Abstract
A method for manufacturing a board as well as a profiled element for manufacturing the board. The method including the steps of providing a material mass including an organic material and a binding agent for binding the organic material together, pressing the material mass so as to form the board, and removing material from the material mass in one or more material zones before pressing so as to obtain after pressing a lower density in those zones compared to the remainder of the board.
Claims
1. A method for manufacturing a board, comprising the steps of: providing a material mass including an organic material and a binding agent for binding the organic material together; pressing the material mass so as to form the board; removing material from the material mass in one or more material zones before the step of pressing so as to obtain after pressing a lower density zone in zones compared to a remainder of the board, the lower density zone defined as a weight per volume unit at a thickness of the board in the lower density zone compared to a thickness of the remainder of the board outside of the lower density zone; and subdividing the board so as to obtain panels.
2. The method of claim 1, wherein the material mass is provided as a substantially homogenous material mass.
3. The method of claim 1, wherein the material mass is provided by strewing.
4. The method of claim 1, wherein a scalper roll is used to remove material from the material mass.
5. The method of claim 1, wherein a profiled element is used to remove material from the material mass.
6. The method of claim 1, wherein the one or more material zones define a surface of less than half of the surface of the board.
7. The method of claim 1, wherein the one or more material zones are aligned according to a width and/or length direction of the board.
8. The method of claim 1, wherein the material mass is pre-densified or de-gassed before pressing but after removing material.
9. The method of claim 1, wherein the organic material is wood material, said wood material comprising at least one of wood flakes, wood chips, wood fibers, and wood powder.
10. The method of claim 1, wherein the binding agent is selected from the group consisting of: urea formaldehyde glue, melamine glue, melamine formaldehyde glue, methane diphenyl diisocyanate glue, phenol formaldehyde glue, resorcinol formaldehyde glue and resorcinol phenol formaldehyde glue.
11. The method of claim 1, wherein the board is substantially made as a wood fiberboard such that the wood fiberboard is a medium density fiberboard (MDF) or a high density fiberboard (HDF).
12. The method of claim 1, wherein the board has a nominal thickness of 5 to 15 millimeters.
13. The method of claim 1, wherein the method is a continuous process.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred embodiments are described, with reference to the accompanying drawings, wherein:
(2) FIG. 1 represents a board with the characteristics of the invention;
(3) FIG. 2, at a larger scale, represents a cross-section according to the line II-II indicated in FIG. 1;
(4) FIG. 3, in the same view, represents a variant of said board;
(5) FIG. 4 represents a method with the characteristics of the invention;
(6) FIG. 5, at a larger scale, represents a cross-section according to the line V-V indicated in FIG. 4;
(7) FIGS. 6 to 9, in the same view as FIG. 5, represent variants;
(8) FIG. 10, at a larger scale, represents a view on the are indicated by F10 in FIG. 9;
(9) FIGS. 11 to 13, in the same view, represent variants;
(10) FIG. 14 represents a panel, more particularly a floor panel, which is obtained from a board according to the invention by means of subdivision;
(11) FIG. 15, in cross-section and at a larger scale, represents a view according to the line XV-XV indicated in FIG. 14; and
(12) FIGS. 16 and 17 represent variants of such panel in the same view as FIG. 15.
DETAILED DESCRIPTION OF THE INVENTION
(13) FIG. 1 represents a board 1 which substantially consists of a pressed material mass 2, wherein this material mass 2 is differently composed in the plane 3 of the board 1, in other words, according to its length direction L and/or width direction B. The example relates to a so-called MDF or HDF board 1, which substantially is composed of wood fibers provided with a binding agent, more particularly is composed of wood fibers interconnected by means of polycondensation glue. Herein, the differing composition required according to the invention occurs in the material zones 5 indicated by dashed line 4.
