U.S. patent application number 10/583379 was filed with the patent office on 2007-06-07 for skirting board, floor covering system and method for manufacturing a skirting board.
Invention is credited to Mark Cappelle, Lode De Boe, Bernard Thiers, Luc Vanhastel.
Application Number | 20070125021 10/583379 |
Document ID | / |
Family ID | 34682723 |
Filed Date | 2007-06-07 |
United States Patent
Application |
20070125021 |
Kind Code |
A1 |
Thiers; Bernard ; et
al. |
June 7, 2007 |
Skirting board, floor covering system and method for manufacturing
a skirting board
Abstract
Skirting board, more particularly a skirting board with a
laminated surface on one or more sides, characterized in that it is
composed of short pieces (59), more particularly with a length of
less than two meters, which can be mounted successively one after
the other in longitudinal direction.
Inventors: |
Thiers; Bernard; (Wielsbeke,
BE) ; De Boe; Lode; (Moorslede, BE) ;
Cappelle; Mark; (Staden, BE) ; Vanhastel; Luc;
(Tielt, BE) |
Correspondence
Address: |
BACON & THOMAS, PLLC
625 SLATERS LANE
FOURTH FLOOR
ALEXANDRIA
VA
22314
US
|
Family ID: |
34682723 |
Appl. No.: |
10/583379 |
Filed: |
December 17, 2004 |
PCT Filed: |
December 17, 2004 |
PCT NO: |
PCT/EP04/14751 |
371 Date: |
June 19, 2006 |
Current U.S.
Class: |
52/288.1 ;
156/297; 52/313; 52/592.1 |
Current CPC
Class: |
E04F 2019/0427 20130101;
Y10T 156/1089 20150115; E04F 2201/0153 20130101; E04F 19/04
20130101; B27D 5/006 20130101; E04F 2201/0115 20130101; B27D 5/003
20130101 |
Class at
Publication: |
052/288.1 ;
052/592.1; 052/313; 156/297 |
International
Class: |
E04F 19/04 20060101
E04F019/04; E04F 15/10 20060101 E04F015/10 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 18, 2003 |
BE |
2003/0669 |
Claims
1-34. (canceled)
35. Skirting board system, comprising board sections having a
lengthwise direction and further having a laminated surface on one
or more sides, each board section having a length of less than two
meters, said board sections being adapted to be mounted
successively one after the other to each other in the lengthwise
direction.
36. Skirting board system according to claim 35, including coupling
devices enabling coupling of the board sections to each other.
37. Skirting board system according to claim 35, wherein the board
sections are provided with positioning devices enabling board
sections to be at least partially aligned with respect to each
other.
38. Skirting board system according to claim 35, wherein the board
sections are provided with attachment devices enabling blind
seating of the board sections by the mounting of a subsequent
adjacent board section.
39. Skirting board system according to claim 35, wherein direct
coupling devices are provided on each board section, said coupling
devices enabling connection of narrow edge extremities of each
board section, said coupling devices comprising first coupling
parts substantially in the form of a tongue and a groove enabling
well-defined locking in a direction perpendicular to the plane of
the board sections, and second coupling parts enabling a
well-defined locking in a direction parallel to the lengthwise
direction of the board sections; said second coupling parts
comprising a first part that can be elastically moved, said first
part when moved elastically being movable transverse to the plane
of the respective board section and being disposed at the edge area
of the board section on which the tongue is present, and a second
part configured to cooperate with said first part, said first and
second parts being located in an area located inwardly of a tip of
the tongue when adjoining board sections are coupled with said
first and second parts coupled to each other.
40. Skirting board system according to claim 39, wherein, said
second part is provided on a protruding lip of each board
section.
41. Skirting board system according to claim 35, wherein the board
sections comprise coupling devices enabling at least a locking of
board sections in a lengthwise direction, said coupling devices
being formed such that adjoining board sections can be engaged and
locked together by at least one of shifting and turning
motions.
42. Skirting board system according to claim 41, wherein the board
sections have narrow sides including first coupling devices
extending parallel to a front side of the board sections and second
coupling devices extending parallel to an upper side of the board
sections.
43. Skirting board system according to claim 35, wherein the board
sections when coupled display a tile pattern, wherein, at the
location of each transition between two coupled board sections, an
imitation joint is presented.
44. Skirting board system according to claim 43, wherein the
configuration of imitation joint is selected from the group
consisting of: a print; an impression; a print combined with an
impression; a removed material portion along an edge of the joint;
a removed material portion in the shape of an inclination or bevel,
optionally including a separate decorative layer; and a difference
in the surface structure at the location of the joint.
45. Skirting board, comprising at least two structural parts,
including a first structural part forming at least a part of a
front side of the skirting board, and a second structural part
forming at least a part of an upper side of the skirting board,
said structural parts being formed from a laminate material that
has been formed under pressure, and having a core and a synthetic
material-based top layer provided on said core.
46. Skirting board according to claim 45, wherein said first and
second structural parts are formed from a plate-shaped
material.
47. Skirting board according to claim 45, wherein said first and
second structural parts are made from a similar or one and the same
laminate material and show the same pattern.
48. Skirting board according to claim 45, wherein said first and
second structural parts have a top layer, and said first and second
structural parts adjoin each other with their respective top layers
located at least at the level of an outer side of the skirting
board.
49. Skirting board according to claim 45, wherein at the location
of a corner edge formed by said first and second structural parts,
a portion of the material forming the structural parts is removed,
and a decorative layer is provided on a surface exposed by said
material removal.
50. Skirting board according to claim 45, wherein said top layer is
formed of at least one resin-impregnated layer joined to the core
by compression.
51. Skirting board according to claim 45, said laminate material of
at least one of said structural parts comprising DPL (Direct
Pressure Laminate).
52. Skirting board according to claim 45, wherein a top layer of
the first and second structural parts is provided with a tile
pattern with joints extending over a front side and an upper side
of the skirting board.
53. Skirting board, comprising a laminated surface both at a front
side and at an upper side thereof, said surface resulting from an
operation under pressure, wherein at least one surface comprises a
previously formed laminate film, and wherein said laminated
surfaces have been subjected to one and the same or a similar
finishing treatment.
54. Skirting board, comprising a laminated surface both at a front
side and at an upper side thereof, wherein at the edge between the
upper side and the front side, an amount of material has been
removed, and wherein a surface exposed by such material removal is
provided with a decorative layer.
55. Skirting board, comprising at least a first part forming at
least a portion of a front side of the skirting board, and a second
part forming at least a portion of an upper side of the skirting
board, wherein both said first and second parts are formed from the
same piece of laminate material having a core and a top layer of
the DPL type, and wherein the second part comprises a part from
which material is removed from the core, and wherein bringing the
first part and the second part together may be carried out by
turning said first and second parts towards each other around a
folding or breaking line.
56. Skirting board according to claim 55, wherein the second part
and the first part are either or both mutually folded around and
broken around either or both a folding and a breaking line, said
breaking line comprising a weakened material zone that had been
formed partially in the top layer.
57. Skirting board according to claim 55, including a post-treated
edge between the upper side and the front side.
58. Skirting board according to claim 57, said post-treated edge
formed by a surface exposed by the removal of an amount of
material, and wherein the exposed surface is provided with a
decorative layer.
59. Floor covering system, comprising floor panels and skirting
boards, wherein the floor panels are formed of laminated panels
with a core and a pressed-thereupon top layer comprising synthetic
material, said skirting boards comprising a skirting board sections
of the skirting board system according to claim 35, wherein top
layers of the skirting board system and of the floor panels are
matched to each other.
60. Floor covering system according to claim 59, wherein the top
layers are matched to each other in appearance, said skirting
boards and floor panels revealing one or more features selected
from the group consisting of: the skirting boards and the floor
panels have been made by a similar manufacturing process; the top
layers of the skirting boards and floor panels comprise DPL (Direct
Pressure Laminate); the top layers of the skirting boards and floor
panels comprise identical decor layers; and the top layers of the
skirting boards and floor panels are finished in a similar manner,
using finishers selected from the group consisting of: impressions
in the surface; impressions in the surface, which are in register
with a pattern of a decor layer used in the top layer; impressions
in the surface, in which a component is provided, comprising either
a color component or an active component; and treatment of the
surface altering a feature of the surface.
61. Floor covering system, comprising floor panels each having at
least at two opposed edge areas having coupling elements for
enabling coupling such floor panels to each other, said coupling
elements comprising coupling parts as recited in claim 39 for
coupling skirting board sections.
62. Method for manufacturing skirting boards recited in claim 45,
comprising pressing a top layer on a laminate material having a
core, said laminate material comprising synthetic material; by
means of one or more machining operations, forming said parts out
of said laminate material; and connecting said parts directly or
indirectly to each other.
63. Method according to claim 62, including the step of starting
from pieces of laminate material having coupling devices on two
opposite sides such that after the assembly of said parts, coupling
devices are created at the extremities of the skirting boards.
