[0001] This invention relates to a floor panel and to methods for manufacturing panels,
more particularly floor panels.
[0002] More particularly, the invention relates to floor panels of the type comprising at
least a substrate and a top layer provided on the substrate, wherein the substrate
substantially is composed of a composite material comprising at least two components,
on the one hand, a first component, which is fiber-shaped, and, on the other hand,
a second component acting as a binding agent for said first component.
[0003] Such floor panels as such are widely known, for example, from
WO 97/47834, wherein a wood-based fiberboard is applied for the substrate, more particularly
MDF or HDF (Medium Density Fiberboard or High Density Fiberboard), and for the top
layer one or more paper layers provided on this substrate are applied. Traditionally,
such fiberboard consists of pressed wood fibers, which are interconnected, for example,
by means of melamine formaldehyde glue (MF) or melamine urea formaldehyde glue (MUF).
However, these boards show the disadvantage that they are very sensitive to moisture
penetration, as they are porous and as the wood fibers absorb moisture. The intake
of moisture by the wood fibers leads to a swelling of the substrate first manifesting
itself at the edges of the panels concerned. As a result thereof, accelerated wear
of said top layer may occur at the location of the edges. Moreover, wood fiber promotes
the growth of fungus and bacteria.
[0004] Moisture penetration also plays an important role in the production of such floor
panels. Namely, when the semi-finished panels take up moisture at one or more of their
edges, they may bend or warp in the plane, such that subsequent treatments of the
edge are tolerance-sensitive. For example, when realizing profiled edge regions comprising,
for example, coupling means, by means of milling tools, relatively much material must
be removed in order to obtain straight panels again after the machining treatment.
Due to this large material removal, it is possible that edge finishing, such as chamfers,
which are provided before milling, will disappear over a portion of the edge concerned.
Therefore, it is difficult, if not impossible, with the existing substrates to form
chamfers at one or more edges of the floor panels prior to the milling process. It
is noted that warping of panels poses a problem in particular with narrow panels having,
for example, a width of less than 20 cm, and pose an even larger problem with panels
having a width of less than 12 cm. It is clear that warped panels also lead to problems
when interconnecting or installing them.
[0005] In order to restrict the effects of moisture penetration, it is known to apply other
or more binding agents and/or to treat the wood fibers. For example, it is known from
US 6,376,582 to apply for this purpose acetylated fibers and/or so-called MDI glue (methane diphenyl
diisocyanate glue). Although with such components, the effects of moisture penetration
can be limited indeed, this still is not sufficient, as the board has to be resistant
against prolonged exposure to water, as may be the case in humid rooms, such as a
bathroom, or outdoors.
[0006] The present invention relates to offering a floor panel or a panel with an alternative
substrate, whereby preferably new possibilities can be offered for applications of
such panels. According to preferred embodiments of the invention, it also aims at
a panel with a substrate which is better resistant against moisture penetration than
traditional MDF or HDF, and/or can offer a remedy for one or more disadvantages of
the state of the art. To this aim, the invention according to its first aspect relates
to a floor panel of the type comprising at least a substrate and a top layer provided
on the substrate, wherein the substrate substantially is composed of a composite material
comprising at least two components, with the characteristic that, on the one hand,
a first of said two components consists of mineral fibers, and, on the other hand,
a second of said two components acts as a binding agent for said first component.
[0007] Said mineral fibers show less absorption of water or other moisture than this is
the case with wood fibers or other organic fibers. Hereby, the damaging consequences
of moisture penetration in the substrate can be avoided to an important extent. Preferably,
said composite material consists for at least 80 percent of said two components, such
that the positive effect of the presence of mineral fibers can be maximized.
[0008] Preferably, for the first component a fiber is applied consisting for at least 20
weight percent of Si02, and preferably consists for at least 10 weight percent of
Al2O3. Such fiber is excellently resistant against the occurrence of fungus or bacteria
growth and hardly takes up moisture or water.
[0009] For the first component, a fiber can be applied which is spun from rock, such as
volcanic rock. Such fiber is known as such because it is already applied, for example,
in insulation wool, such as rockwool.