(14) From FIG. 1, it is clear that according to the invention it is preferred that said differing composition manifests at least in material zones 5 which are aligned according to said length direction L and/or width direction B. According to the example, said material zones 5 are applied both in length and in width directions L-B, and every material portion 6 of the normally pressed material mass 2 is surrounded by a material portion 7 of the differently pressed material mass 2. It is clear that said material zones 5 of differing composition also may be performed solely in the length direction L or solely in the width direction B, wherein then strips or board portions are created, which are flanked at least at one side by a material portion 7 of differing composition.
(15) FIG. 2 shows that the board 1 of FIG. 1 has the features that the differently composed material in this case extends over the entire thickness D of the respective material zones 5 and that the surface 8 of the board 1 is formed by normally pressed material portions 6 as well as by differently composed pressed material portions 7. These two features, each apart as well as in combination, are preferred practical features, which can be applied in a useful manner, amongst others, in boards which are intended for being subdivided into smaller panels, and in particular in boards which are intended for being subdivided into panels which are applied or can be applied as a substrate for the manufacture of floor panels with a top layer. In connection with the first-mentioned feature, it is clear that the differently pressed material portions 7 in this manner possibly form at least a portion or the entire circumference of the final panel over the entire thickness D thereof, whereas the normally pressed material portions 6 usually are cheaper and can be applied as a bulk material for the floor panel. In connection with the second feature mentioned, it is clear that the fact that the surface 8 of the board 1 is formed at least by normally pressed material portions 6 and differently composed pressed material portions 7 can be applied usefully in a variety of manners, for example, for the, whether or not automatic, recognition of the boards 1 of the present invention.
(16) The example of FIG. 2, by means of the dash-dotted lines, clearly shows the locations where cutting lines 10 are intended for being applied for subdividing the board 1 into smaller panels 11. From this, it becomes clear that said differing composition manifests itself at least in material zones 5 which are intended for forming at least a portion of an edge 12 of the aforementioned smaller panels 11. In this case, the board 1 of FIG. 1 is intended for being subdivided into rectangular oblong panels 11 with two pairs of opposite edges 12, and said material zones 5 are intended for forming at least a portion of a long edge or even the entire circumference of said smaller panels 11.
(17) It is clear that said differing composition of the material zones 5 may consist, amongst others, of the first, second or third possibility mentioned in the introduction or of any combination of one or more of these possibilities. It is also possible that the differing composition represented here results in a board 1 with the characteristics of the second aspect of the present invention, wherein the material portions 7 of differing composition then preferably have a higher density than the normally pressed material portions 6.
(18) FIG. 3 represents another example of a board 1 with the characteristics of the invention. Herein, the differing composition of the material zones 5 concerned substantially consists of inclusions 13 of any kind, such as an inclusion of synthetic material or metal, provided in the board 1. By such inclusion 13, various advantages may be obtained. So, for example, is it possible to provide for that the edge 12 of the smaller panels 11 obtained by subdivision is formed at least partially or even substantially by said inclusion 13. If the inclusion 13 is formed from synthetic material, then a synthetic material from the series of polyethylene, polyethylene terephthalate, polyurethane, polypropylene, polystyrene, polycarbonate and polyvinyl chloride can be selected. Also, an inclusion 13 of a wood-plastic composite can be chosen, preferably on the basis of at least one of the aforementioned synthetic materials, wherein then wood particles, such as wood powder, wood chips or wood fibers are applied as fillers. This latter is a possibility which can be considered in particular in the case that the board 1 substantially consists of MDF or HDF material, wood particle board or OSB.
(19) FIG. 4 represents a method for manufacturing a board 1, wherein this method shows the characteristics of the third aspect of the invention. In the example, this relates to a method performed by means of a production line 14 substantially corresponding to a typical MDF or HDF production line. Herein, it is started from a material mass 2 which is composed at least by means of two components. In this case, both components simultaneously are supplied to a strewing machine 15 in the form of organic material 16 previously provided with binding agent, in this case in the form of wood fibers provided with polycondensation glue, wherein then said binding agent or the condensation glue forms the second component mentioned in the third aspect and the organic material 16 or the wood fibers form the first component mentioned in this aspect. Of course, it is possible that the second component or the binding agent is added separately to the material 2, for example, by spraying or moisturizing in any other manner the organic material 16 with the respective binding agent during the construction of the material mass 2.
