HK1112951B - Flooring system having sub-panels with complementary edge patterns - Google Patents

Description

Flooring system having sub-panels with complementary edge patterns

The present application is incorporated by reference for a partial continuation application of the application entitled "flooring system with complementary subpanels," application No. 10/689,510, applied on day 10/21/2003, entitled "flooring system with complementary subpanels," application No. 10/374,751 (attorney docket No. 5724.017.22), applied on day 2/27/2003, for a partial continuation application of the co-pending application entitled "flooring system with complementary subpanels," application No. 10/352,248 (attorney docket No. 5724.017.21), applied on day 1/28/2003, for a partial continuation application of the co-pending application entitled "embossed registration plate system," application No. 10/137,319 (attorney docket No. 5724.017.00), applied on day 5/3/2002, and applied on day 7/31/2001, and for a partial continuation application of the co-pending application No. 5724.017.00, applied on day 7/31/2001, The co-pending application entitled "embossed registration manufacturing method", application No. 09/903,807 (attorney docket No. 5724.016.00), and U.S. patent No.6,401,415 entitled "direct laminate flooring", filed on 12/13/1999, are incorporated by reference as if fully set forth herein.

Technical Field

The present invention relates to a laminate. In particular, the present invention relates to flooring systems of interlocking laminates having decorative patterns and surface textures that are mechanically embossed in registration with their decorative patterns.

Background

Due to their look and feel, consumers often prefer traditional building and finishing flooring materials, such as good wood, slate, granite, stone, brick, and concrete. However, such conventional building and finishing flooring materials tend to be costly to manufacture and install. For example, while solid wood flooring has a luxurious aesthetic appearance, the materials and labor required to install such flooring are unacceptably expensive.

There are many alternatives to conventional building and finishing flooring materials, including laminates such as high-pressure laminates (HPL), direct-pressure laminates (DPL), and continuous-pressure laminates (CPL). However, these alternatives typically do not have the realistic look and texture of traditional building and finishing flooring materials. For example, most alternatives having an outer surface with wood grains look counterfeit and can be easily identified as other materials than real wood. Furthermore, while high quality HPL, DPL, or CPL boards visually look like wood, their texture readily reveals that they are not wood.

One problem with most alternatives to conventional building and finishing flooring materials is that their surface texture does not match their decorative motifs. For example, the visual depiction of the knots of the alternative flooring material does not match the surface texture features of the knots. Thus, the appeal of these alternative materials is greatly compromised.

One method for matching the surface texture of alternative flooring materials and their decorative patterns includes a technique known as chemical embossing. In chemical embossing, the surface texture of the replacement material is formed by chemically reacting an ink that forms the decorative motif with an agent that is added to the underlying surface. Although somewhat successful, the resulting surface texture tends to lack the texture definition and three-dimensional characteristics of conventional materials.

As an alternative to conventional building and finishing flooring materials, the laminate may be mechanically embossed to create a surface texture. See, for example, U.S. patent application 09/903,807 and U.S. patent No.6,401,415, which are incorporated herein by reference. Such a process produces an embossed registration laminate having a decorative pattern and matching high quality three-dimensional texture. Embossed registration laminates require precise registration of mechanical embossing and decorative patterns. One advantage of embossed registration laminates is that they can realistically replicate the look and feel of traditional products.

Regardless of the type of flooring system used, the flooring system must be easily moved to the worksite while being easy and quick to install. To this end, assembly and locking mechanisms may be incorporated into the flooring system to facilitate field installation. One type of assembly and locking mechanism is a tongue and groove system for connecting multiple panels. It will be appreciated that such tongue and groove systems are disclosed in U.S. patent No.2,057,135 to Cherry and U.S. patent No.2,046,593 to Urbain. For example, FIG. 1 may be understood to show a tongue and groove system 11 that uses clips 12 to secure panels together.

Another type of known assembly and locking mechanism is disclosed in Chevaux, U.S. patent No.3,946,529, where with reference to fig. 2, flooring system 13 appears to be connected using a tongue and groove system disposed below the flooring.

Yet another type of assembly and locking mechanism is taught in U.S. patent No.5,295,341 to Kajiwara. There, it is understood that the laminate is provided with a snap-together system, such as a groove-tongue joint. Thus, the assembly of the laminate may be made without glue. Referring to figure 3, the laminate is provided with locking elements in the form of groove connectors 16 and tongue connectors 18. The groove connection 16 has a forwardly projecting groove 20, while the tongue 18 has a pair of forwardly diverging side walls 22 and 24 separated by an elongate groove 26. Each side wall includes a rear locking surface 28 and 36. The side walls may be compressed together to lock.

Another type of assembly and locking mechanism is at MA snap-fit joint is proposed in U.S. patent No.6,101,778 to rtensson. As shown in fig. 4, it will be appreciated that the laminate is provided with a locking element consisting of a groove 6 and a tongue 7, which form a groove-tongue assembly. Groove6 and tongue 7 may be made of waterproof material and snap together with a portion 9 fitting in slot 4.

While the foregoing assembly and locking mechanisms have proven useful, they have not been used with embossed registration lamination systems in which embossed registration decorative patterns or graphics are aligned across seams between individual embossed registration plies. This significantly reduces the visual and textural impression of a system consisting of embossed registration laminates. Therefore, a new embossed registration lamination system in which the visual and textural patterns cross the seam while maintaining the embossed registration features would be advantageous. More advantageous are embossed registration lamination systems consisting of interlocked embossed registration laminates in which the visual and textural patterns span the seam while maintaining the embossed registration features.

In addition, the aforementioned flooring systems have a low resistance to wear. While not wishing to be bound by any particular theory, it is hypothesized that premature aging (wear) begins at or near the perimeter and/or along the tongue and groove lines. The aforementioned flooring systems have a generally flat (horizontal) surface texture such that the center and perimeter of each panel contact the user (e.g., a pedestrian) equally. However, the periphery of each plate is generally weaker than the center of the plate, and so degrades first.

In addition, flooring systems typically do not have decorative motifs or designs that are longer than the length of the plank. For example, in flooring systems designed to replicate wood flooring with wood slats, the length of the wood slat pattern is typically equal to or shorter than the length of a single plank. This is desirable in related art flooring systems because it does not require the installer to plan more than one plank in addition to the plank being installed.

Accordingly, there is a need for a viable method of manufacturing an alternative to building or finishing materials, wherein the alternative material has the realistic look and feel of traditional products and has an enhanced ability to prevent premature wear, and wherein a minimum number of planks are used while still being able to produce design motifs or pattern elements having a length greater than the length of a single plank.

Disclosure of Invention

Accordingly, the present invention is directed to an embossed registration flooring system that substantially obviates one or more problems due to limitations and disadvantages of the related art.

One advantage of the present invention provides an embossed registration flooring system comprising a single adjacent flooring plank having an embossed registration decorative pattern, wherein at least one of the surface texture and the decorative pattern are generally aligned between the adjacent flooring planks.

Another advantage of the present invention provides an embossed registration flooring system comprising interlocked flooring planks having an embossed registration decorative pattern, wherein at least one of the surface texture and the decorative pattern are generally aligned between adjacent flooring planks such that a generally continuous embossed registration pattern is formed across the interlocked flooring planks.

