U.S. patent application number 09/770581 was filed with the patent office on 2002-08-01 for textured laminate flooring.
Invention is credited to Brownlee, David M., Miller, Robert J., Thompson, Kevin Allen.
Application Number | 20020100231 09/770581 |
Document ID | / |
Family ID | 25089046 |
Filed Date | 2002-08-01 |
United States Patent
Application |
20020100231 |
Kind Code |
A1 |
Miller, Robert J. ; et
al. |
August 1, 2002 |
Textured laminate flooring
Abstract
A decorated floor panel having a core with a top surface and an
opposite bottom surface; a decorative layer coupled to the top
surface of the core, the decorative layer having a desired
aesthetic appearance; and a wear layer coupled to and substantially
covering the decorative layer for protecting the decorative layer.
The wear layer has an exposed wear surface with depressions therein
of a variable depth below the wear surface, the depressions being
arranged to display a desired texture pattern. It is noted that
this abstract is provided to comply with the rules requiring an
abstract that will allow a searcher or other reader to ascertain
quickly the subject matter of the technical disclosure. The
abstract is submitted with the understanding that it will not be
used to interpret or limit the scope or meaning of the claims
pursuant to 37 C.F.R. .sctn. 1.72(b).
Inventors: |
Miller, Robert J.; (Dalton,
GA) ; Thompson, Kevin Allen; (Dalton, GA) ;
Brownlee, David M.; (Chattanooga, TN) |
Correspondence
Address: |
Allan G. Altera, Esq.
NEEDLE & ROSENBERG, P.C.
The Candler Building, Suite 1200
127 Peachtree Street, N.E.
Atlanta
GA
30303-1811
US
|
Family ID: |
25089046 |
Appl. No.: |
09/770581 |
Filed: |
January 26, 2001 |
Current U.S.
Class: |
52/177 ; 52/313;
52/314; 52/316; 52/390 |
Current CPC
Class: |
B44F 11/06 20130101;
B44C 5/0469 20130101; B44F 9/02 20130101; Y10T 428/24777 20150115;
E04F 15/02 20130101; B32B 2419/00 20130101; B32B 3/30 20130101;
D21H 27/28 20130101; B44C 5/0476 20130101; B32B 21/02 20130101;
Y10T 428/24355 20150115 |
Class at
Publication: |
52/177 ; 52/313;
52/314; 52/316; 52/390 |
International
Class: |
E04F 015/022 |
Claims
What is claimed is:
1. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
a desired aesthetic appearance; and c. a wear layer coupled to and
substantially covering the decorative layer for protecting the
decorative layer, the wear layer having an exposed wear surface
with depressions therein of a variable depth below the wear
surface, the depressions being arranged to display a desired
texture pattern.
2. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
a desired aesthetic appearance; and c. a wear layer coupled to and
substantially covering the decorative layer for protecting the
decorative layer, the wear layer having an exposed wear surface
with depressions therein, at least one depression reaching a depth
of at least 0.50 millimeters below the wear surface, the
depressions being arranged to display a desired texture
pattern.
3. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
a desired aesthetic appearance; and c. a wear layer coupled to and
substantially covering the decorative layer for protecting the
decorative layer, the wear layer having an exposed wear surface
with depressions therein, at least one depression reaching a depth
of at least 1.0 millimeters below the wear surface, the depressions
being arranged to display a desired texture pattern.
4. The decorated floor panel of claim 1, wherein the panel includes
a first pair of parallel sides, wherein the parallel sides have
tongue and groove cuts along the parallel sides to provide
interlocking engagement.
5. The decorated floor panel of claim 4, wherein the panel includes
a second pair of parallel sides, the second pair of parallel sides
being perpendicular to each of the first pair of parallel sides and
wherein the second pair of parallel sides have tongue and groove
cuts to provide interlocking engagement.
6. The decorated floor panel of claim 1, wherein the core comprises
fiber board.
7. The decorated floor panel of claim 1, wherein the decorative
layer comprises paper and substantially covers the top surface of
the core.
8. The decorated floor panel of claim 1, wherein the wear layer
comprises melamine reinforced with aluminum oxide.
9. The decorated floor panel of claim 1, further comprising a
backing layer coupled to and substantially covering the bottom
surface of the core as a reinforcing element.