[0010] Preferably, for the second component a polycondensation glue is applied. Preferably,
this relates to a thermo-hardening synthetic material and still better this synthetic
material is chosen from the series of urea formaldehyde glue, melamine glue, melamine
formaldehyde glue, methane diphenyl diisocyanate glue, phenol formaldehyde glue, resorcinol
formaldehyde glue, resorcinol phenol formaldehyde glue and a mixture of one or more
of the aforementioned glues. The inventors have found that thermo-hardening binding
agents lead to obtaining a board which is easier to provide with a top layer. Namely,
it is simpler to provide such board with a top layer by means of a press treatment
under increased temperature, as such board is resistant against a higher temperature
without losing strength to a considerable extent. This provides for that at an increased
temperature, for example, of more than 150°C, it is still possible to apply reasonable
pressures, for example, of more than 20 bars. A combination of more than 175°C with
more than 40 bars is not excluded.
[0011] Preferably, for the first component a fiber is applied, which is covered with an
agent promoting the adherence to the second component, such as silane.
[0012] Preferably, said substrate shows a density of more than 500 kg/m
3, or even of more than 750 kg/m
3. In such case, it is obtained that the substrate concerned also is sufficiently resistant
against impact damages. Such substrate can be obtained by pressing the respective
mineral fibers and the respective binding agent to a board in a similar manner as
it is the case with MDF or HDF. Herein, prior to the press treatment, the fibers are
provided with binding agent and strewn to form a mat, the thickness of which is at
least 30 times larger than the thickness of the final board to be obtained. In a first
step, during a so-called pre-pressing, this mat is de-aired, wherein also the thickness
of the mat already is reduced to a certain extent. In a second, subsequent step, the
mat then is increasingly pressed and heated until approximately the final thickness
of the board remains. After possible cooling of the board, it may or may not be ground
at one or both flat sides. The production process of the boards, in particular said
press treatments, preferably is performed in a continuous manner. However, it is not
excluded that one works with presses which open and close or so-called cycle presses.
It is clear that by such production process preferably larger boards are obtained,
from which, by dividing them, substrates for several final panels can be obtained.
Such dividing may take place prior or subsequently to applying said top layer.
[0013] Preferably, said top layer shows a printed motif, such as a wood motif or a stone
motif. For example, this motif depicts only one wooden plank, only one stone or tile,
respectively, per panel.
[0014] A printed motif can have been obtained in a variety of possible manners.
[0015] According to a first possibility, the printed motif is applied on a material sheet
taken up into said top layer. To this aim, for example, use can be made of a printing
process by means of printing cylinders, which, for example, is performed on a paper
web, wherein said material sheet then is obtained by dividing this paper web and subsequently
is taken up into the top layer as a decor layer. For taking up the material sheet
in the top layer, for example, use can be made of a process of the so-called DPL type
(Direct Pressure Laminate), wherein at least the respective printed material sheet,
whether or not provided with synthetic material, together with the substrate is brought
into a press device, where they are commonly pressed under increased temperature.
Possibly, in the same press treatment also a wear-resistant layer can be provided
above the decor layer, wherein this wear-resistant layer, apart from hard particles,
then preferably also comprises a material layer provided with resin, such as a paper
layer. For performing a DPL process, it is advantageous when said substrate comprises
a thermo-hardening synthetic material as a second component.
[0016] According to a second possibility, the printed motif is obtained at least partially
by means of a print performed directly on the substrate, whether or not by the intermediary
of primer layers. Directly performing a print on a substrate for forming panels showing
a motif is known as such, for example, from
US 1,971,067,
US 3,173,804,
US 3,554,827,
US 3,811,915,
WO 01/48333,
WO 01/47724,
US 2004/0026017,
WO 2004/042168,
EP 1 872 959 or
DE 195 32 819 A1. However, it is not known to perform such technique on the particular substrates
of the present invention. Prior to printing, one or more primer layers can be provided
on the substrate, and/or one or more finishing layers can be provided above the print.
Such finishing layers may comprise, for example, transparent or translucent layers
of synthetic material forming a protective layer above the, whether or not printed,
motif and may comprise, for example, wear-resistant particles, such as aluminum oxide.
It is not excluded that this protective layer contains a material sheet, such as a
paper sheet, which, for example, is provided with a synthetic material, such as amino
resin. In principle, any printing technique can be applied for forming the print,
such as a printing technique, wherein one or more printing cylinders are applied,
or a digital printing technique, wherein one or more inkjet print heads are applied.