Another advantage of the present invention provides an embossed registration flooring system that may include, for example, flooring planks, wherein a surface of the perimeter of each individual flooring plank may be recessed such that an upper surface of the perimeter of the flooring plank underlies a portion of the upper surface of the flooring plank surrounded by the perimeter.

Another advantage of the present invention provides a plank comprising: a plurality of sides defining a perimeter; a plurality of edge patterns disposed proximate at least one first portion of the perimeter, wherein at least two of the plurality of edge patterns are substantially identical; and at least one body pattern disposed adjacent to the plurality of edge patterns and proximate to the at least one second portion of the perimeter, wherein the at least one body pattern and the edge patterns adjacent to the at least one body pattern form a substantially continuous pattern.

Another advantage of the present invention provides a flooring system comprising at least two planks adjacent to each other along a predetermined direction, wherein each plank comprises: a plurality of sides defining a perimeter; a plurality of edge patterns disposed proximate at least one first portion of the perimeter, wherein at least two of the plurality of edge patterns are substantially identical; and at least one body pattern disposed adjacent to the plurality of edge patterns and proximate to the at least one second portion of the perimeter, wherein the at least one body pattern and the edge patterns adjacent to the at least one body pattern form a substantially continuous pattern; where the edge patterns of the at least two planks form a substantially continuous pattern.

Another advantage of the present invention provides a flooring panel that includes a plurality of edges defining a perimeter; a surface having a decorative motif thereon, the decorative motif including at least two edge patterns adjacent each edge of the panel and at least one body pattern in the interior of the panel and adjacent the edge patterns on each edge, wherein at least one edge pattern along one edge is substantially the same as the edge pattern in a corresponding location along the opposite edge; and wherein at least a portion of the decorative pattern along one edge is substantially different from a corresponding portion of the decorative pattern along an opposite edge.

Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the invention. These and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

Drawings

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

In the figure:

FIG. 1 illustrates a related art assembly and locking mechanism;

FIG. 2 illustrates another related art assembly and locking mechanism;

FIG. 3 illustrates yet another related art assembly and locking mechanism;

FIG. 4 illustrates yet another related art assembly and locking mechanism;

FIG. 5 illustrates a perspective view of components in an embossed registered flooring plank according to the principles of the present invention;

FIG. 6 illustrates a press capable of manufacturing embossed registered flooring planks according to the principles of the present invention;

FIG. 7 illustrates embossed registered flooring planks in one aspect of the present invention;

FIG. 8 shows a top view of a system of embossing registration flooring planks in another aspect of the present invention;

FIG. 9 shows a cross-sectional view along line 9-9 shown in FIG. 8;

FIG. 10 shows a top view of a system of embossing registration flooring planks in yet another aspect of the present invention;

FIG. 11 shows a cross-sectional view along the line 11-11 shown in FIG. 10;

FIGS. 12A and 12B show schematic views of a perimeter surface portion including a flooring plank according to the principles of the present invention;

FIGS. 13A and 13B illustrate a flooring system in yet another aspect of the present invention;

14A-14C show illustrative planks of a flooring system in yet another aspect of the present invention; while

15A-15E illustrate an exemplary method of forming a pattern on a flooring plank according to the principles of the present invention.

Figures 16A-16E illustrate another exemplary method of forming a pattern on a flooring plank according to the principles of the present invention.

FIG. 17 illustrates another exemplary method of forming a pattern on a flooring plank according to the principles of the present invention.

FIG. 18 illustrates another exemplary method of forming a pattern on a flooring plank according to the principles of the present invention.

FIG. 19 shows another illustrative method of forming a pattern on a flooring plank in accordance with the principles of the invention.

Detailed description of the preferred embodiments

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

FIG. 5 generally illustrates the components of a flooring plank according to the principles of the present invention.

Referring to fig. 5, an embossed registered flooring system, for example, may include at least one flooring plank. In one aspect of the present invention each flooring plank may comprise a board substrate 34 made of a substrate material (e.g., medium or high density fiberboard, particle board, etc.), at least one bottom layer 36 (e.g., kraft paper layer) impregnated with a predetermined resin and disposed on and/or under the board substrate 34, a decorative paper layer 38 disposed on the board substrate, having a thickness of about 0.15mm, and impregnated with a polymerizable resin (e.g., phenol such as melamine), and at least one protective cover layer 30 disposed on the decorative paper layer 38. In one aspect of the invention, each protective covering 30 may be formed of gold-bearing steel grit (Al) impregnated with₂O₃) Highly resistant paper of melamine solutions of silica, etc. In another aspect of the present invention, a different paper may be disposed between the decorative paper layer 38 and the board substrate 34. In one aspect of the invention, the at least one protective cover layer 30 and the bottom layer36 may be impregnated with a resin. In another aspect of the present invention, the resin impregnating the at least one protective cover layer 30 and the base layer 36 may be different from the melamine resin used to impregnate the decorative paper layer 38.

In one aspect of the invention, the flooring planks in the flooring system may be made of substantially the same paper, resin, or the like. For example, flooring planks in a flooring system may be manufactured using paper made from substantially the same paper fibers (e.g., having substantially the same ash content, color, and orientation) on the same paper machine. In addition, the flooring planks in a flooring system may be manufactured using paper from a single, continuous section on a manufacturing reel. All of the aforementioned limitations of paper use that can be used to make flooring planks in flooring systems ensure that the impregnated papers will always have substantially the same final dimensions after they are pressed and cured. In one aspect of the invention, the warehouse of paper used to manufacture the flooring planks in the flooring system may be controlled such that the time, temperature, and humidity of storing the paper are maintained to facilitate consistency of flooring plank dimensions. In another aspect of the invention, the flooring planks in the flooring system may be manufactured using cellulose pulp manufactured by the same manufacturer. In yet another aspect of the present invention, the flooring planks in the flooring system may be manufactured using resins manufactured by the same manufacturer. In yet another aspect of the invention, the resins may comprise powders derived from substantially the same raw materials, have substantially the same chemical and physical properties, and are mixed in the same reactor. In addition, the flooring planks in the flooring system may be manufactured using a resin having a substantially constant solids content. All of the aforementioned limitations of paper use that can be used to make flooring planks ensure that the impregnated papers will always have substantially the same final dimensions after they are pressed and cured. In yet another aspect of the invention, each flooring plank in the flooring system may be manufactured using substantially the same impregnation process. For example, when various paper layers are dipped into melamine resin, the paper should be subjected to a constant, uniform melamine load. In addition, the belt tension and vibration of the impregnator should be precisely controlled, as they will affect the degree to which the various paper layers are impregnated with resin.

In accordance with the principles of the present invention, the aforementioned layers and substrates may be manufactured in an embossed-in-registration flooring system comprising a plurality of interlocked flooring planks. To produce such a flooring system, a press, such as the press shown in fig. 6, may be used to mechanically emboss each flooring plank in registration with the decorative pattern disposed on the decorative paper layer 44.

Referring to fig. 6, the press may include, for example, a base 42, a press bed 54, and an upper platen 56. In one aspect of the present invention, the upper platen may include an embossed pattern (e.g., a three-dimensional textured surface). Thus, the embossing pattern may include, for example, any design of ridges, dots, dimples, etc. that is capable of aligning with the decorative pattern formed on the decorative paper layer 44.

