U.S. patent application number 11/326492 was filed with the patent office on 2006-07-06 for floor panel and method for manufacturing a floor panel.
Invention is credited to Laurent Meersseman, Oke Nollet.
Application Number | 20060144004 11/326492 |
Document ID | / |
Family ID | 36638775 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060144004 |
Kind Code |
A1 |
Nollet; Oke ; et
al. |
July 6, 2006 |
Floor panel and method for manufacturing a floor panel
Abstract
Floor panel, whereby this floor panel (1) comprises a decor
(10), as well as a top layer (11) on the basis of synthetic
material (12), and whereby the upper side (2) of the floor panel
(1) imitates slate or another flaky kind of stone, characterized in
that the floor panel (1) comprises terrace-shaped impressions (18)
at its upper side (2).
Inventors: |
Nollet; Oke; (Aalter,
BE) ; Meersseman; Laurent; (Kortrijk, BE) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE
FOURTH FLOOR
ALEXANDRIA
VA
22314
US
|
Family ID: |
36638775 |
Appl. No.: |
11/326492 |
Filed: |
January 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60674717 |
Apr 26, 2005 |
|
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|
Current U.S.
Class: |
52/578 |
Current CPC
Class: |
E04F 2201/0115 20130101;
B44C 1/24 20130101; B44C 5/0492 20130101; B44F 9/04 20130101; E04F
15/02 20130101; E04F 15/02033 20130101 |
Class at
Publication: |
052/578 |
International
Class: |
E04C 3/00 20060101
E04C003/00; E04C 3/30 20060101 E04C003/30 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 6, 2005 |
BE |
2005/0009 |
Claims
1. Floor panel, comprising a decor, as well as a top layer on the
basis of synthetic material, and wherein the upper side of the
floor panel imitates slate or another flaky kind of stone, further
wherein the floor panel comprises terrace-shaped impressions at its
upper side.
2. Floor panel according to claim 1, wherein the decor represents a
pattern that is realized as a function of the kind of stone to be
imitated.
3. Floor panel according to claim 1, wherein the printed decor
comprises shadow lines and/or transition lines following at least
partially the contour of a flake of the imitated kind of stone.
4. Floor panel according to claim 1, wherein the terrace-shaped
impressions are at least partially corresponding to a pattern
represented by the decor.
5. Floor panel according to claim 1, wherein the terrace-shaped
impressions comprise terraces, which are substantially situated in
planes that are substantially parallel to the plane in which the
floor panel extends, such that the terraces form zones that are
realized from terrace to terrace at a different depth.
6. Floor panel according to claim 1, wherein the terrace-shaped
impressions are obtained as the result of a press treatment with a
press plate, the latter having obtained a terraced surface by means
of several etching treatments.
7. Floor panel according to claim 1, wherein the terrace-shaped
impressions are obtained as a result of a press treatment with a
press plate, in which partially overlapping portions have been
etched away and that, in these etching treatments as such, one
works with two or more different etching depths (E1-E2), such that
the number of different heights, at which impressed terraces are
situated on the floor panel, is larger than the number of etching
treatments performed on the press plate.
8. Floor panel according to claim 7, wherein the terrace-shaped
impressions are the result of an embossment with a press plate, on
which at least five and still better at least eight etching
treatments have been performed, and further wherein at least a
number thereof, as such, has been realized with different etching
depths.
9. Floor panel according to claim 1, wherein the terrace-shaped
impressions that are formed by successive step-wise transitions,
such that the surface of the zones lying in between as such changes
in height, such that the height difference between two successive
terrace edges is smaller than the height difference at the location
of a transition, and preferably is zero or almost zero.
10. Floor panel according to claim 1, wherein the panel shows at
least two zones of different gloss degree, so that each of the
zones substantially corresponds to a visible portion of a flake of
the imitated kind of stone.
11. Floor panel according to claim 1, wherein the imitation of the
flaky stone continues over the entire floor panel, possibly with
the exception of the edges of the floor panel, whereby the floor
panel then imitates a single tile.
12. Floor panel according to claim 1, wherein the panel comprises
cut-away edge portions at one or more edges, so that the surface
formed by said cut-away edge portions is colored, for example, by
means of a covering applied by means of transfer printing, or by
means of a coloring agent, for example, a coloring agent applied by
means of a felt-tip pen, a lacquer or the like.
13. Floor panel according to claim 1, said panel comprising at
least at two opposite edges, and in the case of a rectangular floor
panel, whether oblong or square, preferably at all edges, coupling
means, which, in the coupled condition of two of such floor panels,
effect a vertical and horizontal locking.
14. Floor panel according to claim 13, wherein height differences
occur along the upper edge of the floor panel as a result of the
terraced construction, and in that along these upper edges
impressed zones are present and that all these zones along the
edges are limited to distances that are smaller than 10
centimeters.