(20) The depicted strewing machine 15 can be constructed in any manner. In the example, a strewing machine 15 is applied such as the one known as such from WO 03/053642. The strewing machine 15 of the example is provided with several agitating elements 17, which bring the organic material 16, which is provided with glue, into movement in the strewing chamber 18. By means of the fibers exiting the strewing chamber at the bottom side 19, the mat or material mass 2 mentioned in the third aspect, or at least a portion thereof, is composed on the transport conveyor 20 situated there beneath. For a further description of such strewing machine 15, reference is made to the aforementioned international patent application. Of course, also other types of strewing machines 15 are suitable, such as, for example, the strewing machines described in the international patent applications WO 99/36623 and WO 2005/044529.
(21) FIG. 5 shows that the finally obtained composed material mass 2, before being pressed according to the invention to a board 1, in this case shows several zones 5 in its width direction B, at the height of which zones its composition in respect to the remainder of the material mass 2 is realized differently. In this case, the different realization consists at least in that the material mass 2 locally comprises a larger quantity of organic material 16 provided with glue, in particular fibers provided with glue. Such material mass 2 can be composed in many ways. So, for example, it may be composed by a special strewing procedure, which allows strewing locally more, for example, by means of an additional strewing machine strewing solely at the height of the aforementioned zones 5, or by means of a strewing machine 15 which is able to dose additional material in the material mass 2 on certain locations. According to another example, which is applied here, material can be removed from a substantially homogenously strewn material mass 2, such that the profile of the material mass 2 from FIG. 5 is obtained. This may be performed, for example, by means of the so-called scalper roll 21 situated downstream of the strewing machine 15. It is noted that a scalper roll 21 according to the state of the art is applied for scraping off possible excess fibers from a strewn material mass, after which then, also according to the state of the art, a material mass 2 with a quasi flat upper surface is obtained. However, the inventors have found that by providing this scalper roll 21 with a profile, they could provide at least the upper surface of the material mass 2 with a structure 22, wherein this structure 22 then automatically may result in a material mass 2 having one or more zones 5, at the height of which its composition is realized differently in respect to the remainder of the material mass 2.
(22) It is noted that the invention according to a further independent aspect thereof also relates to a scalper roll 21 for manufacturing boards 1 obtained from a pressed material mass 2, with the characteristic that said scalper roll 21 is provided with a structure with which said material mass 2 can be provided with a corresponding structure 22 before the material mass 2 is pressed to form said board 1. It is clear that said scalper roll 21 preferably is applied in a production line 14 for manufacturing a MDF or HDF board 1, which either does or does not show the characteristics of the remaining aspects of the present invention. As a variant of the present independent aspect, instead of a scalper roll 21 also another profiled element, which can provide the material mass 2 with a structure 22, can be used, for example, with a whether or not curved profiled plate element.
(23) It is noted that the material mat or material mass 2 obtained by strewing may have a thickness T which is up to 50 times or more larger than the thickness D of the board material finally to be obtained, as it can be densified and pressed to the required thickness D of the board in further steps of the manufacturing process. These further steps are shown schematically in FIG. 4.
(24) In the production line 14 depicted in FIG. 4, downstream after said whether or not profiled scalper roll 21, further also a densification device or pre-press 23 is situated, in which the composed material mass 2 prior to the actual hot pressing gradually is densified to a condition in which it can be transported in a simpler manner compared to the un-densified strewn material mat 2. To this aim, the material mass 2 preferably is transported between press belts 24 having an intermediate space which decreases in downstream direction. In this pre-densification, preferably no heat is supplied, and/or preferably the binding agent present is not yet or only partially activated. Rather, in the pre-densification preferably an at least partial removal of the gasses present in the material mass 2, such as air, is concerned.
