Untitled record

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DESCRIPTION

Floor covering system that has subpanels with complementary edge patterns and non-coplanar upper surfaces

Background of the invention

Field of the Invention

The present invention relates to a floor covering system comprising at least two floor panels, each floor panel comprising a plurality of side surfaces and at least one partial subpanel.

Discussion of related technique

Due to their appearance and feel, traditional building and finishing floor covering materials such as hardwoods, slate, granite, stones, brick and concrete are generally preferred by consumers. However, such traditional building and finishing floor covering materials tend to be expensive to produce and install. For example, while a solid wood floor has a very appreciable luxurious appearance, the materials and labor required for the installation of such floors may have a prohibitive cost.

Many alternatives to traditional building and finishing floor covering 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 appearance and texture of traditional building and finishing floor covering materials. For example, most of the alternatives that have a wood-like exterior surface appear false and can easily be identified as something other than genuine wood. In addition, while high quality HPL, DPL or CPL boards may look visually wood, their texture quickly reveals that they are not.

A problem with most alternatives to traditional building and finishing floor covering materials is that their surface textures do not match their decorative motifs. For example, the visual representation of wood knots in alternative floor covering materials does not match the surface textures characteristic of wood knots. Consequently, the attractiveness of these alternative materials is greatly reduced.

An approach used to match the surface texture of alternative floor covering materials with their decorative motifs includes a technique known as chemical relief. In chemical relief, 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 subsurface layer. Although somehow successful, the resulting surface texture tends to lack the three-dimensional characteristics and textural sharpness of traditional materials.

As an alternative to traditional building and finishing floor covering materials, laminated materials can be mechanically enhanced to produce a surface texture. See, for example, U.S. Patent Application 09 / 903,807 and U.S. Patent No. 6,401,415. Such procedures produce laminated embossed materials on record that have decorative motifs and match high-quality three-dimensional textures. Laminated materials with synchronized relief require precise registration of mechanical relief and decorative motif. An advantage of laminated embossed materials is that they can realistically reproduce the look and feel of traditional products.

No matter the type of floor covering system used, the floor covering system must be easily moved to a construction site and be easy and quick to install. To this end, mounting and locking mechanisms can be incorporated into the system or to facilitate on-site installation. One type of mounting and locking mechanism is the tongue and groove system used to connect panels. It is understood that such tongue and groove systems are disclosed in United States Patent No. 2,057,135 to Cherry, and in United States Patent No. 2,046,596 to Urbain. For example, it can be interpreted that Figure 1 illustrates a tongue and groove system 11 that uses clips 12 to secure panels together.

Another type of mounting and locking mechanism is understood to be disclosed in U.S. Patent No.

3,946,529 to Chevaux where a floor covering system 13 appears to be connected using a tongue and groove system arranged below the ground, reference figure 2.

Another additional mounting and locking mechanism is taught in US Patent No. 5,295,341 to Kajiwara. It is understood that laminated boards are provided with a pressure bonding system such as a

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tongue and groove joint. Consequently laminated boards can be assembled without glue. With reference to Figure 3, the laminated boards are provided with a locking means in the form of a slot connector 16, and a tongue connector 18. The slot connector 16 has grooves that protrude forward 20 while the tongue 18 it is provided with a pair of side walls that diverge forward 22 and 24 that are separated by an elongated groove 26. The side walls include rear locking surfaces 28 and 36. The side walls can be compressed together to allow locking.

Another type of mounting and locking mechanism is the pressure union suggested in the US Parente No. 6,101,778 to Martensson. As shown in Figure 4, it is understood that the laminated boards are provided with a locking means comprising a groove 6 and a tongue 7 forming a tongue and groove assembly. The groove 6 and the tongue 7 can be produced in water-tight material and pressurized with a portion 9 that fits in the groove 4.

Although the mounting and locking mechanisms mentioned above have proven useful, they have not been used with embossed laminate systems in registration in which the decorative graphic embossed motifs are aligned through the joints between the individual embossed laminates on record This notably limits the visual and textural printing of systems comprising laminate boards with embossed on record. Therefore, a new system of laminate with relief in registration in which the cross joints of visual and textural patterns retain aspects of relief in registration would be advantageous. Even more advantageous would be a system of embossing laminate in register comprising laminated boards with embossing in interlocking register in which cross joints of visual and textural patterns retain aspects of relief in registration.

Also, the floor covering systems mentioned above have a relatively low capacity to resist wear. Although it is not desired to adhere to any particular theory, it is hypothesized that premature aging (wear) begins at or near the perimeter edges and / or along the tongue and groove lines. The floor covering systems mentioned above have a substantially regular surface texture (level) so that the center or perimeter of each panel comes in the same proportion in contact with the user (eg, pedestrians) The perimeter of each panel , however, it is substantially weaker than the center of the panel and therefore deteriorates in the first place.

Consequently, there is a need for viable alternative construction or finishing materials where the alternatives have the realistic look and feel of traditional products and have a greater capacity to resist premature wear.

US Pat. No. 4,131,705 refers to a structural laminate having a groove printed on its surface useful as an outer coating.

United States patent application US-2002/100231 describes a decorated floor panel having a core with an upper surface and an opposite lower surface.

United States patent application US-2002/14047 A refers to a floor covering system that has a plurality of floor boards.

Summary of the invention

The present invention is defined in the attached claim 1.