[0017] In the most preferred embodiment of the present invention, the floor panel is rectangular
and, at least at two opposite edges, is provided with coupling means allowing that
two of such floor panels can be connected to each other. For example, such coupling
means substantially may be performed as a tongue in groove connection, which can effect
a locking in a vertical direction perpendicular to the plane of the connected floor
panels. Preferably, the coupling means also are provided with additional locking elements,
by which also a locking can be obtained in a horizontal direction perpendicular to
the connected edges and in the plane of the connected floor panels. Coupling means
of the type allowing that between said floor panels a connection is obtained in a
vertical direction perpendicular to the plane of the connected floor panels as well
as in a horizontal direction perpendicular to the connected edges and in the plane
of the connected floor panels, are known as such, for example, from
WO 97/47834. However, it was not known that they could also be applied in floor panels with a
substrate comprising mineral fibers. Preferably, said coupling means consist of profiles
milled directly into the substrate. The inventors have found that a substrate which
comprises mineral fibers most surprisingly can be milled with a high quality without
an adaptation of the usual milling tools which are applied when processing wood fiberboard.
Herein, competitive milling speeds can be obtained, even of more than 100 m/min or
more than 150 m/min.
[0018] Preferably, the floor panel of the invention has a width of less than 20 cm and still
better of less than 12 cm. From the preceding, it is clear that the floor panel of
the invention has particular advantages in these embodiments. As the floor panel of
the invention can be made less sensitive to moisture penetration, this floor panel
in fact may show a lesser tendency to warping in its plane, such that the advantages,
which may be created thereby, are not present or only present to a lesser extent.
The length of the floor panels can vary between 40 cm and 140 cm. It is clear that
the invention is not restricted to these dimensions. The floor panels also may be
made longer, such as up to 250 cm, and/or wider, such as up to 35 cm.
[0019] Preferably, the floor panel of the invention has a chamfer at one or more edges.
This can be realized in various possible manners. For example, the chamfer may be
realized, according to a first possibility, by removing a material portion at the
edge concerned, such as is known as such from
EP 1 290 291. It is clear that exposing a portion of the substrate by this material removal at
the edge does not induce particular problems in the floor panel of the invention as
a result of possible moisture penetration. The obtained surface of the chamfer may
or may not be provided with a separate covering. According to a second possibility,
the chamfer can be realized by deforming the substrate and/or the upper surface of
the panel, or the larger board from which the panel is obtained, for example, by means
of a press treatment. In the floor panel of the invention, such impressed chamfer
can be formed before further edge treatment, for example, by means of milling tools,
is applied. The floor panel of the invention in fact can show a smaller risk of warping
by moisture penetration, such that the risk that the already formed chamfer is removed
by a subsequent milling process, for example, for forming at least a portion of the
coupling means, can be minimized.
[0020] According to a second aspect, the invention further, in an independent manner, relates
to a method for manufacturing covered panels, more particularly floor panels, wherein
it is started from a basic board or a basic panel upon which a top layer with a printed
motif is provided, wherein the method for forming the top layer comprises at least
a step wherein, by means of a press treatment under increased temperature, a material
sheet is provided on the substrate, with the characteristic that for said basic board
or basic panel, a composite material is applied comprising at least two components,
on the one hand, a first component consisting of mineral fibers, and, on the other
hand, a second component consisting of a thermo-hardening polycondensation glue and
acting as a binding agent for said first component. It is clear that this method can
be applied for manufacturing the floor panels of the first aspect or the preferred
embodiments thereof and that the method possibly can also show one or more of the
following steps:
- the step of forming a chamfer at one or more edges of the panel, preferably according
to one of the possibilities therefor mentioned in the first aspect;
- the step of realizing profiled edge regions at least at two opposite edges and still
better at all opposite edges thereof, wherein these profiled edge regions show coupling
means, preferably with the characteristics of the possibilities therefor discussed
in the first aspect.
[0021] The inventors have found that the composite material of the invention is excellently
suitable for applying thereon a top layer by means of a press treatment and heat.
This suitability can be explained, on the one hand, in that the presence of thermo-hardening
material as a binding agent minimizes a possible softening of the substrate, and,
on the other hand, in that the composite material can be provided with an almost smooth
surface, as a consequence of which possible unevennesses hardly exert an influence
on the quality of the provided top layer.
[0022] According to a third aspect, the invention further independently relates to a method
for manufacturing panels, more particularly floor panels, of the type comprising at
least a substrate and a top layer provided on the substrate, wherein these panels
are rectangular and profiled edge regions are formed at least at two opposite edges,
wherein the method for forming said profiled edge regions comprises at least a step
wherein the substrate is processed at the edges concerned by means of a milling process,
with the characteristic that for said basic board or basic panel, a composite material
is applied comprising at least two components, on the one hand, a first component
consisting of mineral fibers, and, on the other hand, a second component consisting
of a polycondensation glue and acting as a binding agent for said first component.