64. Method for manufacturing skirting boards recited in claim 55,
comprising forming by compression a laminate material with a core
and a pressed- thereupon top layer of the DPL type; starting from
laths or strips of said laminate material, forming the skirting
boards; removing from at least one longitudinal edge of said laths
or strips a portion of material, such that a first part and a
second part are formed, wherein both parts remain connected at
least by a portion of the top layer; and said parts are turned
towards each other while they are joined together and attached to
each other.
65. Method according to claim 64, including forming a weakened zone
when removing said material such that said material is removed
partially from the top layer.
66. Method according to claim 64, wherein, after joining said
parts, a post-treatment is performed at the top of an exterior side
of the skirting board where said parts adjoin each other.
67. Method according to claim 66, wherein for the post-treatment,
at least one process is selected from the group consisting of:
coloring; removing an amount of material at the top of the exterior
side of the skirting board where said parts adjoin each other;
sanding; providing a bevel; and providing a decorative layer at the
edge.
Description
[0001] This invention relates to a skirting board, a floor covering
system, in particular a floor covering system applying such
skirting board, and a method for manufacturing such skirting
board.
[0002] It is known that a floor covering can be formed by means of
floor panels which are laid on a subfloor and preferably are
mutually joined either by means of a glued-together tongue and
groove coupling, or by means of coupling parts effecting an
interlocking of the floor panels. Examples of mechanically locking
coupling parts, which are integrated in the floor panels, are
known, amongst others, from the international patent applications
WO 97/47834, WO 01/98603 and WO 01/96688.
[0003] Such floor panels may be of various construction, whereby
mostly, use is made of a substrate or core, on top of which a top
layer, whether or not formed of several layers, is provided. The
core mostly consists of a plate of a wood-based material, for
example, fibreboard or chipboard, more particularly MDF (Medium
Density Fibreboard) or HDF (High Density Fibreboard), although the
use of other materials for the core, for example, synthetic
material, so-called compact laminate and the like, is not excluded.
The top layer may be realized on the basis of synthetic material or
another material, for example, veneer, a wood layer with a
thickness of several millimetres, cork, linoleum, stone or the
like.
[0004] In case the top layer consists of veneer or a wood layer
with a thickness of several millimetres, a skirting board
pertaining to the flooring can simply be realized from solid wood
of the same kind of wood as the veneer of the top layer.
[0005] In the case that the top layer of the floor panels is
realized on the basis of synthetic material, for example, is formed
of one or more pressed and cured resin-impregnated carrier sheets,
amongst which a printed decor layer, which are provided on a core
layer, more particularly DPL (Direct Pressure Laminate) or HPL
(High Pressure Laminate), the problem arises that it is rather
difficult to realize a skirting board that is optimally matched to
the flooring, and such in a industrially and economically
responsible manner.
[0006] Up to now, in combination with such floor panels skirting
boards are applied that are covered by a printed film, whereby said
film is glued onto the actual skirting board. Those known skirting
boards show the disadvantage that the print of the film of the
skirting board is never optimally matched to the print of the decor
layer of the floor panels, in view of the fact that usually, one
starts from different manufacturing and printing techniques and
furthermore such film and decorative layer also are realized at
different manufacturers'. Besides, developing a new adapted print
for the film of the skirting boards for each newly developed
pattern for the decor layer is expensive. Another disadvantage of
such film-covered skirting boards consists in that, due to the
nature of the film material, namely, simply printed paper or
synthetic material, they never show one and the same appearance as
the surface of the floor panels that is obtained by means of a
pressing and curing procedure.
[0007] Also, such film does not allow to realize well-defined
effects on the surface, which indeed are possible when
manufacturing the floor panels, such as providing impressions,
whether or not in register with the underlying printed pattern,
providing impressions which are filled with a colour component or
another component, finishing the surface, for example, glossing it,
and so on.
[0008] Another important disadvantage of such film-covered skirting
board consists in that it is impossible to realize skirting boards
whereby the front side and the upper side adjoin each other at an
angle, because, when applying a covering film, always a certain
rounding radius must be provided.
[0009] From the patent documents FR 2.192.895 and FR 1.530.769, it
is also known to provide covered plates with an edge covering. The
manufacturing of such plates, however, is situated in another
technical field than the production of skirting boards, resulting
in that the skilled person will not see an evident solution for
constructing skirting boards in the aforementioned documents.
[0010] The present invention aims at a skirting board which is
constructed such that a solution for one or more of the
aforementioned disadvantages is provided.
[0011] According to a first aspect, the invention thus relates to a
skirting board with the characteristic that it consists of at least
two structural parts, a first part forming at least a portion of
the front side, and a second part forming at least a portion of the
upper side of the skirting board, respectively, whereby both parts
are formed from a laminate material formed by means of pressing
power, with a core and, provided thereupon, a top layer on the
basis of synthetic material. As the skirting board according to the
invention is composed of two parts each consisting of a laminate
material, the realization of the skirting board of the invention is
no longer restricted by the limitations of the use of a covering
film, and all effects can be created that are possible with the
floor panels, too. Also, it is possible to realize skirting boards
with a front side and an upper side mutually adjoining at an angle,
without having to take a rounding radius into account. Also, the
skirting board according to the invention has a surface quality
entirely corresponding to that of the floor panels.
[0012] It is noted that by structural parts, it is meant that these
parts have a core or substrate, on top of which a top layer is
provided, contrary to, for example, thin laminate ribbons which
sometimes are used for covering the lateral edge of a laminate
board. Basically, such laminate ribbons might also be used for
covering the upper side of a skirting board, however, it is known
from practice that the use of such laminate ribbons in general has
the disadvantage that they can loosen very easily and that the
connection with the front side is not always perfect.
[0013] Preferably, said two parts are formed of a plate-shaped
material, with the advantage that this material can be manufactured
in one and the same production process or a similar production
process as the basic board from which floor panels are formed.
Thereby, the basic material of the skirting boards can be
manufactured, for example, with the same presses as those applied
for manufacturing the floor panels, without the necessity of taking
particular measures when pressing.
[0014] Preferably, said two parts are manufactured of a similar or
one and the same laminate material and are provided with one and
the same pattern, such that, consequently, the appearance of the
front and upper sides completely match each other. More
particularly, it is preferred that said two parts originate from
one and the same laminate plate, such that possible minor
differences that, for which reasons whatever, might occur in the
production of subsequent laminate plates, never result in
differences between the front and upper sides of one and the same
skirting board.
[0015] In the most preferred form of embodiment, said two parts
adjoin each other at least at the height of the outer side of the
skirting board, and they show patterns at their visible sides which
fade into each other, whereby, for example, in the case of a wood
motive, it is obtained that the grain of the wood at the upper side
fades into the grain of the wood at the front side, which creates
an appearance as if the skirting board consisted of solid wood.
[0016] In the first place, the invention is useful with classical
laminate of the type whereby the top layer of said two parts is
formed of one or more pressed, resin-immersed layers, amongst which
a so-called decor layer that is printed either with a uniform print
or with a well-defined pattern imitating, for example, wood,
ceramics, stone or the like. More particularly, it is preferred
that said laminate material of at least one of said two parts, and
preferably of both parts, consists of so-called DPL (Direct
Pressure Laminate) or so-called HPL (High Pressure Laminate) that
is attached to a substrate or core.
[0017] The aforementioned two parts can be attached to each other
directly or indirectly, for example, by means of glue or in any
other manner.
[0018] As aforementioned, the skirting board according to the
invention can be realized without a rounding between the front and
upper sides, whereas the decorative top layers still adjoin each
other. Therefore, according to a preferred form of embodiment, said
two parts with their outer sides will adjoin each other at an
angle.
[0019] According to an important preferred form of embodiment, said
two parts extend with their top layer at an angle of 90 degrees in
respect to each other, whereby thus a skirting board with a
rectangular outer side is obtained.
[0020] Preferably, said two parts at least partially adjoin each
other with a mitre joint, whereby this mitre joint preferably
extends at least up to the outer side of the skirting board.
Hereby, at least in those embodiments in which said parts are
situated directly against each other, an adjoining of the top
layers in the external angle of the skirting board without visible
seams is obtained. Hereby, the mitre preferably extends according
to an angle coinciding or approximately coinciding with the
bisecting line of the external angle of the skirting board.
However, other possibilities are not excluded.
[0021] In a particular form of embodiment, the top layer of at
least one of said parts, however, preferably of both parts, is
provided with impressions, more particularly impressions imitating
a relief, for example, of a natural material, such as wood pores,
unevenness of a stone surface or the like. Hereby, these
impressions possibly may correspond to the pattern, more
particularly the printed pattern, of the top layer, which often is
called "registered embossment". This latter is particularly useful
when imitating wood, because in this manner a very realistic
imitation can be obtained.