More in detail, the invention relates to a floor covering system, comprising:

at least two floor panels, each floor panel comprising:

a plurality of lateral surfaces: a first upper surface adjacent at least a portion of the plurality of lateral surfaces; a second upper surface adjacent at least a portion of the plurality of lateral surfaces, wherein the first upper surface is smaller than the second upper surface; and at least one partial subpanel, in which the neighboring partial subpanels of adjacent floor panels are complementary so that at least one of at least one decorative motif and at least one relief surface texture is substantially continuous through at least a portion of a neighboring partial subpanel.

Also, each floor panel comprises at least three subpanels, in which at least one of said subpanels is a unitary subpanel and in which at least two of said subpanels are partial subpanels.

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At least two neighboring partial subpanels of two floor panels are complementary to each other so that they provide a decorative motif and / or a substantially complete surface substance and appear as a substantially continuous unitary subpanel, and in which said first upper surfaces are beveled. .

Brief description of the drawings

5 The accompanying drawings, which are included to provide a further understanding of the invention and which are incorporated therein and constitute part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.

In the drawings:

Figure 1 illustrates a mounting and locking mechanism of related technique;

10 Figure 2 illustrates another mounting and locking mechanism related technique Figure 3 illustrates another mounting and locking mechanism more related technique Figure 4 illustrates another additional mounting and locking mechanism related technique Figure 5 illustrates a perspective view of components in a floor plank with embossing in register Figure 6 illustrates a pressing machine capable of manufacturing floor planks with embossing in register;

fifteen Figure 7 illustrates a floor plank with embossed on record; Figure 8 illustrates a top view of a floor plank system with relief in registration; Figure 9 illustrates a cross-sectional view along line 9-9 shown in Figure 8; Figure 10 illustrates a top view of a floor plank system with embossed on record; Figure 11 illustrates a cross-sectional view along line 11-11 shown in Figure 10;

twenty Figures 12A and 12B illustrate schematic views that include a perimeter surface portion of a floor plank; Figures 13A and 13B illustrate a floor covering system according to the present invention; Figures 14A-14C illustrate an exemplary plank of a floor covering system according to the present invention, and

25 Figures 15A-15D illustrate an exemplary method of forming patterns on a floor plank in accordance with the principles of the present invention.

Detailed description of the illustrated embodiments

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

30 Figure 5 generally illustrates components of a floor plank in accordance with the principles of the present invention.

With reference to Figure 5, the relief floor covering system on record may, for example, include at least one floor plank. Each floor plank may include a board substrate 40 made of substrate material (for example, a fiber board, medium or high density chipboard), at least one base sheet 35 (for example, one sheet of paper Kraft) impregnated with predetermined resins and arranged above and / or below the board substrate 40, a sheet of decorative paper 44 approximately 0.15 mm thick and impregnated with a polymerizable resin (for example, phenols such as melanin) disposed on the board substrate, and at least one protective overlay sheet 46 arranged on the decorative paper sheet 44. Each protective overlay sheet 46 can be formed from a highly resistant paper impregnated with a solution

40 of melanin containing for example corundum (Al2O3), silica.

Different papers can be arranged between the decorative paper sheet 44 and the board substrate 40. The at least one protective overlay sheet 46 and the base sheet 48 can be impregnated with a resin. The resin that permeates the at least one protective overlay sheet 46 and the base sheet 48 may be different from the melanin resin used to impregnate the decorative paper sheet 44.

Four. Five Floor boards within a floor covering system can be manufactured from substantially the same paper, the same resin. For example, floorboards within a floor covering system can be manufactured using paper made from substantially the same paper fibers (which have, for example, substantially the same ash content, color and orientation) on it. paper making machine.

fifty Also, floorboards within a floor covering system can be made using paper that originates from a simple contiguous section on the manufacturing coil. All the paper use restrictions mentioned above that can be used in the manufacture of floorboards of a floor covering system ensure that the impregnated papers will always have substantially the same final dimensions after being pressed and hardened. Storage of paper used for

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Floor boards manufactured within a floor covering system can be controlled so that the time, temperature and humidity in which the paper is stored are maintained to facilitate the consistent dimensions of the floorboards. Floor boards within a floor covering system can be manufactured using cellulose pulp made by the same manufacturer. Floor boards within a floor covering system can be manufactured using resins made by the same manufacturer. The resins may contain powder that originates from substantially the same source, have substantially the same physicochemical qualities, and be mixed in the same reactor. Also, floorboards within a floor covering system can be manufactured using resins that have a substantially constant solids content.

All restrictions on the use of the above-mentioned resins that can be used in the manufacture of floorboards ensure that the impregnated papers will always have substantially the same final dimensions after being pressed and hardened. Each of the floor boards within a floor covering system can be manufactured using substantially the same impregnation process. For example, when the various sheets of paper are immersed in melanin resin, the paper should experience a constant and uniform load of melanin. Also, a tension and oscillation of the impregnation machine band should be precisely controlled as they influence the degree to which the various sheets of paper are impregnated with the resin.

The aforementioned sheets and substrates can be manufactured in a floor covering system with embossed on record that includes a plurality of interlocking floor planks. To produce such a floor covering system, a pressing machine, such as a pressing machine shown in Figure 6, can be used to mechanically highlight each floor plank in record with a decorative motif arranged on the paper sheet decorative 44.

With reference to FIG. 6, the pressing machine may, for example, include a base 42, an upper press 54, and an upper press plate 56. The upper press plate may include a relief pattern (for example three-dimensional textured surface ). Consequently, the relief pattern may, for example, include edges, dots, depressions of any design capable of aligning with a decorative motif formed on the decorative paper sheet 44.