15. Floor panel, comprising a single-layer or multi-layer or
single- or multipartite substrate, a decor, as well as a top layer
on the basis of synthetic material, wherein impressed zones are
present on the upper side of the floor panel, said zones extending
along at least a part of at least one upper edge of the floor panel
and that the floor panel, at least at the edge where said upper
edge is situated and at an opposed edge, is provided with
mechanical coupling means allowing to couple two of such floor
panels to each other, which coupling means thereby can effect a
locking in vertical and horizontal directions; and that these
coupling means are the result of a machining treatment, so that the
upper side of the floor panel is used as a reference, whereby the
location of the coupling means as a result of the impressed zones
fluctuates in height in respect to the substrate.
16. Floor panel according to claim 15, wherein the floor panel, at
the upper edge, is provided with a cut-away edge portion that is
colored.
17. Floor panel, comprising a single-layer or multi-layer or
single- or multipartite substrate, a decor, as well as a top layer
on the basis of synthetic material, and wherein the floor panel, at
least at two opposite edges is provided with mechanical coupling
means allowing to couple two of such floor panels to each other,
which coupling means thereby can effect a locking in vertical and
horizontal directions; wherein at the upper side of the floor panel
at least one impressed zone is present that is situated along an
upper edge of at least one of the aforementioned two opposite edges
of the floor panel; and wherein this impressed zone shows an
impression which, at least on the upper edge, effects a height
difference with as the largest value at least 0,1 mm; and that this
impressed zone extends along said upper edge over a distance of at
least 10 centimeters.
18. Method for manufacturing a floor panel, of the type that is
intended for forming a floating floor covering, wherein the floor
panel comprises a basic board with at the upper side a top layer on
the basis of synthetic material with impressions, and further
wherein the impressions are applied during a press treatment with a
press plate, on which at least five and still better at least eight
etching treatments have been performed, so that at least a number
of which, as such, have been performed with differing etching
depths and at least a number have been performed partially
overlapping.
Description
[0001] This invention relates to a floor panel, as well as to a
method for manufacturing such floor panel.
[0002] More particularly, the invention relates to a floor panel of
the type mostly called laminate panel.
[0003] It is known that such floor panel can be of varying
construction. Mostly, such floor panels comprise at least a
substrate, a printed decor, as well as top layer on the basis of
synthetic material.
[0004] It is also known that such floor panels can be applied for
forming a floating floor covering. Hereby, these floor panels,
during installation, are coupled at their edges, either by means of
a classical tongue and groove connection, whereby these possibly
are glued into each other, or by means of a mechanical coupling
providing for a mutual locking of the floor panels in horizontal as
well as in vertical directions, for example, as described in the
international patent application No. WO 97/47834. This patent
document also describes a possibility for manufacturing such
coupling means. Hereby, in the machining operation, the edge of the
upper side of the floor panel is used as a reference plane.
[0005] From the patent application No. WO 01/96689, it is known to
provide, by means of a press treatment with a structured press
plate, impressions in the transparent top layer, whereby these
impressions imitate a wood structure, such as wood pores and wood
knots. Hereby, the applied impressions may follow the printed wood
decor, with the intention of rendering the imitation more
realistic. In the case of such wood imitation, the impressions are
restricted to small impressions embossed at a substantially
constant depth.
[0006] The present invention has as an aim to imitate, with a floor
panel of the above-mentioned type, a flaky kind of stone, in
particular flaky natural stone, for example, slate, in a realistic
manner.
[0007] To this aim, the invention, according to its first aspect,
relates to a floor panel, whereby this floor panel comprises a
decor, as well as a top layer on the basis of synthetic material,
and whereby the upper side of the floor panel imitates slate or
another flaky kind of stone, with the characteristic that the floor
panel comprises terrace-shaped impressions at its upper side.
[0008] By "terrace-shaped impressions", impressions have to be
understood having at least two step-wise transitions in the same
direction, either downward or upward, between substantially
continuously impressions, further indicated as "terraces". The
application of such impression offers a technical solution
improving the realistic appearance of a floor panel imitating a
flaky kind of stone. Namely, such terrace-shaped impressions do
form a technical means, due to which flakes lying on top of each
other, the lowermost of which partially projects from under the
uppermost, can be imitated very true to nature. The terraces then
imitate, for example, each in its turn a visible portion of a
flake, whereas the step-wise transitions in the terrace-shaped
impressions imitate the transition between each two successive
flakes.
[0009] It is noted that, although these impressions substantially
are provided in a mostly transparent top layer of synthetic
material, contrary to all expectations, such terraces are clearly
perceptible and therefore the flaky structure to be imitated is
underlined in an optimum manner.
[0010] Preferably, the deepest impressions will be less deep than
the largest thickness of the top layer, still better they will be
less than 350 .mu.m deep. Deeper impressions, however, are not
excluded. These may even continue up into the underlying
substrate.
[0011] Globally, the decor may show substantially only one color.
In the case of imitating slate, this may be, for example, black or
gray, although other colors, amongst which light-tinted colors, are
not excluded.
[0012] Preferably, however, the decor represents a pattern that is
realized in function of the kind of stone to be imitated, whereby
then mostly indeed several colors and/or tints of a color are
applied. More particular, it is preferred that the pattern is
formed by an image of the flaky kind of stone to be imitated.
