Floor panel

A method for manufacturing a plurality of floor, wall or ceiling panels, said panels being rectangular, having at least a pair of longitudinal opposite edges and a pair of short opposite edges;

• the method comprising:
• forming a board larger than a single one of said panels;
• said board comprising at least a synthetic material substrate, a printed film located on top of said synthetic material substrate, and a transparent or translucent wear layer located on top of said film;
• said synthetic material substrate having a density of more than 450 kilograms per cubic meter and comprising fillers;
• said transparent or translucent wear layer having a thickness of 0.2 mm to 1 mm;
• wherein at least the pair of longitudinal opposite edges of said plurality of panels comprises mechanical coupling parts configured to allow two of said plurality of panels to couple to each other at the corresponding pair of longitudinal opposite edges;
• wherein said mechanical coupling parts comprise a tongue and a groove;
• wherein said groove is defined by an upper lip and a lower lip extending in a horizontal direction beyond said upper lip in a plane of the coupled floor panels;
• wherein said mechanical coupling parts include a first pair of vertically active locking surfaces formed between an upper surface of the tongue and a lower side of the upper lip configured to provide locking in a vertical direction between the two of said plurality of panels perpendicular to the plane of the coupled panels;
• wherein the first pair of vertically active locking surfaces are realized in said synthetic material substrate;
• wherein said mechanical coupling parts include a first pair of horizontally active locking surfaces formed between an opstanding part on the lower lip and a recess on a lower side of the tongue configured to provide locking in a horizontal direction between the two of said plurality of floor panels in the plane of the coupled floor panels;
• wherein said first pair of horizontally active locking surfaces are realized from said synthetic material substrate and are oriented at an angle with said plane of the coupled panels;
• said angle being more than 30 degrees;
• wherein a second pair of horizontally active locking surfaces is formed adjacent to the respective top layers of coupled panels;
• said second pair of horizontally active locking surfaces being substantially vertical:
• wherein forming said board includes:
• a first step of extruding said synthetic material substrate;
• a second step of providing a top layer on said synthetic material substrate by at least adhering the printed film to said synthetic material substrate by at least one of heating or pressing and providing said transparent or translucent wear layer on said printed film by at least adhering the transparent or translucent wear layer to said film by at least one of heating or pressing;
• and
• a third step of mechanically embossing said top layer in such a way that impressions formed from said mechanically embossing are limited in depth to said transparent or translucent wear layer;
• wherein said first step and said second step are performed in a continuous manner on a same production line;
• and
• obtaining said plurality of panels from said board, wherein said obtaining said plurality of panels from said board comprises a dividing operation;
• wherein said obtaining said plurality of panels from said board comprises a milling treatment with rotating milling tools at least for providing said mechanical coupling parts;
• wherein said obtaining said plurality of panels from said board comprises forming a recessed edge at least on one or both edges of said pair of longitudinal opposite edges by removing a portion on the respective edges;
• wherein said recessed edge has a shape of a chamfer limited in depth to the thickness of said transparent or translucent wear layer;
• wherein said transparent or translucent wear layer is free from filler materials and hard particles.

A method for manufacturing a plurality of floor, wall or ceiling panels, said panels being rectangular, having at least a pair of longitudinal opposite edges and a pair of short opposite edges;

• the method comprising:
• forming a board larger than a single one of said panels;
• said board comprising at least a synthetic material substrate, a printed film located on top of said synthetic material substrate, and a transparent or translucent wear layer located on top of said printed film;
• said synthetic material substrate having a density of more than 450 kilograms per cubic meter and comprising fillers;
• said transparent or translucent wear layer having a thickness of 0.2 mm to 1 mm;
• wherein forming said board includes:
• a first step of extruding said synthetic material substrate;
• a second step of providing a top layer on said synthetic material substrate by at least adhering the printed film to said synthetic material substrate by at least one of heating or pressing and providing said transparent or translucent wear layer on said printed film by at least adhering the transparent or translucent wear layer to said film by at least one of heating or pressing;
• and
• a third step of mechanically embossing said top layer in such a way that impressions formed from said mechanically embossing are limited in depth to said transparent or translucent wear layer;
• wherein said first step and said second step are performed in a continuous manner on a same production line;
• obtaining said plurality of panels from said board;
• wherein said obtaining said plurality of panels from said board comprises a dividing operation;
• wherein said obtaining said plurality of panels from said board comprises a milling treatment with rotating milling tools at least for providing mechanical coupling parts to at least the pair of longitudinal opposite edges of said plurality of panels;
• wherein said mechanical coupling parts are configured to allow two of said plurality of panels to couple to each other at the corresponding pair of longitudinal opposite edges;
• wherein said mechanical coupling parts include vertically active locking surfaces configured to provide locking in a vertical direction between the two of said plurality of panels perpendicular to a plane of the coupled panels;
• wherein the vertically active locking surfaces are realized in said synthetic material substrate;
• wherein said milling treatment further comprises forming a recessed edge at least on one or both edges of said pair of longitudinal opposite edges by removing a portion on the respective edges;
• wherein said milling treatment occurs after said dividing operation;
• wherein said transparent or translucent wear layer is free from filler materials and hard particles;
• and
• wherein a surface of said recessed edge is formed by a separate decorative covering provided on said synthetic material substrate.