U.S. patent application number 11/066101 was filed with the patent office on 2006-08-31 for flooring system having large floor pattern.
Invention is credited to Eugenio Cruz Garcia, Vincente Sabater.
Application Number | 20060191222 11/066101 |
Document ID | / |
Family ID | 36930786 |
Filed Date | 2006-08-31 |
United States Patent
Application |
20060191222 |
Kind Code |
A1 |
Sabater; Vincente ; et
al. |
August 31, 2006 |
Flooring system having large floor pattern
Abstract
Laminated flooring planks include decorative motifs,
mechanically embossed-in-registration surface textures, recessed
perimeters, and locking mechanisms. By arranging portions of the
decorative motifs along edges of a flooring plank, a periodic
flooring pattern larger than an individual plank and that spans
across both the length and width of a number of planks may be
formed by placing identical planks adjacent to one another in a
horizontal direction and adjacent in a vertical direction.
Inventors: |
Sabater; Vincente;
(Valencia, ES) ; Garcia; Eugenio Cruz; (Gandia,
ES) |
Correspondence
Address: |
MCKENNA LONG & ALDRIDGE LLP;Song K. Jung
1900 K Street, N.W.
Washington
DC
20006
US
|
Family ID: |
36930786 |
Appl. No.: |
11/066101 |
Filed: |
February 28, 2005 |
Current U.S.
Class: |
52/311.2 |
Current CPC
Class: |
E04F 15/02033 20130101;
E04F 15/02 20130101; B44F 9/02 20130101; B44F 11/06 20130101 |
Class at
Publication: |
052/311.2 |
International
Class: |
E04F 15/00 20060101
E04F015/00 |
Claims
1. A system of forming a decorative pattern, the system comprising:
a first unit, the first unit comprising: a first plurality of
subunits having a pattern, wherein a subunit of the first plurality
of subunits includes a decorative motif substantially different
from the unit pattern; and a second unit adjacent the first unit,
the second unit comprising: a second plurality of subunits having
the pattern, wherein a subunit of the second plurality of subunits
includes the decorative motif where the first subunit and the
second subunit align with one another such that the decorative
motifs of the first subunit and the second subunit align with one
another thereby forming the decorative pattern.
2. The system as recited in claim 1, the system further comprising:
a third unit, the third unit comprising: a third plurality of
subunits having the pattern, wherein a subunit of the third
plurality of subunits includes the decorative motif such that the
decorative motif of the third subunit forms the decorative pattern
with the decorative motif of both the first subunit and the second
subunit.
3. The system as recited in claim 2, the system further comprising:
a fourth unit, the fourth unit having at least four subunits.
4. The system as recited in claim 3, wherein the subunit of the
first unit having the decorative motif is adjacent the subunit of
the second unit having the decorative motif.
5. The system as recited in claim 4, wherein an edge unit of the
first unit has the decorative motif.
6. The system as recited in claim 4, wherein a subunit adjacent an
edge unit of the second unit has the decorative motif.
7. The system as recited in claim 1, wherein the first unit
includes at least four subunits.
8. The system as recited in claim 1, wherein the second unit
includes at least four subunits.
9. The system as recited in claim 1, wherein the first unit and the
second unit are laminate flooring planks having wood grain
patterns.
10. The system as recited in claim 1, wherein the subunits comprise
an embossed surface texture in registration with the decorative
motif.
11. The system as recited in claim 1, the first unit comprising: a
tongue extending from a perimeter of one edge of the first unit;
and a groove running along a perimeter of an opposite edge of the
first unit.
12. The system as recited in claim 11, the second unit comprising:
a tongue extending from a perimeter of one edge of the second unit;
and a groove running along a perimeter of an opposite edge of the
second unit where any of the grooves are capable of receiving any
of the tongues.
13. The system as recited in claim 9, wherein the pattern comprises
an embossed surface texture.
14. The system as recited in claim 1, wherein the first and second
units are laminate flooring planks having a ceramic tile surface
pattern.
15. A method of forming a decorative pattern, the method
comprising: arranging a first unit, the first unit having a
plurality of subunits with a pattern where a first subunit of the
first plurality of subunits has a decorative motif with a pattern
different from the subunit pattern; and placing a second unit
adjacent the first unit, the second unit having a plurality of
subunits with the subunit pattern where one subunit of the second
plurality of subunits has the decorative motif where the first
subunit having the decorative motif is adjacent the second subunit
having the decorative motif thereby forming the decorative
pattern.
16. The method as recited in claim 15, the method further
comprising: arranging a third unit adjacent the first unit or the
second unit, the third unit having a plurality of subunits where
one subunit of the third plurality of subunits has the decorative
motif where the third subunit having the decorative motif is
adjacent one of the first subunits having the decorative motif and
the second subunit having the decorative motif.
17. The method as recited an claim 15, wherein the first unit has a
tongue extending from a perimeter of a first edge and a groove at a
perimeter of a second edge opposite the first edge.
18. The method as recited in claim 17, wherein the second unit has
a tongue extending from a perimeter of a first edge and a groove at
a perimeter of a second edge opposite the first edge.
19. The method as recited in claim 18, further comprising:
interlocking the second unit tongue with the first unit groove.
20. The method as recited in claim 15, wherein the first unit and
the second unit are laminate flooring planks having wood flooring
planks.
21. The method as recited in claim 15, wherein the subunits
comprise an embossed surface texture in registration with the
decorative motif.
22. The method as recited in claim 20, wherein the pattern
comprises an embossed surface texture.
23. The method as recited in claim 15, wherein the first and second
units are laminate flooring planks having ceramic tile
patterns.
24. The method as recited in claim 15, wherein both the first unit
and the second unit include at least four subunits.
25. A system for forming a decorative pattern, the system
comprising: a first unit having a plurality of subunits where the
first plurality of subunits have a pattern disposed thereon, one
subunit of the first plurality of subunits having a decorative
motif where the decorative motif is substantially different from
the subunit pattern; and a second unit having a plurality of
subunits where the second plurality of subunits have the subunit
pattern and one subunit of the second plurality of subunits has the
decorative motif where the decorative motifs of the first subunit
and the second subunit align with each other when the first unit is
set offset relative to the second unit wherein the aligned
decorative motifs form the decorative pattern.
26. The system as recited in claim 25, the system further
comprising: a third unit having at least four subunits, where one
of the one subunits has the decorative motif such that when the
third unit is set offset relative to both the first and second
units, the decorative motif of the third subunit aligns with the
decorative motifs on the first subunit and the second subunit.
27. The system as recited in claim 25, the system further
comprising: a fourth unit having at least four subunits.
28. The system as recited in claim 25, wherein both the first unit
and the second unit have at least four subunits.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to laminated materials. More
particularly, the present invention relates to a flooring system of
interlocked laminated materials having decorative motifs and
surface textures that are mechanically embossed in registration
with their decorative motifs.
[0003] 2. Discussion of the Related Art
[0004] Because of their look and feel, traditional building and
finishing flooring materials such as fine woods, slate, granite,
stones, brick, and concrete are generally preferred by consumers.
However, such traditional building and finishing flooring materials
tend to be expensive to produce and install. For example, while a
solid wood floor has a highly valued luxurious appearance, the
materials and labor required to install such floors can be
prohibitively expensive.
[0005] Many alternatives to traditional building and finishing
flooring materials are available, including laminates such as
high-pressure laminates (HPL), direct-pressure laminates (DPL), and
continuous-pressure laminates (CPL). However, such alternatives
typically do not possess the realistic look and texture of the
traditional building and finishing flooring materials. For example,
most alternatives having an outer surface with a wood motif look
fake and can readily be identified as something other than
authentic wood. Furthermore, while high quality HPL, DPL, or CPL
boards may visually look like wood, their textures readily reveal
that they are not.
[0006] One problem with most alternatives to traditional building
and finishing flooring materials is that their surface textures do
not match their decorative motifs. For example, visual depictions
of wood knots in alternative flooring materials are not matched
with surface textures characteristic of the wood knots.
Accordingly, the attractiveness of these alternative materials is
significantly reduced.
[0007] One approach used to match the surface texture of
alternative flooring materials to their decorative motifs includes
a technique known as chemical embossing. In chemical embossing, the
surface texture of the alternative material is developed by
chemically reacting an ink that forms the decorative motif with an
agent added to a sub-surface layer. While somewhat successful, the
resulting surface texture tends to lack the textual sharpness and
three-dimensional characteristics of traditional materials.
[0008] As an alternative to the traditional building and finishing
flooring materials laminated materials may be mechanically embossed
to produce a surface texture. See, for example U.S. patent
application Ser. No. 09/903,807 and U.S. Pat. No. 6,401,415, which
are hereby incorporated by reference. Such methods produce
embossed-in-registration laminated materials having decorative
motifs and matching high-quality three-dimensional textures.
Embossed-in-registration laminated materials require accurate
registration of mechanical embossment and the decorative motif. An
advantage of embossed-in-registration laminated materials is that
they can realistically reproduce the look and feel of traditional
products.
[0009] No matter what type of flooring system is used, the flooring
system must be easily moved to a work site while being easy and
quick to install. To this end, assembly and locking mechanisms may
be incorporated within flooring systems to facilitate on-site
installation. One type of assembly and locking mechanism is the
tongue and groove system used for connecting panels. It is
understood that such tongue and groove systems are disclosed in
Cherry, U.S. Pat. No. 2,057,135, and in Urbain, U.S. Pat. No.