The impregnated decorative paper sheet 44 disposed on the board substrate 40 must be accurately positioned with respect to the relief pattern of the upper press plate to allow a floor plank with embossed on record. The alignment between the relief 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, the alignment of a motif with relief in wood grain register through adjacent relief floor planks requires a greater degree of alignment than the alignment of a motif with relief in wood grain registration that is not aligned with adjacent floorboards.

The alignment between the decorative motif on the decorative paper sheet 44 and the relief pattern on the upper press plate 56 can be achieved by removing approximately 2 to 3 mm of material around the perimeter of the board substrate 40 in a milling process by producing in this way several reference planes (for example board edges) and a board substrate having very controlled dimensions. Next, an impregnated decorative paper sheet 44 having outer dimensions of approximately 8 or 10 mm smaller than the board substrate 40 is arranged on the board substrate 40. The impregnated decorative paper sheet 44 can be arranged on the board substrate 40 using board edges as means of alignment. Alignment marks can be arranged on the board substrate 40 and can be aligned with the alignment marks arranged on the decorative paper sheet 44.

The decorative paper sheet 44 can be fixed to the board substrate 40 through static electricity. After being fixed, the decorative paper sheet 44 and the board substrate 40 are arranged on a carriage that feeds the borrowing machine. Static electricity can substantially prevent the decorative paper sheet 44 from accidentally moving as the board substrate 40 moves with the carriage. The carriage can be stopped just before entering the pressing machine so that the decorative sheet of paper 44 can be accurately arranged on the board substrate 40 using, for example, tweezers (not shown). The tweezers can be used to accurately arrange the decorative paper sheet 44 on the board substrate 40 disposed on the upper press plate. The decorative paper sheet 44, the at least one protective overlay sheet 46, and the optional base sheet 48 can be arranged on the board substrate 40 before being placed inside the pressing machine. After arranging the decorative sheet of paper 44 on the board substrate 40, the carriage can exit the pressing machine. Next, an alignment system substantially aligns the decorative paper sheet system 44 / board substrate 40 with the relief pattern on the upper press plate 56.

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The alignment system can use the board edges to substantially align the decorative pattern 44 with the relief pattern on the upper press plate 56. The pressing machine can be operated after finishing the alignment.

After arranging the components illustrated in Figure 5 inside the pressing machine and aligning with the relief pattern, the various sheets and substrate can be pressed and hardened for a predetermined period of time until the resins harden, producing a extremely hard wear resistant floor plank. For example, after being inserted into the pressing machine and aligned with the relief pattern, the board substrate 40, the decorative paper sheet 44, the protective overlay sheet 46 and the optional base sheet 48 can be heated to a temperature of about 160-220 ° C and press together at a pressure of about 20-40 kg / cm2 for about 20 to 60 seconds. Accordingly, the upper press 54 presses the relief pattern of the upper press plate 56 within the decorative paper sheet structure 44 and the board substrate 40. The combination of heat and pressure applied melts 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 relief pattern on the upper press plate 56. Consequently, the melanin resin within the various sheets can harden and a raised plank can be produced.

The porosity within the casting can be minimized by slowly hardening the resins (for example, melanin) Consequently, as the operating temperature is reduced, the time during which the various sheets within the pressing machine are pressed increases. As the press plate 56 is heated to approximately 160-220 ° C, the relief pattern included within the press plate can be expanded. Accordingly, the relief pattern on the press plate 56 may be arranged to compensate for the pattern expansion.

Therefore, the dimensions of the relief model are arranged so that they correspond substantially to the design of the decorative motif when the resins within the components of Figure 5 are hardened.

A mechanical embossed surface texture can be provided to an individual floor plank that has a decorative motif. The mechanical relief surface texture can be arranged in register with the decorative motif.

Consequently, a floor plank with embossed on record can be manufactured. A plurality of floor planks with embossed on record can be joined together to form a floor covering system with embossed on record. At least a portion of embossed patterns in registration of adjacent floor planks can be substantially aligned with each other to substantially form substantially contiguous embossed patterns in registration through adjacent floor planks within the floor covering system.

While the embossing process described above is appropriate for embossed surface textures that are less than about 0.2 mm deep, deeper surface textures can be problematic. Embossing patterns capable of providing deep surface textures, for example, require relatively large press plate protrusions that tend to affect the homogeneity of pressure applied across the board surface. This pressure disturbance can cause distortions in the final product. Embossed surface textures can be formed with a depth greater than about 0.2 mm by recessing the board substrate 40 in places where deep surface textures are desired. The cupping process can be carried out before, during or after the perimeter of the board substrate 40 being milled as described above. The board edges can be used to locate the boundaries of the recessed portions of the board substrate 40.

With reference to Figure 7, the floor plank with embossed in register 60, manufactured according to the process described above may optionally include a protective padding layer 50 on one side. The mechanical relief surface texture is in register with the decorative motif 68 of the decorative paper sheet 44. By registration, it is understood that the relief surface texture is substantially aligned with the decorative motif of the decorative paper sheet 44. By providing a floor plank with embossed on record, a realistic representation of a natural material can be provided to individual floor planks. While the decorative motif illustrated in Figure 7 realistically depicts the image and texture of a wood grain, it should be appreciated that other embossed designs can be produced in register such as ceramic, concrete, marble planks.

