Floor panel, as well as method, device and accessories for manufacturing such floor panel

1. Floor panel having an upper surface; said floor panel comprising:

a printed décor extending over a substantial part of said upper surface;

a top layer on the basis of synthetic material having a nominal thickness D 3 ; and

a wood-based substrate whereupon said printed décor and said top layer are provided;

said wood-based substrate having at least two opposite edges, said edges being provided with coupling parts;

wherein said substantial part of said upper surface over which the printed décor extends is provided with at least one embossed portion; said embossed portion forming a sunk edge area located at least one of said two opposite edges and having a depth D 2 that continues up into said wood-based substrate; said depth D 2 being larger than said nominal thickness D 3 of said top layer;

wherein the printed décor continuously extends over and along the at least one embossed section so as to follow the contours of the at least one embossed portion;

wherein said wood-based substrate comprises a compacted region located at said sunk edge area;

wherein said compacted region is compacted more than 1%;

wherein the printed décor is provided on a paper layer, and the paper layer extends continuously across the panel from the nominal thickness to the sunk edge area;

wherein the at least one embossed portion is formed by at least the top layer, the paper layer and the wood-based substrate, and increases in compression from the nominal thickness D 3 to the sunk edge area.

2. The floor panel of claim 1 , wherein said wood-based substrate comprises locations without embossments; said compacted region being compacted more than said locations without embossments.

3. The floor panel of claim 1 , wherein said floor panel has a lower surface; said wood-based substrate adjacent said lower surface being undeformed.

4. The floor panel of claim 1 , wherein said sunk edge area comprises a sloping portion.

5. The floor panel of claim 4 , wherein said sloping portion is immediately adjacent said one of said two opposite edges.

6. The floor panel of claim 1 , wherein said sunk edge area comprises a sloping bent portion.

7. The floor panel of claim 1 , wherein said sunk edge area comprises a sloping portion; said at least one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion extends at an angle; said angle altering in function of said longitudinal direction.

8. The floor panel of claim 1 , wherein said sunk edge area comprises a sloping portion; said at least one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion has a shape; said shape altering in function of said longitudinal direction.

9. The floor panel of claim 1 , wherein said sunk edge area comprises a sloping portion; said at least one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion has a highest point; said highest point varying laterally in function of said longitudinal direction.

10. The floor panel of claim 1 , wherein said synthetic material is a thermo-setting resin.

11. The floor panel of claim 1 , said at least one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said at least one of said two opposite edges having an upper edge; wherein said printed décor extends up to said upper edge.

12. Floor panel having an upper surface; said floor panel comprising:

a printed décor extending over a substantial part of said upper surface;

a top layer on the basis of synthetic material having a nominal thickness D 3 ; and

a wood-based substrate whereupon said printed décor and said top layer are provided;

said wood-based substrate having at least two opposite edges, said edges being provided with coupling parts;

wherein at least at one of said two opposite edges said floor panel is provided with a sunk edge area; said sunk edge area comprising a sloping portion; said one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion has an overall shape; said overall shape altering in function of said longitudinal direction such that the cross-sectional shape of the sloping of the sloping portion varies along the longitudinal direction;

wherein the printed décor is provided on a paper layer, and the paper layer extends continuously across the panel from the nominal thickness to the sunk edge area;

wherein the at least one embossed portion is formed by at least the top layer, the paper layer and the wood-based substrate, and increases in compression from the nominal thickness D 3 to the sunk edge area, and;

wherein said at least one of said opposite edges having a length extending in said longitudinal direction; wherein, seen in said plane, said at least one of said two opposite edges has an upper edge and said sloping portion comprises at least a first part and a second part; said first part adjoining said upper edge and having a first shape; said first shape being constant in function of said longitudinal direction over a substantial part of said length; said second part having a second shape; said second shape altering in function of said longitudinal direction.

13. The floor panel of claim 12 , wherein, seen in said plane, said sloping portion has a highest point; said second part extending from said first part to said highest point.

14. The floor panel of claim 12 , wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion has a highest point; said highest point varying laterally in function of said longitudinal direction.

15. The floor panel of claim 12 , wherein said substantial part of said upper surface over which the printed décor extends at least partially comprises said sunk edge area.

16. The floor panel of claim 12 , wherein, seen in a plane perpendicular to said longitudinal direction, said sloping portion has a highest point; said highest point varying laterally in function of said longitudinal direction.

17. The floor panel of claim 12 , wherein said substantial part of said upper surface over which the printed décor extends at least partially comprises said sunk edge area.

18. The floor panel of claim 12 , wherein said synthetic material is a thermo-setting resin.

19. The floor panel of claim 12 , said at least one of said two opposite edges having a longitudinal direction; wherein, seen in a plane perpendicular to said longitudinal direction, said at least one of said two opposite edges having an upper edge; wherein said printed décor extends up to said upper edge.

20. The floor panel of claim 12 , wherein the sunk edge area has a generally flat edge portion along the edge periphery of the floor panel, the sloping portion extending to the flat portion.

21. Floor panel having an upper surface; said floor panel comprising:

a printed décor extending over a substantial part of said upper surface;

a top layer on the basis of synthetic material having a nominal thickness D 3 ; and

a wood-based substrate whereupon said printed décor and said top layer are provided;

said substrate having at least two opposite edges, said edges being provided with coupling parts;

wherein said substantial part of said upper surface over which the printed décor extends and including at least the top layer and substrate forms at least one embossed portion; said embossed portion forming a sunk edge area located at least one of said two opposite edges and extending into the wood-based substrate;

wherein the printed décor continuously extends over and along the at least one embossed section so as to follow the contours of the at least one embossed portion; wherein at least said top layer and the substrate gradually increase in compaction across the embossment from a first thickness of the floor panel to a region located at said sunk edge area.

22. The floor panel of claim 21 , wherein the printed décor is provided on a paper layer extending continuously across the panel from the first thickness to the sunk edge area.

23. Floor panel having an upper surface; said floor panel comprising:

a printed décor provided on a paper layer and extending over a substantial part of said upper surface;

a top layer on the basis of synthetic material having a nominal thickness D 3 ; and

a wood-based substrate such that at least the substrate, the paper layer and the top layer are laminated together to form a laminated structure;

said substrate having at least two opposite edges, said edges being provided with coupling parts;

wherein said substantial part of said upper surface of the laminated structure forms at least one embossed portion; said embossed portion forming a sunk edge area located at least one of said two opposite edges and extending into the wood-based substrate;

wherein the printed décor continuously extends over and along the at least one embossed section so as to follow the contours of the at least one embossed portion;

wherein the laminated structure gradually increases in compaction across the at least one embossed portion from a first thickness of the floor panel to a region located at said sunk edge area.

24. The floor panel of claim 23 , wherein the printed décor is provided on a paper layer extending continuously across the panel from the first thickness to the sunk edge area.