[0022] According to another particular form of embodiment, use is
made of a laminate material, whereby in said impressions, or at
least in a part thereof, a component is provided in the form of a
colouring product and/or an active component. By means of such
colouring product, special effects can be realized that also are
applied for floor panels, such as, for example, imitating
lime-washed wood. By using an active component, other effects can
be created. By an active component, amongst others, anti-bacterial,
mildewproofing, fluorescent, antistatic, sound dampening and other
components are to be understood.
[0023] According to another particular form of embodiment, parts
are used whereby the top layer comprises a decor layer, whereby
above the decor layer, whether or not directly thereupon, at least
one coloured overlay is present, which also allows to realize
particular effects, as this is the case with floor panels.
[0024] So, for example, a very realistic imitation of coloured, and
more particularly lime-washed wood, also called "ceruse", can be
obtained by forming the parts of a material having a top layer with
a decor layer representing a wood pattern, whereby this top layer
is provided with impressions in which a colouring component is
applied, and moreover by applying a coloured overlay. The
impressions, filled with the colouring component, imitate the
colour remaining in the pores of a coloured real wooden floor,
whereas the coloured overlay imitates the thin tinge of colour
remaining on the smooth wood surface when colouring real wood.
[0025] In respect to said impressions, the use of components in
these impressions, the use of coloured overlays, as well as
performing special finishing operations, such as the glossing of
the surface of the top layer, reference is made to the patent
applications WO 01/96689, BE 2003/0339 and BE 2003/0585, whereby
the information which is given in these patent applications,
although described for floor panels, should be considered
incorporated by reference in the present application, however, as
being applied to said skirting board.
[0026] According to a particular possibility, at the height of the
corner edge formed by said two parts, a material part is removed,
preferably in the form of a bevelled edge, whereby then a
decorative layer is applied on the obtained surface, for example,
in the form of a lacquer, varnish, impregnating agent, whether or
not coloured, transfer print or other print.
[0027] It is clear that the core of said parts preferably consists
of the same material as the core material applied when
manufacturing floor panels. In the most preferred form of
embodiment thus MDF or HDF are used. MDF and HDF also show the
advantage of being materials that are easy to machine, which is
important when forming said two parts.
[0028] In principle, said core may consist of any material. Other
examples thus are particle board, extruded wood, extruded paper
pulp or other board materials, whether or not on the basis of wood.
In the case of extruded wood or paper pulp, it is not excluded to
start from basic parts, which already are extruded in the shape of
the final skirting board, or more or less in the shape thereof, and
are laminated afterwards in order to arrive at the two structural
parts.
[0029] In the case that a hydrophilic material, as, for example,
MDF/HDF is used, the bottom side of the skirting board possibly can
be treated with a hydrophobic material, a sealing material, or the
like.
[0030] Preferably, said two parts respectively consist of a larger
standing part forming the front side of the skirting board and a
smaller top part provided on top of the standing part and forming
the upper side of the skirting board.
[0031] For practical reasons, it is preferred that said two parts
are formed of plate-shaped material and that the sides of those
parts facing each other are realized by means of a machining
operation, i.e. a material-cutting operation. In fact, board-shaped
material, which has been obtained by means of processing by a
press, is subjected to relatively large thickness tolerances.
However, by attaching the two parts against each other exclusively
with sides obtained by means of a machining operation, which
operation can be realized with very small tolerance deviations, the
influence of thickness tolerances of the original board-shaped
material is avoided.
[0032] In an important preferred form of embodiment, the two parts
are formed of a board-shaped material which, opposed to the top
layer, also comprises a backing layer, whereby the part forming the
lateral edge of the skirting board still comprises this backing
layer, whereas the backing layer at the part forming the upper side
of the skirting board has been removed.
[0033] Preferably, the components of the skirting board, and more
particularly said two parts, have matching forms, for example, in
the shape of a male and a female part, which, when joining these
parts, effect an automatic mutual positioning. So, for example, the
sides of the mutually adjoining parts can be realized with an
internal angle, external angle, respectively, fitting into each
other. When pressing the parts against each other, they
consequently automatically are put in a correct mutual position,
which excludes an imprecise adjoining of the top layers at the
external corner of the skirting board.
[0034] Although the skirting board according to the invention
preferably consists of only two parts, it is not excluded to
compose it of more parts. Hereby, it is also possible to use a
common support or connecting structure to which said two or more
parts are attached. The same support or connecting structure then
is preferably used for attaching the skirting board assembly at the
wall, possibly by cooperation with other attachment
accessories.
[0035] It is clear that the components of the skirting board, and
more particularly said two parts, do not necessarily have to be
attached to each other by means of a glue connection, but that any
kind of connection can be applied for this purpose. According to a
particular form of embodiment, thus two or more of the components,
and more particularly said two parts, can be interconnected by
means of profiled areas engaging each other, which preferably
provide for a snap connection, whereby the use of glue or separate
elements, such as staples, nails, screws or the like can be
excluded.
[0036] It is clear that the skirting board can show a globally
straight shape as well as any other shape. So, for example, it may
be realized with a functional profiled rear side, as, for example,
a rear side with a re-entering part in order to limit the contact
with the wall or floor, a rear side that is intended to cooperate
with one or more attachment accessories, such as attachment clips,
a rear side that is provided with one or more recesses, for
example, for accommodating cables, and so on. The recesses may be
either continuous or discontinuous in the longitudinal direction.
Preferably, the removed material of the profiled part at the rear
side of the skirting board provides for a sufficient flexibility of
the skirting board. This flexibility also allows for a proper
adjoining of the skirting board in the longitudinal direction
against an uneven or not straight wall. The space created in the
rear side of the skirting board can be used when packaging the
latter for accommodating the necessary attachment accessories
therein.
[0037] The invention is not restricted to skirting boards with a
classical appearance, in other words, skirting boards having a
uniform appearance or continuous pattern continuing over their
length. So, for example, the top layer of said two parts can be
realized with a printed tile pattern with joints extending over the
front side and upper side of the respective skirting board. Hereby,
possibly at the height of the imitated joints, a relief difference
may be present, which is preferably formed by an impression,
removal of material or a recess. The relief difference whether or
not can be combined with a difference in the surface structure.
Possibly, only a difference in the surface structure can be applied
for imitating the joint.
[0038] Another problem arising with traditional skirting boards
that conventionally have a length of two or more meters, is that
the application thereof may lead to certain disadvantages. So, for
example, skirting boards of such classical length may easily be
damaged during transport. Also, they are difficult to transport
together with traditional laminated floor panels, as their length
is considerably larger than the length of such floor panels.
[0039] When continuous skirting boards are realized with a repeated
tile pattern, which skirting boards are intended for being used
with tile-shaped laminated floor panels, also the disadvantage is
created that it is difficult to create a skirting board in which
the distance between the successive imitated joints corresponds to
the distance between the imitated joints of the floor panels, in
particular when one would start from a basic plate with one and the
same tile pattern for forming the skirting board and forming the
floor panels in accordance with the first aspect of the invention.
As, when manufacturing the tile-shaped laminated floor panels, at
the height of each joint a portion is sawn off and milled off,
whereas this is not the case when manufacturing a continuous
skirting board of the same material, it is clear that the distance
differs between the joints of the skirting board and the joints of
the floor panels. Thus, it is not possible to provide such skirting
board having joints imitated thereupon in accordance with the
joints of the floor panels along an installed floor.
[0040] Even if one would start for the skirting board from a basic
plate with a separate decor layer, whereby the joints are
represented closer to each other, the disadvantage remains that it
is impossible to guarantee a perfect conformity between the joints
on the skirting boards and the joints at the tile-shaped floor
panels. In fact, such printed decor layer is subjected to extension
and shrinkage, which renders it difficult to guarantee a fixed
distance between the joints on the skirting board.
[0041] In order to remedy one or more of said disadvantages,
according to a second aspect the present invention provides a
skirting board, more particularly a skirting board with a laminated
surface on one or more sides, which is characterized in that it is
composed of short pieces, more particularly shorter than the
aforementioned length of two meters, which can be mounted
successively in longitudinal direction. It is clear that thereby
industrially produced lengths of skirting boards are concerned.
[0042] According to a first possibility of this second aspect, one
will work with pieces, the length of which is almost equal, equal
to or shorter than the length of the floor panels with which the
skirting board is intended to be applied. In this manner, rather
short pieces are obtained, which, on the one hand, will less easily
become damaged and, on the other hand, can be easily transported
together with boxes of packaged floor tiles, either by sending them
along therewith separately, whether or not in their own box, or by
packaging them together with floor panels in on and the same
box.
[0043] According to another possibility of the second aspect of the
invention, the pieces are realized with such a length that they
precisely correspond to the length of a tile-shaped floor panel,
whereby then a joint is imitated at the extremities of each piece,
with the result that a skirting board can be realized of such
pieces whereby the joints can precisely correspond to the joints of
the tile-shaped floor panels. In fact, said pieces can be
manufactured with small length tolerances, like the tile-shaped
floor panels, so that differences will hardly occur.