Each of the individual floorboards may, for example, include at least one locking mechanism.

The locking mechanisms can be incorporated into the board substrate 40 before being presented to the surface of the board substrate 40 in registration with the decorative motif.

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Accordingly, the locking mechanisms can be manufactured within individual board substrates 40. Next, the locking mechanisms can be used to join individual board substrates together to form a plank structure. The plank structure can then be inserted into the press 54. After presenting the relief pattern to the plank structure and the molten components melt together, the plank structure is removed from the press 54. Next, the floor planks with relief in register 60 within the molten tab structure are separated by unlocking the locking mechanisms. Cutting tools can be used to aid in separation and ensure that the decorative motif is not damaged.

The locking mechanisms can be incorporated into the board substrate 40 after presenting the relief pattern 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, 1.2 mx 2.4 m, can be provided with relief with the press 54. Next, the resulting registration relief substrate can be cut into a plurality of individual registration relief floor boards 60. The edges of the individual registration relief floor boards 60 may have soft edges and precise dimensions. Cutting can be carried out using forming tools, milling tools, cutting tools, breaking tools. The board substrate can be cut by the press machine.

Accordingly, the board substrate 40 can be cut into units (for example bands) having dimensions of, for example, 300 x 300 mm, 400 x 400 mm, 600 x 600 mm, 1,200 x 300 mm, 1,200 x 400 m. Next, the locking mechanisms can be incorporated into the individual registration floor planks 60. The locking mechanisms may be hidden below the surface of the floor boards or they may be visible.

The locking mechanisms can be incorporated into the individual registration floor planks 60 by aligning the at least one of the board edges, alignment marks, decorative patterns, and surface textures of the floor plank with a milling tool. By aligning the milling tool with any of the alignment features mentioned above, the locking mechanisms can be milled on the sides of the board substrates 40, so that, when the floor boards 60 are joined together the at least a portion of the decorative patterns forms a continuous pattern and at least a portion of the embossed patterns in registration forms a substantially continuous surface texture through the adjacent floorboards.

The raised relief floor plank 60 may include a locking mechanism 64 (for example, at least one of a tongue and groove locking system, a pressure-binding locking system) that extends along the four sides of the relief laminate in register 60. For example, a pressure joint locking system can be added to all four sides of the relief floor plank in register 60 and used to connect multiple relief floor planks in register 60 in a relief floor covering system in record 300 (as shown in figure 8). The number and location of the locking mechanisms may depend on the desired configuration of the relief floor covering system on record. For example, when a relief floor covering system in registration bumps into a corner, only two locking mechanisms (along the sides) are necessary.

With reference to Figure 8, the relief floor planks in register A and B can, for example, include locking mechanisms along four sides (for example, along the joints J1, J2, J3 and J4 ). The raised floor planks in register C and D may, for example, include locking mechanisms along four sides (for example, along the junctions J1, J2, J3 and other junction not shown).

The raised relief floor planks that include the aforementioned locking mechanisms can be securely fixed together with or without glue to form a laminated relief system in register 300. Multiple raised relief floor planks can be joined together for Obtain any desired shape for floors or planks. The embossed floor planks in registration can be joined together so that at least portions of embossed patterns in registration of adjacent floor planks are substantially aligned with each other and form a substantially continuous image and an embossed surface texture through of floorboards inside a floor covering system.

Figures 8 and 9 illustrate an exemplary registration floor covering system 300 incorporating a type of locking mechanism on each of the individual registration floor planks 60. Figure 9 illustrates a system of floor covering of relief in record as an example that includes floor planks that incorporate a tongue and groove locking mechanism of brooch type. The tongue-and-groove locking mechanism of the snap type can be integrated into the side walls of each relief laminate in register 60 to thereby ensure that the relief patterns in registration of adjacent floor planks are substantially aligned with each other and are substantially continuous in the floor covering system.

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Figure 9 illustrates a cross-sectional view of Figure 8 taken along line 9-9. As shown, the locking mechanism can be manufactured by forming a groove 230, a tongue 200. A channel 210, a lip 220 along the edges of the raised floor planks in register 60. The locking mechanisms on the raised floor planks in register 60 can be joined together by inserting the tongue 200 into the groove 230 of an adjacent floor plank in adjacent register 60.

Subsequently, the lip 220 is secured within the channel 210, thereby joining the relief floor planks in register 60 in a relief floor covering system in register 300. The relief floor planks in register 60 labeled A, B, C and D can be joined together with or without a tail.

It should be noted that other types of locking mechanisms can be incorporated into the sides of the floor planks in individual registration 60.

With reference again to FIG. 8, each of the relief floor planks in register 60 may, for example, exhibit a pattern of relief ceramic plank in register G1. The ceramic plank motif may comprise a plurality of planks in the form of squares, rectangles, triangles, circles, ovals, any other shape or design that is separated by fill lines. The widths of the filling lines Wh, Wv, and the filling width between boards W can be substantially equal. When the press-type tongue and groove locking mechanism is incorporated in the relief floor planks in register 60 the filling width adjacent to joints J1, J2, J3 and J4 on each relief laminate in register A, B, C and D It is approximately half the filling width between W boards. For example, the filling width of vertical planks (Wv) through the joint J1 is constituted by filling lines on the relief laminates in register A, B, C and D, so that when the relief laminates in registration A, B, C and D are joined at J1, the vertical fill width (Wv) is approximately equal to (W).