In accordance with the principles of the present invention, the impregnated decorative paper sheet 44 disposed on the board substrate 40 must be precisely positioned relative to the embossing pattern of the upper platen to achieve embossing in register with the flooring planks. In one aspect of the invention, alignment between the embossing pattern and the decorative motif of the press plate must be ensured when the press is locked in place and the plate is under pressure. The degree of control required may vary depending on the type of decorative pattern used. For example, the degree of alignment required for the registration pattern of the wood grain embossments across adjacent embossed registration flooring planks is higher than the degree of alignment of the registration pattern of the wood grain embossments that are not aligned with adjacent flooring planks.

Registration between the decorative pattern on the decorative paper sheet 44 and the embossing pattern on the upper platen 56 may be achieved by removing approximately 2 to 3 millimeters of material around the periphery of the board substrate 40 during grinding and thereby creating several reference surfaces (e.g., board edges) and a board substrate with strictly controlled dimensions. Next, an impregnated decorative paper layer 44 having an outer dimension approximately 8 or 10mm smaller than the board substrate 40 is disposed on the board substrate 40. In one aspect of the invention, the impregnated paper layer 44 may be arranged on the board substrate 40 using the board edge as an alignment feature. In one aspect of the present invention, the alignment marks may be disposed on the board substrate 40 and may be aligned with the alignment marks provided on the decorative paper layer 44.

In one aspect of the present invention, the decorative paper layer 44 may be attached to the board substrate 40 by static electricity. After they are attached, the decorative paper sheet 44 and the board substrate 40 are arranged on a slide fed into the press. Static electricity may substantially prevent the decorative paper sheet 44 from being accidentally displaced as the board substrate 40 moves with the carriage. In one aspect of the invention, the carriage may stop just before it enters the press so that the decorative paper layer 44 may be precisely placed on the board substrate 40, for example using tweezers (not shown). In another aspect of the present invention, tweezers may be used to precisely place the decorative paper sheet 44 on the board substrate 40 on the lower press plate. In one aspect of the invention, the decorative paper layer 44, the at least one protective overlay 46, and optionally the base layer 48 may be disposed on the board substrate 40 prior to being disposed into the press. After the decorative paper layer 44 is arranged on the board substrate 40, the slide can be moved out of the press. The alignment system then generally aligns the system of decorative paper ply 44/board substrate 40 with the embossing pattern in the upper platen 56. In one aspect of the invention, the alignment system may use the board edges to generally align the decorative paper sheet 44 with the embossing pattern on the upper platen 56. The press may be operated after the alignment is completed.

In one aspect of the invention, after the components shown in FIG. 5 are placed in a press and aligned with the embossing pattern, the various layers and substrates can be pressed and cured for a predetermined time until the resin solidifies, resulting in an extremely hard and abrasion resistant flooring plank. For example, after insertion into the press and alignment with the embossing pattern, the board substrate 40, the decorative paper layer 44, the protective cover layer 46, and optionally the bottom layer 48 may be heated at a temperature of about 160-220 ℃ and at about 20-40Kg/cm²Is pressed together under pressure and for about 20-60 seconds. The top press 54 thus presses the embossing pattern of the upper press plate 56 into the structure of the decorative paper sheet 44 and the board substrate 40. The combination of applied heat and pressure fuses the decorative paper layer 44 and the board substrate 40 together. The alignment system ensures that the decorative paper ply 44 substantially matches the embossing pattern in the upper platen 56And (4) aligning the patterns. Thus, the melamine resin in the various layers can be cured and embossed registration planks can be produced.

In one aspect of the invention, porosity in the weld can be minimized by applying a slow cure to the resin (e.g., melamine). Accordingly, as the operating temperature decreases, the time to apply compression to the various layers in the press increases. In another aspect of the present invention, the embossing pattern included in the platen may expand when the platen 56 is heated to approximately 160-220 ℃. Accordingly, the embossing pattern on the platen 56 may be provided in a manner that compensates for the expansion of the pattern. Thus, the dimensions of the embossing pattern are provided: such that when the resins in the component of fig. 5 are cured, they generally correspond to the design of the decorative motif.

In accordance with the principles of the present invention, a mechanically embossed surface texture can be imparted to individual flooring planks having a decorative pattern. In one aspect of the invention, the mechanically embossed surface texture may be provided in registration with the decorative motif. Thus, embossed flooring planks may be manufactured. In another aspect of the present invention, a plurality of embossed flooring planks may be joined together to form an embossed flooring system. In yet another aspect of the present invention, at least a portion of the embossed registration pattern of each adjacent flooring plank may be generally aligned with one another to form a generally continuous embossed registration pattern across each adjacent flooring plank in the flooring system.

Although the embossing registration process described above is suitable for embossing surface textures of less than about 0.2mm depth, deeper surface textures may be problematic. Embossing of patterns that can impart deep surface textures requires large platen extensions, which tend to interfere with the uniformity of pressure applied across the plate surface. This pressure disturbance can lead to deformation of the finished product. In one aspect of the present invention, an embossed surface texture greater than about 0.2mm in depth may be formed by hollowing out the plate substrate 40 at locations where a deep surface texture is desired. In one aspect of the present invention, the hollowing process may be performed before, during, or after the periphery of the plate substrate 40 is ground as described above. In another aspect of the invention, the plate edges may be used to position the boundaries of the hollowed-out portion of the plate substrate 40.

Referring to fig. 7, an embossed flooring plank 60 manufactured according to the above process may optionally include a protective cushion layer 50 on one side. The mechanically embossed surface texture is aligned with the decorative pattern 68 of the decorative paper ply 44. By aligned, it is meant that the embossed surface texture is generally aligned with the decorative pattern of the decorative paper layer 44. By providing embossed registered flooring planks, the individual flooring planks can be provided with a realistic appearance of natural materials. Although the decorative motifs shown in fig. 7 realistically represent the image and texture of wood grain, it will be appreciated that other embossed register designs may be produced, such as ceramic planks, concrete, marble, etc.

In accordance with the principles of the present invention, each individual flooring plank may, for example, include at least one locking mechanism.

In one aspect of the present invention, a plurality of locking mechanisms may be incorporated into the plate substrate 40 prior to imparting the embossed pattern to the surface of the plate substrate 40 in registration with the decorative motif. Thus, a plurality of locking mechanisms can be manufactured in a single board substrate 40. In turn, the locking mechanisms can be used to join the plate substrates together to form a slab structure. The plank structure can then be inserted into the press 54. After the embossing pattern is imparted to the plank structure and the molten components are fused together, the plank structure is removed from the press 54. The embossing in the molten plank configuration is then separated from the flooring plank 60 in registration by unlocking each locking mechanism. In one aspect of the invention, a cutting tool may be used to aid in separation and to ensure that the decorative motif is not damaged.

In another aspect of the present invention, the locking mechanism may be incorporated into the plate substrate 40 after the embossed pattern is imparted to the surface of the plate substrate 40 in registration with the decorative motif. Accordingly, a plate substrate 40 having a larger size, e.g., 4 'x 8', may be embossed by a press machine 54. The resulting embossed registration substrate may then be cut into a plurality of individual embossed registration flooring planks 60. In one aspect of the invention, the edges of the individual embossed registration flooring planks 60 may have smooth edges and precise dimensions. In one aspect of the invention, the cutting may be performed using a shaping tool, an abrasive tool, a cutting tool, a crushing tool, or the like. In one aspect of the invention, the plate substrate may be cut by a press. Thus, the board substrate 40 may be cut into units (e.g., slats) having dimensions of, for example, 300 × 300mm, 400 × 400mm, 600 × 600mm, 1,200 × 300mm, 1,200 × 400mm, and the like. Multiple locking mechanisms can then be incorporated into a single embossed registered flooring plank 60. In one aspect of the invention, the locking mechanisms may be hidden under the surface of the flooring planks or they may be visible.