2,046,593. For example, FIG. 1 can be interpreted to illustrate a
tongue and groove system 11 that uses clips 12 to secure panels
together.
[0010] Another type of assembly and locking mechanism is understood
to be disclosed in Chevaux, U.S. Pat. No. 3,946,529 where a
flooring system 13 appears to be connected using a tongue and
groove system arranged underneath the flooring, reference FIG.
2.
[0011] Still another assembly and locking mechanism is taught in
Kajiwara, U.S. Pat. No. 5,295,341. There, it is understood that
laminated boards are provided with a snap-together system such as a
groove-tongue joint. As a result the laminated boards can be
assembled without glue. Referring to FIG. 3, the laminated boards
are provided with a locking means in the form of a groove connector
16, and a tongue connector 18. The groove connector 16 has
forwardly protruding grooves 20, while the tongue 18 is provided
with a pair of forwardly diverging sidewalls 22 and 24 that are
separated by an elongated groove 26. The sidewalls include rear
locking surfaces 28 and 36. The sidewalls can be compressed
together to enable locking.
[0012] Another type of assembly and locking mechanism is the
snap-together joint is suggested in Martensson, U.S. Pat. No.
6,101,778. As shown in FIG. 4, it is understood that laminated
boards are provided with a locking means comprised of a groove 6
and a tongue 7 that form a tongue-groove assembly. The groove 6 and
tongue 7 may be made of water tight material and snapped together
with a portion 9 fitting in a slot 4.
[0013] While the aforementioned assembly and locking mechanisms
have proven useful, they have not been used with
embossed-in-registration laminate systems in which
embossed-in-registration decorative motifs or graphics align across
joints between the individual embossed-in-registration laminates.
This significantly detracts from the visual and textural impression
of systems comprised of embossed-in-registration laminate boards.
Therefore, a new embossed-in-registration laminate system in which
the visual and textural patterns cross joints while retaining the
embossed-in-registration aspects would be beneficial. Even more
beneficial would be an embossed-in-registration laminate system
comprised of interlocking embossed-in-registration laminate boards
in which the visual and textural patterns cross joints while
retaining embossed-in-registration aspects.
[0014] Further, the aforementioned flooring systems have a
relatively low ability to resist wear. While not wishing to be
bound by any particular theory, it is hypothesized that premature
aging (wear) begins at or near the perimeter edges and/or along
tongue and groove lines. The aforementioned flooring systems have a
substantially even (level) surface texture such that the center and
perimeter of each panel contact users (e.g., pedestrians) an equal
amount. The perimeter of each panel, however, is substantially
weaker than the center of the panel and therefore deteriorates
first.
[0015] In addition, flooring systems typically do not have
decorative motifs or pattern designs that are longer than the
length of a plank. For example, in a flooring system designed to
reproduce a wood floor having wood strips, the length of the wood
strip pattern is typically equal to or shorter than the length of a
single plank. This is desirable in related art flooring systems
because it does not require the installer to plan more than one
plank beyond the plank being installed.
[0016] Accordingly, there is a need for a workable method of
fabricating alternative building or finishing materials where the
alternatives have the realistic look and feel of traditional
products and have an increased capacity to resist premature wear,
and in which the minimum number of planks is used maintained while
still being able to create design motifs or pattern elements with a
length greater than that of a single plank.
SUMMARY OF THE INVENTION
[0017] Accordingly, the present invention is directed to
embossed-in-registration flooring system that substantially
obviates one or more of the problems due to limitations and
disadvantages of the related art.
[0018] An advantage of the present invention provides an
embossed-in-registration flooring system including individual
adjacent flooring planks having embossed-in-registration decorative
motifs where at least one of a surface texture and decorative motif
is substantially aligned between adjacent flooring plank.
[0019] Another advantage of the present invention provides an
embossed-in-registration flooring system including interlocked
flooring planks having embossed-in-registration decorative motifs
where at least one of a surface texture and decorative motif is
substantially aligned between adjacent flooring planks such that
substantially continuous embossed-in-registration patterns are
formed across the interlocked flooring planks.
[0020] Another advantage of the present invention provides an
embossed-in-registration flooring system may, for example, include
flooring planks wherein a surface of a perimeter of each individual
flooring plank may be recessed such that an upper surface of the
perimeter of the flooring planks is below a portion of an upper
surface of the flooring planks surrounded by the perimeter.
[0021] Another advantage of the present invention provides a plank
comprising a plurality of sides defining a perimeter; a plurality
of edge patterns arranged proximate at least one first portion of
the perimeter, wherein at least two of the plurality of edge
patterns are substantially identical; and at least one bulk pattern
arranged adjacent the plurality of edge patterns and proximate at
least one second portion of the perimeter, wherein at least one
bulk pattern and an edge pattern adjacent the at least one bulk
pattern forms a substantially continuous pattern.
[0022] Another advantage of the present invention provides a
flooring system, comprising at least two planks adjacent each other
along a predetermined direction, wherein each plank comprises: a
plurality of sides defining a perimeter; a plurality of edge
patterns arranged proximate at least one first portion of the
perimeter, wherein at least two of the plurality of edge patterns
are substantially identical; and at least one bulk pattern arranged
adjacent the plurality of edge patterns and proximate at least one
second portion of the perimeter, wherein at least one bulk pattern
and an edge pattern adjacent the at one least bulk pattern forms
substantially continuous pattern; herein edge patterns of the at
least two planks form a substantially continuous pattern.
[0023] A further advantage of the present invention provides a
floor panel, comprising a plurality of sides defining a perimeter;
a surface having thereon a decorative motif, said decorative motif
comprising at least two edge patterns adjacent each of the sides of
the panel and at least one bulk pattern in the interior of the
panel and adjacent the edge pattern on each side, wherein at least
one edge pattern along a side is substantially identical to the
edge pattern in a corresponding position along an opposite side;
and wherein at least one portion of the decorative motif along a
side is substantially different from the corresponding portion of
the decorative motif along an opposite side.
[0024] Additional features and advantages of the invention will be
set forth in the description which follows, and in part will be
apparent from the description, or may be learned by practice of the
invention. These and other advantages of the invention will be
realized and attained by the structure particularly pointed out in
the written description and claims hereof as well as the appended
drawings.
[0025] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory and are intended to provide further explanation of
the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The accompanying drawings, which are included to provide a
further understanding of the invention and are incorporated in and
constitute a part of this specification, illustrate embodiments of
the invention and together with the description serve to explain
the principles of the invention.
[0027] In the drawings:
[0028] FIG. 1 illustrates a related art assembly and locking
mechanism;
[0029] FIG. 2 illustrates another related art assembly and locking
mechanism;
[0030] FIG. 3 illustrates yet another related art assembly and
locking mechanism;
[0031] FIG. 4 illustrates still another related art assembly and
locking mechanism;
[0032] FIG. 5 illustrates a perspective view of components in an
embossed-in-registration flooring plank according to the principles
of the present invention;
[0033] FIG. 6 illustrates a press machine capable of fabricating
embossed-in-registration flooring planks in accordance with the
principles of the present invention;
[0034] FIG. 7 illustrates an embossed-in-registration flooring
plank in one aspect of the present invention;
[0035] FIG. 8 illustrates a top view of a system of
embossed-in-registration flooring planks in another aspect of the
present invention;
[0036] FIG. 9 illustrates a cross-sectional view along line 9-9
shown in FIG. 8;
[0037] FIG. 10 illustrates a top view of a system of
embossed-in-registration flooring planks in yet another aspect of
the present invention;
[0038] FIG. 11 illustrates a cross-sectional view along line 11-11
shown in FIG. 10;
[0039] FIGS. 12A and 12B illustrate schematic views including a
perimeter surface portion of a flooring plank in accordance with
the principles of the present invention;
[0040] FIGS. 13A and 13B illustrate a flooring system in still
another aspect of the present invention;
[0041] FIGS. 14A-14C illustrate an exemplary plank of a flooring
system in still another aspect of the present invention and
[0042] FIGS. 15A-15E illustrate an exemplary method of forming
patterns on a flooring plank in accordance with the principles of
the present invention.
[0043] FIG. 16 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention;
[0044] FIG. 17 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention;
[0045] FIG. 18 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention;
[0046] FIG. 19 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention;
[0047] FIG. 20 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention;
[0048] FIG. 21 illustrates an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention; and
[0049] FIGS. 22A-22D illustrate an exemplary method of forming
patterns on a flooring plank in accordance with the principles of
the present invention.
[0050] FIG. 23 illustrate an exemplary method of forming patterns
on a flooring plank in accordance with the principles of the
present invention.
[0051] FIG. 24 illustrate an exemplary method of forming patterns
of a first size on a flooring plank in accordance with the
principles of the present invention.
[0052] FIG. 25 illustrate an exemplary method of forming patterns
of a second size on a flooring plank in accordance with the
principles of the present invention.
[0053] FIG. 26 illustrate an exemplary method of forming patterns
of a third size on a flooring plank in accordance with the
principles of the present invention.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0054] Reference will now be made in detail to embodiments of the
present invention, examples of which are illustrated in the
accompanying drawings.
[0055] FIG. 5 generally illustrates components of a flooring plank
according to the principles of the present invention.