Consequently, the width of padding on raised floor plank in individual register 60 adjacent to a joint is half the width of padding between boards (W). The horizontal and vertical fill widths Wh and Wv can be controlled so that they are substantially equal to the dimensions of the fill width between boards W. It should be noted, however, that the dimensions of the fill widths in the floor planks in relief record depend on the type of locking mechanism incorporated and the decorative motif presented.

In addition to the filling lines, many other decorative motifs can be used in the relief floor covering system of the present invention. With reference to Figures 10 and 11, a decorative motif can be provided that has, for example, a wooden grain surface G2 substantially aligned through the joints J5 and J6 of adjacent floor boards. Wood grain patterns generally include more elements (for example, wood grain lines, wood knots 423) that extend to the perimeters of the floor boards that need to be aligned than the ceramic plank patterns. Consequently, the alignment of the wood grain motif is generally more difficult than the alignment of fill line portions of the ceramic plank motifs. For example, the alignment of a first portion of a wooden knot 423 on the relief floor plank in register E with a second portion of the wood knot 423 on the relief floor plank in register F is generally more complex than the alignment of fill line widths across adjacent floor plank joints. Consequently, when a locking mechanism is manufactured, consideration should be given to all graphic elements (for example, wood grain lines and wood knots 423) to ensure a realistic floor covering system in a realistic register. 400. At least a portion of the decorative motif can be used as alignment marks that ensure consistent alignment of adjacent floorboards.

The individual floor planks within the relief floor covering system in register 400 can be joined together with a snap-type mechanical system as illustrated in Figure 11 illustrating a cross-sectional view of Figure 10 along the line 11-11. Again, the alignment techniques used in the manufacturing of the locking mechanism are such that the embossed laminate system 400 has a surface texture surface 423 that is substantially continuous across the joints, J5 and J6. Optionally, the relief laminates in register 60 have a protective padding layer 70 under the base sheet 48.

Figures 12A and 12B illustrate schematic views of a floor plank in accordance with the principles of the present invention.

With reference to Figures 12A and 12B, an upper surface on the perimeter P of each floor plank in relief can be lowered below an upper surface in the portions of the floor plank surrounded by the perimeter. An object O (for example, a user shoe, a wheel) does not generally come into contact with the surface of the perimeter Os, due to the lowered surface of the perimeter. The perimeter may include a portion of the floor plank that extends from the edge of the floor plank approximately 3,175 mm toward the center of the

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floor plank The depth at which the perimeter surface of the floor plank is lowered is approximately 0.794 mm. The surface of at least a portion of the perimeter of a floor plank may not be lowered, as will be explained in greater detail below with reference to Figure 13.

Accordingly, the registration relief pattern can be arranged at the edges of the floor plank and can be aligned with registration relief patterns formed on adjacent floor boards, while it is possible to prevent the edges of each individual floor plank from being wear prematurely

Although it has been shown in Figures 8 and 10 that the individual floor boards within a floor covering system are substantially of the same dimension and shape and that they are joined together so that each side of each plank is attached to only an adjacent floor plank, it is to be appreciated that individual floor planks within a floor covering system can vary in size (for example width and / or length) and form (for example, rectangular, square, triangular, hexagonal, etc.). Individual floorboards may have complementary shapes capable of being assembled in a manner similar to a puzzle or mosaic. Also, the sides of the individual floorboards may come into contact with more than one adjacent floorboard.

Floor boards within a floor covering system may be arranged such that at least one side of each plank includes at least one subpanel adjacent to at least two other subpanels. Each board includes, in whole or in part, at least one subpanel, as will be described in greater detail below.

In Figure 13A, the partial subpanel 134A of the plank 130A is a complementary subpanel with respect to the neighboring partial subpanel 136B of the plank 130B, adjacent to the plank 130A. With this arrangement, partial subpanels 134A and 136B are presented so that they look like a unit subpanel.

With reference still to Figure 13A, each of the planks 130A-F comprises at least three subpanels in which at least one of the subpanels is a unitary subpanel and at least two of the subpanels are partial subpanels. For example, 132A is a unit subpanel and 134A and 136A are partial subpanels.

Unitary subpanel 132A can provide a complete decorative motif with or without a raised surface texture that may or may not be in register with the decorative motif. The partial subpanels 134A and 136A of a plank can provide separate, incomplete decorative motifs with or without embossed surface textures. The neighboring partial subpanels of adjacent planks may be complementary to each other so that they provide a substantially complete decorative motif and / or a surface texture and appear as a substantially continuous unitary subpanel. Complementary partial subpanels may have complementary decorative motifs and / or embossed surface textures.

Consequently, when the complementary partial subpanels of adjacent planks are properly aligned, a substantially continuous (i.e. complete) decorative motif and / or an embossed surface texture can be formed through neighboring complementary partial subpanels.

The subpanels within a plank may or may not substantially comprise the same decorative motif and / or the same embossed surface texture.

Figure 13B illustrates a schematic view of an exemplary plank 130 as shown in Figure 13A.