In accordance with the principles of the present invention, each locking mechanism may be incorporated into a single embossed registration flooring plank 60 by aligning at least one of the flooring plank's panel edges, alignment marks, decorative motifs, and surface motifs with an abrasive tool. By aligning the abrasive tool with any of the previously described alignable features, a locking mechanism can be milled into each side of the board substrate 40 such that when the flooring planks 60 are joined together, at least a portion of the decorative motif forms a continuous pattern and at least a portion of the embossed registration pattern forms a substantially continuous surface texture across adjacent flooring planks.

In accordance with the principles of the present invention, the embossed registration flooring plank 60 may include a locking mechanism 64 (e.g., at least one of a tongue and groove locking system, a snap-lock system, etc.) extending along all four edges of the embossed registration laminate 60. For example, a snap lock system may be added to all four sides of the embossed flooring plank 60 and used to attach a plurality of embossed flooring planks 60 into the embossed flooring system 300 (as shown in fig. 8). The number and location of the locking mechanisms may depend on the desired configuration of the embossed registration flooring system. For example, when the embossed-in-registration flooring system is adjacent a corner, only two locking mechanisms (along each side) are required.

Referring to fig. 8, embossed co-flooring planks a and B may include, for example, a locking mechanism along four sides (e.g., along seams J1, J2, J3, and J4). Embossed registered flooring planks C and D may, for example, include a locking mechanism along four sides (e.g., along seams J1, J2, J3, and another seam not shown).

Embossed registration flooring planks including the aforementioned locking mechanisms may be securely joined together with or without glue to form an embossed registration laminate system 300. Multiple embossed registered flooring planks may be joined together to achieve any desired shape for flooring, decking, etc. The embossed registration flooring planks may be engaged with one another such that the embossed registration patterns of adjacent flooring planks are at least partially generally aligned with one another and form a generally continuous image and embossed surface texture across the flooring planks in the flooring system.

Fig. 8 and 9 illustrate a typical embossed registration flooring system 300 that incorporates one type of locking mechanism on each individual embossed registration flooring plank 60. FIG. 9 illustrates a typical embossed registered flooring system including a flooring plank having a clinching tongue and groove locking mechanism. In one aspect of the invention, a clinch-type tongue and groove locking mechanism may be integrated into the side walls of each embossed registration ply 60 to ensure that the embossed registration patterns of adjacent flooring planks are generally aligned with each other and generally continuous in the flooring system.

Fig. 9 shows a cross-sectional view taken along line 9-9 of fig. 8. As shown, the locking mechanism can be formed by forming a groove 230, tongue 200, groove 210, and lip 220 along the edges of the embossed registering flooring planks 60. The locking mechanism of each embossed flooring plank 60 may be engaged together by inserting the tongue 200 into the groove 230 of an adjacent embossed flooring plank 60. Subsequently, the lip 220 is secured into the groove 210, thereby engaging the adjacent embossed flooring planks 60 into the embossed flooring system 300. In one aspect of the invention, the embossed registered flooring planks 60 labeled A, B, C and D may or may not be joined together with glue. It is understood that other types of locking mechanisms may be incorporated into the various sides of a single registering flooring plank 60.

Referring back to fig. 8, each embossed registered flooring plank 60 may, for example, take the form of an embossed registered ceramic plank pattern G1. The ceramic slab pattern may include a plurality of slabs in the shape of squares, rectangles, triangles, circles, ovals, and other shapes or designs separated by mud lines. In one aspect of the invention, the width of the mudline Wh, Wv and the inboard mud width W may be substantially the same. After incorporating the snap-fit tongue and groove locking mechanism into the embossed registration flooring plank 60, the grout width adjacent the seams J1, J2, J3, and J4 on each embossed registration ply A, B, C and D is about half the in-board grout width W. For example, the vertical slab mud width (Wv) across the seam J1 consists of mud lines on the embossed registration plies A, B, C and D such that the vertical mud width (Wv) is approximately equal to (W) when the embossed registration plies A, B, C and D are joined at J1. Accordingly, the mud width on any single embossed register flooring plank 60 adjacent the seam is half the in-board mud width (W). In another aspect of the invention, the horizontal and vertical mud widths Wh and Wv may be controlled such that they are substantially equal to the size of the in-plate mud width W. It will be appreciated, however, that the size of the width of the grout in embossed register flooring planks depends on the type of locking mechanism included and the decorative motif present.

In addition to grout lines, many other decorative patterns may be used in the embossed registered flooring system of the present invention. Referring to fig. 10 and 11, a decorative motif, for example, in the form of a wood-textured surface G2, may be provided that is generally aligned across the seams J5 and J6 of adjacent flooring planks. In accordance with the principles of the present invention, wood grain patterns typically include more elements (e.g., wood grain lines, knots 423, etc.) that need to be aligned extending to the perimeter of the flooring plank than ceramic plank patterns. Thus, aligning wood grain patterns is generally more difficult than aligning mud line portions of ceramic plank patterns. For example, aligning a first portion of a nub 423 on an embossed registered flooring plank E with a second portion of a nub 423 on an embossed registered flooring plank F is generally more complicated than aligning the grout line width across the seam of adjacent flooring planks. Thus, when manufacturing the locking mechanism, all graphical elements (e.g., wood grain lines and wood knots 423) must be considered to ensure a realistic embossed registration flooring system 400. In one aspect of the invention, at least a portion of the decorative motif can be used as an alignment mark to ensure consistent alignment of adjacent flooring planks.

In another aspect of the present invention, the individual flooring planks in embossed registration flooring system 400 may be joined together with a buckle-type mechanical system as shown in FIG. 11, which depicts a cross-sectional view along line 11-11 in FIG. 10. Here, alignment techniques are also used to make the locking mechanism so that the embossed registration laminate system 400 has a surface textured surface 423 that is generally continuous across seams J5 and J6. Optionally, the embossed registration laminate 60 has a protective backing layer 70 beneath the bottom layer 48.

Figures 12A and 12B show schematic views of a flooring plank according to the principles of the present invention.

Referring to fig. 12A and 12B, the upper surface of the perimeter P of the flooring plank in registration with each embossment may be recessed below the upper surface of the portion of the flooring plank surrounded by the perimeter. An object O (e.g., a user's shoe, wheel, etc.) contacting the major surface Ms of the flooring plank will not normally contact the peripheral surface Ps due to the peripheral concave surface. In one aspect of the invention, the perimeter can include a portion of the flooring plank extending approximately 3.175mm from an edge of the flooring plank toward a center of the flooring plank. In another aspect of the invention, the depth of the surface depression of the perimeter of the flooring plank is about 0.794 mm. In another aspect of the invention, the surface of at least a portion of the perimeter of the flooring plank may not be recessed, as will be discussed in more detail below with reference to fig. 13.

Thus, the embossed registration pattern may be provided to the edges of the flooring planks and may be aligned with the embossed registration pattern formed on an adjacent flooring plank, while the edges of each individual flooring plank may be prevented from prematurely wearing.