It is clear that this method can be applied for forming the floor panels of the first
aspect or the preferred embodiments thereof and that the method possibly can comprise
still one or more of the following steps:
- the step of forming a chamfer at one or more edges of the panel, preferably according
to any of the possibilities therefor mentioned in the first aspect;
- the step of the previous paragraph, wherein said milling process is applied for forming
said chamfer;
- the step of realizing profiled edge regions at least at two opposite edges and still
better at all opposite edges thereof, wherein these profiled edge regions show coupling
means, preferably with the characteristics of the possibilities therefor discussed
in the first aspect;
- the step of the previous paragraph, wherein said milling process is applied for forming
at least a portion of the coupling means;
- one or more steps of the method of the second aspect and/or the preferred embodiments
thereof.
[0023] From the above, the advantages of a method with the characteristics of the third
aspect are clear.
[0024] 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:
Figure 1 represents a floor panel according to the invention;
Figure 2, at a larger scale, represents a cross-section according to the line II-II
represented in figure 1;
Figure 3 represents a step in a method according to the invention;
Figure 4, in a view similar to that of figure 1, represents a variant;
Figure 5, at a larger scale, represents a cross-section according to the line IV-IV
represented in figure 4; and
Figures 6 and 7, in a similar view as that of figure 5, represent variants.
[0025] Figure 1 represents an oblong and rectangular floor panel 1, which, as becomes clear
from figure 2, is of the type comprising a substrate 2 and a top layer 3 provided
on the substrate 2. The top layer 3 shows a wood motif, the nerves 4 of which extend
in the longitudinal direction of the floor panel 1. The floor panel 1 forms an imitation
of a single wood part or wooden plank. Of course, it is not excluded that the floor
panel 1 should imitate several wood parts, as may be the case with the design of a
so-called two- or three-plank.
[0026] The floor panel 1, at the pair of long opposite edges 5-6 as well as at the pair
of short opposite edges 7-8, is provided with coupling means allowing that two of
such floor panels 1 can be connected to each other, either in a vertical direction
V1 or in a horizontal direction H1 or in both directions V1 and H1, as it is the case
here at both pairs of edges 5-6 and 7-8. To this aim, each time two opposite edges
5-6-7-8 are provided with coupling means 9 substantially having the form of a tongue
10 and a groove 11, wherein this tongue 10 and groove 11, in coupled condition of
two of such floor panels 1, realize a locking or connection in vertical direction
V1. Said coupling means 9 are also provided with locking elements 12, wherein these
locking elements 12 in coupled condition of two of such floor panels 1 realize a locking
or connection in horizontal direction H1. As aforementioned, the represented coupling
means 9 can be realized as profiles directly milled into the substrate 2.
[0027] Figure 2 represents that the coupling means 9 and locking elements 12 of the example
allow that two of such floor panels 1 can be coupled at their edges at choice by means
of a turning movement W around the edge 5-6 concerned or by a horizontal shifting
movement T of the floor panels 1 towards each other. Of course, the invention is not
restricted to this kind of coupling means 9 and locking elements 12. It is also possible
to apply coupling means 9 allowing that two of such floor panels 1 can be coupled
only in one of the above-mentioned manners or allowing that two of such floor panels
1 can also be coupled to each other in still another manner, for example, by means
of a substantially downward movement. For examples of floor panels 1 which can be
connected at their edges 5-6 and/or 7-8 by means of a substantially downward movement,
reference is made to
DE 20 2008 008597 U1.
[0028] The particularity of the floor panel 1 from figures 1 and 2 is that this panel 1
comprises a substrate 2 which substantially is composed of a composite material comprising
at least two components, amongst which a first component consisting of mineral fibers.
In this case, this relates to a substrate 2 in which the mineral fibers are distributed
homogenously or at least quasi-homogenously. Figure 2 clearly shows that the coupling
means 9 can be made in one piece with this substrate 2 and that on this substrate
2, a top layer 3 consisting of one or more material layers 13 can be provided, wherein
this top layer 3 represents a motif, in this case, a wood motif. As mentioned in the
introduction, the floor panel 1 of the invention can be provided with lowered edges
or chamfers 14 at one or more edges 5-6-7-8. Such chamfers 14 are represented in figure
2 in dashed line and here show the form of bevels. It is noted that the quality of
a chamfer surface of the substrate 2, said surface possibly being obtained by milling,
allows covering this surface with a separate decorative layer consisting of a transfer
film. Other decorative layers, such as lacquer or ink layers, are not excluded, either.