Portions of the perimeter surface of each plank can be lowered in places where neighboring subpanels are not complementary. Portions of the perimeter surface of each plank are not recessed in places where neighboring subpanels are complementary. With reference to FIG. 13B, the portions of the upper surface of the perimeter "P" of each of the planks 130 indicated with the numerical reference 138a may be slightly reduced compared to the larger surface of each of the planks (see also Figure 12B) to prevent premature wear of each of the boards. Also, the portions of the upper surface of the perimeter of each of the planks 130 indicated with reference numeral 138b may not be recessed and be substantially coplanar with the larger surface of the subpanels. Reducing only the unoccupied portions for decorative motifs and / or embossed surface textures of partial subpanels of a plank allows complementary partial subpanels to appear as part of a unit subpanel while not significantly limiting durability global of each of the boards. The surface portions of each plank may be recessed in places where the subpanels of a plank are adjacent to each other. With reference to Figure 13B, the portions of the upper surface of each of the planks 130 indicated with the numerical reference 138c may be slightly lowered compared to the greater surface of each of the planks (see also Figure 12B) for provide a visual and textural effect in which each of the board's subpanels is not part of the same board.

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Figures 14A-14C illustrate an exemplary plank of a floor covering system according to the present invention.

With reference to Figures 14A-14C, like the plank shown in Figures 13A and 13B, the portions of the upper surface of the perimeter "P" of each of the planks 130 indicated with reference 138a may be beveled to avoid premature wear of each of the boards. Also, the upper surface portions of the perimeter of each of the planks 130 indicated with numerical reference 138b cannot be beveled so that they are thus substantially coplanar with the larger surface of the subpanels. The beveling of the perimeter surface of each of the boards in the positions corresponding to the decorative motifs and / or the embossed surface textures of partial subpanels of a plank allows complementary partial subpanels to appear as part of a unit subpanel while It is not significantly limited to the overall durability of each of the boards. The surface portions of each plank may be provided with a groove in places where the subpanels of a plank are adjacent to each other.

Figures 14B and 14C illustrate cross-sectional views of plank 130 taken through lines I-I 'and II-II', respectively. With reference to Figures 14B and 14C, the upper surface portions of each of the planks 130 indicated with reference numeral 138c may be beveled to form a groove. This groove can also prevent premature wear of each of the boards. In this way, the slot provides a visual and textural effect in which the subpanels of a plank are separated. The bevel at 138c can produce a groove having a substantially V-shaped groove. It is appreciated, however, that the bevel can produce other groove topographies (eg, U-shaped grooves). The bevelling of each of the planks 130 in the perimeter surface portion 138a creates a groove between adjacent planks. Consequently, the groove formed between the adjacent grooves of the planks, through the chamfering at 138a, has substantially the same width and topography as the grooves formed on the planks, by the chamfering at 138c.

The pattern and / or the surface texture present in the recessed surface of the perimeter of each plank may or may not correspond to the surface pattern / texture present in the main surface of a corresponding plank. Thus, a substantially continuous motif and / or a surface texture may or may not be present across the perimeter surfaces and the interior of any individual plank. Alignment marks or markings (not shown) can be used for the self-alignment of a decorative motif on the boards. The embossed pattern in register can be a free form or a custom design. It is to be understood that substantially any embossed pattern in registration and any decorative motif can be made. The alignment of the boards can be done visually by joining them together. Accordingly, the alignment of the planks 130 can be carried out using the decorative motif and / or the raised surface texture of each of the planks.

Although it has been illustrated that the planks in Figures 13A, 13B and 14A-14C are substantially regular, the principles of the present invention allow the planks in the floor covering system to have other shapes and dimensions (e.g., geometric, free form ) or different or similar dimensions so that the floorboards can be assembled in a "mosaic" type arrangement or other regular, semi-repetitive or random arrangement of panels. Also, although it is illustrated that each plank comprises an identical subpanel composition, the principles of the present invention allow the planks within the floor covering system to have other subpanel compositions (for example other shapes, subpanel dimensions). The individual boards within the floor covering system can be cut from a board so that the joints between the floor panels of the floor covering system are not visible. Also, the planks in the floor covering system illustrated in Figures 13 and 14 can be joined together with or without glue. In addition, although it has been explained that the embossed surface texture is substantially aligned with an underlying decorative motif, it is to be understood that substantially any embossed surface texture can be presented to the planks of the present invention, regardless of the underlying decorative motif. Also, the decorative motifs and / or the surface texture in relief of a plank may not be aligned or even remotely similar in appearance and / or in texture to the decorative motifs and / or embossed surface textures of adjacent planks.

In accordance with the principles of the present invention, Any of the decorative motifs and / or embossed surface textures mentioned above that may or may not be embossed in register with the decorative motifs (collectively referred to herein as "patterns" dome) can be applied to any of the mentioned planks above to form a substantially continuous pattern through adjacent planks arranged along a predetermined direction forming each of the patterns Plank using at least one volume pattern and at least one edge pattern.

Each edge pattern may be present in a perimeter portion of the plank that extends along at least a portion of at least one edge of each plank. Each edge pattern can extend a predetermined distance (for example, approximately one millimeter, approximately 2.54 centimeters) inside the plank, separated from the perimeter of the plank. At least one volume pattern may be arranged adjacent to the

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minus an edge pattern, in which a pattern present at the edge of the volume pattern adjacent to the edge pattern can form a substantially continuous visual / textural pattern with a pattern present at the edge of the edge pattern adjacent to the volume pattern.

Individual plank patterns, arranged adjacent to each other along a predetermined direction in a floor covering system, can complement adjacent plank patterns (i.e., form substantially continuous patterns through adjacent planks) when patterns of Edge of adjacent planks form a substantially continuous pattern. When the floor covering system described above comprises a plurality of adjacent planks arranged along the predetermined direction, and when the edges of each plank are arranged adjacent to edge patterns of other planks along the predetermined direction, the Border patterns of adjacent planks are identical or substantially identical. Identical or substantially identical edge patterns of adjacent planks allow a continuous pattern to form across adjacent planks.