[0013] In the latter case, one may start, for example, from a real
slate or other flaky kind of stone, of which the image is
reproduced, for example, by scanning it. When scanning or such,
colors as well as height differences can be stored. These data do
form, after a possible processing thereof, for example, in order to
compensate paper shrinkage, the basis of the pattern of the printed
decor and the design of the press plate. Neither is it excluded,
according to the present invention, to construct an image for the
decor and/or to determine the structure for the impressions, more
particularly the aforementioned terrace-shaped impressions, and
possible other impressions in an artificial manner. Of course, it
is also possible to form a combination of, on the one hand, data
obtained starting from a real example of a flaky kind of stone and,
on the other hand, data constructed artificially.
[0014] The decor preferably is realized by means of a printing
technique.
[0015] The possible addition of dark shadow lines and/or transition
lines on the decor, where height differences occur in the natural
material, is advantageous for the imitation. Hereby, the shadow
lines and/or transition lines follow at least partially the contour
of one or more imitated flakes.
[0016] In a preferred form of embodiment of the invention, the
terrace-shaped impressions are at least partially corresponding to
the pattern of the decor. In this case, some, and preferably more
than 50% of the transitions between flakes represented in the decor
show a corresponding step-wise transition in the terrace-shaped
impressions of the top layer. In this case, the terraces formed
thereby will coincide at least partially with the visible portions
of the flakes depicted in the pattern of the decor.
[0017] In a particular form of embodiment, shadow lines and/or
explicit transitions are represented in the pattern and are the
terrace-shaped impressions at least partially applied in
correspondence to these shadow lines and/or transition lines. The
presence of a shadow line or transition line in the pattern at the
location where a step-wise transition is present in the
terrace-shaped impressions, enhances the natural appearance of the
imitation of a flaky kind of stone. Within the scope of the
invention, it is clear that the floor panel may also comprise
shadow lines having no corresponding impression in the top
layer.
[0018] According to a first possibility of the invention, the
terrace-shaped impressions will comprise terraces, which are
substantially situated in planes that are substantially parallel to
the plane in which the floor panel extends, whereby these terraces
form zones that are realized from terrace to terrace at a different
depth.
[0019] Such terrace-shaped impression can be obtained as the result
of a press treatment with a press plate, which has obtained a
terraced surface by means of several etching treatments, for
example, at least five and still better at least eight etching
treatments. Preferably, partially overlapping portions are etched
into the press plate, and still more preferably, these etching
treatments in their turn are realized with different etching
depths. The use of such press plate for producing the
terrace-shaped impressions provides for that the number of
different heights at which impressed terraces are located on the
floor panel, is larger than the number of etching treatments
performed on the press plate. In order to fully take advantage of
this specific technique, it is preferred that the overlapping areas
are chosen at least such that in one and the same floor panel at
least the double amount of height levels are present than etching
treatments have been applied in the corresponding portion of the
press plate.
[0020] A method for manufacturing a floor panel, where such press
plate has been applied, offers a broad range of new possibilities
for designing surface structures, more particularly surface
structures matching printed decors that represent natural
materials, such as natural stone. Therefore, the invention also
relates to a method for manufacturing a floor panel, of the type
that is intended for forming a floating floor covering, whereby
this floor panel consists of a basic board with at the upper side a
top layer on the basis of synthetic material, with impressions,
with the characteristic that the impressions are applied during a
press treatment with a press plate on which at least five and still
better at least eight etching treatments have been performed, at
least a number of which in their turn have been performed with
differing etching depths and at least a number have been performed
partially overlapping. It is clear that this method is not
restricted to the imitation of flaky kinds of stone.
[0021] Of course, such terrace-shaped impressions may also be
obtained as a result of a press treatment, whereby the press plate
is manufactured in another manner than described herein above.
Also, such terrace-shaped impressions can be realized as a result
of a treatment other than a press treatment, for example, by
systematically depositing synthetic materials to obtain a terraced
construction.
[0022] According to a second possibility of the invention, the
floor panel comprises terrace-shaped impressions that are formed by
successive terrace-shaped step-wise transitions, whereby the
surface of the zones lying in between as such changes in height,
such that the height difference between two successive terrace
edges is smaller than the height difference at the location of a
transition, and preferably is zero or almost zero. A floor panel
with such impressions has the same desired appearance of
terrace-shaped impressions, as well as the same tactile structure,
and moreover has the advantage that more step-wise transitions can
be realized in a top layer of the same thickness. Such technique
for manufacturing a laminate panel imitating a flaky kind of stone
is advantageous in view of the fact that preferably the deepest
impression is smaller than the largest thickness of the top layer,
and even better is smaller than 350 .mu.m. If desired, consequently
the top layer for the same impressed structure also can be made
thinner, for example, by forming it of a less thick layer of
resin.
[0023] Other possibilities for realizing the aforementioned
terrace-shaped impressions are not excluded.
