two counter rollers 32A-32B leads to a better reproduction or copying of the relief of the embossing roller <NUM> and/or structured roller <NUM> into the decorative top layer <NUM>, in particular into at least the transparent wear layer <NUM>. The increase of the contact pressure in feeding direction F and/or the decrease of the gap <NUM> in feeding direction F is beneficial in moving the material of the decorative top layer <NUM>, such as at least the material of the transparent wear layer <NUM>, and potentially the material of the substrate <NUM>, in the case of deep structures requiring a deformation of the substrate <NUM>. An enhanced flow of the material of the decorative top layer <NUM> and/or the substrate <NUM> leads to a better conformity of the obtained relief to the structure on the embossing roller <NUM> and/or the structured roller <NUM> that forms the lower edge areas <NUM>.

It is clear that one or more of the counter rollers 32A-32B-32C may be provided with protrusions <NUM> for indenting the bottom of the larger material <NUM>, similar to the protrusions <NUM> illustrated by means of <FIG>. In this way reference portions <NUM> may be formed at a fixed distance D3 from an upper edge <NUM>, for example for positioning the larger material <NUM> in the cutting operation S1.

<FIG> and <FIG> show an alternative for the structured roller <NUM> used in said forming operation S2. Herein the mold portions <NUM> are comprised on belts <NUM> which are pressed down on the decorative top layer <NUM> and/or the substrate <NUM> by means of a roller 26A. The roller 26A is paired with a counter roller <NUM> at the bottom of the substrate <NUM>. The position of the belts <NUM> may be controlled or controllable in the transverse direction as indicated with the arrows <NUM>, for example based on a tactile and/or optical section of an upstream portion of said decorative top layer <NUM>.

<FIG> shows a further method for forming lowered edge areas <NUM>, such in accordance with the second possibility therefor as mentioned in the introduction. Herein, in accordance with the invention, the lowered edge areas <NUM> are formed prior to the cutting operation S1.

As shown in <FIG>, the substrate <NUM> is provided in a continuous manner, namely in accordance with the invention with an extrusion operation S3. An additional foamable layer <NUM>, for example a PVC comprising a foaming agent, such as azodicarbonamide, is applied on top of the extruded substrate layer 2A. The foamable layer <NUM> is then provided with a foaming inhibitor by means of a printing operation, in this case by means of the roller <NUM>. The foaming inhibitor is applied in a pattern corresponding to areas where less foaming is desired, such as at least in positions corresponding to lower edge areas <NUM> to be formed.

Downstream from said roller <NUM>, in the feeding direction F, a heat treatment, for example by means of an oven <NUM> is used to initiate the foaming. In the represented case the foaming takes place after the lamination step S4, and before the not represented dividing operation S1. Alternatively, the heat treatment may be executed with an oven 62A prior to said lamination operation S4. As a further alternative, the heat treatment may be executed after or simultaneously with said dividing operation S1.

<FIG> illustrates a cross-section of the larger material <NUM> obtained through the method of <FIG>. The substrate <NUM>, which included the extruded substrate layer 2A and the foam layer <NUM> is shaped in accordance with the lower edge areas <NUM>, at least in part due to the differential foaming caused by means of the foaming inhibitor.

It is repeated in connection to the drawings and/or any of the above mentioned independent aspects, that said substrate <NUM> is a thermoplastic material containing board or layer, preferably a filled synthetic composite comprising thermoplastic material and filler material, preferably mineral filler materials, such as sand, talcum, chalk or other forms of CaCO3.

Preferably, said decorative top layer <NUM> comprises a motif preferably formed by a printed pattern <NUM>. Said decorative top layer may comprise a carrier layer <NUM> upon which said printed pattern <NUM> is provided and a transparent wear layer <NUM> applied on top of said printed pattern <NUM>. Said carrier layer may be a thermoplastic foil, preferably a PVC foil, a paper layer or a wood veneer. Preferably, said wear layer <NUM> is a thermoplastic foil, preferably a PVC foil. In some embodiments, said decorative top layer may have a thickness of between <NUM>,<NUM> and <NUM>,<NUM>, by preference of about <NUM>,<NUM>. In some embodiments, said wear layer <NUM> may have a thickness of between <NUM>,<NUM> and <NUM>,<NUM>, more by preference of about <NUM>,<NUM> or about <NUM>,<NUM>. Most by preference, the thickness of the wear layer <NUM> is about <NUM>,<NUM>.

In accordance with some embodiments, said decorative top layer comprises a backing layer <NUM>, wherein said backing layer preferably forms the majority of the thickness T of said decorative top layer <NUM>, or at least <NUM> percent thereof. Said decorative top layer <NUM> may be assembled from said backing layer, printed carrier layer and wear layer by means of thermal lamination, i.e. preferably in the absence of separate glue layers in between said layers. Preferably said decorative top layer <NUM>, or at least the bottom layer thereof, is connected to said substrate <NUM> by means of thermal lamination as well, i.e. in the absence of a separate glue layer. However it is not excluded that said decorative top layer <NUM>, or at least the bottom layer thereof, is glued to said substrate <NUM>.

Further it is remarked that using a counter roller <NUM>-<NUM>' with a soft and/or rubber surface paired up with an embossing roller <NUM> or structured roller <NUM> for forming lowered edge areas leads to a better reproduction of the embossing roller's or structured roller's relief into the decorative top layer <NUM> and/or the substrate <NUM>. This is especially the case where hot embossing is practiced, namely in the cases where the embossing roller <NUM> and/or the structured roller <NUM> is heated.