10. The decorated floor panel of claim 9, wherein the backing layer
comprises melamine reinforced with aluminum oxide.
11. The decorated floor panel of claim 1, wherein the aesthetic
appearance of the decorative layer is a hardwood flooring
design.
12. The decorated floor panel of claim 1, wherein the aesthetic
appearance of the decorative layer is a ceramic flooring tile
design.
13. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 0.50
millimeters.
14. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 1.0
millimeters.
15. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 1.50
millimeters.
16. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 2.0
millimeters.
17. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 2.50
millimeters.
18. The decorated floor panel of claim 1, wherein at least one
depression in the wear surface reaches a depth of at least 3.0
millimeters.
19. The decorated floor panel of claim 11, wherein the hard wood
flooring design includes the visual appearance of at least one
knothole, and wherein the wear surface has at least one depression
therein in registration with the knothole.
20. The decorated floor panel of claim 19, wherein the knothole is
substantially circular and wherein the corresponding depression in
registration with the knothole is also substantially circular in
top plan view.
21. The decorated floor panel of claim 12, wherein the ceramic
flooring tile design includes the visual appearance of at least one
groutline, and wherein the wear surface has at least one depression
therein in registration with the groutline.
22. The decorated floor panel of claim 21, wherein the groutline is
substantially square and wherein the corresponding depression in
registration with the groutline is also substantially square in top
plan view.
23. The decorated floor panel of claim 21, wherein the
corresponding depression in registration with the groutline has a
non-smooth and rough texture.
24. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
an appearance of a hardwood flooring design including at least one
knothole; and c. a wear layer coupled to and substantially covering
the decorative layer for protecting the decorative layer, the wear
layer having an exposed wear surface with depressions therein of a
variable depth below the wear surface, the depressions being
arranged to display a desired texture pattern including at least
one depression in registration with the knothole.
25. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
a desired aesthetic appearance forming a decorative pattern; and c.
a wear layer coupled to and substantially covering the decorative
layer for protecting the decorative layer, the wear layer having an
exposed wear surface having a desired texture pattern thereon, the
texture pattern comprising a plurality of depressions imparted to
the wear layer, the relative orientation of the texture pattern and
the decorative pattern being controlled such that the decorative
pattern and the texture pattern are substantially in
registration.
26. The decorated floor panel of claim 25 wherein the aesthetic
appearance of the decorative layer is a hardwood flooring
design.
27. The decorated floor panel of claim 25 wherein the aesthetic
appearance of the decorative layer is a ceramic flooring tile
design.
28. A floor system including at least two interlocking panels, each
panel comprising: a. a core having a top surface, an opposite
bottom surface, a first pair of parallel sides having tongue and
groove cuts and a second pair of parallel sides having tongue and
groove cuts, each of the second pair of parallel sides being
perpendicular to each of the first pair of parallel sides; b. a
decorative layer coupled to the top surface of the core, the
decorative layer having a desired aesthetic appearance; and c. a
wear layer coupled to and substantially covering the decorative
layer for protecting the decorative layer, the wear layer having an
exposed wear surface with depressions therein of a variable depth
below the wear surface, the depressions being arranged to display a
desired texture pattern.
29. A decorated floor panel comprising: a. a core having a top
surface and an opposite bottom surface; b. a decorative layer
coupled to the top surface of the core, the decorative layer having
a desired aesthetic appearance; and c. a wear layer having a
thickness and being coupled to and substantially covering the
decorative layer for protecting the decorative layer, the wear
layer having an exposed wear surface with at least one depression
that extends at least 0.50 millimeters below the wear surface and
to a depth up to 0.25 millimeters less than the thickness of the
wear layer.
30. The decorated floor panel of claim 29, wherein at least one
depression in the wear surface extends at least 0.50 millimeters
below the wear surface and to a depth up to 0.50 millimeters less
than the thickness of the wear layer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to flooring panels
for use in commercial, industrial or residential environments. More
particularly, this invention relates to flooring panels having an
aesthetically pleasing appearance provided by texturing imparted to
the surface of the panels. In certain embodiments, the texture is
aligned in registration with a visible graphic design displayed by
the panel to further enhance the aesthetic appearance of the
flooring panel.