[0044] Also, it is not excluded to realize the length of the pieces
with a multiple of the length of a tile.
[0045] It is clear that the present invention also relates to the
pieces themselves of which such skirting board is composed.
[0046] According to a particular form of embodiment, the successive
pieces can be provided with coupling means for coupling them,
whether directly or not, to each other. Hereby, those may be
coupling means on the extremities that engage each other and effect
a mechanical locking, and/or coupling means with which each piece
can be provided on a common underlying support structure, for
example, a strip of MDF/HDF, synthetic material, metal or the like,
or common attachment clips, whereby this support structure then,
for example, first is attached to the wall.
[0047] The coupling means on the extremities may have different
forms and consist, for example, of a tongue and groove, whether or
not combined with locking means that also effect an interlocking in
the longitudinal direction of the skirting board pieces.
[0048] According to another particular form of embodiment, the
successive pieces are provided with positioning means, which are
realized such that the successive pieces, due to their placement,
automatically are aligned in mutual respect, or at least are
aligned at least partially in mutual respect. The positioning
means, for example, can realize a proper alignment of the upper
sides and/or front sides of two skirting boards that are mounted
against each other. According to a preferred form of embodiment,
the successive pieces of the skirting board are provided with
coupling means as well as positioning means, which, whether or not,
are formed by means of the same parts.
[0049] According to a particular form of embodiment, the pieces of
skirting board comprise, at their extremities, coupling means
extending both parallel to the front side and parallel to the upper
side, in such a manner that a locking in three directions is
obtained, namely the two directions in the plane of the front side
and the direction perpendicular to this front side.
[0050] Said imitation of a joint at the height of the extremities
of said pieces of the skirting board can be realized in different
ways. Preferably, this is performed according to one of the
following possibilities: [0051] by means of a print; [0052] by
means of an impression; [0053] by means of a print combined with an
impression; [0054] by means of a removed material portion along the
edge of the joint; [0055] by means of a removed material portion in
the shape of an inclination or so-called bevel, upon which, whether
or not, a separate decorative layer is provided; [0056] by means of
a difference in surface structure between the joint and the tile
pattern.
[0057] It is noted that the invention also relates to a skirting
board whereby one or more characteristics of said first aspect are
combined with one or more characteristics of said second aspect of
the invention.
[0058] The present invention also relates to a floor covering
system consisting of floor panels and skirting boards, whereby the
floor panels are formed by laminated panels with a core and a top
layer based on synthetic material, more particularly resin, pressed
thereupon, preferably so-called DPL (Direct Pressure Laminate),
with the characteristic that hereby skirting boards according to
the first aspect of the invention are applied and that the top
layers of the skirting boards and the floor panels are matched to
each other.
[0059] Preferably, these top layers are matched to each other in
that they show one or more of the following features: [0060] the
skirting boards and the floor panels have been realized by a
similar manufacturing process; [0061] both top layers consist of
so-called DPL (Direct Pressure Laminate); [0062] the top layers are
formed by means of identical decor layers, more particular
identical paper layers printed with a pattern and impregnated with
resin; [0063] the top layers are finished in a similar manner, more
particular, both are provided with one or more of the following
finishes: [0064] impressions in the surface; [0065] impressions in
the surface, which are in register with the pattern of a decor
layer applied in the top layer; [0066] impressions in the surface,
in which a component is provided, either a colour component or an
active component; [0067] a finishing treatment of the surface,
whereby the feature thereof is altered, such as, amongst others, a
glossed surface.
[0068] Further, the invention also relates to a method for
manufacturing skirting boards according to said first aspect,
whereby this method is characterized in that, by means of pressing
power, a laminate material, with a core and a pressed-thereupon top
layer on the basis of synthetic material, is formed; that from this
laminate material, the aforementioned two parts are formed by means
of one or more machining operations; and that said two parts are
connected to each other directly or indirectly.
[0069] Preferably, hereby strips are formed of the laminate
material; these strips are joined with a mitre joint and attached
to each other; and subsequently portions are removed from the
joined strips, more particularly, are sawn off, in order to obtain
a skirting board. As the assembly takes place by means of larger
strips, after which then a portion of one or both strips is sawn
off, the strips can be properly clamped when assembling them.
[0070] According to a particular technique, said strips are
assembled in a tubular shape, such that by sawing this tubular
arrangement in a suitable manner, several skirting boards are
obtained at a time. Such tubular structure offers the advantage
that the different strips can easily be assembled until they are
adhered to each other. It is noted that such tubular structure
preferably, however, not necessarily, is realized with a square or
rectangular shape.
[0071] According to another technique of the invention, one starts
from a lath or strip, which preferably is sawn off a plate, whereby
both longitudinal edges are provided with a profile, after which
this lath is cut in longitudinal direction, for example, sawn, and
the two obtained parts that formerly were situated at the
longitudinal edges are assembled such that a skirting board in
accordance with the invention is obtained.
[0072] According to a particular characteristic of the invention,
the basic plates for forming said parts of the skirting board and
the floor panels are realized by means of a similar manufacturing
process, with the only essential difference that, for forming the
parts of the skirting board, one starts from a plate-shaped
material having a thicker core than the plate-shaped material used
for forming the floor panels.
[0073] According to a preferred method, one starts from pieces of
laminate material having coupling means at two opposite sides, such
that, after assembling the two parts, also coupling means at the
extremities of the skirting board are created.
[0074] More particularly, in case that the skirting board shows a
tile pattern and the skirting board is intended for being used with
a floor covering of the type consisting of separate floor panels,
which in their turn each represent a tile, with or without
imitation of a joint, a method is recommended whereby the
structural parts of the skirting board are manufactured from panels
of the respective floor covering. Such method provides for that the
dimensions of the skirting board are identical to the dimensions of
the floor, such that the possible imitation of a joint on the
skirting board perfectly coincides with the same imitation on the
floor covering. This method also provides for that the skirting
board, at its extremities, will be provided with the same coupling
means as the floor covering.
[0075] Although the use of a thin ribbon-shaped part at the upper
side of the skirting board instead of a structural part, as
aforementioned, leads to certain disadvantages, it is noted that
the use of such ribbon-shaped part still can offer particular
advantages when thinking about applying certain finishing
treatments. Such finishing treatments might also be performed on a
film, more particularly a thin laminate film, before and/or after
such film has been cut to ribbons or strips, after which the
obtained ribbons or strips are attached to the upper side of the
skirting board. Hereby, not only the advantage is created that a
laminated surface is obtained at the front side as well as at the
upper side, but that similar treatments and, thus, effects can be
created at those surfaces, which also can be optimally matched to
the floor panels.
[0076] Also, it is not excluded to provide the front side of the
skirting board with such film, or the upper side as well as the
front side.
[0077] According to a third aspect, the invention thus also relates
to a skirting board, characterized in that it has a laminated
surface both at the front side and the upper side, which surface is
obtained by means of a press operation, whereby at least one
surface is formed by a previously formed laminate film, whereby
both laminated surfaces have been subjected to one and the same or
a similar finishing treatment.
[0078] The finishing treatments are, for example, one or more of
the treatments described above, such as providing impressions that
follow the pattern, filling the impressions with a component,
glossing the panels and the like.
[0079] When the laminate film is combined with a classical
laminate, for example, when the body of the skirting board and the
front face are formed by a core with a top layer pressed thereupon,
for example, of the DPL type, and the upper side consists of a
subsequently adhered laminate film, preferably use is made of one
and the same decor layer. Preferably, the laminate and the decor
layer are realized in one and the same press, in the case of
impressions even with one and the same press platen.
[0080] According to its fourth aspect, the present invention
relates to a skirting board, with as a characteristic that it
consists at least of a first part forming at least a portion of the
front side of the skirting board, and a second part forming at
least a portion of the upper side of the skirting board, whereby
both parts are formed of the same piece of laminate material, with
a core and a top layer of the DPL type, and whereby the second part
consists of a part obtained in that a material portion is removed
from the material of the core of the laminate material, whereby the
first part and the second part have been brought together by
turning them towards each other around a folding or breaking
line.
[0081] The folding or breaking line preferably is determined by a
locally weakened zone, although this does not necessarily have to
be so. In the case of a locally weakened zone, the latter
preferably is located at the rear side of the top layer, although
the use of such weakened zone at the front side is not
excluded.
[0082] Such skirting board has the advantage that the front side
and the upper side of the skirting board may show continuous
patterns. Moreover, the skirting board may be assorted with the
floor covering, as it possibly may be manufactured of the same
laminate material as the floor covering itself.
[0083] Another advantage with a skirting board according to the
fourth aspect of the invention consists in that, due to the fact
that for the top layer, DPL is applied, which latter, as known, is
thin and brittle, a very fine fold or break can be obtained when
turning the first and second parts towards each other.