[0056] Referring to FIG. 5, an embossed-in-registration flooring
system may, for example, include at least one flooring plank. In
one aspect of the present invention each flooring plank may include
a board substrate 40 made out of a substrate material (e.g., a
medium or high density fiberboard, chipboard, etc.), at least one
base sheet 48 (e.g., a kraft paper sheet) impregnated with
predetermined resins and arranged over and/or under the board
substrate 40, a decorative paper sheet 44 about 0.15 mm thick and
impregnated with a polymerizable resin (e.g., phenols such as
melamine) arranged over the board substrate, and at least one
protective overlay sheet 46 arranged over the decorative paper
sheet 44. In one aspect of the present invention, each protective
overlay sheet 46 may be formed from a highly resistant paper
impregnated with a melamine solution containing corundum
(Al.sub.2O.sub.3), silica, etc. In another aspect of the present
invention, different papers may be arranged between the decorative
paper sheet 44 and the board substrate 40. In one aspect of the
present invention, the at least one protective overlay sheet 46 and
the base sheet 48 may be impregnated with a resin. In another
aspect of the present invention the resin impregnating the at least
one protective overlay sheet 46 and the base sheet 48 may be
different from the melamine resin used to impregnate the decorative
paper sheet 44.
[0057] In one aspect of the present invention, flooring planks
within a flooring system may be fabricated from substantially the
same paper, resin, etc. For example, flooring planks within a
flooring system may be fabricated using paper made from
substantially the same paper fibers (having, for example,
substantially the same ash content, color, and orientation) on the
same on the same paper making machine. Further, flooring planks
within a flooring system may be fabricated using paper originating
from a single, contiguous section on the manufacturing spool. All
of the aforementioned paper use restrictions that may be employed
in fabricating flooring planks of a flooring system ensure that
impregnated papers will always have substantially the same final
dimensions after they are pressed and cured. In one aspect of the
present invention, the warehousing of paper used to fabricated
flooring planks within a flooring system may be controlled such
that the time, temperature, and humidity in which the paper is
stored is maintained to facilitate consistent flooring plank
dimensions. In another aspect of the present invention, flooring
planks within a flooring system may be fabricated using cellulose
paste made from the same manufacturer. In yet another aspect of the
present invention, flooring planks within a flooring system may be
fabricated using resins made from the same manufacturer. In still
another aspect of the present invention, the resins may contain
powder originating from substantially the same source, have
substantially the same chemical and physical qualities, and be
mixed in the same reactor. Further, flooring planks within a
flooring system may be fabricated using resins have a substantially
constant solids content. All of the aforementioned resin use
restrictions that may be employed in fabricating the flooring
planks ensure that impregnated papers will always have
substantially the same final dimensions after they are pressed and
cured. In still another aspect of the present invention, each of
the flooring planks within a flooring system may be fabricated
using substantially the same impregnation process. For example,
when dipping the various sheets of paper into melamine resin, the
paper should experience a constant, uniform melamine load. Further,
a band tension and oscillation of the impregnation machine should
be precisely controlled as they influence the degree to which the
various paper sheets are impregnated with the resin.
[0058] According to the principles of the present invention, the
aforementioned sheets and substrates may be fabricated into an
embossed-in-registration flooring system including a plurality of
interlocking flooring planks. To produce such a flooring system, a
press machine, such as a press machine shown in FIG. 6, may be used
to mechanically emboss each flooring plank in registration with a
decorative motif arranged on the decorative paper sheet 44.
[0059] Referring to FIG. 6, the press machine may, for example,
include a base 42, a top press 54, and an upper press plate 56. In
one aspect of the present invention, the upper press plate may
include an embossing pattern (e.g., a three-dimensionally textured
surface). Accordingly, the embossing pattern may, for example,
include elevated ridges, dots, depressions, etc., of any design
capable of being aligned with a decorative motif formed on the
decorative paper sheet 44.
[0060] According to the principles of the present invention, the
impregnated decorative paper sheet 44 arranged on the board
substrate 40 must be accurately positioned relative to the
embossing pattern of the upper press plate to enable an
embossed-in-registration flooring plank. In one aspect of the
present invention, alignment between the embossing pattern of the
press plate and the decorative motif must be ensured when the press
is in a locked position and the board is under pressure. The degree
of control required may vary depending on the type of decorative
motif used. For example, alignment of a wood grain
embossed-in-registration motif across adjacent
embossed-in-registration flooring planks requires a higher degree
of alignment than alignment of a wood grain
embossed-in-registration motif that is not aligned with adjacent
flooring planks.
[0061] Alignment between the decorative motif on the decorative
paper sheet 44 and the embossing pattern on the upper press plate
56 may be achieved by removing about 2 to 3 millimeters of material
around the perimeter of the board substrate 40 in a milling process
thereby yielding several reference planes (e.g., board edges) and a
board substrate having tightly controlled dimensions. Next, an
impregnated decorative paper sheet 44 having exterior dimensions
about 8 or 10 mm smaller than the board substrate 40 is arranged on
the board substrate 40. In one aspect of the present invention, the
impregnated decorative paper sheet 44 may be arranged on the board
substrate 40 using the board edges as alignment means. In one
aspect of the present invention, alignment marks may be arranged on
the board substrate 40 and be alignable with alignment marks
provided on the decorative paper sheet 44.
[0062] In one aspect of the present invention, the decorative paper
sheet 44 may be attached to the board substrate 40 via static
electricity. After they are attached, the decorative paper sheet 44
and the board substrate 40 are arranged on a carriage feeding into
the press machine. The static electricity may substantially prevent
the decorative paper sheet 44 from being accidentally displaced as
the board substrate 40 is moved with the carriage. In one aspect of
the present invention, the carriage may be stopped just before it
enters into the press machine such that the decorative paper sheet
44 may be precisely arranged over the board substrate 40 using, for
example, tweezers (not shown). In another aspect of the present
invention, the tweezers may be used to precisely arrange the
decorative paper sheet 44 over the board substrate 40 arranged on
the lower press plate. In one aspect of the present invention, the
decorative paper sheet 44, the at least one protective overlay
sheet 46, and the optional base sheet 48 may be arranged over the
board substrate 40 prior to being arranged within the press
machine. After the decorative paper sheet 44 is arranged over the
board substrate 40, the carriage may be moved out of the press
machine. Next, an alignment system substantially aligns the
decorative paper sheet 44/board substrate 40 system with the
embossing pattern in the upper press plate 56. In one aspect of the
present invention, the alignment system may use the board edges to
substantially align the decorative motif 44 with the embossing
pattern on the upper press plate 56. The press machine may be
operated after the alignment is complete.
[0063] In one aspect of the present invention, after the components
illustrated in FIG. 5 are arranged within the press machine and
aligned with the embossing pattern, the various sheets and
substrate may be pressed and cured for predetermined amount of time
until the resins set, yielding an extremely hard and wear resistant
flooring plank. For example, after being inserted into the press
machine and aligned with the embossing pattern, the board substrate
40, decorative paper sheet 44, protective overlay sheet 46, and
optional base sheet 48 may be heated at a temperature of about
160-220.degree. C. and pressed together under a pressure of about
20-40 Kg/cm.sup.2 for about 20 to 60 seconds. Accordingly, the top
press 54 presses the embossing pattern of the upper press plate 56
into the decorative paper sheet 44 and board substrate 40
structure. The combination of the applied heat and pressure fuses
the decorative paper sheet 44 and the board substrate 40 together.
The alignment system ensures that the decorative paper sheet 44 is
substantially aligned with the embossing pattern in the upper press
plate 56. Accordingly, melamine resin within the various sheets may
be cured and an embossed-in-registration plank may be produced.
[0064] In one aspect of the present invention, porosity within the
fused piece may be minimized by slowly curing the resins (e.g., the
melamine). Accordingly, as the operating temperature is reduced,
the time during which the various sheets within the press machine
are pressed is increased. In another aspect of the present
invention, as the press plate 56 is heated to about 160-220.degree.
C. the embossing pattern included within the press plate may
expand. Accordingly, the embossing pattern on the press plate 56
may be provided so as to compensate for the expansion of the
pattern. Therefore, the dimensions of the embossing pattern are
provided such that they substantially correspond to the design of
the decorative motif when the resins within the components of FIG.
5 are cured.
[0065] According to the principles of the present invention, a
mechanically embossed surface texture may be imparted to an
individual flooring plank having a decorative motif. In one aspect
of the present invention, the mechanically embossed surface texture
may be provided in registration with the decorative motif.
Accordingly, an embossed-in-registration flooring plank may be
fabricated. In another aspect of the present invention, a plurality
of embossed-in-registration flooring planks may be joined together
to form an embossed-in-registration flooring system. In yet another
aspect of the present invention, at least a portion of
embossed-in-registration patterns of adjacent flooring planks may
be substantially aligned with each other to form substantially
contiguous embossed-in-registration patterns across adjacent
flooring planks within the flooring system.
[0066] While the embossed-in-registration process described above
is suitable for embossed surface textures that are less than about
0.2 mm deep, deeper surface textures may be problematic. Embossing
patterns capable of imparting deep surface textures, for example,
require relatively large press plate protrusions that tend to
disturb the pressure homogeneity applied across the board surface.