Although it is shown in fig. 8 and 10 that the individual flooring planks in the flooring system are of substantially the same size and shape and are joined to each other such that each side of each flooring plank is joined to only one adjacent flooring plank, it is understood that the individual flooring planks in the flooring system may vary in size (e.g., width and/or length) and shape (e.g., rectangular, square, triangular, hexagonal, etc.). In one aspect of the invention, individual flooring planks may have complementary shapes that can be assembled similar to a puzzle or mosaic or the like. In addition, one aspect of the present invention contemplates that the edges of a single flooring plank may contact more than one adjacent flooring plank.

In accordance with the principles of the present invention, the flooring planks in a flooring system may be arranged such that at least one edge of each plank comprises at least one secondary panel adjacent to at least two other secondary panels. In another aspect of the invention, each plank can include, in whole or in part, at least one secondary panel, as will be described in more detail below.

In FIG. 13A, for example, a partial secondary plate 134A of a plank 130A can be a complementary secondary plate relative to an adjacent partial secondary plate 136B of a plank 130B adjacent to the plank 130A. With this arrangement, the partial sub-panels 134A and 136B can be made to look like one integral sub-panel.

Still referring to FIG. 13A, each of the planks 130A-F can include at least three secondary panels, wherein at least one of the secondary panels is an integral secondary panel and at least two of the secondary panels are partial secondary panels. For example, 132A is an integral sub-panel and 134A and 136A are partial sub-panels.

In one aspect of the invention, the integral sub-panel 132A may provide a complete decorative pattern with or without an embossed surface texture, which may or may not be registered with the decorative pattern. In another aspect of the invention, the partial sub-panels 134A and 136A of the plank may provide a separate, incomplete decorative pattern with or without an embossed surface texture that may or may not be registered with the decorative pattern. In one aspect of the invention, adjacent partial sub-panels of adjacent planks can complement each other such that they provide a substantially complete decorative pattern and/or surface texture and appear as a substantially continuous, complete sub-panel. In one aspect of the invention, the complementary partial sub-panels may have complementary decorative motifs and/or embossed surface textures. Thus, when the complementary partial sub-panels of adjacent planks are properly aligned, a substantially continuous (i.e., complete) decorative pattern and/or embossed surface texture can be formed across the adjacent complementary partial sub-panels. In one aspect of the invention, the secondary panels in the plank may or may not include substantially the same decorative motif and/or embossed surface texture.

FIG. 13B shows a schematic view of an illustrative plank 130 such as that shown in FIG. 13A.

In one aspect of the invention, a portion of the peripheral surface of each plank can be provided with a depression at a location where adjacent sub-panels are not complementary. In another aspect of the present invention, a portion of the peripheral surface of each plank can be provided without a depression at a complementary location in an adjacent sub-panel. Referring to FIG. 13B, the partial upper surface of the perimeter "P" of each plank 130, indicated by reference numeral 138a, can also be slightly recessed compared to the major surface of each plank (see also FIG. 12B) to prevent premature wear of each plank. In addition, a portion of the upper surface of the perimeter of each plank 130, indicated by reference numeral 138b, may be non-recessed and generally coplanar with the major surfaces of the secondary panels. Recessing only a portion of the peripheral surface of each plank in locations not occupied by the decorative motif and/or embossed surface texture of the partial sub-panels of planks allows the complementary partial sub-panels to appear as part of a complete sub-panel without significantly reducing the overall durability of each plank. In yet another aspect of the present invention, a portion of the surface of each plank can be recessed where the minor panels of the plank are adjacent to each other. Referring to FIG. 13B, the portion of the upper surface of each plank 130 indicated by reference numeral 138c can be slightly recessed compared to the major surface of each plank (see also FIG. 12B) to provide a visual and textural effect that each minor panel of a plank is not part of the same plank.

Fig. 14A-14C show illustrative planks of a flooring system in yet another aspect of the present invention.

Referring to fig. 14A-14C, similar to the planks shown in fig. 13A and 13B, portions of the upper surface of the perimeter "P" of each plank 130, indicated by reference numeral 138a, can be sloped to prevent premature wear of each plank. In addition, portions of the upper surface of the perimeter of each plank 130, indicated by reference numeral 138b, may not be sloped such that they are generally coplanar with the major surfaces of the secondary panels. Tilting the peripheral surface of each plank at a location corresponding to the decorative motif and/or embossed surface texture of the partial sub-panels of the plank allows the complementary partial sub-panels to appear as part of a unitary sub-panel without significantly reducing the overall durability of each plank. In yet another aspect of the present invention, a portion of the surface of each plank can be grooved where the minor panels of the plank are adjacent to each other.

FIGS. 14B and 14C show cross-sectional views of the plank 130 taken along lines I-I 'and II-II', respectively. Referring to fig. 14B and 14C, a portion of the upper surface of each slab 130, indicated by reference numeral 138C, may be sloped to form a groove. Thus, the groove provides a visual and textural effect of the separation of the secondary panels of the plank. In one aspect of the invention, the chamfer at 138c may create a groove having a generally V-shaped groove. However, it is understood that the chamfer may create other groove configurations (e.g., U-shaped grooves, etc.). In one aspect of the invention, the inclination of each plank 130 at the peripheral surface portion 138a creates a groove between adjacent planks. Thus, the groove formed between adjacent ones of the planks by the tilting at 138a has substantially the same width and form as the groove formed in the planks by the tilting at 138 c.

The pattern and/or surface texture of the concave surface present at the periphery of each slab may or may not correspond to the pattern/surface texture present at the major surface of the respective slab. Thus, there may or may not be a substantially continuous pattern and/or surface texture across the surface of the perimeter and interior of any single thick sheet. Alignment marks or indicia (not shown) may be used to self-align the decorative motifs on the plank. In one aspect of the invention, the embossed registration pattern may be a free form or custom design. It is to be understood that substantially any embossed registration pattern and any decorative motif can be achieved by applying the principles of the present invention. In one aspect of the invention, alignment of the planks can be done visually when joining the planks together. Accordingly, alignment of the planks 130 can be performed using the decorative motif and/or embossed surface texture of each plank.

Although the planks in FIGS. 13A, 13B and 14A-14C are shown as being generally rectangular, the principles of the present invention allow for planks in flooring systems having other shapes and sizes (e.g., geometric, free-form, etc.) or different or similar sizes so that the flooring planks can be assembled in a "mosaic" arrangement of boards or other regular, semi-repeating or free arrangements. Additionally, although each plank is shown to include the same sub-plank design, the principles of the present invention allow planks in flooring systems to have other sub-plank designs (e.g., other sub-plank shapes, sizes, etc.). Individual planks in a flooring system may be cut from the plank such that seams between flooring panels of the flooring system are not visible. In addition, the planks in the flooring system shown in FIGS. 13 and 14 may be joined together with or without glue. Also, while the embossed surface texture has been discussed as being generally aligned with the underlying decorative pattern, it is to be understood that virtually any embossed surface texture can be imparted to the planks of the present invention regardless of the underlying decorative pattern. Further, the decorative pattern and/or embossed surface texture of one plank may be misaligned with the decorative pattern and/or embossed surface texture of an adjacent plank or even remotely correspond in appearance and/or texture.

In accordance with the principles of the present invention, any of the foregoing decorative patterns and/or embossed surface textures (collectively referred to herein as "patterns"), which may or may not be in registration with the decorative pattern embossments, may be applied to any of the foregoing planks to form a generally continuous pattern across adjacent planks arranged along a predetermined direction by using at least one body pattern and at least one edge pattern to form each plank pattern.