[0003] 2. Background Art
[0004] Various laminates, including high pressure laminates and
fiberboard core laminates, are commonly used in flooring
applications. Fiberboard core laminates used to manufacture
flooring products include a plurality of layers, including a
fiberboard or organic composite core section, a decorative layer,
and a hard and flat protective wear layer of resin-impregnated
melamine material.
[0005] The wear layer of the laminate in such systems is typically
clear, such that the aesthetic appearance, including any color
and/or printed image of the decorative layer, is not obscured by
the wear layer. Further, the top surface of the wear layer is
typically flat, such that the flooring panel exhibits a
two-dimensional appearance to the onlooker. Thus, while the
decorative layer may exhibit an appearance that simulates "natural"
flooring materials such as hardwood or ceramic tile, the typical
laminate wear layer simply allows an unobstructed view of the
laminate decorative layer, and does not add to or enhance the
aesthetic properties of the flooring panel.
[0006] Some prior art laminate flooring systems have included
barely-perceptible indentations imparted to the laminate wear layer
to interrupt the aforementioned two-dimensional appearance. Those
systems feature shallow indentations of a depth not exceeding 0.25
millimeters ("mm"). Further, the location of individual
indentations or the "pattern" of indentations provided in prior art
systems are unrelated and unlinked to the aesthetic image provided
by the decorative laminate layer. Thus, any indentation pattern in
prior art laminate wear layers is not related in any way to the
selected aesthetic appearance of the decorative laminate layer.
SUMMARY OF THE INVENTION
[0007] The present invention, in one embodiment, is a decorated
floor panel including a core having a top surface and an opposite
bottom surface. A decorative layer is adhered to the top surface of
the core and, in one embodiment, substantially covers the core. A
desired aesthetic appearance, such as a hardwood or ceramic tile
appearance, is displayed by the decorative layer of the laminate.
Finally, a wear layer is provided over the decorative layer,
substantially covering the decorative layer and providing
protection from the ambient environment. The wear layer has an
exposed wear surface with depressions therein of a variable depth
below the wear surface, the depressions being arranged to display a
desired texture pattern.
[0008] In another aspect, the present invention is a decorated
floor panel as set forth above, wherein the depressions in the wear
surface have a depth of at least 0.50 mm below the nominal surface
of the wear layer. In this embodiment, the depressions may all be
of a constant depth or, alternatively, of a variable depth as
exists for the embodiment discussed above.
[0009] In yet another aspect, the present invention is a decorated
floor panel in which the decorative layer is provided with a
decorative pattern. In one embodiment, a plurality of depressions
imparted to the wear layer form a desired texture pattern thereon.
The relative orientation of the texture pattern and the decorative
pattern is controlled such that the depression pattern and the
texture pattern are substantially in registration, creating an
enhanced, three-dimensional aesthetic appearance to the decorated
floor panel.
[0010] In yet another aspect, the present invention is a floor
system comprised of a plurality of individual decorated floor
panels assembled together and interlocking with each other by
tongue and groove engagement, which is not visible after the floor
panels are assembled.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of an embodiment of the
decorated floor panel according to the present invention.
[0012] FIG. 1A is an enlarged fragmentary view of an embodiment of
the decorated floor panel of FIG. 1, the texture pattern being
represented out of registration with the decorative pattern.
[0013] FIG. 1B is an enlarged fragmentary view of an embodiment of
the decorated floor panel of FIG. 1, the texture pattern being
represented in registration with the decorative pattern.
[0014] FIG. 2 is a section taken along lines 2-2 in FIG. 1.
[0015] FIG. 3 is a perspective cut-away view of an embodiment of
the decorated floor panel according to the present invention.
[0016] FIG. 4 is a perspective view of a group of decorated floor
panels according to the present invention assembled to form a
portion of a floor system.
[0017] FIG. 5 is a section taken along lines 5-5 in FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The present invention is more particularly described in the
following examples that are intended as illustrative only since
numerous modifications and variations therein will be apparent to
those skilled in the art. As used in the specification and in the
claims, "a," "an," or "the" can mean one or more, depending upon
the context in which it is used. The preferred embodiment is now
described with reference to the figures, in which like numbers
indicate like parts throughout the figures.