For example, with reference to Figure 15A, an exemplary plank pattern of plank 150 may comprise two edge patterns 152 substantially identical to each other and a volume pattern 154. As shown in Figure 15A, the two substantially identical edge patterns 152 are present in a perimeter portion of the plank 150, extend along a portion of the opposite edges of the plank, and extend a predetermined distance in the inside of the board 150. Referring also to Figure 15A, the pattern present at the edge of the volume pattern 154 adjacent to the edge patterns 152 forms a substantially continuous pattern with the pattern present at the edge patterns 152 adjacent to the volume pattern.

Referring now to Figure 15B, a plurality of planks 150A, 150B, 150C, such as those illustrated in Figure 15A can be arranged adjacent to each other within a floor covering system along a predetermined direction so that the edges of each plank are arranged adjacent to the edges of other planks, along the predetermined direction (for example, a plank edge 150A is adjacent to a plank edge 150B, a plank edge 150C is adjacent to a plank edge 150D). As mentioned above, a substantially continuous pattern can be formed through an individual plank 150 because the volume pattern 154 is substantially aligned with the edge patterns 152.

In one embodiment of the invention, the predetermined direction in which the planks are arranged is based on adjacent edge patterns 152 on the planks, so that only by arranging the planks in the predetermined direction will the pattern formed be continuous and natural in appearance. . In this embodiment, inverting a plank or turning a plank around will produce 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 inverting, or turning around or redisposing the planks does not interrupt the pattern, ie the pattern is continuous.

In another embodiment, the predetermined direction is based on the interlocking mechanism that joins adjacent planks, so that the planks will not fit together properly if they are arranged in a direction other than the predetermined direction. An example of such an interlocking mechanism is a tongue and groove system without glue, in which the tongue is formed along at least one edge of the plank and the groove is formed along the opposite edge. In another additional embodiment, the predetermined address is based on both edge patterns 152 and the glueless locking mechanism.

In accordance with the principles of the present invention, volume patterns 154A-154F may or may not be identical. Each of the volume patterns 154 within a floor covering system can be unique. Also, in accordance with the principles of the present invention, the edge patterns of individual edge planks may be substantially identical. Therefore, the border patterns of adjacent planks in a floor covering system, through which a substantially continuous pattern is formed along the predetermined direction, are also substantially identical. A substantially continuous pattern may be arranged through the board 150A because the volume pattern 154A and the edge patterns 152A are aligned with each other to produce a substantially continuous pattern. The substantially continuous patterns can be arranged individually through planks 150B, 150C, because their respective volume patterns 154B, 154C, and edge patterns 152B, 152C are similarly aligned with each other to produce a substantially continuous pattern.

Because the plank edge patterns 150A-150F within the floor covering system illustrated in Figure 15B are identical, the edge pattern 152A forms a substantially continuous pattern with the edge pattern 152B, the edge pattern 152C forms a substantially continuous pattern with the edge pattern 152D, and so on. Accordingly, a substantially continuous pattern can be formed through planks 150A and 150B, through planks 150C and 150D, and so on. The boundary or junction between the edge pattern 152A and the edge pattern 152B is not substantially visible, or the appearance of the presence of the boundary or joint is limited. Also, the boundary or junction between edge pattern 152C and edge pattern 152D is not substantially visible, or the appearance of the presence of the boundary or joint is minimized. The boundary or union between the border pattern

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152E and edge pattern 152F is not substantially visible, or the appearance of the presence of the boundary is minimized

or union.

In an embodiment of the present invention, in which the edge patterns 152 are all substantially identical, any of the boards 150A-150F can replace any other plank within the floor covering system while also maintaining the presence of a substantially continuous pattern through planks arranged adjacent to each other along the predetermined direction. This is because all the volume patterns of a plank are substantially aligned with their respective edge patterns to form substantially continuous patterns within a plank and because all the border patterns of planks adjacent to each other within a cladding system of soils are identical, forming substantially continuous patterns along the predetermined direction.

In another embodiment, the planks may have substantially identical adjacent right and left edge patterns 152, while the opposite left and right edge patterns 152 are not.

For example, in Fig. 15C, the unit board subpanel 132 may have a pattern provided by a volume pattern 154G, the partial subpanel 134 may have a pattern provided by the volume pattern 151I and the edge pattern 152, and partial subpanel 136 may have a pattern provided by volume pattern 154H and edge pattern 152, in which volume patterns 154G-154I may or may not be identical. As mentioned above, however, the edge pattern 152, present on the perimeter of the partial subpanel portions 134 and 136 of the board 150 and extending along a portion of the edges of the board 150, are identical each. Accordingly, in view of Figure 13A, when, for example, planks 130A and 130B are arranged adjacent to each other along a predetermined direction, the edge patterns 152 of the complementary partial subpanels 134A and 136B are substantially identical between yes and a substantially continuous pattern can be formed through adjacent planks, wherein the volume patterns of the complementary partial subpanels become a part of a substantially continuous pattern, visually and / or texturally appearing as a unitary subpanel.

Also, with reference now to Figures 15C and 15D, floor covering systems incorporating planks such as those illustrated in Figures 13A-14C may be provided with substantially continuous patterns through planks adjacent to each other along directions. predetermined by applying the techniques described above with reference to Figures 15A and 15B. Figure 15D shows planks that have a wood grain pattern in the arrangement shown in Figure 15B. Because the edge pattern 152A is substantially identical to the adjacent edge pattern 152B, the planks 150A and 150B have the appearance of a substantially continuous wood grain pattern that runs without interruption through the boundary or junction between the edge pattern 152A and the border pattern 152B of the adjacent plank.