[0084] In a preferred form of embodiment, the skirting board has
the characteristic that said two parts are folded and/or broken in
respect to each other around a folding or breaking line, which
originally had been present as a weakened material zone partially
realized up into the top layer. In the combined condition of said
two parts, the realization of such weakened material zone up into
the top layer results in that the quality of the edge where both
parts adjoin each other is better than might be expected.
[0085] It is noted that the application of such weakened material
zone partially extending up into the top layer also is useful when
composing skirting boards with other kinds of top layers than DPL
in the aforementioned manner, for example, also in the case of
laminate materials with a top layer formed by HPL (High Pressure
Laminate). The application of such weakened material zone extending
partially up into the top layer, with any form of laminate, more
particularly synthetic material laminate, thus can be seen as a
particular additional aspect of the invention.
[0086] Further, the invention also relates to a method for
manufacturing skirting boards according to said fourth aspect. To
this aim, the invention relates to a method with as a
characteristic that, by means of pressing power, a laminate
material with a core and a pressed-thereupon top layer of the
so-called DPL type is formed; that, for forming the skirting
boards, one starts from laths or strips of said laminate material,
whereby at least at one longitudinal edge of these laths, a
material part is removed, such that said first and second parts are
formed, whereby both parts remain connected at least by a portion
of the top layer, and possibly by a weakened core portion below the
top layer; and that said parts are turned towards each other and
are joined and attached to each other.
[0087] Preferably, at least one of said parts is structural. Then,
the second part consists at least of a portion of the top layer,
whether or not provided with a portion of the core below the top
layer.
[0088] Preferably, the two parts are gradually forced towards each
other in a continuous process, whereby the second part, by means of
a torsion movement, gradually is pushed into the direction of the
first part, preferably by means of a sliding block or other guide
means extending at least over a considerable length, for example,
over 1 m or more. This gradual turning has the advantage that a
high-quality edge between the two parts is obtained in a very
repeatable manner. The process results in a rather straight break
line of the DPL.
[0089] If desired, a post-treatment can be performed at the
obtained edge after joining said two parts, at the height of the
exterior side of the skirting board, where said two parts adjoin
each other. This post-treatment may consist of colouring the edge
with a colour, whether or not matching the top layer of both parts,
removing an amount of material, or the like. Also, the
post-treatment may consist of a sanding treatment or the removal of
a larger material portion, for example, in order to form a bevel,
after which, whether or not, a decorative layer can be provided on
the treated surface, for example, in the form of a lacquer,
varnish, impregnating agent, whether or not coloured, transfer
print or other print.
[0090] According to a fifth aspect of the invention, it relates to
a skirting board with as a characteristic that this skirting board
has a laminated surface both at the front side and the upper side,
whereby at the edge between the upper side and the front side, an
amount of material has been removed, preferably in the form of a
bevel, and whereby the obtained surface is provided with a
decorative layer. According to this aspect, by a laminated surface
each form of laminate can be understood. A general advantage
thereof is that a proper edge finish can be obtained and in
particular the occurrence of problems as a result of a difficult
mutual adjoining of the laminated surfaces is excluded.
[0091] The decorative layer can be of any kind and may consist, for
example, of a lacquer, a print, such as a transfer print, an
impregnation, and so on.
[0092] It is noted that the surface for providing the decorative
layer possibly can be subjected to a smoothing treatment, for
example, by contacting the surface with a pressing-on element, such
as a sliding block, pressure roller, or the like. More
particularly, hereby use shall be made of a pressing-on element
that is brought to a high temperature. This is particularly
advantageous when applying MDF or HDF, as possibly protruding wood
fibres then are flattened and are consolidated with the surface.
Also, then possibly a kind of sealing can be created at the surface
by the heating of the binding agent present in the MDF or HDF. In
this manner, a very smooth surface is obtained, as a result of
which also a smooth lacquer layer, transfer print or the like can
be realized.
[0093] The technique, mentioned in the preceding paragraph, of
smoothening also can be applied in general with laminated floor
panels for treating a bevel or the like at such panels, for
example, in order to subsequently provide a decorative layer on the
treated surface. Here, too, this technique is particularly useful
for floor panels whereby the aforementioned surface of the bevel or
the like extends through MDF or HDF.
[0094] According to a sixth aspect, the invention relates to
another particular form of embodiment of a floor panel. The
characteristics and advantages hereof will become clear from the
detailed description.
[0095] 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:
[0096] FIG. 1 represents in perspective view a portion of a
skirting board according to the first aspect of the invention;
[0097] FIG. 2 represents a cross-section according to line II-II in
FIG. 1;
[0098] FIG. 3, at a larger scale, represents the portion indicated
by F3 in FIG. 2;
[0099] FIGS. 4 to 12 represent different variants of the skirting
board according to the invention;
[0100] FIG. 13, at a larger scale, represents the portion indicated
by F13 in FIG. 12;
[0101] FIGS. 14 and 15 represent views analogous to that of FIG.
13, for two variants;
[0102] FIG. 16 represents another form of embodiment of a skirting
board according to the invention, in mounted condition;
[0103] FIG. 17 represents a view similar to that of FIG. 3,
however, for a variant;
[0104] FIG. 18 represents a floor covering system according to the
invention;
[0105] FIG. 19 represents another skirting board according to the
invention;
[0106] FIG. 20 schematically represents a method for manufacturing
the skirting board according to the invention;
[0107] FIGS. 21 and 22 represent two particular techniques that can
be applied when manufacturing such skirting board;
[0108] FIG. 23 represents a floor covering system with a skirting
board that is realized in accordance with the second aspect of the
invention;
[0109] FIGS. 24 and 25, at a larger scale, represent cross-sections
according to lines XXIV-XXIV and XXV-XXV in FIG. 23;
[0110] FIGS. 26 and 27 represent views analogous to that of FIG.
24, for two variants of the skirting board according to the
invention;
[0111] FIGS. 28 to 30 represent another skirting board according to
the invention;
[0112] FIGS. 31, 32 and 33, at different scales, represent
cross-sections according to lines XXXI-XXXI, XXXII-XXXII and
XXXIII-XXXIII, respectively, in FIG. 30;
[0113] FIG. 34 shows a possibility for realizing a skirting board
according to the invention;
[0114] FIG. 35 is an enlargement of the portion indicated by F35 in
FIG. 34;
[0115] FIG. 36 is an enlargement of the portion indicated by F36 in
FIG. 34, for the final form of the skirting board;
[0116] FIGS. 37, 38 and 39 represent views similar to that of FIG.
36, for different variants of the invention.
[0117] As represented in the form of embodiment of FIGS. 1 to 3, a
skirting board 1, which is realized in accordance with the first
aspect of the invention, consists of at least two structural parts
2-3, a first part 2 forming at least a portion of the front side 4
of the skirting board 1, and a second part 3 forming at least a
portion of the upper side 5 of the skirting board 1, respectively,
whereby both parts 2-3 are formed of a laminate material 6, which
is formed by means of pressing power, with a core 7 and a synthetic
material-based top layer 8 applied thereupon. As will become clear
from the further description, the parts 2-3 preferably are formed
of a plate-shaped laminate material 6, whereby for forming the two
parts 2-3, one preferably has started from a similar or one and the
same laminate material, which preferably shows one and the same
pattern.
[0118] The core 7 of the parts 2-3 consists, for example, of MDF or
HDF, whereas the top layer 8 preferably consists of one or more
resin-impregnated layers, which are pressed upon the core. In FIG.
3, by way of example a detail is represented, in which the top
layer 8 is composed of two layers, a so-called decor layer 9, which
preferably is provided with a print, and a so-called overlay 10,
respectively. Said print may represent a well-defined pattern, for
example, a wood pattern, a stone pattern or the like, or may also
consist of a monochrome print. The resins applied with these layers
preferably are melamine resins, however, other possibilities are
not excluded.
[0119] At the rear side, in this case, of part 2, a so-called
backing layer 11 may be present.
[0120] Preferably, the laminate material 6 formed by the core 7,
the top layer 8 and the possible backing layer 11, is realized as
so-called DPL (Direct Pressure Laminate).
[0121] In the embodiment of FIGS. 1 to 3, the parts 2 and 3 are
directly attached to each other by being glued together at their
sides 12-13 directed towards each other.
[0122] As clearly visible in FIGS. 2 and 3, said two parts 2-3
adjoin each other with their outer sides 14-15 at an angle, whereby
the top layers 8 extend at an angle of 90 degrees up to the outer
corner 16 of the skirting board 1.
[0123] In order to obtain that the top layers 8 neatly adjoin each
other at the location of the outer corner 16, said parts 2 and 3
are realized such that, at least at the height of the outer corner
16, adjoin each other in a mitre joint.