[0019] Referring to FIG. 1, the present invention, in one
embodiment, is a decorated floor panel 10. In the illustrated
embodiment, the panel 10 is manufactured from a laminated material
having a fiberboard core. Alternatively, the floor panel 10 of the
invention may be manufactured from other materials, including other
laminates such as high pressure laminate ("HPL"), which have been
marketed under such trade names as Formica and Pergo. Other
materials may also be utilized to construct the floor panel, such
as other natural, recycled or synthetic materials.
[0020] The fiberboard core laminate illustrated in FIG. 3 includes
a plurality of discrete layers, including a wear layer 12, a
decorative layer 14, a core 16 and a backing layer 24. The
illustrated core 16 is preferably manufactured of fiberboard, such
as that marketed by companies including Louisiana Pacific, Georgia
Pacific, Temple Inland and Weyerhauser. The presently preferred
fiberboard core material is formed of high density fiberboard,
which is a hardwood/softwood fiber compound compressed at 900-960
kg/m.sup.3. The preferred fiberboard core material is usually
available in 4 or 5 feet widths and lengths of up to 18 feet. In
other embodiments, cores 16 of different materials or having
different properties may be utilized, including other timber-based
products, such as plywood, chipboard or particleboard.
[0021] Referring now to FIGS. 2 and 3, the core 16 has a top
surface 18 and an opposite bottom surface 20. When installed, the
bottom surface 20 of the core 16 faces the underlying subfloor (not
shown). FIG. 3 illustrates an embodiment having an optional backing
layer 24 adhered to the bottom surface 20 of the core 16. Because
the illustrated fiberboard core is not completely impervious to
moisture and contaminants, such a backing layer 24 may be provided
to improve moisture resistance of the floor panel 10. Additionally,
the backing layer 24 may improve structural integrity of the floor
panel 10 by increasing overall thickness and reducing the warp and
wear tendencies of uncoated core material. In one embodiment, a
clear backing layer 24 of melamine, reinforced with aluminum oxide
(AlO.sub.2) and impregnated with a thermosetting resin, is
utilized. In such an embodiment, an optional layer (not shown) may
be interposed between the bottom surface 20 of the core 16 and the
backing layer 24. In one embodiment, the optional layer is
constructed of paper. The optional layer may display a printed
image, such as a trademark, product number or name, or any other
desired marking or designation. In other embodiments, backing
layers 24 may be constructed of other materials providing suitable
moisture resistance, such as phenolic resins or other natural,
synthetic or recycled materials.
[0022] A decorative layer or "decor" layer 14 is adhered, joined,
or coupled to the top surface 18 of the core 16 by a chemical
adhesive, mechanical connection, or other means known in the art.
In the illustrated embodiment, the decorative layer 14 is a sheet
of paper that substantially covers the top surface 18 of the core
16. Thus, in the illustrated embodiment, the top and bottom
surfaces 18, 20 of the core 16 are covered by the decorative layer
14 and the backing layer 24, respectively. The visible side of the
decorative layer 14, i.e., the side not adhered to the core 16, is
capable of displaying a desired aesthetic appearance, such as a
color or pattern. Virtually any color or pattern may be imparted to
the decorative layer 14. For example, currently contemplated
patterns include simulated hardwood flooring and simulated ceramic
tile, each in a variety of styles, shades and colors. Currently
contemplated simulated hardwood styles include pine, heart pine,
cherry, maple, beech, oak and mahogany. Simulated tile appearances
are contemplated in a range of styles, including a variety of
marble and ceramic tile colors, including groutlines in ceramic
tile styles. Other currently contemplated patterns include floral
patterns, abstract designs, geometric designs and company logos.
Other patterns may be selected by the manufacturer or user
according to aesthetic preference or design objectives.
[0023] As mentioned above, in one embodiment the decorative layer
14 is manufactured from paper that may be impregnated with a
thermosetting resin and provided with the desired aesthetic color
and/or pattern. In other embodiments that are not shown, other
materials may make up the decorative layer 14, such as real wood
veneer, pulverized stone, or other materials. Additionally, it is
possible to achieve a similar decorative appearance by either a
direct or indirect printing process directly onto the top surface
18 of the core 16. In such an embodiment, the decorative layer 14
comprises whatever ink, dye, pigment or other marking substance
applied to the core 16. Alternatively, the decorative appearance
may be provided by etching, burning or otherwise marring the top
surface 18 of the core 16. Any such treatment that supplies such a
decorative appearance on the top surface 18 of the core 16 is
contemplated to comprise the decorative layer 14 as defined
herein.
