Long plastic layer with embossing in register with pattern and rolling method and device therefor

A method for manufacturing flooring planks comprising a plastic base and a long plastic layer;

• said long plastic layer comprising at least a portion of a single unit of a printed continuous pattern and an embossing in register with said printed continuous pattern;
• said method comprising providing a decorative material of continuous length by at least feeding a plastic base layer and a long plastic layer into oppositely rolling rollers;
• said long plastic layer having a front side and a back side;
• wherein said long plastic layer comprises at least a repetition of units of said printed continuous pattern;
• wherein a unit of said printed continuous pattern has an unstretched length;
• said oppositely rolling rollers comprising an embossing roller and a backing roller;
• said embossing roller having an outer cylinder and an embossed pattern disposed around said outer cylinder;
• wherein the length of said embossed pattern is 1.01 to 1.5 times said unstretched length of said unit of said printed continuous pattern;
• wherein the front side of said long plastic layer is stretched to yield a stretched length of said unit of said printed continuous pattern that matches said length of said embossed pattern, and wherein said front side of said long plastic layer is adjacent to said embossing roller;
• wherein the plastic base layer is adjacent to said backing roller and adjacent to said back side of said long plastic layer;
• and
• said method further comprises cutting said decorative material in a plurality of cut blocks that are devoid of repeating units of said printed continuous pattern, and forming a flooring plank using a single cut block;
• wherein the method further comprises the step of controlling the heating temperature of the embossing roller and/or the backing roller;
• wherein said step of controlling is executed by a control device controlling a hot medium flowing into the oppositely rolling rollers.