[0124] It is clear that the parts 2 and 3 may be realized in
different shapes. For clarity's sake, in the following a number of
variants is described with reference to FIGS. 4 to 16.
[0125] FIG. 4 shows an embodiment in which the second part 3 is
made triangular and fits into a triangular recess 17 in the upper
side of the first part 2.
[0126] FIG. 5 shows an embodiment in which the upper side 5 is
realized inclined.
[0127] FIG. 6 shows an embodiment, in which the second part 3 is
trapezoid and fits into a similarly formed recess 18 in the upper
side of the first part 2.
[0128] It is noted that in the forms of embodiment of FIGS. 1 to 6,
the sides 12 and 13, which are turned towards each other, have been
created by a machining operation, as a consequence of which the
parts 2-3 can be realized very accurately and thus fit very
precisely into each other, whereby the seam at the outer corner 16
is not or almost not visible. However, this does not exclude other
possibilities. So, in FIG. 7 an example is represented, whereby at
the second part 3 still a portion of backing layer 11 is present
and thus on that location no surface, obtained by a machining
operation, is present, which, as discussed in the preamble, in
certain cases may lead to a less precise embodiment.
[0129] Also, it is noted that, by using shapes that fit into each
other, as is represented, for example, in the forms of embodiment
of FIGS. 4, 6 and 7, automatically a mutually correct positioning
is obtained when assembling the parts 2 and 3.
[0130] In FIG. 8, the second part 3 protrudes towards the rear,
such that a space or receding portion 20 is formed at the rear side
19 of the skirting board 1, whereby the contact with the floor
and/or wall is restricted when the skirting board is installed,
such that a better adjoining can be guaranteed when the wall is
irregularly formed at the bottom. As represented in FIG. 8, also
one or more additional recesses may be formed in the rear side of
the first part 2, having the same purpose.
[0131] FIG. 9 shows a variant, whereby at the location of the
corner edge a material portion has been removed, in this case in
the shape of a bevel 22, upon which a decorative layer 23 is
applied, for example, according to any of the techniques mentioned
in the introduction.
[0132] FIG. 10 represents an embodiment, whereby the parts 2-3 are
attached to a common support structure or connecting structure, in
this case a common basic profile 24. Hereby, the assembly of the
components possibly may or may not be performed at the
manufacturers'.
[0133] FIG. 11 shows a variant, whereby an insert 25 is provided
between the parts 2-3.
[0134] In FIGS. 12 and 13, a variant is represented, whereby the
parts 2 and 3, at their sides directed towards each other, are
provided with parts 12A-13A and 12B-13B that are situated crosswise
in respect to each other, such that, during the assembly of the
parts 2 and 3, more particularly, the gluing thereof, pressing
forces can be exerted in two directions by means of pressing
elements 26 and 27, for example, pressing rollers. By this
technique, a mutual shifting of the parts 2 and 3 during the
pressing together can be completely excluded.
[0135] In FIGS. 14 and 15, two variants are represented, whereby
one of the two parts, in this case, part 3, has a bendable, more
particularly elastically bendable, portion 28, in such a manner
that, when assembling the parts 2 and 3, and by bending the part
28, a tension force is realized, which contributes to a good
closure of the parts 2 and 3 at the location of the top layers 8.
It is clear that hereby, preferably a space is present under the
portion 28, said space allowing such pressing that the portion 28
can bend.
[0136] In FIG. 15, the parts 2 and 3 are provided with positioning
means, which in their turn prevent a lateral shifting of the parts
2 and 3 in mutual respect, which positioning means in this case are
formed by a tongue-shaped part 29 at the part 3 and a groove 30 in
the part 2.
[0137] In FIGS. 14 and 15 is also shown that glue chambers 31 for
providing glue and/or collecting surplus glue can be provided at
the necessary places.
[0138] FIG. 16 shows that at the rear side, not only a space 20 can
be provided in order to reduce the contact of the skirting board 1
with the floor 32 or wall 33, but that also a profile 34 can be
provided at the rear side, said profile being intended for
cooperating with attachment accessories, in this case an attachment
clip 35 that is attached to the wall 33.
[0139] In general, it is clear that, as a benefit of the invention,
the top layers 8 of both parts 2-3 can be optimally matched to each
other and that it is even possible to let the possible patterns,
which are represented on the top layers of the parts 2 and 3, fade
into each other.
[0140] Because one can start from plate-shaped material, also the
advantage is created that all special effects, which can be created
when forming plate-shaped material, can be integrated in a skirting
board 1 in an identical manner, with the intended particular effect
both at the front side 4 and the upper side 5 thereof.
[0141] In FIG. 17, an example of a particular effect is
represented, whereby the top layer 8 of both parts 2-3 is provided
with impressions 36 in which a component 37 is provided, for
example, a colour component, by which, for example, as discussed in
the introduction, lime-washed wood can be imitated.
[0142] It is clear that the use of such impressions 36 does not
necessarily have to be combined with the use of a component that
must be provided therein. Also, such impressions 36 can solely be
applied for imitating a relief, more particularly for imitating
natural surfaces.
[0143] Said impressions may be in register with a pattern
represented on the decor layer. This is particularly useful when
imitating wood, however, is also not excluded for imitating other
materials.
[0144] Also, it is possible to apply a coloured overlay, whereby
particular effects, whether or not in combination with the use of
impressions that may be coloured or not, can be realized.
[0145] FIG. 18 shows a floor covering system according to the
invention, with floor panels 38 and a skirting board 1, which are
matched to each other in that they are manufactured of a similar
laminate material.
[0146] In FIG. 19, an embodiment of a skirting board 1 according to
the invention is represented, whereby the top layer 8 of the two
parts 2-3 is provided with a tile pattern with joints 39 extending
over the front side 4 and upper side 5. In FIG. 19, those are wide
joints obtained by means of a print. At the location of these
joints, possibly an impression can be realized. Instead of joints
obtained by means of a print, according to an alternative they can
also be formed by material removal or recesses, whereby at the
location thereof possibly a separate colouring or print is
provided.
[0147] FIG. 20 schematically represents a possible form of
embodiment of the method for manufacturing the skirting board 1. In
a first step 40, a plate-shaped substrate 41, more particularly a
material for forming the core 7, for example, an MDF or HDF plate,
and a resin-impregnated printed decor layer 9, an overlay 10 and a
backing layer 11 are brought together. In a second step 42, this
assembly of layers is pressed together in a press 43 and
consolidated by means of the resin. Hereby, simultaneously
impressions can be formed in the upper side, for example, by means
of an intermediate plate 44 that is provided with a relief 45. In
this manner, a plate of laminate material 6 is obtained. In step
46, a lacquer 47 or the like is rolled into the impressions.
According to not-represented steps, then a forced drying of the
lacquer 47 can be provided, as well as a cleaning in order to
remove a possibly remaining tinge of lacquer. Subsequently, the
laminate material 6 is divided into strips, more particularly sawn
to laths 48. By machining treatments, from those then the parts 2
and 3 can be formed, for example, by means of the necessary milling
and/or planing treatments, after which those parts 2-3 are
connected to each other.
[0148] It is clear that different variants to this are possible.
So, for example, it might be possible to provide the lacquer 47 in
the impressions only after the skirting board 1 itself already has
been manufactured.
[0149] It is noted that the laminate material also might be
realized in a continuous press and that the possibly provided
impressions also might be pressed into the surface in a separate
press.
[0150] In FIG. 21, a particular method is represented in order to
attach the parts 2 and 3 to each other. Hereby, laths or strips 48
are connected, preferably glued, to each other in a tubular shape
and with a mitre, such as shown centrally in the figure. The
tubular structure offers the advantage that the laths 48 can be
clamped in a stable manner during gluing. By subsequently cutting,
more particularly, sawing the tubular piece according to lines 49,
four skirting boards 1 according to the invention are obtained.
[0151] In FIG. 22, a technique is represented whereby one starts
from a lath or strip 50, which preferably is sawn off a plate,
whereby in a first step 51, a profile is applied at both
longitudinal edges 52-53, after which this lath 50, as represented
in step 54, is cut in longitudinal direction, in this case by means
of a saw 55. In this manner, two parts 2 and 3 for forming the
skirting board 1 are obtained. In the represented step 56, another
portion of the part 2 is removed, for example, milled away.
Finally, the parts 2 and 3, as represented in step 57, are
assembled, after which, as represented in step 58, they are
attached to each other, in this case by means of glue. This
technique offers the advantage that the edge 52 can be formed while
the portion 3 still is present at the lath 50, whereby a proper
clamping and/or guiding during milling is possible. Also, both
edges 52 and 53 can be formed simultaneously by passing such lath
60 in between two oppositely-situated milling cutters.
[0152] FIGS. 23 to 25 relate to a skirting board and a floor
covering system, whereby both the first and second aspects of the
invention are applied. To this aim, the skirting board 1 consists
of short pieces 59, which are mounted successively one after the
other, whereas each piece 59 consists of at least two composed
parts 2 and 3, as described above.