In one aspect of the invention, each edge pattern can be present in a peripheral portion of each plank extending along at least a portion of at least one edge of each plank. In another aspect of the invention, each edge pattern can extend into the interior of the plank a predetermined distance (e.g., about one millimeter, about one inch, etc.) away from the perimeter of the plank. In another aspect of the present invention, at least one body pattern may be disposed adjacent to at least one edge pattern, wherein a pattern present at an edge of the body pattern adjacent to the edge pattern may form a substantially continuous visual/texture pattern with a pattern present at an edge of the edge pattern adjacent to the body pattern.

In one aspect of the invention, the pattern of individual planks arranged adjacent to each other in the flooring system along the predetermined direction can complement the pattern of adjacent planks (i.e., form a substantially continuous pattern across the adjacent planks) when the edge patterns of the adjacent planks form a substantially continuous pattern. Where the flooring system described above includes a plurality of adjacent planks arranged along a predetermined direction, and where the edge of each plank is arranged adjacent to the edge pattern of the other planks along the predetermined direction, the edge patterns of the adjacent planks are the same or substantially the same. The same or substantially the same edge pattern of adjacent planks allows for a continuous pattern to be formed across the adjacent planks.

For example, referring to fig. 15A, an exemplary plank pattern of the plank 150 can include two edge patterns 152 and one body pattern 154 that are substantially identical to each other. As shown in FIG. 15A, two substantially identical edge patterns 152 are present at a peripheral portion of the plank 150, extend along a portion of opposite edges of the plank, and extend a predetermined distance into the interior of the plank 150. Still referring to fig. 15A, the pattern at the edge of the body pattern 154 adjacent to the edge pattern 152 forms a substantially continuous pattern with the pattern present at the edge pattern 152 adjacent to the body pattern.

Referring now to FIG. 15B, a plurality of planks 150A, 150B, 150C, etc., such as those shown in FIG. 15A, can be arranged adjacent to each other in a flooring system along a predetermined direction such that an edge of each plank is arranged adjacent to an edge of the other plank along the predetermined direction (e.g., an edge of plank 150A is adjacent to an edge of plank 150B, an edge of plank 150C is adjacent to an edge of plank 150D, etc.). As described above, a substantially continuous pattern can be formed across a single plank 150 because the body pattern 154 is substantially aligned with the edge pattern 152.

In one embodiment of the present invention, the predetermined direction in which the planks are arranged is based on the adjacent edge pattern 152 in the planks such that a continuous and natural looking pattern can only be formed by arranging the planks in the predetermined direction. In this embodiment, reversing the plank or flipping the plank over will result in a discontinuous pattern. However, it is understood that in another embodiment, the edge pattern along a portion of the perimeter can be selected such that inverting, flipping, or otherwise rearranging the plank does not disrupt the pattern, i.e., the pattern is continuous.

In another embodiment, the predetermined direction is based on an interlocking mechanism that engages adjacent planks such that they will not properly fit together when the planks are arranged in a direction other than the predetermined direction. One example of such an interlocking mechanism is a glueless tongue and groove system wherein the tongue is formed along at least one edge of the plank and the groove is formed along the opposite edge. In yet another embodiment, the predetermined direction is based on both the edge pattern 152 and the glue-free locking mechanism.

The body patterns 154A-154F may be the same or different, in accordance with the principles of the present invention. In one aspect of the invention, each body pattern 154 in the flooring system may be unique. In addition, the edge patterns of the individual planks may be substantially identical in accordance with the principles of the present invention. Thus, the edge patterns of adjacent planks in the flooring system (forming a substantially continuous pattern across them in a predetermined direction) are also substantially the same. A substantially continuous pattern can be provided across the plank 150A because the body pattern 154A and the edge pattern 152A are aligned with each other to create a substantially continuous pattern. The substantially continuous pattern can be provided individually across the planks 150B, 150C, etc., as their respective body patterns 154B, 154C, etc., and edge patterns 152B, 152C, etc., are similarly aligned with one another to create a substantially continuous pattern.

Since the edge patterns of planks 150A-150F in the flooring system shown in FIG. 15B are the same, edge pattern 152A forms a substantially continuous pattern with edge pattern 152B, edge pattern 152C forms a substantially continuous pattern with edge pattern 152D, and so on. Thus, a substantially continuous pattern can be formed across planks 150A and 150B, a substantially continuous pattern across planks 150C and 150D, and so on. The boundary or seam between edge pattern 152A and edge pattern 152B is substantially invisible or the presence of the appearance of the boundary or seam is minimized. Similarly, the boundary or seam between edge pattern 152C and edge pattern 152D is substantially invisible or the presence of the appearance of the boundary or seam is minimized. The boundary or seam between edge pattern 152E and edge pattern 152F is substantially invisible or the presence of the appearance of the boundary or seam is minimized.

In one embodiment of the present invention, where all of the edge patterns 152 are substantially identical, any one plank 150A-150F can replace any other plank in the flooring system while still maintaining a substantially continuous pattern across planks arranged adjacent to each other along the predetermined direction. This is because all of the body patterns of the planks are generally aligned with their respective edge patterns to form a generally continuous pattern in one plank, and all of the edge patterns of planks adjacent to each other in the flooring system are the same, forming a generally continuous pattern across planks adjacent to each other along the predetermined direction.

In another embodiment, the planks may have substantially the same adjacent right and left edge patterns 152, while the opposing left and right edges 152 are different.

For example, in FIG. 15C, the integral sub-panel 132 of the plank 150 can have a pattern provided by the body pattern 154G, the partial sub-panel 134 can have a pattern provided by the body pattern 154I and the edge pattern 152, and the partial sub-panel 136 can have a pattern provided by the body pattern 154H and the edge pattern 152, wherein the body patterns 154G-154I can be the same or different. However, as described above, the edge patterns 152 existing at the peripheries of the partial sub-plate portions 134 and 136 of the thick plate 150 and extending along a part of the edge of the thick plate 150 are identical to each other. Thus, referring to FIG. 13A, for example, when planks 130A and 130B are arranged adjacent to each other along a predetermined direction, edge patterns 152 of complementary partial sub-panels 134A and 136B are substantially identical to each other and may form a substantially continuous pattern across the adjacent planks, wherein the body pattern of the complementary partial sub-panels becomes part of the substantially continuous pattern, visually and/or textually appearing to be a unitary sub-panel.

Further, referring now to fig. 15C and 15D, a flooring system containing planks such as those shown in fig. 13A-14C may be provided with a generally continuous pattern across planks adjacent to each other along a predetermined direction by applying the techniques described above with reference to fig. 15A and 15B. FIG. 15D shows planks having a wood grain pattern in the arrangement shown in FIG. 15B. Because edge pattern 152A is substantially identical to edge pattern 152B, planks 150A and 150B have the appearance of a substantially continuous wood grain pattern that extends uninterrupted across the boundaries or seams of the edge pattern 152A and edge pattern 152B of adjacent planks.

In addition, because the edge patterns 152A and 152B do not extend along the entire length of the boundary or seam between the planks 150A and 150B, but only along the portion corresponding to the height of the partial board on the bottom half of the plank, the pattern is discontinuous across the portion of the boundary between planks 150A and 150B corresponding to the height of the full board on the top half of the plank.