[0024] Also, it is clear that within the scope of the invention,
terrace-shaped impressions according to the aforementioned first
possibility can be combined with terrace-shaped impressions
according to the aforementioned second possibility in one and the
same floor panel.
[0025] Within the scope of the invention, it is also possible that
the laminate panel additionally, either over its entire surface, or
over only a part thereof, for example, in several terraces,
comprises impressions that imitate the surface texture of a natural
stone, more particularly imitate a surface texture usually
occurring on a visible portion of a flake of real stone.
[0026] According to a particular form of embodiment, the floor
panel of this invention comprises several gloss degrees.
Preferably, it has at least two zones of different gloss degree,
whereby each of these zones substantially corresponds to a visible
portion of a flake of the imitated kind of stone. Preferably, at
least the entire or almost entire surface of one or more terraces
is matte, whereas the entire or almost entire surface of other
terraces then is relatively glossy. The use of different gloss
degrees causes the optical illusion that the matte impression seems
deeper than it really is. By making a number of terraces matte, the
number of optically "perceived" height differences on the floor
panel can be increased, whereas the real number of height
differences remains restricted. In this manner, by a press
treatment by means of a press plate that is etched a restricted
number of times and is rendered matte on some places, still a
realistic result, with a visual impression of several height
differences in the imitated kind of stone, can be achieved.
[0027] It is clear that, without leaving the scope of the
invention, also additional impressions can be realized in the top
layer of the floor panel by means of the press plate, for example,
impressions imitating a joint. Also, it is possible to realize the
different characteristics of the surface of the flaky kind of stone
by means of different press treatments, for example, a press
treatment providing the difference in gloss degree and the surface
texture, and a subsequent press treatment providing the
terrace-shaped impressions. Also, it is possible that the
aforementioned structure or certain portions thereof can be
obtained in another manner than by means of a profiled press plate,
for example, by means of a structured foil, a profiled roller, and
so on.
[0028] In order to further enhance the feeling of authenticity
during installation, a basic board or substrate can be provided
with a color matching the imitated kind of stone. In the case of
MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard),
this is possible, for example, by coloring the basic board with a
color component and/or by coloring the profiled edges entirely or
almost entirely. In this manner, a floor panel imitating slate can
be provided with a MDF or HDF basic board, which is colored with a
black-gray color component.
[0029] The imitation of the flaky kind of stone preferably will
continue over the entire floor panel, possibly with the exception
of the edges. At the edges, a joint can be imitated. However, the
invention does not exclude that several tiles are represented on
one floor panel, which tiles possibly are separated from each other
by an imitation of a joint. The shape of the floor panel basically
can be chosen freely, however, preferably the floor panel is
rectangular, either oblong or square. Also, the size of the floor
panel can be chosen freely. So, for example, relatively small floor
panels with all sides smaller than 20 cm are possible, as well as
large floor panels with two or more sides larger than 40 cm. Other
dimensions are, of course, not excluded. A particularly useful tile
format when imitating flaky kinds of stone, more particularly
slate, is in the order of magnitude of 40.times.40 cm, in
consideration of the fact that these dimensions in practice also
are the most merchantable for real flaky natural stone.
[0030] For one and the same floor covering, preferably several
tiles with different patterns are produced, for example, with more
than five and even better at least nine patterns, whereby tiles
with different patterns are packaged in a mixed manner, such that
there are different patterns in one package of floor panels,
whereby automatically a good mixture is obtained when installing
the floor covering.
[0031] According to a preferred form of embodiment of the
invention, the floor panel comprises, at one or more edges,
preferably at least at two opposite edges, and still better at all
edges, cut-away edge portions, such as, for example, bevels. The
surface obtained by the cut-away edge portions may or may not be
colored. This can be realized, for example, by means of a covering
provided on the surface, for example, by means of transfer
printing. The surface can also be provided with a color by direct
coloring with a coloring agent, such as a coloring agent applied by
means of a felt-tip pen or by means of impregnation, a lacquer, a
paint, or the like. The coloring either can be matched to the color
of the imitated kind of stone or not. In the case of a coloring
with a matched color, such cut-off edge portions imitate the small
rounding always present at the edges of real natural stone tiles.
In the case of the floor panels of this invention, they can be
applied solely in order to provide a more truthful representation
or in order to imitate, for example, a small joint. In both cases,
the size of the cut-away portion in horizontal direction best will
be smaller than three millimeters, and even better smaller than two
millimeters. The size of the cut-away portion in height is
preferably at least one millimeter. Also, the color can be chosen
such that it imitates a filled joint, such as a groutline.
[0032] When the coloring of the obtained surface also continues
downward up to over the edge of the cut-away portion, it is
prevented that, due to a possibly faulty height alignment of
adjacent floor panels, the material of the basic board becomes
visible in a disturbing manner.
[0033] In order to enable the installation of the floor panel of
this invention in a floating floor covering, the floor panel
comprises coupling means preferably at least at two opposite edges.
In the case of a rectangular or square floor panel, it preferably
comprises coupling means at all four edges. These coupling means
preferably provide for a locking in vertical and horizontal
directions.