[0029] Figure 3 represents that for manufacturing the floor panels 1 of figure 1 or 2, it
may be started from larger basic boards 15, which, in a press device 16, are provided
with a top layer 3 and possibly an underlay 17. Herein, the basic board 15 concerned,
which as such substantially is constructed of a composite material comprising at least
two components, amongst which a component consisting of mineral fibers, is brought,
together with the material layers 13 to be provided thereon and/or there below, between
a lower press plate 18 and upper press plate 19, where they will be connected to each
other under the influence of increased temperature and pressure. In this case, at
the upper side of the basic board 15 a top layer 3 is formed on the basis of a decor
paper 21 provided with resin 20, which forms a decor layer 22, and a paper layer 23
provided with resin 20, which extends as a protective layer 24 above the decor layer
22. On the decor paper 21, a motif is provided by means of a print 25, for example,
performed by means of printing cylinders. At the underside, as a balancing layer or
backing layer 17, also a paper layer 23 provided with resin 20 is provided, which
compensates possibly created residual tensions in the top layer 3 and/or the substrate
2.
[0030] As represented in figure 3, it is possible that by means of the upper press plate
19 simultaneously a structure is provided in the top layer 3. This structure possibly
can be realized corresponding to the motif of the decor paper 21. It is also possible
that this structure comprises impressions for imitating chamfers, joints or bevels,
which are present at one or more edges 5-6-7-8 of the final floor panels 1.
[0031] In the top layer 3, either in the protective layer 24 or in the decor layer 22 or
in both, further also hard particles can be present imparting a certain wear resistance
to the floor panel 1. As a result, ceramic particles, such as aluminum oxide granules,
with an average grain size of less than 200 µm can be applied. Such particles are
not represented here. For examples of top layers with hard particles and possibilities
for manufacturing panels with such top layers, reference is made to
WO 2007/144718.
[0032] It is clear that the final floor panels 1 or semi-finished products for manufacturing
such floor panels 1 then can be obtained at least by subdivision from the larger basic
boards 15. Further, it is clear that other covered panels than floor panels 1 can
be obtained in a similar manner. Examples of such other covered panels are furniture
panels, ceiling panels, wall panels and the like.
[0033] Figure 4 represents a variant wherein the mineral fibers are concentrated in the
material zones 26 situated at one or more edges 5-6-7-8 of the final floor panels
1, whereas the remaining material of the substrate 2 is composed differently, for
example, shows the usual composition of a MDF or HDF board. It is clear that the presence
of the mineral fibers on the edges 5-6-7-8 of the floor panel 1 is advantageous, for
example, for counteracting the effects of moisture penetration. In fact, at the flat
bottom side and top side of such floor panels 1, already a vapour-tight layer can
be present in the form of a laminate layer or top layer 3 on the basis of one or more
material layers 13 containing amino resin. Thus, with the embodiment of figure 4 a
practically entirely waterproof floor panel 1 can be obtained, whereas the cost price
thereof is limited. It is noted that according to the invention, this is also possible
vice versa, namely, that the mineral fibers are concentrated in the bulk of the final
floor panel 1.
[0034] Figure 5 shows that the material zone 26 comprising the material fibers preferably
extends so deep in the substrate 2 that the entire coupling means 9 can be formed
therein.
[0035] Figure 6 represents a variant, wherein the mineral fibers are situated in a material
zone 26 which, in the final floor panel 1, concentrates at one or more upper edges
27 of the floor panel 1. As the upper edges 27 are the most sensitive for the effects
of possible moisture penetration, a considerable improvement may already be obtained
with the embodiment of figure 6.
[0036] Figure 7 in its turn represents a variant wherein the mineral fibers are situated
in a material zone 26 which, in the final floor panel 1, concentrates at the height
of the actual coupling means 9, in other words, at the height of the aforementioned
tongue 10 and groove 11. Such embodiment may be combined, for example, with a separate
sealing of the upper edges, said sealing preferably being simple to apply, in order
to obtain a good result. Such separate sealing is not represented here, however, may
consist, for example, of a hardened substance. For examples of such substances and
possibilities for applying them thereon, reference is made to
WO 2008/078181 and
WO 2007/113676.