[0024] Referring now to FIG. 3, a wear layer 12 is provided over
the decorative layer 14, substantially covering the decorative
layer 14 and providing protection from the ambient environment. The
wear layer 12 is adhered, joined, or coupled to the decorative
layer 14, just as the decorative layer 14 is joined to the
underlying core 16. In one embodiment, the wear layer 12 is
comprised of a melamine sheet, reinforced with aluminum oxide
(AlO.sub.2) and impregnated with a thermosetting resin. It is
preferred, though not required, that the material selected to
comprise the wear layer 12 be the same or similar material as that
selected to comprise the backing layer 24, if a backing layer 24 is
utilized. Using "matched" materials for those layers has been found
to minimize "warping" and "bowing" of the laminate material.
[0025] Alternatively, a layer of varnish or a UV curable scratch
resistant coating may be used in place of the melamine sheet to
comprise the wear layer 12. As further alternatives, other
materials providing suitable moisture resistance and resilience to
loads and wear to which a floor is subjected may be utilized, such
as phenolic resins or other natural, synthetic or recycled
materials.
[0026] After manufacture of the laminate material, the wear layer
12 is substantially transparent, so that the aesthetic appearance
of the decorative layer 14 is substantially unobstructed by the
wear layer 12. It has been determined that the inclusion of a wear
layer 12 as the outermost layer of the laminate generally improves
the resistance of the floor panel 10 to wear, including staining or
fading of the aesthetic image imparted to the decorative layer
14.
[0027] As illustrated in FIGS. 2 and 5, the outermost wear surface
26, i.e., the top surface of the wear layer 12 that is exposed to
the ambient environment, is provided with a textured surface
condition. Thus, in addition to the decorative aesthetic image
displayed by the decorative layer 14, further aesthetic effect may
be achieved by imparting depressions of a constant or variable
depth to the wear surface 26, arranged to display a desired texture
pattern. For example, in the embodiment illustrated in FIG. 1 in
which the decorative pattern is a wood grain, a texture pattern
featuring depressions designed to simulate wood grain may be
provided. As a further example, in an embodiment in which the
decorative pattern is a simulated ceramic tile having tile portions
surrounded by groutlines, a texture pattern having an irregular
simulated stone texture and roughened or non-smoothed depressions
to simulate recessed grout may be provided. These examples are
merely illustrative and are not intended to be exhaustive. Other
decorative patterns and texture patterns may be selected by the
manufacturer or user according to aesthetic preference or design
objectives. When referencing depressions, one skilled in the art
will appreciate that this term excludes the edges circumscribing
the panel and instead encompasses "depressions" within the
periphery of the edges.
[0028] In the embodiment shown in FIG. 1A, the texture pattern is
imparted to the floor panel 10 without regard to the positioning of
the decorative pattern. Thus, in this embodiment, the wood grain
pattern displayed in the decorative layer 14 (depicted in dashed
lines in FIG. 1A) does not necessarily "match," register with, or
correspond to the wood grain pattern imparted as three-dimensional
texture in the wear layer 12 (depicted in solid lines in FIG.
1A).
[0029] In another embodiment, shown in FIG. 1B, the texture pattern
and the decorative pattern may be controlled during the
manufacturing process such that the patterns "match." In the
hardwood floor panel example, therefore, the textured grain pattern
may be imparted to wear layer 12 (solid lines) in registration with
the visible grain pattern in the decorative layer 14 (dashed
lines). In such an embodiment, lines of depression in the wear
layer 12 are located adjacent or substantially on top of the
printed grain lines in the decorative layer 14 of the laminate,
providing an enhanced and more realistic aesthetic appearance.
[0030] As a further example, "knothole" patterns 30 in the
decorative layer 14 are substantially overlaid by correspondingly
shaped depressions in the wear layer 12 in FIG. 1 B. Thus, in this
embodiment, the hard wood flooring design displayed by the
decorative layer 14 includes the visual appearance of at least one
knothole 30. The wear surface 26 has at least one depression
therein in registration with the knothole 30. The knothole 30 may
be of a variety of shapes. In one embodiment, the knothole 30 is
substantially circular, and the corresponding depression in
registration with the knothole 30 is also substantially circular in
top plan view. Other embodiments are contemplated in which the
knothole 30 has other shapes, such as an oval shape or some
irregular shape similar to those found in natural hardwood planks.