(25) After the densification device or pre-press 23, in FIG. 4, seen in downstream direction, there is the actual press device 25, in which the material mass 2, whether or not already pre-densified, is pressed under the influence of heat. The applied temperature may lie, for example, between 100 and 150° C., and the applied pressure may lie on average between 4 and 10 bar; herein, however, short peak pressures up to 40 bar are not excluded. Preferably, the activation of the binding agents takes place in this press device 25. In the case of polycondensation glue, water or rather steam can be created in this press device.
(26) The press device 25 depicted here is of the continuous type, wherein the material mass 2 is transported between press belts 26 and gradually is pressed. In the pathway of such press device 25, a pressure and/or temperature regime may be set. It is clear that the method of the third aspect can also be performed with other press devices 25, such as, for example, with a steam pressure press, a multiple opening press or with a so-called short-cycle press. In these other press devices 25, the applied pressure and/or temperature can be set in function of the time during which the material mass concerned remains in the press device.
(27) After the actual press device 25, preferably a board 1 with two substantially flat panel sides 27-28 is obtained, however, wherein the originally profiled material mass 2 of the present example is pressed to a board 1 showing the characteristics of the first and/or of the second aspect of the invention. Such board 1 may be subjected to a number of treatments in order to finish the pressed board 1. So, amongst others, it can also be ground at one or both of its flat board sides 27-28.
(28) The method of the third aspect preferably is used for manufacturing boards 1 with a nominal thickness D of 5 to 15 millimeters.
(29) It is also noted that the method of the third aspect, as it is the case in FIG. 4, preferably comprises at least the steps of strewing at least a portion of said material mass 2, pre-densifying or de-gassing the material mass 2 and pressing the material mass 2, and that said different realization of the material mass 2 preferably is obtained before said pre-densification step is performed. Preferably, a production line is chosen which substantially corresponds to the production lines known for manufacturing particle board or wood fiberboard of the MDF or HDF type. Apart from the devices represented in FIG. 4, such production line may also comprise other devices, such as an installation for providing binding agent on the organic material, or a grinding installation for grinding away the outermost layers of the pressed boards.
(30) FIG. 6 shows that it is possible to compose the material mass 2 such that it has one or more zones 5 where at least a third material or component has been applied. In the represented case, this is obtained by depositing said third material or component on the surface of a practically homogenous material mass 2, by which again a material mass 2 to be pressed with a profiled upper surface is obtained.
(31) FIG. 7 shows that it is also possible to apply a third material or component by initially providing an original material mass 2 with recesses 29, which then can be filled at least by means of said third component, such that preferably again a flat material mass 2 to be pressed is created. It is clear that these recesses 29, as discussed in respect to FIG. 5, can be formed, for example, by strewing or by profiling a homogenously strewn material mass 2, for example, by means of a profiled scalper roll 21. In dashed line 30, it is shown that it is also possible, whether or not in combination with the possibilities of FIGS. 5 to 7, to introduce the third component into the lowermost portion of the material mass 2, in this case at the bottom of the material mass 2. To this end, this third component, for example, may be provided first on the conveyor belt 20, after which the remainder of the material mass 2 then is composed, for example, by homogenous strewing glue-provided organic material 16.
(32) It is noted that a similar composition as the material mass 2 from FIG. 7 can be obtained by other methods than by filling recesses 29 formed in the material mass 2. So, for example, may such material mass 2 be obtained by pre-densifying a material mass 2 similar to that from FIG. 6.
(33) FIG. 8 shows that it is possible to compose the material mass 2 such that it comprises one or more zones 5, where a third component is provided on a location in the bulk 31 of the material mass 2, in other words, on a location where this third component is surrounded by the actual material of the material mass 2. Such embodiment may be obtained, for example, by composing the material mass 2 in layers according to the layers 33A-33B-33C represented in dashed line 32 and by herein applying for the non-homogenously composed layer 33B the techniques such as discussed in respect to FIGS. 6 and 7.
(34) Further, FIG. 8 shows by the arrows 34 that the third component possibly can diffuse into the actual material of the material mass 2, either already before pressing, for example, during the pre-densification thereof or even still before this, or during pressing, or during a possible, whether or not intentional, post-treatment of the pressed material mass 2, such as when cooling the obtained board 1, or when hot stacking (English: hot stacking) such boards 1, wherein these boards 1 then preferably remain one or more hours in a space in which a controlled temperature is prevailing.