This pressure disturbance can cause distortions in the final
product. In one aspect of the present invention, embossed surface
textures may be formed greater than about 0.2 mm deep by hollowing
out the board substrate 40 at locations where deep surface textures
are desired. In one aspect of the present invention, the hollowing
out process may be performed before, during, or after the perimeter
of the board substrate 40 is milled as described above. In another
aspect of the present invention, the board edges may be used to
locate the boundaries of the hollowed out portions of the board
substrate 40.
[0067] Referring to FIG. 7, an embossed-in-registration flooring
plank 60, fabricated according to the process described above may
optionally include a protective padding layer 50 on one side. The
mechanically embossed surface texture is registered with the
decorative motif 68 of the decorative paper sheet 44. By
registration, it is meant that the embossed surface texture is
substantially aligned with the decorative motif of the decorative
paper sheet 44. By providing an embossed-in-registration flooring
plank, a realistic representation of a natural material may
provided to individual flooring planks. While the decorative motif
illustrated in FIG. 7 realistically represents the image and
texture of a wood grain, it should be appreciated that other
embossed-in-registration designs such as ceramic planks, concrete,
marble, etc., may be produced.
[0068] According to the principles of the present invention, each
of the individual flooring planks may, for example, include at
least one locking mechanism.
[0069] In one aspect of the present invention, locking mechanisms
may be incorporated within the board substrate 40 before the
embossing pattern is imparted to the surface of the board substrate
40 in registration with the decorative motif. Accordingly, locking
mechanisms may be fabricated within individual board substrates 40.
Next, the locking mechanisms may be used to join individual board
substrates together to form a plank structure. The plank structure
may then be inserted into the press 54. After the embossing pattern
is imparted to the plank structure and the fused components are
fused together, the plank structure is removed from the press 54.
Next, embossed-in-registration flooring planks 60 within the fused
plank structure are separated by unlocking the locking mechanisms.
In one aspect of the present invention, cutting tools may be used
to assist in the separation and to ensure the decorative motif is
not damaged.
[0070] In another aspect of the present invention, the locking
mechanisms may be incorporated within the board substrate 40 after
the embossing pattern is imparted to the surface of the board
substrate 40 in registration with the decorative motif.
Accordingly, a board substrate 40 having relatively large
dimensions of, for example, 4'.times.8', may be embossed by the
press 54. Next, the resulting embossed-in-registration substrate
may be cut into a plurality of individual embossed-in-registration
flooring planks 60. In one aspect of the present invention, edges
of the individual embossed-in-registration flooring planks 60 may
have smooth edges and precise dimensions. In one aspect of the
present invention, the cutting may be performed using shaping
tools, milling tools, cutting tools, breaking tools, etc. In one
aspect of the present invention, the board substrate may be cut by
the press machine. Accordingly, the board substrate 40 may be cut
into units (e.g., strips) having dimensions of, for example,
300.times.300 mm, 400.times.400 mm, 600.times.600 mm,
1,200.times.300 mm, 1,200.times.400 mm, etc. Next, the locking
mechanisms may be incorporated within the individual
embossed-in-registration flooring planks 60. In one aspect of the
present invention, the locking mechanisms may be hidden beneath the
surface of the flooring planks or they may be visible.
[0071] According to the principles of the present invention, the
locking mechanisms may be incorporated within the individual
embossed-in-registration flooring planks 60 by aligning the at
least one of the board edges, alignment marks, decorative motifs,
and surface textures of the flooring plank with a milling tool. By
aligning the milling tool with any of the aforementioned alignable
features, locking mechanisms may be milled into the sides of the
board substrates 40 such that, when flooring planks 60 are joined
together the at least a portion of the decorative motifs form a
continuous pattern and at least a portion of the
embossed-in-registration patterns form a substantially continuous
surface texture across adjacent flooring planks.
[0072] According to the principles of the present invention, the
embossed-in-registration flooring plank 60 may include a locking
mechanism 64 (e.g., at least one of a tongue and groove locking
system, a snap-together locking system, etc.) extending along all
four sides of the embossed-in-registration laminate 60. For
example, a snap-together locking system may be added to all four
sides of the embossed-in-registration flooring plank 60 and used to
connect multiple embossed-in-registration flooring planks 60 into
an embossed-in-registration flooring system 300 (as shown in FIG.
8). The number and location of locking mechanisms may depend on the
desired configuration of the embossed-in-registration flooring
system. For example, when an embossed-in-registration flooring
system abuts a corner, only two locking mechanisms are required
(along the sides).
[0073] Referring to FIG. 8, the embossed-in-registration flooring
planks A and B may, for example, include locking mechanisms along
four sides (e.g., along joints J1, J2, J3, and J4).
Embossed-in-registration flooring planks C and D may, for example,
include locking mechanisms along four sides (e.g., along joints J1,
J2, J3, and another joint not shown).
[0074] Embossed-in-registration flooring planks including the
aforementioned locking mechanisms may be securely attached together
with or without glue to form an embossed-in-registration laminate
system 300. Multiple embossed-in-registration flooring planks may
be joined together to obtain any desired shape for flooring,
planking, or the like. The embossed-in-registration flooring planks
may be joined to each other such that at least portions of
embossed-in-registration patterns of adjacent flooring planks are
substantially aligned with each other and form a substantially
continuous image and embossed surface texture across flooring
planks within a flooring system.
[0075] FIGS. 8 and 9 illustrate an exemplary
embossed-in-registration flooring system 300 incorporating one type
of locking mechanism on each of the individual
embossed-in-registration flooring planks 60. FIG. 9 illustrates an
exemplary embossed-in-registration flooring system including
flooring planks incorporating a snap-type tongue and groove locking
mechanism. In one aspect of the present invention, the snap-type
tongue and groove locking mechanism may be integrated into the
sidewalls of each embossed-in-registration laminate 60 so as to
ensure that embossed-in-registration patterns of adjacent flooring
planks are substantially aligned with each other and substantially
continuous within the flooring system.
[0076] FIG. 9 illustrates a cross sectional view of FIG. 8 taken
along line 9-9. As shown, the locking mechanism may be fabricated
by forming a groove 230, a tongue 200, a channel 210, and a lip 220
along the edges of the embossed-in-registration flooring planks 60.
The locking mechanisms on the embossed-in-registration flooring
planks 60 may be joined together by inserting the tongue 200 into
the groove 230 of an adjacent embossed-in-registration flooring
plank 60. Subsequently, the lip 220 is secured within channel 210,
thereby joining adjacent embossed-in-registration flooring planks
60 into an embossed-in-registration flooring system 300. In one
aspect of the present invention, the embossed-in-registration
flooring planks 60 labeled A, B, C and D may be joined together
with or without glue. It should is appreciated that other types of
locking mechanisms may be incorporated within the sides of the
individual embossed-in-registration flooring planks 60.
[0077] Referring back to FIG. 8, each of the
embossed-in-registration flooring planks 60 may, for example,
exhibit an embossed-in-registration ceramic plank motif G1. The
ceramic plank motif may comprise a plurality of planks in the shape
of squares, rectangles, triangles, circles, ovals, any other shape
or design that are separated by grout lines. In one aspect of the
present invention, widths of grout lines Wh, Wv, and the intraboard
grout width W may be substantially equal. When incorporating the
snap-type tongue and groove locking mechanism into the
embossed-in-registration flooring planks 60 the grout width
adjacent the joints J1, J2, J3, and J4 on each
embossed-in-registration laminate A, B, C, and D are approximately
one-half the intraboard grout width W. For example, the vertical
plank grout width (Wv) across joint J1 is made up of grout lines on
embossed-in-registration laminates A, B, C and D, such that when
the embossed-in-registration laminates A, B, C, and D are joined at
J1 the vertical grout width (Wv) is approximately equal to (W).
Accordingly, the grout width on any individual
embossed-in-registration flooring plank 60 adjacent a joint is
one-half of intraboard grout width (W). In another aspect of the
present invention, the horizontal and vertical grout widths Wh and
Wv may be controlled such they are substantially equal to the
dimensions of the intraboard grout width W. It should be
appreciated, however, that the dimensions of the grout widths in
the embossed-in-registration flooring planks depend on the type of
locking mechanism incorporated and the decorative motif
exhibited.
[0078] In addition to grout lines, many other decorative motifs may
be used in the embossed-in-registration flooring system of the
present invention. Referring to FIGS. 10 and 11, a decorative motif
exhibiting, for example, a wood grain surface G2 substantially
aligned across joints J5 and J6 of adjacent flooring planks may be
provided. According to the principles of the present invention,
wood grain patterns generally include more elements (e.g., wood
grain lines, wood knot 423, etc.) that extend to the perimeters of
the flooring planks that need to be aligned than ceramic plank
motifs. Accordingly, aligning the wood grain motif is generally
more difficult than aligning grout line portions of the ceramic
plank motifs. For example, aligning a first portion of a wood knot
423 on embossed-in-registration flooring plank E with a second
portion of the wood knot 423 on embossed-in-registration flooring
plank F is generally more complex than aligning grout line widths
across joints of adjacent flooring planks. Accordingly, when
fabricating a locking mechanism, consideration of all the graphic
elements (e.g., wood grains lines and wood knots 423) must be
considered to ensure a realistic embossed-in-registration flooring
system 400. In one aspect of the present invention, at least one
portion of the decorative motif may be used as an alignment marks
ensuring consistent alignment of adjacent flooring planks.