Such alternate embodiments are within the scope of the present
invention.
[0031] In a currently contemplated hardwood embodiment, the
depressions in the wear layer 12 in registration with the
decorative pattern are imparted to a depth of at least 0.30 mm
below the wear surface 26. In another contemplated embodiment, the
depressions in the wear layer 12 in registration with the
decorative pattern are imparted to a depth of at least 0.50 mm
below the wear surface 26. In still another contemplated
embodiment, the depressions are imparted to a depth of at least 1.0
mm below the wear surface 26. In yet other contemplated
embodiments, the depressions are imparted to a depth of at least
1.50 mm, 2.0 mm, 2.50 mm, or 3.0 mm, respectively, below the wear
surface 26. The possible width of the depressions is unlimited, but
in presently preferred embodiments, widths of between approximately
1.0 mm and 25.0 mm have been utilized.
[0032] Similarly, in the simulated ceramic tile embodiment shown in
FIGS. 4 and 5, the texture pattern may be imparted to the wear
layer 12 in registration with the image imparted to the decorative
layer 14. In one embodiment, the ceramic tile design of the
decorative layer 14 includes the visual appearance of at least one
groutline 40, and the wear layer 12 has at least one depression
therein in registration with the groutline 40. In embodiments where
the groutline 40 imparted to the decorative layer 14 is
substantially square in shape, the corresponding depression in
registration with the groutline 40 is also substantially square in
top plan view. In another embodiments, the groutline 40 may be
provided in any selected pattern, including but not limited to
triangular, hexagonal, octagonal, or other patterns. Such alternate
embodiments are within the scope of the present invention.
[0033] In a currently contemplated simulated ceramic tile
embodiment, the depressions in the wear layer 12 in registration
with the groutline 40 are imparted to a depth below the wear
surface 26 of at least 0.30 mm. In another contemplated embodiment,
the depressions in the wear layer 24 in registration with the
groutline 40 are imparted to a depth below the wear surface 26 of
at least 0.50 mm. In still another contemplated embodiment, the
depressions are imparted to a depth below the wear surface 26 of at
least 1.0 mm. In yet other contemplated embodiments, the
depressions are imparted to a depth of at least 1.50 mm, 2.0 mm,
2.5 mm, or 3.0 mm, respectively, below the wear surface 26. The
possible width of the depressions is unlimited, but in presently
preferred embodiments, widths of between approximately 5.0 mm and
10.0 mm have been utilized.
[0034] Also in simulated ceramic tile embodiments of the present
invention, a "rough" simulated stone texture may be imparted to the
areas of the wear layer 12 overlaying the simulated stone image 42
in the decorative layer 14. Further, any recessed depression in the
wear layer 12 substantially overlaying the simulated groutline 40
in the decorative layer 14 may be provided with a "rough" simulated
grout texture that is non-smooth visually and to the touch. This
non-smooth and "rough" appearance more closely emulates the
appearance of stone.
[0035] The selected texture pattern is usually, though not always,
imparted to the wear layer 12 in a single manufacturing step, at
the time the laminate layers are laminated together. In such an
embodiment, the various laminate layers are positioned within a
press (not shown) having a caul plate (also not shown) provided
with an inverse impression of the selected texture pattern. After
the laminate layers are positioned within the press, the caul plate
is lowered to contact the wear layer 12 of the laminate. In a
single step, under heat and pressure for a selected period of time,
the layers are laminated together and the texture pattern is
imparted to the wear layer 12 by the action of the caul plate.
Through experimentation, it has been noted that satisfactory
results may be obtained by the application of between 380-420 psi
at between 350.degree. F. -400.degree. F. for a period of 18-60
seconds. These parameters are set forth by way of example only for
an approximately 6.0 mm thick melamine wear layer product sold by
the Mead Corporation. It is expected that any of these parameters
will vary depending on the degree and depth of depressions sought
to be imparted to the wear layer or depending on the
characteristics of the selected wear layer material. One skilled in
the art will appreciate that after experimentation, other
parameters may produce similarly satisfactory results.