(35) Such diffusion as shown by the arrows 34 can also be obtained when working with a third component which expands or foams. As already mentioned above, such foaming or expanding agent, according to a deviating particular independent aspect, also may be present more or less homogenously in the material mass or board, or may be concentrated in one or more layers of such material mass or board.
(36) FIG. 9 shows still another example of a material mass 2 having in its width direction B zones 5, the composition of which is realized differently in that a third component is applied in the zone 5 concerned. Herein, these zones 5 extend over the entire depth or thickness T of the material mass 2 concerned. Such material mass 2 can be composed, for example, by strewing other materials in the width direction B of the material mass 2 to be composed, for example, by means of adjacently positioned strewing devices 15.
(37) In connection with FIGS. 6 through 9, it is noted that it is clear that instead of said third component, also said first and/or second component may be applied, which then are present in an altered concentration in the material portion 7 concerned, or possibly are absent from this material portion 7. In the zones 5 concerned, one may, of course, also work with a material which as such consists of several components, such as a wood-plastic composite.
(38) Further, it is noted that the material masses 2 represented in FIGS. 7 to 9 have the advantage that they can be made with a substantially flat surface. Such flat material masses 2 can be pressed more simply.
(39) It is clear that the zones of different realization represented in FIGS. 5 to 9 are aligned according to the longitudinal direction L of the material mass 2. However, it is not excluded that they are aligned in another direction or even are provided randomly. Also, it is not excluded that such zones 5 in one and the same board 1 are aligned according to several directions. So, for example, may such zones 5 of different realization be aligned both in length and in width directions L-B. It is clear that in such case a board 1, such as the board 1 of FIG. 1, can be obtained by means of a method of the third aspect.
(40) FIG. 10 represents an example, wherein said third component 35 relates to a particle-shaped component, for example, a synthetic material, which is supplied to the material mass 2 in the form of granules. This embodiment is illustrated here by means of a material mass 2 to be pressed, which substantially consists of fibers 37 provided with binding agent 36, as it is the case with the material mass 2 for a board 1 substantially made as a MDF or HDF board. The represented organic fibers 37 or wood fibers are provided with polycondensation glue in the form of droplets, which substantially occurs with relatively low gluing degrees, such as with a glue content smaller than 10 weight percent. It is clear that according to a not represented variant of this embodiment, also a fiber-shaped third component instead of a particle-shaped third component 35 may be applied. So, for example, reinforcement fibers, such as glass fiber or carbon fiber, may be used. Further, it is clear that the third component 35 as such can consist of several components, as this may be the case, for example, with a third component 35 consisting of wood-plastic composite or a semi-finished product therefor, which then as such is supplied in the form of fibers or granules.
(41) FIG. 11 shows an example in which the material mass 2 for the board 1 substantially is constructed as in the case of FIG. 10, however, wherein the differing composition of the depicted material zone 2 consists in that the fiber material 37 is provided with binding agent 36 in another manner, more particularly is differently provided with glue, either in that the fibers 37 are provided with another quantity of this binding agent 36, or in that the fibers 37 are provided with another binding agent 36A, or by a combination of both. So, for example, in the respective material zone 5, so-called MDI glue (methane diphenyl diisocyanate glue) can be applied, whereas substantially in the material mass 2 for the board 1 another binding agent 36A, such as MUF glue (melamine urea formaldehyde glue) is applied. Preferably, the fibers 37 in such material zone 5 are glued in a waterproof manner or acetylated.