[0079] In another aspect of the present invention, individual
flooring planks within the embossed-in-registration flooring system
400 may be joined together with a snap-type mechanical system as
illustrated in FIG. 11 depicting a cross sectional view of FIG. 10
along line 11-11. Again, alignment techniques used in the
fabrication of the locking mechanism such that the
embossed-in-registration laminate system 400 has a surface texture
surface 423 that is substantially continuous across joints, J5 and
J6. Optionally, the embossed-in-registration laminates 60 have a
protective padding layer 70 under the base sheet 48.
[0080] FIGS. 12A and 12B illustrate schematic views of a flooring
plank in accordance with the principles of the present
invention.
[0081] Referring to FIGS. 12A and 12B, an upper surface at the
perimeter, P, of each embossed-in-registration flooring plank may
be recessed below an upper surface at the portions of the flooring
plank surrounded by the perimeter. An object O (e.g., a users shoe,
a wheel, etc.) contacting the major surface, Ms, of a flooring
plank does not generally contact the surface of the perimeter, Ps,
due to the perimeter's recessed surface. In one aspect of the
present invention, the perimeter may include a portion of the
flooring plank extending from the edge of the flooring plank
approximately 3.175 mm toward the center of the flooring plank. In
another aspect of the present invention, the depth to which the
surface of the perimeter of the flooring plank is recessed is
approximately 0.794 mm. In another aspect of the present invention,
the surface of at least one portion of the perimeter of a flooring
plank may not be recessed, as will be discussed in greater detail
below with reference to FIG. 13.
[0082] Accordingly, the embossed-in-registration pattern may be
provided to the edges of the flooring plank and may be aligned with
embossed-in-registration patterns formed on adjacent flooring
planks while the edges of each individual flooring plank may be
prevented from prematurely wearing.
[0083] Although it has been shown in FIGS. 8 and 10 that individual
flooring planks within a flooring system are substantially the same
size and shape and are joined to each other such that each side of
each flooring plank is joined to only one adjacent flooring plank,
it should be appreciated that individual flooring planks within a
flooring system may vary in size (e.g., width and/or length) and
shape (e.g., rectangular, square, triangular, hexagonal, etc.). In
one aspect of the present invention, individual flooring planks may
have complementary shapes capable of being assembled similar to a
puzzle or mosaic. Further, one aspect of the present invention
contemplates that sides of individual flooring planks may contact
more than one adjacent flooring plank.
[0084] In accordance with the principles of the present invention,
flooring planks within a flooring system may be arranged such that
at least one side of each plank includes at least one sub-panel
adjacent at least two other sub-panels. In another aspect of the
present invention, each plank may include, either entirely or
partially, at least one sub-panel, as will be described in greater
detail below.
[0085] In FIG. 13A, for example, partial sub-panel 134A of plank
130A may be a complementary sub-panel with respect to neighboring
partial sub-panel 136B of plank 130B, adjacent plank 130A. With
this arrangement, the partial sub-panels 134A and 136B may be made
to appear as one unitary sub-panel.
[0086] Still referring to FIG. 13A, each of the planks 130A-F may
comprise at least three sub-panels wherein at least one of the
sub-panels is a unitary sub-panel and at least two of the
sub-panels are partial sub-panels. For example, 132A is a unitary
sub-panel and 134A and 136A are partial sub-panels.
[0087] In one aspect of the present invention, the unitary
sub-panel 132A may provide a complete decorative motif with or
without an embossed surface texture that may or may not be in
registration with the decorative motif. In another aspect of the
present invention, the partial sub-panels 134A and 136A of a plank
may provide separated, incomplete decorative motifs with or without
embossed surface textures that may or may not be in registration
with the decorative motifs. In one aspect of the present invention,
neighboring partial sub-panels of adjacent planks may be
complementary to each other such that they provide a substantially
complete decorative motif and/or surface texture and appear as a
substantially continuous, unitary sub-panel. In one aspect of the
present invention, complementary partial sub-panels may have
complementary decorative motifs and/or embossed surface textures.
Accordingly, when complementary partial sub-panels of adjacent
planks are properly aligned, a substantially continuous (i.e.,
complete) decorative motif and/or embossed surface texture may be
formed across neighboring complementary partial sub-panels. In one
aspect of the present invention, sub-panels within a plank may or
may not comprise substantially the same decorative motif and/or
embossed surface texture.
[0088] FIG. 13B illustrates a schematic view of an exemplary plank
130 such as that shown in FIG. 13A.
[0089] In one aspect of the present invention, portions of the
perimeter surface of each plank may be recessed at locations where
neighboring sub-panels are not complementary. In another aspect of
the present invention, portions of the perimeter surface of each
plank may be non-recessed at locations where neighboring sub-panels
are complementary. Referring to FIG. 13B, portions of the upper
surface of the perimeter "P" of each of the planks 130 indicated by
reference numeral 138a may be slightly recessed compared to the
major surface of each of the planks (see also FIG. 12B) to prevent
premature wear of each of the planks. Further, portions of the
upper surface of the perimeter of each of the planks 130 indicated
by reference numeral 138b may be non-recessed and substantially
coplanar with the major surface of the sub-panels. Recessing only
portions of the perimeter surface of each of the planks at
positions not occupied by the decorative motifs and/or embossed
surface textures of partial sub-panels of a plank allows
complementary partial sub-panels to appear as a part of a unitary
sub-panel while not significantly detracting from the overall
durability of each of the planks. In yet another aspect of the
present invention, portions of the surface of each plank may be
recessed at locations where sub-panels of a plank are adjacent one
another. Referring to FIG. 13B, portions of the upper surface of
each of the planks 130 indicated by reference numeral 138c may be
slightly recessed compared to the major surface of each of the
planks (see also FIG. 12B) to provide a visual and textural effect
that each of the sub-panels of the plank are not a part of the same
plank.
[0090] FIGS. 14A-14C illustrate an exemplary plank of a flooring
system in still another aspect of the present invention.
[0091] Referring to FIGS. 14A-14C, similar to the plank shown in
FIGS. 13A and 13B, portions of the upper surface of the perimeter
"P" of each of the planks 130 indicated by reference numeral 138a
may be beveled to prevent premature wear of each of the planks.
Further, portions upper surface of the perimeter of each of the
planks 130 indicated by reference numeral 138b may not be beveled
such that they are substantially coplanar with the major surface of
the sub-panels. Beveling the perimeter surface of each of the
planks at positions corresponding to the decorative motifs and/or
embossed surface textures of partial sub-panels of a plank allows
complementary partial sub-panels to appear as a part of a unitary
sub-panel while not significantly detracting from the overall
durability of each of the planks. In yet another aspect of the
present invention, portions of the surface of each plank may be
provided with a groove at locations where sub-panels of a plank are
adjacent to one another.
[0092] FIGS. 14B and 14C illustrate cross-sectional views of plank
130 taken across lines I-I' and II-II', respectively. Referring to
FIGS. 14B and 14C, portions of the upper surface of each of the
planks 130 indicated by reference numeral 138c may be beveled to
form a groove. This groove may also prevent premature wear of each
of the planks. Thus, the groove provides a visual and textural
effect that sub-panels of a plank are separate. In one aspect of
the present invention, the bevel at 138c may produce a groove
having a substantially V-shaped groove. It is appreciated, however,
that the bevel may produce other groove topographies (e.g.,
U-shaped grooves, etc.). In one aspect of the present invention,
the beveling of each of the planks 130 at perimeter surface portion
138a creates a groove between adjacent planks. Accordingly, the
groove formed between adjacent ones of the planks, via beveling at
138a, has substantially the same width and topography as grooves
formed within the planks, via beveling at 138c.
[0093] The motif and/or surface texture present at the recessed
surface of the perimeter of each plank may or may not correspond to
the motif/surface texture present at the main surface of a
corresponding plank. Thus, a substantially continuous motif and/or
surface texture may or may not be present across the surfaces of
the perimeter and the interior of any individual plank. Alignment
marks or markings (not shown) can be used to self-align a
decorative motif on the planks. In one aspect of the present
invention, the embossed in-registration pattern may be a free form
or custom design. It is to be understood that substantially any
embossed-in-registration pattern and any decorative motif may be
realized by applying the principles of the present invention. In
one aspect of the present invention, alignment of the planks may be
done visually upon joining them together. Accordingly, alignment of
the planks 130 may be performed using the decorative motif and/or
embossed surface texture of each of the planks.
[0094] While it has been illustrated that the planks in FIGS. 13A,
13B, and 14A-14C are substantially rectangular, the principles of
the present invention allow the planks within the flooring system
to have other shapes and sizes (e.g., geometric, freeform, etc.) or
different or similar dimensions such that the flooring planks may
be assembled in a "mosaic"-type arrangement or other regular,
semi-repetitious, or random arrangement of panels. Further, while
it is illustrated that each plank comprises an identical sub-panel
layout, the principles of the present invention allow the planks
within the flooring system to have other sub-panel layouts (e.g.,
other sub-panel shapes, sizes, etc.) The individual planks within
the flooring system may be cut from a board such that joints
between the flooring panels of the flooring system are not visible.
Further, the planks within the flooring system illustrated in FIGS.
13 and 14 may be joined together with or without glue. Still
further, while it has been discussed that the embossed surface
texture is substantially aligned with an underlying decorative
motif, it is to be understood that substantially any embossed
surface texture may be imparted to the planks of the present
invention, regardless of the underlying decorative motif. Still
further, the decorative motifs and/or the embossed surface texture
of one plank may not be aligned or even be remotely similar in
appearance and/or texture to decorative motifs and/or embossed
surface textures of adjacent planks.