[0153] In the example, the pieces 59 are provided with coupling
means by which they can be coupled to each other in an indirect
manner. In the represented example, these coupling means consist of
coupling parts 60 in the form of recesses, with which the pieces 59
can be clamped onto a common profile 61 that, in its turn, is
attached to the wall.
[0154] According to an important, although preferred characteristic
of the second aspect, an imitation of a joint 62 is present at the
location of each transition between two pieces 59. Possibly,
additional joint imitations may be present between the extremities
of each piece 59. In the represented example, the imitations of the
joints 62 are realized by means of removed material portions, in
this case in the form of bevels 63, which preferably are provided
with a decorative layer or coating 64, for example, by means of a
lacquer, print or impregnation.
[0155] According to another important preferred characteristic, the
pieces 59 have a length that corresponds to the length of the floor
panels 38 with which they are intended to be used, which is
particularly useful for floor panels imitating stone tiles. In this
manner, it becomes possible to realize skirting boards 1, whereby
the joints 62 are situated precisely opposite to the joints 65 of
the tile-shaped floor panels 38, as is illustrated in detail in
FIGS. 24 and 25.
[0156] In FIGS. 26 and 27, two variants are represented, whereby,
instead of using indirect coupling means, use is made of direct
coupling means 66 in order to interconnect the pieces 59, which
coupling means 66 allow for a connection between the narrow sides
of the pieces 59, more particularly between the extremities or edge
areas 67 and 68.
[0157] The coupling means 66 consist of first coupling parts 69,
substantially in the form of a tongue 70 and a groove 71, which
realize at least a well-defined locking in a direction R1
perpendicularly to the plane of the skirting board 1, and second
coupling parts 72, which realize at least a well-defined locking in
a direction R2 according to the length of the skirting board 1,
whereby the second coupling parts 72 at least comprise, on the one
hand, a part 73 which can be pressed down in an elastic manner,
crosswise to the plane of the skirting board 1, whether or not
perpendicularly thereto, which part 73 is situated at one of the
edge areas 67-68, preferably at the edge area 68 at which the
tongue 70 is present, and, on the other hand, a part 74 cooperating
therewith, said part 74 preferably not being able to be pressed
down or being less compressible, at the other edge area, whereby
these two coupling parts 72 are situated in a zone behind the tip
of the tongue 70, and even better entirely or almost entirely
behind the zone T taken by the actual tongue 70. By "behind the tip
or zone T" is meant that the coupling parts 72, and in the first
place the locking contact surfaces of these coupling parts, are
situated more towards the inside at those respective parts. In this
case, the zone T must be considered as the distance with which the
tongue is sitting behind the shortest groove-bordering lip.
[0158] The part 74, which cooperates with the part 73 as a
hook-shaped part, preferably is situated on a protruding lip
76.
[0159] FIG. 26 shows an embodiment in one piece, whereby the part
73 that can be pressed down is formed by a portion of an
elastically bendable lip 77, whereby the impression thus is the
consequence of bending, whereas FIG. 27 shows a variant in which
the compressible part 73 consists of an elastically compressible
material, such as a relatively stiff rubber strip, whereby the
impression thus is the result of a material compression. It is
clear that the lip 77 also may extend in other directions. As
represented, in both cases the part 73 is situated at the rear side
of the tongue, in other words, the side which is directed towards
the wall. According to a variant, the part 73 might also be
situated at the front side.
[0160] In a laminate structure with pressed layers of resin, the
layer that is situated against the lip 76 preferably extends up to
or into the proximity of the coupling part 74 in order to thereby
maximally maintain the rigidity of the lip 76.
[0161] As schematically indicated by arrows, the coupling means
hereby preferably are realized such that the pieces 59 can be
engaged into each other by shifting and/or turning. Hereby, turning
around the front edge is the most practical technique, however,
shifting may be necessary if pieces 59 have to be installed against
a wall, at places that are difficult to reach. Hereby, the coupling
can be realized without play.
[0162] The coupling means of FIGS. 26 and 27 allow to smoothly
shift and turn the pieces 59 into each other. In that, at least in
the represented form of embodiment, the part 73 can be pressed down
almost separately from the remaining material parts, these
remaining parts are stressed little or not at all.
[0163] It is noted that the coupling means described above by means
of FIGS. 26 and 27 for connecting the pieces 59 of a skirting board
can be applied, according to the invention, in a similar manner for
connecting floor panels, more particularly laminated floor panels,
whether this takes place in combination with the application of a
skirting board according to the invention or not. According to this
sixth aspect of the invention, then the wall in the drawings must
be omitted, whereby the front side of the pieces 59 then must be
seen as the upper side of such floor panel. Such floor panels then
can be laid in a floating manner, without connection to the
subfloor. Preferably, such floor panels are rectangular and are
provided on four sides, in other words, edges, with coupling means
realizing a vertical and horizontal locking, whereby at two
opposite sides, coupling means as described above are provided,
whereas at the other two sides coupling means may be provided which
are realized in another manner; preferably, however, not
necessarily, coupling means allowing exclusively a coupling by
turning-in and not by shifting. In the case of floor panels, the
coupling parts preferably are realized from MDF, and even better,
HDF, preferably in one piece out of the substrate of the floor
panel.
[0164] In front view and a rear view, respectively, FIGS. 28 and 29
show a further variant of a piece of skirting board 59 for
realizing a skirting board 1 according to the invention, whereas
FIGS. 30 to 33 represent how several of such pieces 59 are
mounted.
[0165] A first particularity of the form of embodiment represented
in FIGS. 28 to 33 consists in that the pieces 59 are provided with
coupling means 66, with which the pieces 59, at their extremity,
can be directly coupled to each other. More particularly, the
pieces 59, at their small faces, comprise coupling means extending
parallel to the front side 4 as well as coupling means extending
parallel to the upper side 5, differently designated by 66A and
66B. In the represented example, these coupling means 66A-66B are
realized in a manner comparable to that of FIG. 26 and to this aim
each substantially consist of first coupling parts 69 in the form
of a tongue and a groove realizing at least a well-defined locking
in a direction perpendicular to the side, the front side 4 or the
upper side 5, respectively, of the piece 59 along which the
coupling means 66A-66B are provided, and second coupling parts 72
realizing at least a well-defined locking in the longitudinal
direction of the skirting board 1.
[0166] It is noted that by applying both coupling means 66A as 66B,
these also function as positioning means providing in that the
successive pieces 59 during the mounting thereof are automatically
aligned in mutual respect both in height and in depth. It is clear
that according to not-represented variants, also other positioning
means can be applied in order to obtain a partial or complete
alignment of the pieces 59 in respect to each other.
[0167] FIGS. 30 to 32 show that the coupling means 66A and 66B
preferably are similar and even identical to each other. This
offers the advantage that, in the case that the pieces 59 are
manufactured of two structural parts 2 and 3, these parts can be
manufactured starting from the same piece of material, more
particular laminate material, which prior thereto has been provided
with the respective coupling means at two opposite sides. By
composing the parts 2 and 3 manufactured therefrom in a mitre
joint, then automatically a design is obtained as illustrated in
FIGS. 28 to 33.
[0168] The coupling means 66A-66B represented in FIGS. 31 and 32
are of such a type that therewith a coupling by means of a turning
movement W, as well as a shifting movement S can be realized,
whereby at least in the latter case, then a locking by means of a
so-called snap action is taking place.
[0169] The coupling of the pieces of skirting board 59 then may
take place as illustrated in FIG. 31, in which the left piece 59
already is mounted against the wall 33 and the piece 59 shown at
the right hand side in the figure first is presented inclined with
one extremity against the already mounted piece, as illustrated in
dashed line 78. By now turning the new piece 59 to be mounted
against the wall 33 by means of the turning movement W, the
coupling means 66A, as indicated in FIG. 31, engage each other.
Thereby, automatically also an engagement at the coupling means 66B
is created, whereby, seen purely in the vertical cross-section of
FIG. 32, exclusively a lateral shifting into each other of the
respective coupling means is taking place.
[0170] However, within the scope of the invention, it is not
excluded that the coupling means 66A and 66B differ from each
other. So, for example, may the coupling means 66A be of the type
that exclusively allows to make a connection by means of a turning
movement, whereas the coupling means 66B may be of the type that
exclusively allows a connection by means of a shifting
movement.