(42) FIG. 12 shows an example, wherein the material mass 2 for the board 1 again substantially is constructed as in the case of FIGS. 10 and 11, however, wherein the differing composition of the depicted material zone 5 consists in that a third component 35 has been added to the glue-provided fibers 37, which component preferably is provided in solid form in the material mass 2, for example, in the form of granules or fibers, but which also may be supplied in liquid form. So, for example, an additional synthetic material may be supplied in particle form to the material zone 5 concerned. Preferably, in the case of MDF or HDF, this either relates to a polycondensation glue selected from the also above-mentioned series, or to a synthetic material selected from the series of polyethylene, polyethylene terephthalate, polypropylene, polystyrene, polycarbonate, polyurethane and polyvinyl chloride. It is also possible that the third component 35 as such is composed of multiple components; so, for example, may the third component 35 as such consist of a wood-plastic composite or a semi-finished product thereof, which then as such is added in the form of granules or in the form of fibers. The third component 35 may also be recovered from recycled materials, such as from PET bottles and the like. Another example of a possible third component 35 relates to reinforcing fibers, such as glass fiber or carbon fiber, which then possibly as such may be provided with glue. Still another example of a third component 35 relates to modified wood fibers, whether or not provided with glue, such as acetylated wood fibers. Still another example relates to locally adding a colorant or other recognition means as the third component 35. Such recognition means are not restricted to visually recognizable means, but may also be materials which can be perceived in any other manner, such as, for example, iron filings, which can be recognized, amongst others, magnetically.
(43) FIG. 13 shows another example of a material mass 2 substantially consisting of the same material as in the case of the FIGS. 10 to 12. Herein, in the material zone 5 concerned the quantity and length of the fibers 37 are varied in respect to the remainder of the material mass 2. In the example, in the material zone 5 concerned a larger quantity of shorter fibers 37A is used. Of course, according to not represented variants, it is also possible to vary only the length of the fibers 37A or only the concentration of fibers 37 in respect to the remainder of the material mass 2. Another not represented variant consists in orienting the fibers 37 in the material zone 5 concerned globally in another direction than the fibers 37 of the remainder of the material mass 2. Techniques for orienting fibers are known as such, for example, from the patent documents U.S. Pat. Nos. 3,954,364, 4,415,324, 4,284,595, 4,287,140, 4,322,380, 4,323,338, 4,111,294, 4,113,812, 4,432,916 and JP 9-158100. From these documents, it is known to orient fibers by means of electrical fields and to compose a homogenous material mass to be pressed by means of these substantially oriented fibers. However, the present invention according to the here described embodiment thereof relates to locally applying oriented fibers. By “oriented” is meant that the fibers substantially have a common direction. So, for example, is it possible that in a material zone with oriented fibers, these fibers substantially are directed according to the longitudinal direction of the material mass. This means that the majority of the fibers in such case form an angle with this longitudinal direction which is smaller than 45°.
(44) It is clear that the FIGS. 10 through 13 relate to all possible forms of differingly composed material masses 2 to be pressed, such as, for example, to the embodiments represented in the FIGS. 6 through 9.
(45) Referring to FIG. 4, it is noted further that a material mass 2, for example, such as the one represented in FIGS. 6 through 9, also can be formed by providing the material 35A to be added in the material mass 2 while the latter is being composed, for example, by adding this material in the form of strips or ribbons to the material mass which is being constructed, for example, in the strewing chamber 18. As represented here, this material 35A might be supplied, for example, from a roll. According to a not represented possibility, the material 35A might be provided on the material mass 2 being constructed, for example, in liquid or quasi liquid form, for example, by means of spraying heads or extruder channels. Supplying as a strip or ribbon, or by means of spraying heads or extruder channels, is of interest, for example, in case the added material 35A is hot melt glue. Such extruder channels may also be applied when the added material is a wood-plastic composite.
(46) FIG. 14 shows a floor panel 38, which is composed starting from a board 1 with the characteristics of the invention. This relates, for example, to a board 1 of the type represented in FIG. 2, which board in a first step in a manufacturing process for a floor panel 38, preferably by means of a DPL process, is provided with a laminate top layer 39. Such laminate top layer 39 comprises one or more material sheets 40 provided with resin and, in the case of a DPL process, is realized by bringing the resinated material sheets 40 together with the substrate 41 into a press, wherein the resin of the material sheets 40 solidifies under the influence of increased temperature and pressure in the press device and thereby provides for the mutual connection of the material sheets 40, in other words, the formation of the laminate top layer 39 itself, as well as for the connection of the top layer 39 and the substrate 41.