[0034] When forming these coupling means, usually the edge of the
upper side of the floor panel is used as a reference for the
machining treatment, in view of the fact that the floor panel is
required to have its upper side perfectly adjoin to the upper side
of all adjacent floor panels in the floor covering. With the fact
that the upper side is used as a reference plane, is meant that the
floor panel, during the shaping of the coupling means, is moved
with its upper side along a reference plane, such as a sliding
shoe, the position of which is adjusted in function of the cutting
tools established along it. In order to prevent that the location
of the coupling means along the edge at which they are present
varies in height in respect to the basic board, it is preferred
that the differences in height occurring along the upper edge of
the floor panel as a consequence of the terrace-shaped impressions,
are restricted to zones smaller than 10 cm, as measured along the
edge of the floor panel. This means that an impressed zone along an
edge of the floor panel, according to this preferred form of
embodiment, never extends over a length of more than 10 cm, such
that the floor panel, during the shaping of the coupling means,
always is supported by the aforementioned sliding shoe or the like
at its highest or almost highest points of its upper edge. In the
known embodiments, such sliding shoe is of such length that
impressions over lengths of less than 10 cm will not be felt at a
floor panel moving along such sliding shoe, with as a result that
the aforementioned impressions have no disadvantageous effect on
the straightness of the profile of the coupling means along the
edges of the floor panels. In this manner, a disadvantageous factor
is excluded or minimized, namely the non-straightness of said
profiles, which, as known, may render the coupling of such floor
panels to each other difficult.
[0035] In general, it is noted that coupling means, the location of
which along the edge where they are located varies in respect to
the basic board, as aforementioned, may lead to difficult coupling
and bad adjoining of floor panels in a floor covering. Therefore,
it was always assumed that the length of impressions varying along
the edges of the floor panels always had to be kept restricted.
Indeed, it is so that, when this is taken into account, as
aforementioned a disadvantageous factor is excluded and minimized.
However, contrary to all expectations, the inventors have found
that this disadvantageous factor, which preferably still shall be
avoided, in fact is less detrimental than always thought up to now.
Thus, this means that also along the edges impressed zones varying
in depth can be created along the edges, said zones extending over
a larger distance than 10 cm along the respective edges. On one
hand, this indeed may render the mutual joining of floor panels
difficult to some extent, however, according to the present
invention it does not form a real problem. On the other hand, in
fact the freedom of design possibilities is enhanced, whereby, for
example, also more true to nature imitations can be realized, in
view of the fact that now it was found that the criteria for
performing impressions along the edges of a floor panel are less
stringent than presumed up to now. It is clear that the unexpected
possibility of providing impressions over such distances along the
edge, enhances the natural appearance of floor panels imitating
flaky kinds of stone. So, for example, starting from this fact, for
example, terrace-shaped impressions can be performed along the edge
of a panel that extend from the beginning to the end of an edge,
globally seen, downward-inclined in one direction.
[0036] This unexpected effect, in other words, the fact that floor
panels with non-straight and/or downward-inclined coupling means,
more particularly coupling parts, still can be interconnected in a
relatively smooth manner, may also be applied in floor panels
having other patterns and structures than for imitating flaky kinds
of stone, in which, for what reasons whatsoever, also along one or
more edges impressed zones are present, which, when providing the
coupling means, cause a fluctuation in the height of these coupling
means in respect to the substrate. Consequently, the invention,
according to a second independent aspect, also relates to a floor
panel, of the type that is intended for forming a floating floor
covering, whereby this floor panel comprises a single-layer or
multi-layer or single- or multipartite substrate, a decor, as well
as a top layer on the basis of synthetic material, with the
characteristic that impressed zones are present on the upper side
of the floor panel, said zones extending along at least a part of
at least one upper edge of the floor panel and that the floor
panel, at least at the edge where said upper edge is situated and
at an opposed edge, is provided with mechanical coupling means
allowing to couple two of such floor panels to each other, which
coupling means thereby can effect a locking in vertical and
horizontal directions; and that these coupling means are the result
of a machining treatment, whereby the upper side of the floor panel
is used as a reference, whereby the location of the coupling means
as a result of the impressed zones fluctuates in height in respect
to the substrate.
[0037] Even with a fluctuation of more than 0,2 mm in height, it
was unexpectedly found that the floor panels still can be
interconnected in an effective manner.
[0038] According to the second aspect of this invention, the floor
panel, at the upper edge, can be provided with a cut-away edge
portion that is colored, such as a beveled edge. Hereby is obtained
that possible differences in height between the substrates and top
layers of coupled-together floor panels are less perceptible.
Masking the bad adjoining of floor panels can also be obtained by
using a basic board with a color matching the imitated kind of
stone, instead by means of a cut-away edge portion.