As described above, in a flooring system including the planks shown in fig. 13A-14C and 15C, the body patterns in the secondary panels of the planks may be the same or different. In one aspect of the invention, each plank pattern in a flooring system can be unique.

Figure 15E shows an embodiment of the present invention wherein the plank edge pattern in each plank is the same (or substantially the same). Specifically, FIG. 15E shows four planks 150A, 150B, 150C, and 150D arranged such that plank 150A is adjacent the left edge of plank 150B and adjacent the top edge of plank 150C. Plank 150D is adjacent to the right edge of plank 150C and adjacent to the bottom edge of plank 150B.

In this embodiment, the decor paper of each plank has a wood design. However, it should be understood that other natural looking designs than wood are equally envisioned by the present invention. The wood design in the plank 150A includes, for example, a complete plate or plank 155A, an incomplete short plate 151A, and an incomplete long plate 153A on the top half of the plate. Each panel had a wood grain pattern. In addition, the incomplete short plate 151A and the incomplete long plate 153A have an edge pattern 152 extending along a portion of the periphery of the thick plate corresponding to the width of the incomplete plates 151A and 153A, and may extend a short distance (e.g., such as one centimeter) into the interior of the plates. The edge patterns 152 of the incomplete plates 151A and 153A are the same. The edge pattern 152 may not extend into the interior of the plate.

Similarly, planks 150B, 150C, and 150D have full plates 155B, 155C, and 155D, respectively, extending along the length of the planks, and short plates 151B, 151C, and 151D, respectively, adjacent to long plates 153B, 153C, and 153D. Each of the short and long plates may have the same edge pattern 152 along a portion of the circumference of the thick plate corresponding to the width of the short and long plates.

All of the short plates 151A-D, long plates 153A-D, and full plates 155A-D have wood grain patterns that are different from one another or somewhat the same as one another. In this particular example, only the edge pattern 152 of the incomplete plate is the same. Further, the edge pattern and the interior wood grain pattern of each incomplete panel form a continuous pattern. In other words, there is a continuous overall wood grain pattern on each of the short and long boards that are different from each other, despite the fact that the edge pattern 152 is the same.

When the planks 150A and 150B are positioned adjacent to each other as shown in FIG. 15E, the full plates 155A and 155B will be adjacent to each other and the long plate 153A and the short plate 151B will be adjacent. The full panels 155A and 155B appear as separate panels and the wood grain pattern is discontinuous across them because the adjacent edges of the full panels are different. However, since the edge pattern 152 in the long plate 153A and the short plate 151B are identical, the unique wood grain pattern of 153A and 151B appears to form a single continuous plate with the unique wood grain pattern extending across the planks 150A and 150B. In addition, the appearance of a complete and continuous panel with a unique wood grain pattern extending across the planks in panels 153A and 151B minimizes the visibility or appearance of seams or boundaries between planks. Similarly, the wood grain pattern across panels 153C and 151D is continuous.

In another embodiment, the planks 150A, 150B, 150C, and 150D can have a surface texture that is registered with the wood design embossments on the decor paper. Since the edge pattern 152 is part of the wood design and can be the same or substantially the same in each plank, the embossed surface texture will appear to be continuous along the incomplete panels of adjacent planks as in the manner described above. In yet another embodiment, the embossed registration surface texture may include a bevel to simulate a seam between the plates, such that, for example, in a plank 150A, a full plate 155A will have a bevel extending along its perimeter, including the boundary between plate 155A and incomplete plates 151A and 153A. The incomplete plates 151A and 153A will have their slopes adjacent thereto, however, in the portion along the perimeter of the thick plate 150A where the edge pattern 152 is located, the incomplete plates will not have the slopes. In this manner, the continuous wood grain pattern and corresponding embossed registration surface grain can extend continuously across planks 150A and 150B without interruption by the chamfer. This will further reduce the perceptibility of the boundary between slabs.

By having all of the edge patterns 152 identical, the present invention allows any plank to fit together in a predetermined orientation with the long panel 153 adjacent the short panel 151 of another plank, because each edge pattern 152 will remain aligned, creating the appearance of a continuous wood grain pattern extending across the adjacent long and short panels of the two planks. For example, if the positions of planks 150A and 150B were reversed (such that plank 150B was adjacent the top edge of plank 150C), the edge pattern 152 of long plate 153B would match or align with the edge pattern of short plate 151A, thereby forming a continuous wood grain pattern in plates 153B and 151A across planks 150B and 150A.

The present invention reduces the complexity involved in installing laminate flooring, as it is not important which planks are positioned adjacent to each other in the predetermined direction. The patterns will be aligned. In another embodiment, the plank 150 is provided with a glueless interlocking tongue and groove system wherein the tongues are formed on two adjacent peripheral edges of the plank and the grooves are formed in the opposing two adjacent peripheral edges such that the planks can be fitted together only in the direction that the long panel 153 will align with the short panel 151, such as where the edge patterns 152 contact.

In the exemplary embodiments described above, decorative motifs and design elements, such as wood slats, span separate adjacent planks. However, in order to allow interchangeability of the planks, the wood lath pattern has a length equal to that of the planks, thereby making installation easy.

Fig. 16 shows another illustrative embodiment of the present invention. In this embodiment, a flooring system comprising at least two different planks 160 and 161 has a wood grain pattern comprising a design pattern that simulates a wood plank. The flooring system has a wood lath pattern across adjacent planks, and the wood lath pattern may have a total length equal to twice the length of a single plank. Specifically, the flooring system shown in FIG. 16 includes a first plank 160 and a second plank 161. The first plank 160 comprises a top plank slat 164 and a bottom plank slat 165. An edge pattern 162 is on a first edge of the top plank slat 164, the edge pattern being selected to continue the wood grain pattern from the plank slat 164 to the adjacent plank. The bottom plank slat 165 includes an edge pattern 163 of edges on one side of the plank opposite the edge of the plank where the edge pattern 162 on the top plank slat 164 is located. The edge pattern (also referred to as a "continuous pattern") 163 similarly continues the wood grain pattern laterally from the bottom plank strip 165 to the adjacent plank. In an alternative aspect of this embodiment, the edge patterns 162 and 163 may be different or may be the same.

As previously mentioned, a variety of materials can be used to make the planks of the present invention. The material may comprise real wood, wood or a plastic composite, such as particle board, or laminate. The planks may also include decorative paper or hardwood plywood that includes decorative patterns. In an alternative embodiment, the planks may be made from one solid wood and a different type of solid wood plywood that has edge patterns aligned as described herein on the precisely cut surface.

The wooden strip has a body pattern in a portion of the wooden strip other than the edges. The body pattern corresponds to the following design pattern. In other words, the body pattern may be a wood grain, a stone grain, a marble pattern, or other patterns. The edge patterns 162 and 163 are continuous with the body pattern such that the edge pattern and the body pattern form a continuous pattern. The seam patterns 168 and 169 are not continuous with the body patterns, but are discontinuous in nature, thereby having a discontinuous pattern between adjacent body patterns that accentuates the appearance discontinuity between adjacent body patterns.

The second thick plate 161 includes a top strip 166 and a bottom strip 167. The top plank 166 includes an edge pattern 162 at one edge of the plank opposite the edge having the edge pattern 162 on the top plank slat 164 of the first plank 160. Similarly, the bottom strip 167 comprises an edge pattern 163 along one edge of the plank 161 opposite the edge having the edge pattern 163 on the first plank 160. In other embodiments, more slats are included in addition to the top and bottom slats.