(47) FIG. 15 clearly shows the structure of the laminate top layer 39. As aforementioned, this latter here consists of two material sheets 40 provided with resin, namely a decor layer 42 with a printed pattern and a protective layer 43 or so-called overlay, which is translucent or transparent and is situated above the decor layer 42. Such protective layer 43 may comprise wear-preventing additives, such as hard particles. Various possibilities for such wear and/or scratch-preventing additives are described in the international patent application PCT/IB2007/0001493 of applicant. In the example, at the underside 28 of the board 1 also a material sheet 40 provided with resin is provided, preferably during said DPL process, which material sheet 40 serves as a so-called balancing layer or backing layer 44.
(48) It is noted that a laminate top layer 39 can also be obtained by means of the so-called HPL process. In this process, the material sheets 40 provided with resin as such first are pressed to form a laminate layer, after which they are provided on the substrate 41 or on the board 1, for example, by gluing them on the substrate 41 or on the board 1. A HPL top layer usually comprises more material sheets 40 than a DPL top layer and therefore is made thicker. It is obvious that within the scope of the present invention also other top layers than laminate top layers 39 can be applied, such as, for example, wooden top layers.
(49) Preferably after the application of the top layer 39, the board 1 concerned, in a second step prior to manufacturing a floor panel 38, is subdivided, according to the cutting lines 10 shown in FIG. 2, into smaller rectangular oblong panels 11, which substantially show the dimensions of the here represented final floor panel 38. The obtained panels 11 are provided with coupling means 49 at least at two and preferably at all opposite edges 45-46 and 47-48, for example, by means of a milling process. FIG. 15 clearly shows that these coupling means 49 can be made at least partially and in this case completely in a modified material portion 7 of the original board 1, by which particularly advantageous features for the final floor panel 38 can be obtained. So, for example, by the different composition of the material an increased strength and/or waterproofness of the connection may be obtained by means of the coupling means 49.
(50) The coupling means 49 which are represented in FIG. 15 substantially are made as a tongue 50 and a groove 51, however, allowing that two of such floor panels 38, when cooperating with each other, can be locked in a vertical direction V1 perpendicular to the plane of the coupled floor panels 38 and in a horizontal direction H1 perpendicular to the coupled side and in the plane of the coupled floor panels 38. Such couplings are known as such and preferably provide for a connection free from play or almost free from play, as may be the case, for example, with the coupling means known from WO 97/47834. Herein, the connection of two of such floor panels 38 may be obtained substantially in three possible ways, namely by means of a turning movement W of the floor panels 38 around the upper edges 52 of the respective sides, by means of a substantially horizontal shifting movement S of the floor panels 38 towards each other, or by means of a substantially downward movement at the edges of the floor panels 38.
(51) It is clear that the board 1, by means of which the substrate 41 of the floor panel 1 of FIG. 15 is formed, can be manufactured by pressing a material mass 2 with the characteristics of, amongst others, FIG. 5 or 9.
(52) FIG. 16 shows another example of such floor panel 38, wherein the board 1, from which the substrate 41 for this floor panel 38 is obtained, can be manufactured by pressing a material mass 2 showing, amongst others, the characteristics of FIG. 6 or 7.
(53) FIG. 17 shows another example of such floor panel 38, wherein the board 1, from which the substrate 41 for this floor panel 1 is obtained, can be manufactured by pressing a material mass 2 showing, amongst others, the characteristics of FIG. 8.
(54) It is noted that in the case of a board which is manufactured by a continuous production process, such as in FIG. 4, preferably the production direction of the respective board is chosen as the longitudinal direction of the board or of the material mass to be pressed, even if this would mean that the obtained boards have a length which is smaller than their width.
(55) The present invention is in no way restricted to the herein above-described embodiments; on the contrary, such boards, panels and methods may be realized according to various variants, without leaving the scope of the present invention.