[0039] According to a third and last aspect, the invention also
relates to a floor panel, of the type intended for forming a
floating floor covering, whereby this floor panel comprises a
single-layer or multi-layer or single- or multipartite substrate, a
decor, as well as a top layer on the basis of synthetic material,
and whereby this floor panel, at least at two opposite edges, is
provided with mechanical coupling means allowing to couple two of
such floor panels to each other, whereby these coupling means can
effect a locking in vertical and horizontal directions, with as a
characteristic that at the upper side of the floor panel at least
one impressed zone is present that is situated along an upper edge
of at least one of the aforementioned two opposite edges of the
floor panel; that this impressed zone shows an impression which, at
least in the upper edge, effects a height difference with as the
largest value at least 0,1 mm; and that this impressed zone extends
along said upper edge over a distance of at least 10 centimeters.
In view of the fact that the inventors unexpectedly found that a
floor panel with the characteristics of this third aspect, for
engaging and adjoining two of such floor panels, has less
detrimental consequences than presumed up to now, the possibility
of nevertheless manufacturing such panels and coupling them
relatively smooth with a relatively good adjoining, opens a broad
range of new design possibilities.
[0040] It is clear that here, too, the application of a cut-away
edge portion at the upper edge offers the already mentioned
advantages.
[0041] According to each aspect, various other preferred forms of
embodiment of the invention are possible. To this aim, reference is
made to the detailed description and appended claims.
[0042] With the intention of better showing the characteristics of
the invention, hereafter, as an example without any limitative
character, several preferred forms of embodiment are described,
with reference to the accompanying drawings, wherein:
[0043] FIG. 1 is a schematic representation of a floor panel
according to the invention;
[0044] FIG. 2, at a larger scale, represents a cross-section
according to line II-II in FIG. 1;
[0045] FIG. 3 represents in cross-section how two of such floor
panels can be coupled to each other;
[0046] FIGS. 4 and 5, strongly schematized and enlarged in height,
represent the portion indicated by F4 in FIG. 2, for two
variants;
[0047] FIG. 6, at a larger scale, represents a variant for the
portion indicated by F6 in FIG. 4;
[0048] FIG. 7, in top view, represents a possible embodiment of the
portion indicated by F7 in FIG. 1;
[0049] FIGS. 8 to 11 show schematic representations in connection
to methods for manufacturing floor panels according to the
invention;
[0050] FIG. 12 represents an enlargement of the portion indicated
by F12 in FIG. 3;
[0051] FIG. 13, at a larger scale, represents the portion indicated
by F13 in FIG. 2;
[0052] FIGS. 14 and 15 represent views analogous to that of FIG.
13, however, for two variants;
[0053] FIGS. 16 and 17, in a schematic manner, represent a possible
form of a cross-section according to line XVI-XVI in FIG. 2.
[0054] FIG. 1 is a strongly schematized representation of a
tile-shaped floor panel 1 according to the invention. The upper
side 2 of the floor panel 2 imitates the typical structure of a
flaky kind of stone. The represented imitated structure relates to
a slate structure, which is determined by portions 3 imitating
flakes lying on top of each other, whereby the lowermost project
only partially from below the uppermost, whereby the transitions 4
between the portions 3, as will be explained below, can be made
more clearly perceptible at least by means of a relief in the upper
side 2.
[0055] As represented in FIGS. 2 and 3, the floor panel 1, at least
at two opposite edges 5A-6A, is provided with coupling means, more
particularly coupling means 7-8, which, in coupled condition,
effect a locking in horizontal and vertical directions. Preferably,
also at the other edges, in this case, the edges 5B-6B, coupling
means are present that can effect a locking in horizontal and
vertical directions, which means either can be made identical to
the coupling means 7-8 or not.
[0056] As represented in FIGS. 2 to 4, the floor panel 1 comprises
a substrate or basic board 1, a preferably printed decor 10 and a
top layer 11 of synthetic material 12.
[0057] The substrate 9 preferably consists of a board on the basis
of wood, such as fiberboard or particle board, more particularly
MDF or HDF. Also, it is not excluded that such substrate 9 consists
of other materials, for example, of synthetic material. Also, such
substrate as such can be composed of several parts and/or
layers.
[0058] The represented floor panel 1 is of the DPL type (Direct
Pressure Laminate), which means that the aforementioned top layer
11 is directly pressed onto the substrate 9.
[0059] Hereby, the top layer 11, at least in the represented
example, consists of a so-called decor layer 13 and overlay 14. The
decor layer 13 is formed of a resin-impregnated carrier 15, such as
a paper web, upon which the printed decor 10 is present in the form
of a print. The overlay 14 is also formed of a resin-impregnated
carrier 16, which preferably also consists of paper or the like and
is of such nature that the carrier becomes transparent after
pressing. The resin of the decor layer 13 and the overlay 14 form
the aforementioned synthetic material 12 of the top layer 11.
[0060] At the underside of the substrate 9, in a known manner a
backing layer 17 can be present.
[0061] FIG. 4 represents the terrace-shaped impressions 18, which,
in accordance with the present invention, are present in the top
layer 11 of the floor panel 1. It is noted that the depth of the
terrace-shaped impressions 18 is represented in a strongly
exaggerated fashion. Whereas the represented cross-section running
according to the line II-II in FIG. 1, in width direction comprises
an entire floor panel with as preferred dimensions 40.times.40 cm,
the here represented impressions 18 in reality have a maximum depth
of, for example, 350 .mu.m. The exaggerated representation has the
purpose of enabling a better description of the geometry of the
terrace-shaped impressions 18.