[0037] According to a not represented variant, it is possible that the mineral fibers are
concentrated in a material zone 26 extending in layers over substantially the entire
substrate 2. When this layer extends, for example, close enough to the surface of
the substrate 2, a similar embodiment as that from figure 6 can be obtained in a simple
manner, namely, wherein the mineral fibers are concentrated at least at the upper
edges 26 of the panels 1.
[0038] It is clear that the method represented in figure 3 also forms an example of said
second aspect and that the floor panels represented in all figures can be obtained
by means of a method conform to the second and/or the third aspect of the invention.
Herein, it is noted that the profiled edge regions, which are mentioned, amongst others,
in the third aspect, in the examples correspond to those regions of the edge where,
amongst others, said coupling means 9 are situated.
[0039] The present invention is in no way limited to the above-described embodiments, however,
such floor panels and methods can be realized according to various variants, without
leaving the scope of the present invention.
1. Floor panel of the type comprising at least a substrate (2) and a top layer (3) provided
on the substrate (2), wherein the substrate (2) substantially is composed of a composite
material comprising at least two components, characterized in that, on the one hand, a first of said two components consists of mineral fibers and,
on the other hand, a second of said two components acts as a binding agent for said
first component.
2. Floor panel according to claim 1, characterized in that a polycondensation glue is applied for the second component.
3. Floor panel according to claim 2, characterized in that for the second component a thermo-hardening synthetic material is applied, such as
a synthetic material selected from the series of urea formaldehyde glue, melamine
glue, melamine formaldehyde glue, methane diphenyl diisocyanate glue, phenol formaldehyde
glue, resorcinol formaldehyde glue and resorcinol phenol formaldehyde glue.
4. Floor panel according to any of the preceding claims, characterized in that for the first component, a fiber is applied which is spun from a volcanic rock.
5. Floor panel according to any of the preceding claims, characterized in that for the first component, a fiber is applied consisting for at least 20 weight percent
of Si02, and preferably at least 10 weight percent A1203.
6. Floor panel according to any of the preceding claims, characterized in that for the first component, a fiber is applied which is covered with an agent promoting
the adherence to the second component.
7. Floor panel according to any of the preceding claims, characterized in that said substrate (2) has a density of more than 500kg/m3.
8. Floor panel according to any of the claims 1 to 8, characterized in that said top layer (3) shows a printed motif.
9. Floor panel according to claim 8, characterized in that the printed motif is provided on a material sheet (23) which is taken up in said
top layer (3).
10. Floor panel according to claim 8, characterized in that the printed pattern is obtained at least partially by means of a print (25) performed
directly on the substrate (2), whether or not by the intermediary of primer layers.
11. Floor panel according to any of the preceding claims, characterized in that the floor panel (1) is rectangular and, at least at two opposite edges (5-6), is
provided with coupling means (9) allowing that two of such floor panels. (1) can be
connected to each other.
12. Floor panel according to claim 11, characterized in that said coupling means (9) are of the type allowing that among said two floor panels
(1) a connection is obtained in a vertical direction (V1) perpendicular to the plane
of the connected floor panels (1), as well as in a horizontal direction (H1) perpendicular
to the connected edges (5-6) and in the plane of the connected floor panels (1).
13. Floor panel according to claim 11 or 12, characterized in that said coupling means (9) consist of profiles milled directly into the substrate (2).
14. Method for manufacturing covered panels, more particularly floor panels (1), wherein
it is started from a basic board or a basic panel upon which a top layer (3) with
a printed motif is provided, wherein the method for forming the top layer (3) comprises
at least a step wherein, by means of a press treatment under increased temperature,
a material sheet (23) is provided on the substrate (2), characterized in that for said basic board or basic panel, a composite material is applied comprising at
least two components, on the one hand, a first component consisting of mineral fibers
and, on the other hand, a second component consisting of a thermo-hardening polycondensation
glue and acting as a binding agent for said first component.
15. Method for manufacturing panels, more particularly floor panels (1), of the type comprising
at least a substrate (2) and a top layer (3) provided on the substrate (2), wherein
these panels (1) are rectangular and profiled edge regions are formed at least at
two opposite edges (5-6), wherein the method for forming said profiled edge regions
comprises at least a step wherein the substrate (2) is processed at the edges (5-6)
concerned by means of a milling process, characterized in that for said basic board or basic panel, a composite material is applied comprising at
least two components, on the one hand, a first component consisting of mineral fibers
and, on the other hand, a second component consisting of a polycondensation glue and
acting as a binding agent for said first component.