In addition, because edge patterns 152A and 152B do not run along the entire length of the boundary or junction between planks 150A and 150B, but only along the portion corresponding to the height of the partial board over half lower than the boards, the pattern is not continuous through that portion of the boundary between the boards 150A and 150B that correspond to the height of the entire boards above the upper half of the boards.

As mentioned above, within the floor covering system that incorporates the planks illustrated in Figures 13A-14C and 15C, the volume patterns within the subpanels of the planks can

or not be identical. Each of the volume boards within the floor covering system can be unique.

Figure 15E shows an embodiment of the invention in which the edge patterns of the planks are identical (or substantially identical) in each plank.

Specifically, Figure 15E shows four planks 150A, 150B, 150C and 150D arranged so that that plank 150A is adjacent to the left edge of the plank 150B and adjacent to an upper edge of the plank 150C. Board 150D is adjacent to the right edge of board 150C and adjacent to the bottom edge of 150B.

In this embodiment, the decorative paper of each plank has a wooden design.

However, it is understood that other natural-looking designs other than wood are contemplated by the present invention. The wooden design on the board 150A includes, for example, a band 155A or full board on an upper half of the board, an incomplete short board 151A and an incomplete long board 153A. Each of the boards has a wood grain model. Likewise, the short and long incomplete boards 151A and 153A have an edge pattern 152 that runs along a portion of the plank perimeter corresponding to the width of the incomplete boards 151A, 153A, and a small distance can be extended (such like a centimeter, for example) inside the boards. Board 152 border patterns

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Incomplete 151A and 153A are identical. Edge patterns 152 may also not extend inside the boards.

Also, boards 150B, 150C and 150D have full boards 155B, 155C and 155D, respectively, which run along the length of the board, and short boards 151B, 151C and 151D that 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 plank perimeter that corresponds to the width of the short and long boards.

All 151A-D short boards, 153A-D long boards and 155A-D full boards have wood grain patterns that are different from each other or some identical to each other. Only the border patterns 152 on the incomplete boards are identical in this particular example. In addition, the border pattern and the interior wood grain pattern of each incomplete board form a continuous pattern. In other words, there is a continuous global wood grain pattern on each of the short boards and long boards that are all different from each other, despite the fact that the edge patterns 152 are identical.

When the boards 150A and 150B are placed adjacent to each other as shown in Figure 15E, the complete boards 155A and 155B will be adjacent to each other, and the long board 153A and the short board 151B will be adjacent. Full boards 155A and 155B appear as separate boards and the wood grain pattern is discontinuous through them, because the adjacent edges of the entire boards are different. But because the edge patterns 152 on the long board 153A and the short board 151B are identical, the unique wood grain patterns of 153A and 151B appear to form a single continuous board with a single wood grain pattern that runs to through board 150A and 150B. Likewise, the appearance of a complete and continuous board with a unique wood grain pattern that runs along the boards 153A and 151B through the boards minimizes the visibility or appearance of the joint or boundary between the boards.

Likewise, the wood grain pattern through the 153C and 151D panels is continuous.

In a further embodiment, planks 150A, 150B, 150C and 150D may have a surface texture that is embossed in relief with the wood design on the decorative paper. Because the edge patterns 152 are part of that wood design and that they can be identical or substantially identical in each plank, the raised surface texture will appear to be continuous along the incomplete boards of adjacent planks in the manner explained previously. In a further embodiment, the embossed surface texture in record may include bevels to mimic seams between boards, so that on board 150A, for example, full board 155A would have a bevel that runs along its perimeter, including the boundary between board 155A and incomplete boards 151A and 153A. Incomplete boards 151A and 153A would have a bevel where they are adjacent, but incomplete boards would not have a bevel along the perimeter portion of plank 150A where edge patterns 152 are located. In this way, a continuous wood grain pattern and the corresponding relief surface texture can run continuously through the planks 150A and 150B interrupted by a bevel. This would also reduce the appearance of the boundary between boards.

Since all edge patterns 152 have to be identical, the present invention allows any plank to fit in the predetermined direction in which a long board 153 is adjacent to a short board 151 of another board, because the edge patterns 152 are always they will line up to form the appearance of a continuous wood grain pattern that runs through the adjacent long and short boards of the two planks. For example, if the positions of the planks 150A and 150B were reversed (so that the plank 150B was adjacent to an upper edge of the plank 150C), the edge pattern 152 of the long board 153B would match or align with the edge pattern of short board 151A, forming a continuous wood grain pattern on boards 153B and 151A through boards 150B and 150A.

The present invention reduces the complexity in the installation of a laminate floor, because it does not matter which boards are located adjacent to each other in the predetermined direction. The patterns will line up.

In a further embodiment, the planks 150 are provided with a glueless tongue-and-groove system in which the tongue is formed on two adjacent perimeter edges of the plank and the groove is formed on the two adjacent adjacent perimeter sides so that the planks can only fit in the direction that will align the long boards 153 with the short boards 151, for example, where the edge patterns 152 are located.

In addition, because in this embodiment it is only necessary that the edge patterns be identical, the interior patterns of the entire long and short plank boards may be different, providing a more natural looking floor.