[0171] A second particularity of the form of embodiment represented
in FIGS. 28 to 33 consists in that the successive pieces 59 are
provided with attachment means, which are constructed such that
they are seated blindly by mounting the next piece of skirting
board 59. In the represented example, these attachment means are
formed by a strip of lath 79 provided against the rear side of each
piece 59, which stroke or lath 79 facilitates the attachment of
each respective piece 59 at the wall or at another common support
structure, possibly by means of screws, glue, or the like. The
strip of lath 79 is provided such that it extends with one
extremity beyond the remainder of the piece of skirting board 59
and in this manner forms an attachment part, more particularly an
attachment lip 80. As represented, this attachment part preferably
is situated at the extremity where the coupling means 66A-66B show
coupling parts 69 in the form of a groove. The thickness of the
strip 79 preferably is such that the skirting board 1 in mounted
position fits in a sufficient manner with its upper side 5 against
the wall 33, as schematically represented in FIG. 33.
[0172] The use of the aforementioned attachment means can simply be
derived from FIGS. 30 to 33 and substantially consists in that each
piece of skirting board 59, after being coupled with one extremity
to a preceding piece 59, is attached at the other extremity against
the wall 33, by providing an element 81, such as a screw, nail, or
the like through the attachment lip 80 up into the wall 33. It is
clear that, when attaching a piece 59, each time the attachment lip
80 of the preceding 59 is put out of sight.
[0173] It is clear that the use of a combination of, on the one
hand, mechanical coupling means allowing a locking between the
successive pieces 59 with, on the other hand, attachment means that
are provided such that they are put out of sight when each
following piece 59 is mounted, allows an advantageous and smooth
mounting of the skirting board, regardless of the nature of these
coupling means and attachment means.
[0174] It is also clear that according to variants, also other
forms of embodiments of attachment means are possible. So, for
example, may the lip B2 represented in FIG. 31 be realized rather
long, as a consequence of which this lip can be used as an
attachment means, on account of the fact that then also a nail,
screw or the like can be applied therethrough.
[0175] According to a variant, also a strip 79 can be provided
against the rear side of the skirting board 1, which strip 79 is
provided with a special profile and allows to connect the skirting
board 1 with accessories provided against a wall 33, for example,
to fasten it on attachment clips.
[0176] FIG. 34 illustrates a method for manufacturing a skirting
board 1 according to the aforementioned fourth aspect of the
invention, whereby here, both a short piece of skirting board 59,
for example, with the typical length of a floor tile, for example,
less than 70 cm, or of a typical floor panel, as a longer piece of
skirting board 1, for example, in the order of magnitude of two
meters or more, may be concerned. In this method, one starts from
laths or strips of a laminate material 6 consisting of a core 7 and
a top layer 8, specifically of the DPL type. As can be seen in FIG.
34, a material part 83 is removed in the longitudinal direction of
this lath, whereby, as represented in the enlargement of FIG. 35,
preferably also a weakened zone 84 is formed, whereby material is
removed, in this example partially up into the top layer 8. Hereby,
two parts are created, in the represented example two structural
parts 2 and 3, which are only connected to each other by a portion
of the top layer 8. Then, the skirting board 1 can simply be
realized by turning the parts 2 and 3 around the thus created
folding or breaking line 85 towards each other and joining them,
whereby they are attached to each other, for example, by means of
glue, and in this manner a condition is obtained as illustrated in
FIG. 36.
[0177] It is underlined that the fourth aspect of the invention is
specifically connected to the use of a top layer 8 in the form of
so-called "DPL", which then, as known, is formed of one or a small
number of resin-impregnated carrier sheets, amongst which mostly a
decor layer, which sheets are directly pressed onto the underlying
substrate, in this case, the material of the core 7. In FIG. 35,
schematically a top layer 8 consisting of DPL is represented, with
only a single printed carrier sheet 87 impregnated with resin 86,
said sheet then forming the aforementioned decor layer 9. It is
noted that FIG. 35 is highly schematised and the top layer 8 is
represented with exaggerated thickness. In reality, with DPL a
layer in the order of magnitude of 0.2 mm or smaller is concerned.
Of course, the invention according to the fourth aspect also
relates to applications in which DPL with more than one support
sheet is applied, for example, DPL formed of the combination of a
decor layer and a so-called overlay.
[0178] Further, it is noted that the inventors surprisingly found
out that, in case a weakened zone 84 is formed whereby material is
removed partially up into the "DPL" top layer 8, the skirting board
1, after joining the two obtained parts 2 and 3, has an edge that
is of a strikingly high quality, whereby little or no
post-treatment is necessary. With thin and brittle top layers 8,
such as the one of "DPL", it was always assumed that forming a
weakened zone 84 extending at least partially into the top layer 8
and/or accurately breaking and/or accurately folding it, was
impossible.
[0179] Due to the fact that a DPL top layer 8 has a very small
thickness, the advantage is obtained that when turning along the
folding or breaking line 85, already a relatively proper finished
corner is obtained affording little or no finishing treatment,
which is even promoted by using, as aforementioned, a weakened zone
84 partially extending up into the top layer 8.
[0180] The inventors also found that in case the weakened zone 84
is realized less deep and below this weakened zone 84 a very small
amount of material of the core 7 is left at the place where the
parts 2 and 3 must be folded and/or broken, still a qualitatively
rather good corner finish is obtained, in particular with a core 7
of MDF or HDF. Preferably, here an amount of material with a
thickness of less than 0.5 mm is concerned.
[0181] According to a not-represented variant of the invention, at
the location of the second part all material except the DPL top
layer 8 is removed, whereby the second part then no longer is a
structural part.
[0182] FIG. 36 represents the obtained product. As represented in
the figure, possible post-treatments of the edge may consist of the
removal of a small material portion, for example, by means of a
sanding treatment, for example, as schematically represented, by
moving along the edge with a sanding element 88, whether or not
followed by the provision of a decorative layer 23 on the obtained
surface, as represented, for example, in FIG. 37, by means of a
colouring treatment, in this case by means of a pen 89 or the like.
Of course, any other colouring method is possible. Nothing impairs
that the colouring treatment takes place without a preceding
sanding treatment, whereby the colouring then is intended for
masking possible discolorations due to the bending and/or breaking
of the top layer 8 and/or to grinning-through of underlying
material.
[0183] Instead of moving along the edge with a sanding element 88,
the edge also can be brought into contact with a preferably heated
pressing-down element, such as a sliding block or roller, such that
the possibly coarse edge is smoothened. Of course, this may also
take place in combination with a sanding treatment.
[0184] FIG. 38 shows that a material portion can be removed on the
edge, for example, for forming a bevel, and whereby the obtained
surface is provided with a decorative layer 23.
[0185] It is noted that the technique of FIG. 38, according to
which a material portion is removed and a decorative layer 23 is
provided, also is advantageous for any other type of skirting board
1, whereby a laminated surface is present both at the front side 4
and the upper side 5. By means of the aforementioned technique, in
fact the advantage is created that a proper edge finish can be
obtained and the occurrence of problems due to a difficult mutual
adjoining of the laminated surfaces is excluded. According to a
fifth aspect, the invention thus in general also relates to
skirting boards with a laminated surface, with as a characteristic
that a material portion is removed at their edge and a decorative
layer 23 is provided at their surface.
[0186] For clarity's sake, FIG. 39 shows another possible form of
embodiment of this fifth aspect. The skirting board 1 has a
laminated surface both at its front side 4 and at its upper side 5.
In this example, the laminated surface at the front side 4 is
formed by DPL or HPL, whereas the laminated surface at the upper
side 5 is formed by a glued-on laminate ribbon 90. In that use is
made of a bevel and a decorative layer 23, which are applied after
the application of the laminate ribbon 90, no high precision is
necessary when applying the laminate ribbon 90 itself.
[0187] In general, it is noted that the invention is intended in
particular for being used with skirting boards with a laminated
surface of the type formed by thermo-hardening laminate, for
example, DPL on the basis of a thermo-hardening resin, such as
thermo-hardening melamine resin. However, this does not imply an
exclusion of other applications.
[0188] The present invention is in no way limited to the forms of
embodiment described by way of example and represented in the
figures, however, such skirting board, such floor covering system,
said floor panels and said methods for manufacturing a skirting
board can be realized according to different variants, without
exceeding the scope of the invention.
[0189] So, for example, the aforementioned finishing treatments,
such as the application of a component in the impressions, the
glossing of the laminate surface, must not necessarily take place
prior to forming the parts 2 and 3 or prior to the application of
the laminate film. This may also take place after the assembly of
the parts 2 and 3 or after the application of the laminate film at
the remaining parts of the skirting board.
[0190] In the previous description the term "laminate material"
always refers to board shaped material having a core and a top
layer. The core may consist of one or more parts or layers. The
term "laminate plate" refers to the basic board before being cut
into pieces. The term "laminated" means that the related surface is
provided of a laminate of any type. The term "laminate film" refers
to a thin foil of any kind of laminate, which is produced as a
separate layer. A "laminate ribbon" is a strip-like portion of a
laminate film.
[0191] The aforementioned "joints" should generally be understood
as being an imitation of "grouts", although they do not always need
to imitate cement.
[0192] The thickness of the laminate material 6 will generally be 7
to 9 mm, although other possibilities are not excluded.
* * * * *