[0095] According to the principles of the present invention, any of
the aforementioned decorative motifs and/or embossed surface
textures that may or may not be embossed in registration with the
decorative motifs (collectively referred to herein as "patterns")
may be applied to any of the aforementioned planks to form a
substantially continuous pattern across adjacent planks arranged
along a predetermined direction by forming each of the plank
patterns using at least one bulk pattern and at least one edge
pattern.
[0096] In one aspect of the present invention, each edge pattern
may be present at a perimeter portion of the plank extending along
at least a portion of at least one edge of each plank. In another
aspect of the present invention, each edge pattern may extend to a
predetermined distance (e.g., about one millimeter, about one inch,
etc.) into the interior of the plank, away from the perimeter of
the plank. In another aspect of the present invention, at least one
bulk pattern may be arranged adjacent at least one edge pattern,
wherein a pattern present at the edge of the bulk pattern adjacent
the edge pattern may form a substantially continuous
visual/textural pattern with a pattern present at the edge of the
edge pattern adjacent the bulk pattern.
[0097] In one aspect of the present invention, patterns of
individual planks, arranged adjacent each other along a
predetermined direction within a flooring system, may complement
patterns of adjacent planks (i.e., form substantially continuous
patterns across adjacent planks) when edge patterns of the adjacent
planks form a substantially continuous pattern. Where the flooring
system described above comprises a plurality of adjacent planks
arranged along the predetermined direction, and where the edges of
each plank are arranged adjacent to edge patterns of other planks
along the predetermined direction, edge patterns of adjacent planks
are identical or substantially identical. The identical or
substantially identical edge patterns of adjacent planks enable a
continuous pattern to be formed across the adjacent planks.
[0098] For example, referring to FIG. 15A, an exemplary plank
pattern of plank 150 may comprise two edge patterns 152
substantially identical to each other and a bulk pattern 154. As
shown in FIG. 15A, the two substantially identical edge patterns
152 are present at a perimeter portion of the plank 150, extend
along a portion of the opposite edges of the plank, and extend a
predetermined distance into the interior of the plank 150. Still
referring to FIG. 15A, the pattern present at the edge of the bulk
pattern 154 adjacent the edge patterns 152 forms a substantially
continuous pattern with the pattern present at the edge patterns
152 adjacent the bulk pattern.
[0099] Referring now to FIG. 15B, a plurality of planks 150A, 150B,
150C, etc., such as those illustrated in FIG. 15A may be arranged
adjacent each other within a flooring system along a predetermined
direction such that edges of each plank are arranged adjacent to
the edges of other planks along the predetermined direction (e.g.,
an edge of plank 150A is adjacent an edge of plank 150B, an edge of
plank 150C is adjacent an edge of plank 150D, etc.). As mentioned
above, a substantially continuous pattern may be formed across an
individual plank 150 because the bulk pattern 154 is substantially
aligned with the edge patterns 152.
[0100] In an embodiment of the invention, the predetermined
direction in which the planks are arranged is based on the adjacent
edge patterns 152 in the planks, such that only by arranging the
planks in the predetermined direction will the pattern formed be
continuous and natural-looking. In this embodiment, reversing a
plank or flipping a plank over will result in a discontinuous
pattern. However, it is understood that in another embodiment, the
edge patterns along a portion of the perimeter may be selected such
that reversing, flipping or otherwise rearranging planks does not
disrupt the pattern, i.e. the pattern is continuous.
[0101] In another embodiment, the predetermined direction is based
on the interlocking mechanism that joins adjacent planks, such that
the planks will not fit together properly if they are arranged in a
direction other than the predetermined direction. One example of
such a interlocking mechanism is a glueless tongue and groove
system, in which the tongue is formed along at least one edge of
the plank and the groove formed along the opposite edge. In yet
another embodiment, the predetermined direction is based on both
the edge patterns 152 and the glueless locking mechanism.
[0102] According to the principles of the present invention, bulk
patterns 154A-154F may or may not be the same. In one aspect of the
present invention, each of the bulk patterns 154 within a flooring
system may be unique. Further, according to the principles of the
present invention, edge patterns of individual planks may be
substantially identical. Therefore, edge patterns of adjacent
planks in a flooring system, across which a substantially
continuous pattern is formed along the predetermined direction, are
also substantially identical. A substantially continuous pattern
may be provided across plank 150A because bulk pattern 154A and
edge patterns 152A are aligned with each other to produce a
substantially continuous pattern. Substantially continuous patterns
may be individually provided across planks 150B, 150C, etc.,
because their respective bulk patterns 154B, 154C, etc., and edge
patterns 152B, 152C, etc. are similarly aligned with each other to
produce a substantially continuous pattern.
[0103] Because the edge patterns of planks 150A-150F within the
flooring system illustrated in FIG. 15B are identical, edge pattern
152A forms a substantially continuous pattern with edge pattern
152B, edge pattern 152C forms a substantially continuous pattern
with edge pattern 152D, and so on. Accordingly, a substantially
continuous pattern may be formed across planks 150A and 150B,
across planks 150C and 150D, and so on. The boundary or joint
between the edge pattern 152A and the edge pattern 152B is
substantially not visible, or the appearance of the presence of the
boundary or joint is minimized. Similarly, the boundary or joint
between the edge pattern 152C and the edge pattern 152D is
substantially not visible, or the appearance of the presence of the
boundary or joint is minimized. The boundary or joint between the
edge pattern 152E and the edge pattern 152F is substantially not
visible, or the appearance of the presence of the boundary or joint
is minimized.
[0104] In one embodiment of the present invention, in which the
edge patterns 152 are all substantially identical, any of the
planks 150A-150F may replace any other plank within the flooring
system while still maintaining the presence of a substantially
continuous pattern across planks arranged adjacent each other along
the predetermined direction. This is because all bulk patterns of a
plank are substantially aligned with their respective edge patterns
to form substantially continuous patterns within a plank and
because all edge patterns of planks adjacent each other within a
flooring system are identical, forming form substantially
continuous patterns across planks adjacent each other along the
predetermined direction.
[0105] In another embodiment, planks may have adjacent right and
left edge patterns 152 substantially identical, while opposite left
and right edge patterns 152 are not.
[0106] For example, in FIG. 15C, the unitary sub-panel 132 of plank
150 may have a pattern provided by a bulk pattern 154G, partial
sub-panel 134 may have a pattern provided by bulk pattern 154I and
edge pattern 152, and partial sub-panel 136 may have a pattern
provided by bulk pattern 154H and edge pattern 152, wherein the
bulk patterns 154G-154I may or may not be the same. As mentioned
above, however, the edge pattern 152, present at the perimeter of
the partial sub-panel portions 134 and 136 of the plank 150 and
extending along a portion of the edges of the plank 150, are
identical to each other. Accordingly, in view of FIG. 13A, when,
for example, planks 130A and 130B are arranged adjacent each other
along a predetermined direction, edge patterns 152 of complementary
partial sub-panels 134A and 136B are substantially identical to
each other and a substantially continuous pattern may be formed
across adjacent planks, wherein the bulk patterns of the
complementary partial-sub panels become a part of a substantially
continuous pattern, appearing, visually and/or texturally as a
unitary sub-panel.
[0107] Furthermore, referring now to FIGS. 15C and 15D, flooring
systems incorporating planks such as those illustrated in FIGS.
13A-14C may be provided with substantially continuous patterns
across planks adjacent each other along predetermined directions by
applying the techniques described above with reference to FIGS. 15A
and 15B. FIG. 15D shows the planks having a wood grain pattern in
the arrangement shown in FIG. 15B. Because the edge pattern 152A is
substantially identical to the adjacent edge pattern 152B, planks
150A and 150B have the appearance of a substantially continuous
wood grain pattern running uninterrupted across the boundary or
joint between edge pattern 152A and edge pattern 152B of the
adjacent plank.
[0108] In addition, because the edge patterns 152A and 152B do not
run along the entire length of the boundary or joint between planks
150A and 150B, but only along the portion corresponding to the
height of the partial board on the bottom half of the planks, the
pattern is not continuous across that portion of the boundary
between planks 150A and 150B corresponding to the height of the
complete boards on the top half of the planks.
[0109] As mentioned above, within the flooring system incorporating
the planks illustrated in FIGS. 13A-14C and 15C, the bulk patterns
within the sub-panels of the planks may or may not be the same. In
one aspect of the present invention, each of the bulk patterns
within the flooring system may be unique.
[0110] FIG. 15E shows an embodiment of the invention in which the
edge patterns of the planks are identical (or substantially
identical) in every plank. Specifically, FIG. 15E shows four
planks, 150A, 150B, 150C, and 150D arranged such that plank 150A is
adjacent the left edge of plank 150B and adjacent to a top edge of
plank 150C. Plank 150D is adjacent to the right edge of plank 150C
and adjacent to the bottom edge of 150B.
[0111] In this embodiment, the decor paper of each plank has a wood
design. However, it is understood that other natural looking
designs other than wood are contemplated by this invention as well.