[0062] In the form of embodiment of FIG. 4, the terrace-shaped
impressions 18 are characterized by substantially flat zones that
form terraces 19 and that are separated by step-wise transitions,
in particular the aforementioned transitions 4. In this case, the
impressions 18, and more particularly the terraces 19, are
substantially parallel to the plane in which the floor panel 1
extends. From terrace to terrace, the depth of the impression 18
changes. In FIG. 4 is also represented that not only the overlay
14, but possibly the decor layer 13, too, can be impressed as a
result of the impressions 18.
[0063] It is noted that in FIG. 4, as well as in the other
respective figures, the carriers 15 and 16 are represented only
schematically, and that these in reality shall not necessarily be
deformed in the illustrated manner.
[0064] FIG. 5 represents a view similar to that of FIG. 4, however,
for a variant. The represented impressions 18 herein are formed by
successive step-wise transitions 4, whereby the surface of the
zones 20 lying in between and forming the terraces 19 as such
varies in height, such that the difference in height between two
successive terrace edges 21, which thus form the transitions 4, is
smaller than the difference in height at the location of a
transition 4, and preferably is zero or almost zero. This latter
means that the terrace edges 21 represented in FIG. 5 all are
situated in the same or almost the same plane 22.
[0065] The embodiment of FIG. 5 allows to perform the impressions
18 less deep, whereas per transition 4 still the same step-wise
step or even a larger step-wise step than at each transition 4 in
FIG. 4 can be applied.
[0066] FIG. 6 shows that the terrace-shaped impressions 18 further
can also be combined with a relief 23 imitating a surface texture
in the terraces, in this case, 19, and/or that certain ones of the
terraces 19 can be provided with a matte-rendering relief 24, such
that the surface shows terraces 19 of different gloss degree. Of
course, various combinations are possible. The reliefs 23 and 24
either can be applied in the same floor panel and/or in the same
terrace or not. Further, all this is also possible in any form of
terrace-shaped impressions 18, thus with embodiments according to
FIGS. 4 and 5, as well as with other possible embodiments.
[0067] FIG. 7 shows, in top view, an embodiment, whereby the
terrace-shaped impressions 18 are corresponding to the pattern of
the printed decor 10, which here is printed in function of the
imitated kind of stone. The step-wise transitions 4 of the terraces
substantially are situated at the location where the decor 10
represents a transition between two flakes. Hereby, the successive
flakes are schematically represented in FIG. 7 by means of
different hatchings.
[0068] As also represented in FIG. 7, at the height of one or more
transitions 4, more particularly next to one or more of the
transitions 4, also a shadow line 25 can be represented in the
decor 10.
[0069] A possible method for manufacturing a floor panel 1
according to the invention is represented in FIG. 8. This relates
to a floor panel of the type that, as already described in respect
to FIG. 4, comprises a basic board 9 of MDF, a in this case printed
decor layer 13, an overlay 14 and a backing layer 17. Hereby, this
basic board 9 and all other layers are compressed in a heated press
26, whereby a consolidated whole is created. As in the press 26, a
press plate 27 is applied that comprises projections 28, which
substantially are the negative of the aforementioned impressions
18, after pressing a surface is obtained having the aforementioned
terrace-shaped impressions 18.
[0070] It is noted that by means of such press treatment, in
reality mostly a larger consolidated board is realized, namely a
board with a typical dimension of, for example, 2.times.5,5 m,
which subsequently is cut to form several floor panels 1. The
possible coupling means 7-8 then are provided per floor panel by
means of a milling treatment at the edges 5A-5B-6A-6B thereof.
[0071] In order to minimize the risk of porosity occurring in the
top layer at the height of the transitions 4, it is preferred that
pressures are applied that are higher than 70 bar, and still better
are at least 77 bar.
[0072] If a coincidence between the pattern of the decor 10 on the
decor layer 13 and the terrace-shaped impressions 18 is required,
at least the decor layer 13 and the press plate 27 must be
precisely aligned in respect to each other. To this aim, several
possibilities are known, such as, for example, providing marks on
the decor paper, such that a positioning under the press is
possible.
[0073] FIGS. 9 and 10 illustrate a particular technique for
realizing a press plate 27 for manufacturing a well-defined form of
embodiment of a floor panel 1 according to the invention. To this
aim, FIG. 9 represents a press plate 27, which has been etched a
first time over a zone Z1 with a depth E1. FIG. 10 shows the result
of a second etching treatment on the same press plate 27. The
second etching treatment is performed over a zone Z2 partially
overlapping the zone Z1 of the first treatment. The second etching
treatment is continued up to a depth E2 differing from E1. From
FIG. 10, it is clear that by means of these etching treatments,
three different depths have been obtained in the press plate,
namely the depth E1, E2 and E3, the latter being the sum of E1 and
E2. Together with the initial level, the two etching treatments
result in four different levels in the press plate. Generally, it
can be stated that by means of n etching treatments of different
depth that partially overlap each other, 2.sup.n different levels
can be obtained.