[0036] Alternatively, the texture pattern may be imparted to the
wear layer 12 in a separate operation, after lamination of the
various layers into a single workpiece.
[0037] The depth to which the wear layer 12 is depressed to provide
the full texture patterns may be controlled during the
manufacturing process. It is contemplated that to provide the most
beneficial texture pattern, depressions of a depth at least 0.25 mm
should be imparted to the wear layer 12. More specifically,
depressions of between 0.30 mm and 5.75 mm in depth, more
preferably between 1.0 mm and 5.75 mm in depth, and most preferably
between 1.5 mm and 5.75 mm in depth, measured from the nominal
surface of the wear layer 12, have been found to provide the
greatest aesthetic effect while not diminishing performance of the
overall floor system. These ranges are applicable in embodiments in
which a melamine wear layer of approximately 6.0 mm thickness,
manufactured by the Mead Corporation, is utilized. It has been
found that depressions of a depth up to 0.25 mm less than the
nominal thickness of such a wear layer 12 may be achieved using the
above-described manufacturing methods; that is, if the nominal
thickness is 5.0 mm, then the deepest depressions preferably should
be no greater than 4.75 mm. In another preferred embodiment, the
deepest depressions should be of a depth up to 0.50 mm less than
the nominal thickness of the wear layer 12.
[0038] It is expected that if other thicknesses, materials or
manufacturing methods are selected to comprise the wear layer 12,
different preferred ranges may exist for each selected
material.
[0039] Additional process controls or equipment may be required to
manufacture flooring panels 10 according to embodiments of the
invention in which substantial registration between the decorative
pattern and the texture pattern are required. In a presently
preferred embodiment, a short-cycle press manufactured by Wemhoner
and operated by Stiles Machinery, 3965 44th St. S. E., Grand
Rapids, Mich. 49512 has been found satisfactory for achieving such
registration between the decorative pattern and the texture
pattern.
[0040] During the manufacturing process, in one embodiment, the
various separate layers are assembled in preparation for
lamination. In the embodiment shown in FIG. 3, for example, a
backing layer 24, a core 16, a decorative layer 14 and a wear layer
12 are stacked together before entering the press. Through
processing equipment controls such as a single sheet alignment
system and electrostatic bonding of the various laminate layers
prior to entry into the press, alignment between the decorative
pattern displayed by the decorative layer 14 and the texture
pattern imparted to the wear layer 12 by the caul plate may be
achieved within a tolerance of 0.125 inches.
[0041] As illustrated in FIG. 5, individual floor panels 10
according to the invention may be assembled to form a complete
floor system. To facilitate assembly, individual floor panels may
be provided with means for interlocking with adjacently placed
panels. As shown in FIG. 1, each floor panel 10 may include a first
pair of parallel sides 50, 52 having tongue and groove cuts along
the first and second parallel sides 50, 52, respectively. Each such
floor panel 10 further includes a second pair of parallel sides 54,
56, perpendicular to each of the first pair of parallel sides 50,
52, also having tongue and groove cuts. Thus, each such floor panel
10 is capable of interlocking engagement with an adjacent panel.
Alternatively, locking edge connections, such as that described in
U.S. Pat. No. 6,006,486 to Moriau et al. (which is incorporated
herein in its entirety by reference), may be utilized to form a
floor covering system in which neighboring floor panels 10 are
detachably secured to one another through a mechanical
interlock.
[0042] Along the edges of the floor system, perimeter panels may be
cut to length as needed to fit the installation environment and
fitted with matching trim pieces (not shown) to provide an
aesthetically attractive fit adjacent walls, stairs, doorways or
other obstructions or transition areas.
[0043] In a presently preferred embodiment, individual floor panels
10 are manufactured to a width of 111/2 inches and a length of
46{fraction (1/16)} inches, with an approximate thickness of
{fraction (5/16)} inches. One skilled in the art will appreciate
that other panel sizes may be used without departing from the scope
of the invention.
[0044] Although the present invention has been described with
reference to specific details of certain embodiments thereof, it is
not intended that such details should be regarded as limitations
upon the scope of the invention except as and to the extent that
they are included in the accompanying claims.
* * * * *