The wood design in plank 150A includes, for example, a complete
board or strip 155A on a top half of the board, a short incomplete
board 151A and a long incomplete board 153A. Each of the boards has
a wood grain pattern. In addition, the short and long incomplete
boards 151A and 153A have an edge pattern 152 running along a
portion of the perimeter of the plank corresponding to the width of
the incomplete boards 151A and 153A, and may extend a small
distance (such as one centimeter, for example) into the interior of
the boards. The edge patterns 152 of incomplete boards 151A and
153A are identical. The edge patterns 152 may also not extend into
the interior of the boards.
[0112] Similarly, planks 150B, 150C, and 150D have complete boards
155B, 155C, and 155D, respectively, running the length of the
plank, and short boards 151B, 151C, and 151D which are adjacent to
long boards 153B, 153C, and 153D, respectively. Each of the short
and long boards may have an identical edge pattern 152 along a
portion of the perimeter of the plank corresponding to the width of
the short and long boards.
[0113] All short boards 151A-D, long boards 153 A-D, and complete
boards 155A-D have wood grain patterns that are different from each
other or some identical to each other. Only the edge patterns 152
in the incomplete boards are identical in this particular example.
Furthermore, the edge pattern and interior wood grain pattern of
each incomplete board form a continuous pattern. In other words,
there is a continuous overall wood grain pattern on each of the
short boards and long boards that are all different from one
another, despite the fact that the edge patterns 152 are the
same.
[0114] When planks 150A and 150B are placed adjacent to one another
as shown in FIG. 15E, complete boards 155A and 155B will be
adjacent to each other, and long board 153A and short board 151B
will be adjacent. Complete boards 155A and 155B appear as separate
boards and the wood grain pattern is discontinuous across them,
because the adjacent edges of the complete boards are different.
But because the edge patterns 152 in long board 153A and short
board 151B are the same, the unique wood grain patterns of 153A and
151B appear to form a single continuous board with a unique wood
grain pattern running across the planks 150A and 150B. Furthermore,
the appearance of a complete and continuous board with a unique
wood grain pattern running in boards 153A and 151B across the
planks minimizes the visibility or appearance of the joint or
boundary between the planks. Similarly, the wood grain pattern
across boards 153C and 151D is continuous.
[0115] In a further embodiment, the planks 150A, 150B, 150C, and
150D may have a surface texture that is embossed in registration
with the wood design on the decor paper. Because edge patterns 152
are part of that wood design and may be the same or substantially
identical in every plank, the embossed surface texture will appear
to be continuous along the incomplete boards of adjacent planks in
the manner discussed above. In still another embodiment, the
embossed in registration surface texture may include bevels to
imitate seams between boards, such that in plank 150A, for example,
the complete board 155A would have a bevel running along its
perimeter, including the boundary between board 155A and incomplete
boards 151A and 153A. The incomplete boards 151A and 153A would
have a bevel where they are adjacent, but the incomplete boards
would not have a bevel along the portion of the perimeter of the
plank 150A where the edge patterns 152 are located. In this way, a
continuous wood grain pattern and corresponding embossed in
registration surface texture can run continuously across planks
150A and 150B uninterrupted by a bevel. This would further reduce
the appearance of the boundary between planks.
[0116] By having all edge patterns 152 to be identical, the present
invention allows any planks to be fit together in the predetermined
direction in which a long board 153 is adjacent a short board 151
of another plank, because the edge patterns 152 will always line up
to form the appearance of a continuous wood grain pattern running
across the adjacent long and short boards of the two planks. For
example, if the positions of planks 150A and 150B were reversed
(such that plank 150B was adjacent a top edge of plank 150C), the
edge pattern 152 of long board 153B would match or be aligned with
the edge pattern of short board 151A, forming a continuous wood
grain pattern in the boards 153B and 151A across planks 150B and
150A.
[0117] The present invention reduces the complexity involved in
installing a laminated floor, because it does not matter which
planks are placed adjacent to one another in the predetermined
direction. The patterns will be aligned. In a further embodiment,
the planks 150 are provided with a glueless interlocking tongue and
groove system in which the tongue is formed on two adjacent
perimeter edges of the plank and the groove is formed in the
opposite two adjacent perimeter edges so that the planks can only
be fit together in the direction that will align long boards 153
with short boards 151, for example, where edge patterns 152
meet.
[0118] In the exemplary embodiment discussed above, the decorative
motifs and design pattern elements such as wood strips run across
separate adjacent planks. However, the wood strip motif has a
length equal to that of the length of the plank, in order to allow
for the interchangeability of planks, ensuring an easy
installation.
[0119] Now making reference to FIG. 16, FIG. 16 illustrates a floor
501 having a floor pattern 500 formed by patterns 500a through 500d
in accordance with an embodiment of the present invention. A
plurality of flooring units having a decorative motif 512 disposed
thereon define the floor 501. In particular, the plurality of
flooring units includes flooring units 504, 506, 508 and 510, as
more clearly shown with reference to FIGS. 17A through 17D.
[0120] FIG. 17A is an embodiment of the present invention
illustrating the flooring unit 504 which includes subunits 504a
through 504d. The subunits 504a through 504d form the flooring unit
504 such that a plank is formed. In the embodiment shown in FIG.
17A, the subunit 504c has the decorative motif 512. It should be
noted that in an alternative embodiment of the present invention,
the subunit 504b may include the decorative motif 512 instead of
the subunit 504c.
[0121] FIG. 17B illustrates the flooring unit 506 in accordance
with an embodiment of the present invention. The flooring unit 506
includes subunits 506a through 506d. In this embodiment, the
subunits 506a through 506d do not include a decorative motif, as
discussed with reference to FIG. 17A and the flooring unit 504.
[0122] FIG. 17C is an embodiment of the present invention showing
the flooring unit 508. The flooring unit 508 has subunits 508a
through 508d. Here, the subunit 508a has the decorative motif 512.
Nonetheless, in accordance with embodiments of the present
invention, the subunit 508d may include the decorative motif 512
instead of the subunit 508a.
[0123] FIG. 17D illustrates the flooring unit 510 in accordance
with an embodiment of the present invention. The flooring unit 510
includes subunits 510a through 510d each having the decorative
motif 512. In accordance with an embodiment of the present
invention, the flooring unit 510, along with the flooring units
504, 506 and 508, includes ceramic tiles. In addition, the flooring
units 504, 506, 508 and 510 may be any material used in flooring
applications, such as wood, cork, marble or the like. It should be
noted that the flooring units 504, 506, 508 and 510 have been
described as having four subunits (e.g., subunits 504a through
504d). However, the flooring units 504, 506, 508 and 510 may have
any number of subunits in accordance with the present invention, as
will be discussed further on.
[0124] Returning attention to FIG. 16 and the floor pattern 500
shown therein, the flooring units 504, 506, 508 and 510 are aligned
with respect to one another such that the decorative motifs 512
form the floor pattern 500. As previously mentioned, each of the
flooring units 504, 506, 508 and 510 comprise four subunits. In
this embodiment, the flooring units 504, 506, 508 and 510 are
aligned such that the decorative motifs 512 disposed on the
flooring units 504, 508 and 510 align with one another.
[0125] In order to form the pattern 500a of the floor pattern 500,
the subunit 504c of the flooring unit 504 aligns with the subunit
508a of the flooring unit 508 along an X-axis of the floor 501.
More specifically, in order to form the pattern 500a, the subunits
504c of the flooring unit 504 align with the subunits 508a of the
flooring unit 508 to form the pattern 500a. Likewise, both the
subunit 508a and the subunit 504c align with the subunit 510a of
the flooring unit 510 thereby forming the pattern 500a. It should
be noted that the pattern 500c is formed in a manner similar to the
pattern 500a, in accordance with an embodiment of the present
invention.
[0126] In the embodiment shown with reference to FIG. 16, the
subunit 510d aligns with the subunit 510a of a second flooring unit
510 along a Y axis of the floor pattern 500 such that decorative
motifs 512 disposed on the first and second flooring unit 510 align
along the Y axis. Additionally, in this embodiment, a subunit 508a
of a second flooring unit 508 aligns with the subunit 510d of the
second flooring unit 510 thereby forming the pattern 500b as shown.
It should be noted that in this embodiment, the pattern 500d is
formed in a manner similar to that described with reference to the
pattern 500b. In addition, the flooring units 506 are disposed
within the floor pattern 500 such that the subunit 506a is adjacent
the subunit 504d of the flooring unit 504 that forms the pattern
500a.
[0127] As may be seen with reference to FIG. 16, an endmost subunit
(e.g., the subunit 508a or 508d) of the flooring unit 508 aligns
with a subunit adjacent an endmost subunit (e.g., the subunit 506a
or 506d) of the flooring unit 506. Furthermore, in the embodiment
shown in FIG. 16, the flooring units 504, 506, 508 and 510 have
four subunits. Nonetheless, the flooring units 504, 506, 508 and
510 may have any number of subunits. For example, flooring units
may have six subunits, as shown in FIGS. 19A through 19D.
[0128] FIG. 19A illustrates a flooring unit 514 having subunits
514a through 514f in accordance with an embodiment of the present
invention. The flooring unit 514 also includes the decorative motif
512 on the subunit 514e. FIG. 19B is an embodiment of the present
invention showing a flooring unit 516. The flooring unit 516 has
subunits 516a through 516f. FIG. 19C shows a flooring unit 518
having subunits 518a through 518f. In addition, the flooring unit
518 has the decorative motif 512 disposed on the subunit 518a.
Flooring unit 520, shown in FIG. 19D, includes subunits 520a
through 520f each having the decorative motif 512 disposed thereon.