<FIG> schematically illustrate a method for manufacturing a decorative panel <NUM>, wherein said panel <NUM> comprises a substrate <NUM> and a decorative top layer <NUM>, wherein said substrate <NUM> is a thermoplastic material containing substrate, wherein said substrate <NUM> and decorative top layer <NUM> is obtained from a larger material <NUM> by means of a dividing operation S1, and wherein said dividing operation S1 is performed to divide the larger material <NUM> into slabs comprising a single panel <NUM> or more than one panel <NUM> in a direction transversely to the feeding direction F of said larger material <NUM>. As shown, said panel <NUM> comprises at at least one and more by preference at both upper edges of a pair of opposite side edges a lower edge area, wherein said lower edge area is obtained prior to said dividing operation S1. Said dividing operation S1 comprises performing a cutting operation releasing at least said substrate <NUM> from said larger material <NUM> at at least two opposite side edges. The slabs that are formed may comprise a single panel <NUM> or more than one panel <NUM>. In the latter case, said slabs comprising more than one panel <NUM> may be further divided into slabs comprising a single panel by means of a secondary dividing operation.

As shown in <FIG>, said dividing operation S1 comprises a cutting operation, more particularly a punching operation, namely an operation in which a stationary, i.e. non-rotating, cutting blade or knife <NUM> is pressed down to, into and through the material <NUM> to be cut. Alternatively in <FIG>, said dividing operation S1 comprises a cutting operation which is non-stationary, i.e. by using a roller <NUM> comprising a knife-shaped protrusion <NUM> which is oriented transversely to the feeding direction of the larger material <NUM>. By the rolling movement of the roller <NUM>, the knife-shaped protrusion <NUM> is thus brought intermittently into engagement and disengagement with the larger material <NUM> in order to divide the larger material <NUM> into slabs comprising a single panel <NUM> or more than one panel <NUM>.

According to an embodiment not pertaining to the present invention, said lower edge area may be formed simultaneously with, i.e. during said dividing operation S1, or practically simultaneously with said dividing operation S1. In particular, <FIG> show the dividing step S1 comprising:.

Said indenting may be executed by means of a mold or mold portions that press down on said substrate <NUM> and/or said decorative top layer <NUM>. In particular, Said mold or mold portions may be engaged with said substrate <NUM> and/or said decorative layer <NUM> at the start of said cutting operation, and are preferably still engaged at the end of said cutting operation. With the mold or mold portions being engaged with the larger material at least during part of said cutting operation, the respective lowered edge area is formed, at least in part, simultaneously with or during the dividing operation S1.

<FIG> thereto shows, in particular where the cutting tool concerns a cutting blade or knife <NUM>, the mold or mold portions <NUM> may be formed together with the cutting blade or knife <NUM> as a singular entity. Alternatively, as shown in <FIG>, the mold or mold portions may be formed as a separate entity <NUM> from the cutting blade or knife <NUM>, wherein the cutting blade or knife <NUM> is moveable with respect to the mold or mold portions <NUM>. Although not explicitly shown in <FIG>, the cutting blade or knife <NUM> and the mold or mold portions <NUM>, either formed together or formed as a separate entity, may be configured as such to allow positioning said opposite cut edges at a mutually different distance from said upper edges of said panel.

<FIG> alternatively shows, where the cutting tool concerns a roller <NUM> comprising a knife-shaped protrusion <NUM>, the mold or mold portions may be formed as secondary protrusions <NUM> on the roller <NUM>, comprised on at least one side, preferably on two sides, of the knife-shaped protrusion <NUM>. Although not explicitly shown in <FIG>, the knife-shaped protrusion <NUM> and the secondary protrusions <NUM> on the roller <NUM>, may be configured as such to allow positioning said opposite cut edges at a mutually different distance from said upper edges of said panel.

Claim 1:
Method for manufacturing a decorative panel, wherein said panel (<NUM>) comprises a substrate (<NUM>) and a decorative top layer (<NUM>), wherein said substrate is a thermoplastic material containing substrate, wherein said method comprises a step of providing a larger material (<NUM>) comprising said substrate (<NUM>) and said decorative top layer (<NUM>) by means of a continuous operation in which said substrate material is extruded and said top layer (<NUM>) is laminated to said substrate material, wherein said substrate (<NUM>) and decorative top layer (<NUM>) is obtained from said larger material (<NUM>) by means of a dividing operation (S1), wherein said panel (<NUM>) comprises at at least one and preferably at both upper edges (<NUM>) of a pair of opposite side edges a lower edge area (<NUM>), wherein said decorative top layer (<NUM>) continues uninterruptedly from on the global upper surface of said panel (<NUM>) to and over said lower edge area (<NUM>), wherein said substrate (<NUM>) is compressed or deformed at the location of said lowered edge area (<NUM>), wherein said dividing operation (S1) comprises performing a cutting operation releasing at least said substrate (<NUM>) from said larger material (<NUM>) at at least two opposite edges, wherein said lower edge area (<NUM>) is formed in line with said dividing operation (S1) releasing at least said substrate (<NUM>) from said larger material (<NUM>) at at least two opposite edges, characterized in that said lower edge area (<NUM>) is formed by means of one or more structured rollers indenting said larger material (<NUM>) and said lower edge area (<NUM>) is obtained prior to said dividing operation (S1).