[0074] FIG. 11 shows in a schematic manner that after the press
treatment with the obtained press plate 27 of FIG. 10, a relief can
be obtained in the top layer 11 of a floor panel 1, with terraces
19 that also are situated on different levels.
[0075] In order to minimize the risk of an adhesion between the
press plate 27 and the synthetic material 12, possibly a so-called
"release" paper can be provided in between them.
[0076] FIG. 12 shows two coupled floor panels 1, of which the
terrace-shaped impressions 18 extend up to the edge of the floor
panels 1. From FIG. 12, it is clear that hereby, due to the
presence of the impressions 18, differences in height may be
created, more particularly an edge 29 can be formed, which possibly
is experienced as disturbing. In particular with dark decors 10,
this edge 29 is less desirable, in view of the fact that it mostly
will show as a white line.
[0077] FIG. 13 shows that the mostly lighter-colored edge 29 of the
floor panel 1 can be colored in order to thereby exclude a possibly
disturbing effect. According to FIG. 13, this simply is performed
by means of a felt-tip pen 30 or the like.
[0078] FIG. 14 shows a floor panel 1 with a cut-away edge portion
31 in the form of a beveled edge, in this case, an inclination
below 45.degree.. This cut-away edge portion 21 preferably has a
dimension H1 in horizontal direction that is smaller than 3 mm and
still better is smaller than 2 mm, whereas the indicated height H2
preferably is larger than 1 mm, however, on the other hand
preferably also is smaller than 3 mm and still better is smaller
than 2 mm.
[0079] In FIG. 14, the surface of the cut-away edge portion is
provided with a covering 32 obtained, for example, by means of
transfer printing. As explained in the introduction, to this aim
also other decorative layers, such as lacquer or the like, can be
used.
[0080] FIG. 15 represents a variant of the cut-away edge portion
31.
[0081] Such cut-away edge portions 31 can be provided at one or
more edges 5A-5B-6A-6B of the floor panel 1.
[0082] FIG. 16 shows, strongly schematized, a floor panel 1,
whereby the coupling means 7, in this case, the groove 33, vary in
height in respect to the basic board 9, this as a result of a
terrace-shaped impressed zone 18A in the edge area of the floor
panel 1, said zone having such a large length L that, when forming
the groove 33, the floor panel 1 locally has moved up and down. In
practice, this will happen with lengths L that are larger than 10
cm. Unexpectedly, it was found that, notwithstanding the
non-straight course of the groove 33, such floor panels still can
be coupled to each other quite well, without any substantial
problem to turn or to snap them into each other. This fact then
also forms the basis for the aforementioned second aspect of the
invention explained in the introduction and claimed in the claims,
whereby it is clear that this second aspect is not limited to
imitations of flaky kinds of stone.
[0083] FIG. 17 shows a variant of the floor panel 1 of FIG. 16,
whereby the coupling means 7, globally seen, slope towards one side
of the floor panel 1, as the impression 18A, globally seen, is also
performed downward-inclined towards one extremity of the floor
panel 1.
[0084] In the top layer 11, in a known manner products, such as
corundum or the like, can be incorporated in order to enhance the
scratch and wear resistance of the surface of the floor panel 1. In
order to enhance the wear resistance of the floor panel 1, it is
also advantageous to use a relatively heavy overlay 14, preferably
an overlay 14 with a weight of the carrier of at least 80 grams per
square meter, preferably still in combination with hard particles,
such as corundum, which latter then are situated, for example, at
the upper side of the overlay 14.
[0085] It is noted that the printed decor 10 does not necessarily
have to consist of a print on a carrier 15 that is impregnated with
resin. So, for example, it is also possible to work with a print
that is printed directly on the basic board 9, whether or not by
the intermediary of additional layers, such as primers or the like,
whereby the top layer 11 then is formed by a layer of synthetic
material, in which the impressions 18 are formed, said layer being
provided over the decor 10 in any manner.
[0086] Finally, it is noted that in a deviating form of embodiment
of the invention, the decor 10, instead of imitating a slate or
another flaky kind of stone, also may have a fashion pattern,
whereby, for example, the aforementioned terrace-shaped impressions
18 simply are provided over a monochrome, brightly colored decor
10.
[0087] The aforementioned terraces preferably are limited by
clearly outlined transitions extending along the entire periphery,
or, at the location where the floor panel terminates, by the
respective edge of the panel.
[0088] By the "upper edge" intended in the second and third
aspects, the edge 34, indicated in FIGS. 13 and 14, of the top
layer 11 is meant. By the largest value intended in the third
aspect, the value is meant that is indicated by W in FIGS. 13 and
14.
[0089] The present invention is in no way limited to the forms of
embodiment described by way of example and represented in the
figures; on the contrary, such floor panels may be realized
according to various variants, without departing from the scope of
the invention.
* * * * *