The flooring units 514, 516, 518 and 520 may be used to form a
floor pattern 522 for the floor 500 as shown in FIG. 18.
[0129] FIG. 18 illustrates an embodiment of the present invention
where the flooring units 514, 516, 518 and 520 form a pattern 522
including patterns 522a through 522d. In this embodiment, subunits
514e, 518a and 520a form the pattern 522a as shown. Likewise,
pattern 522c is formed in a manner similar to that used for the
pattern 522a. In addition, subunits 520a through 520f and subunits
518a form the patterns 522b and 522d as illustrated.
[0130] As may be seen with reference to FIGS. 16 and 18, the
patterns of the floor 501 are formed with decorative motifs
disposed on the following: an edge most subunit of a flooring
member, a subunit immediately adjacent an edge most subunit, and a
flooring unit having decorative motifs disposed on all subunits of
the flooring unit. Additionally, a flooring unit which does not
include decorative motifs is also used in forming the patterns of
the floor 501. Therefore, flooring units having at least three
subunits may be used to form patterns on a floor in accordance with
the present invention.
[0131] In addition, in an embodiment of the present invention where
a flooring unit includes four subunits, three flooring units may be
used as illustrated in FIG. 20. In this embodiment, one flooring
unit includes a decorative motif on all of the subunits, such as
the flooring unit 510. A second flooring unit has a decorative
motif on any one of the subunits, such as either the flooring unit
504 or 508. The subunits of the third flooring unit are all devoid
of the decorative motif similar to the flooring unit 506. In FIG.
20, the subunits 508a and 510a form patterns 513a and 513c of
pattern 513. In addition, the flooring unit 510 and the subunits
508a from patterns 513b and 513d of the pattern 513.
[0132] In a further embodiment, where a flooring unit includes five
subunits, four flooring units 524, 526, 528 and 530 may be used as
more clearly illustrated in FIG. 21 to form the pattern 531 having
patterns 531a through 531d. Making reference to FIGS. 22A through
22D, the flooring units 524, 526, 528 and 530 include five
subunits. The flooring unit 524 includes subunits 524a through
524e. The flooring unit 526 has subunits 526a through 526e where
all the subunits include the decorative motif 512. The flooring
unit 528 has the subunits 528a through 528e. Here, the subunit 528d
has the decorative motif 512. The flooring unit 530 includes
subunits 530a through 530e where the subunit 530c has the
decorative motif 512.
[0133] Returning attention to FIG. 21, the subunits 526a and 528d
form the pattern 531a. The flooring unit 526 also forms the
patterns 531b and 531d. Furthermore, the subunits 526e and 530c
form the pattern 531c such that the pattern 531 is formed on the
floor 501.
[0134] It should be noted that in accordance with embodiments of
the present invention, many types of patterns for the floor 501,
such as the patterns 500 and 522, may be formed using either of the
flooring units 504, 506, 508 and 510 or the flooring units 514,
516, 518 and 520.
[0135] Furthermore, in one embodiment of the present invention, the
subunits may be staggered from one another, as more clearly shown
in FIG. 16 where the subunit 500a aligns with the subunit 504c. In
embodiments where the subunits are offset from one another, four
flooring units, (e.g., the flooring units 504, 506, 508 and 510)
may be used irrespective of the number of subunits.
[0136] FIG. 23 illustrates a further embodiment of the present
invention. FIG. 23 illustrates a flooring system having four (prior
to milling the tongue and groove edges of each plank) distinctly
patterned planks 1000, 1002, 1004 and 1006, each divisible into
four equal subunits a, b, c, and d). The embodiment in FIG. 23
includes a decorative motif that has a width less than the width of
a subunit.
[0137] As illustrated in FIG. 23, plank 1000 does not include the
decorative motif FIG. 1002 includes the decorative motif on only a
portion of one of the four subunits of the plank 1002. In this
example, the decorative motif has a height (the direction parallel
to the length of the plank) substantially equal to half of the
height of a subunit. Plank 1004 includes the decorative motif on a
different subunit of the plank. In other words, the subunit of
plank 1004 that includes the decorative motif is different from the
subunit of plank 1002 that includes the decorative motif.
[0138] Finally, plank 1006 includes the decorative motif running
the entire length of the plank but only in a portion of each of the
subunits. For example, the decorative motif may have a width (the
direction parallel to the short side of the plank) equal to half
the width of the plank, but runs the entire length of the plank. In
other embodiments or other aspects of this embodiment the
decorative motif may have a different width, that width being less
than the total width of a plank.
[0139] After the planks are milled with the profiled edges, at
least seven different planks are required in the flooring system
according to this embodiment. However, if the planks have a joint
system in which the joining mechanism or joint profile on opposite
edges of the planks are the same, then only the four planks
discussed above are required for this flooring system.
[0140] Because the decorative motif is on only a portion of each
subunit, if the subunits are placed adjacent to one another such
that entire subunits are adjacent to an entire subunit, then, as
illustrated in FIG. 24, the flooring system will include a plank
1000 which is the same as that illustrated in FIG. 23, a plank 1002
which is similar to that illustrated in FIG. 23, and a plank 1004
which is similar to that illustrated in FIG. 23. However, there are
also additional planks, including plank 1003, which is the same as
plank 1004 rotated 180.degree.. Plank 1003 may be placed adjacent
to planks 1006 and 1002 such that the decorative motif on the
adjacent planks are aligned. There is also a plank 1005, similar to
the plank 1002 rotated 180.degree., that may be placed adjacent to
plank 1003 such that the decorative motif lines up across adjacent
subunits of the planks. Furthermore, the flooring system includes
plank 1007 which is similar to plank 1006 rotated 180.degree.. Thus
the flooring system having planks 1000, 1002, 1003, 1004, 1005,
1006 and 1007 is able to create a flooring pattern illustrated in
FIG. 24 which has a height equal to the length of two planks (or
eight subunits in which each plank had a total of four subunits and
a width of nine planks, however, because the decorative motif is
only on a portion of the width of the planks 1006 and 1007, the
actual width of the decorative motif is eight planks wide, although
it requires a total of nine planks to create the pattern.
[0141] FIG. 24 illustrates a flooring pattern created using the
seven planks of this flooring system in which the decorative motifs
occupy only on a portion of a subunit of the plank rather than the
entirety of the subunit as was illustrated in embodiments discussed
earlier. Because the decorative motif is offset within each subunit
in this fashion, this flooring system is able to disguise the
physical joints between adjacent planks using this flooring system.
More specifically, in FIG. 24, plank 1003 is placed adjacent to
plank 1006 such that the second subunit of plank 1003, identified
as subunit 1003b, is adjacent to the first subunit 1006a of plank
1006. Similarly, subunit 1005d is adjacent to subunit 1003b of
plank 1003. In this way, planks 1003 and 1005 are offset from each
other by a distance of two subunits, or half of the total length of
the plank, whereas, plank 1003 is offset from plank 1006 by a
distance of only one subunit or a quarter of the length of the
plank. This difference in offsets between planks 1006 and 1003 and
1003 and 1005 further aids in disguising the physical joints
between adjacent planks.
[0142] The arrangement of planks 1003 and 1005 discussed above may
be repeated to create a flooring pattern having a variable width,
as illustrated in FIGS. 24 through 26. The width of the overall
pattern in this embodiment is equal to the total number of planks
1003 and 1005 placed adjacent to one another plus one plank width
which is the total decorative motif width from the portion of the
decorative motif on plank 1006 plus the portion of the decorative
motif on plank 1007. This is the case because, in this example, the
width of the decorative motif equals one half the width of a plank.
Thus, in FIG. 24 there are seven planks 1003 and 1005 (four of
plank 1003 and three of plank 1005) between planks 1006 and 1007 to
create a decorative motif in a flooring pattern having a width
equal to eight plank widths even though the flooring pattern itself
is created with nine physical flooring planks.
[0143] Furthermore, as illustrated in FIG. 25, the height of the
flooring pattern may be extended to any multiple of plank lengths
simply by running additional planks 1006 adjacent to one another in
the vertical direction--the vertical direction being parallel to
the length of the plank. Therefore, by adding additional planks
1006 adjacent to one another on one side and additional planks 1007
adjacent to one another on the opposite side, the height of the
overall flooring pattern may be extended. This is further
illustrated in FIG. 25 which has a flooring pattern with a height
equal to three plank lengths created by three planks 1006 adjacent
to one another on one side and three planks 1007 adjacent to one
another on the other side. The flooring pattern has a width equal
to the width of twelve flooring planks even though thirteen planks
are required to complete the flooring pattern in the width
direction.
[0144] Furthermore, and as illustrated in FIG. 26, with the
flooring system of the embodiment currently discussed, the smallest
flooring pattern that may be created is a flooring pattern having a
height equal to the length of one plank and a width equal to the
width of four planks and requires five planks placed adjacent to
one another in the width direction, specifically planks 1006, 1005,
1003, 1005 and 1007 to create this flooring pattern.
[0145] It is understood that the various additional embodiments in
which the decorative motif has a width less than the total width of
a plank and not equal to half the width of the plank, and in which
the height of the decorative motif is some height other than the
total height of the subunit and different from half the height of
the subunit. Furthermore, it is understood that depending on the
width of the flooring motif of the decorative motif greater or
fewer planks may be required in the flooring system to enable the
creation of floors having flooring patterns of various widths and
heights.
* * * * *