The first panel 160 includes decorative patterns for representing seams between the decorative patterns of the panel. In the top plate strip 164 there is a seam pattern 168 on one edge of the plank opposite the edge where the edge pattern 162 is located and there is a complete seam pattern 169 between the top plate strip 164 and the bottom plate strip 165. In addition, there is a seam pattern 168 on one edge of the floor strip 165, which is opposite to the edge of the floor strip where the edge pattern 163 is located.

Similarly, in the second plank 161 there is a seam pattern 168 on the edge of the plank opposite the edge where the edge pattern 162 is located, and there is a seam pattern 168 on the edge of the plank opposite the edge where the edge pattern 163 is located. In addition, seam 169 extends between top panel strip 166 and bottom panel strip 167.

The seams 168 may be full width seams, i.e., they may be the same width as the thickness of the seam pattern 166, or in an alternative embodiment, the width of the seam pattern 168 may be half the width of the seam pattern 169, such that when two adjacent seam patterns 168 are disposed adjacent to each other, they form a seam pattern having a thickness equal to the thickness of the seam pattern 169.

When the flooring plank 160 is positioned adjacent the flooring plank 161 the bottom panels 165 and 167 are adjacent to each other and the edge patterns 163 on the edges of the planks at the opposite ends of the panels 165 and 167 abut each other to form a continuous wood panel design across the wood planks 162 and 161, resulting in a wood panel that is twice the length of the flooring plank 160 or 161. The plank bar extends laterally from one end of the flooring plank 160 to the distal edge of the second plank 161. If another first flooring plank 160 is provided on the other side of the second flooring plank 161, the top flooring plank 166 of the second flooring plank 161 will be adjacent to the top plank 164 of that first flooring plank 160 such that the edge patterns 162 and the top planks 166 and 164 abut each other, thereby creating a plank across the top of the adjacent flooring planks 161 and 160 that is twice as long as a single flooring plank. Thus, the flooring system of the present invention can reproduce a wood slat design using only two different planks, wherein the wood slat motif has a length that is twice the length of the plank.

In an alternative aspect of the embodiment, the seam pattern 168 at the edge of a plank is replaced by a pattern that is discontinuous from the body pattern in the center of the plank, yet aligned with the corresponding discontinuous pattern on the adjacent plank.

The present invention is not limited to wood grain patterns, but stone and marble patterns as well as artificial or artistic designs are envisioned. In another exemplary embodiment using a marble pattern instead of a wood grain pattern, the edge patterns 162 and 163 may be partial marbleizing that aligns with the corresponding edge patterns of adjacent planks to form a continuous marbleizing across each plank, creating the effect of a marble strip or brick that is longer than the physical length of the plank.

In another embodiment, the present invention includes beveled edges and embossed registration surface texture in addition to the decorative pattern. Specifically, the chamfer may be embossed or cut over the seam patterns 168 and 169 such that the chamfer has the same width as the seam pattern, thereby further enhancing the optical effect of the separated panels. In addition, planks 160 and 161 may also have a surface texture that is registered with the decorative pattern embossings, such that the emboss registration texture includes a corresponding surface texture for edge patterns 162 and 163. In this manner, the embossed registration surface texture continues laterally from one plank to the next plank. In addition, the installation of the planks is simple, since the flooring system has only two different planks. The planks are installed in an alternating manner such that flooring planks 160 alternate with flooring planks 161 in a horizontal direction to produce wood planks having a length twice that of the flooring planks, such that the wood planks at the top and bottom of the planks are staggered.

The present invention envisions additional embodiments, such as the exemplary embodiment shown in fig. 16B, wherein the flooring system includes up to four different flooring planks. These four flooring planks include first and second flooring planks 160 and 161 and two additional flooring planks 171 and 172 shown in FIG. 16A. The third flooring plank 171 comprises a top plank 173 and a bottom plank 174. Here, the top plate strip 173 has a seam pattern 168 on both edges of the plank, and the bottom plate strip 174 has an edge pattern 163 on both ends of the plank. In addition, the fourth plank 172 has a top plank 175 and a bottom plank 176, wherein the top plank 175 has an edge pattern 162 on both ends of the plank, and the bottom plank 176 is surrounded by the seam pattern 168. In the flooring system the planks may be arranged adjacent to each other provided that when two planks are arranged adjacent to each other they have a seam pattern 168 that will be adjacent to each other in one plank and an edge pattern 162 or 163 that is adjacent in two planks. As previously described, the seam pattern 168 may be replaced by a pattern of seams that is not continuous from the body pattern in the center of the slats.

In the exemplary embodiment shown in FIG. 16B, plank 160 can be disposed on a first side of plank 171 or 161 adjacent to flooring planks 171 or 161 (left hand side in FIG. 16B), or it can be disposed on a second side of planks 161 or 172 adjacent to flooring planks 161 or 172 (right hand side in FIG. 16B). Similarly, the flooring plank 171 may be disposed on the first or left side adjacent to planks 160 or 161 or may be disposed on the first (left) or second (right) side adjacent to the other plank 171. Plank 161 can be positioned to the right of plank 160 or plank 171 or to the left of planks 172 and 160. Finally, the plank 172 can be positioned to the right of the plank 161 or the right of another plank 172 or the left of the plank 160 or the left of another plank 172. This provides for a variety of combinations and arrangements of four flooring planks, thereby providing a number of wood planks of different lengths in the overall flooring pattern design that are greater than or equal to the length of a single flooring plank. For example, if planks 160, 171, 161, and 172 were positioned adjacent to one another in the manner shown in FIG. 16B, the resulting flooring design would include wood planks having a length equal to the length of the single plank in the bottom of flooring planks 171 and 172. However, the flooring design will also include a wood strip having a length equal to three times the length of the flooring plank, such that the bottom strip from plank 160 extends across the bottom strip plank 171 and across the end of the bottom strip of plank 161 to the distal end of plank 161. In addition, planks 171 or 172 are repeated adjacent to each other as many times as necessary to further increase the length of the plank to several times the length of a single plank in the flooring design. This is possible because the planks 171 and 172 provide plank strips 174 and 172, respectively, which are not surrounded on both sides by the discontinuous seam pattern 168 or 169, but instead have the same edge pattern 163 or 162 on both sides. Such a flooring system shown in figure 16B with flooring planks 160, 161, 171, and 172 can provide different lengths of plank without increasing the complexity of the overall flooring plank system.

Specifically, the installer can install any other flooring plank adjacent to any flooring plank such that there will be an edge pattern or a discontinuous pattern (e.g., seam pattern 168) in the top plank or in the bottom plank that is adjacent to the corresponding pattern in the corresponding plank of the adjacent plank. The installer is able to design a flooring pattern using four different planks of the system, with the confidence that the increased installation complexity does not exceed the requirement to place the seam pattern 168 adjacent to another seam pattern 168 or the seam pattern 169 adjacent to another pattern 169.

The flooring system can be further simplified requiring only three different planks: slabs 160, 161, and either slab 171 or 172. For example, in embodiments with planks 160, 161, and 171, any number of planks 171 can be disposed between planks 160 and 161 as shown in FIG. 16B to create a long plank formed from bottom plank 165, plurality of bottom planks 174, and bottom plank 167. Additionally, the planks 160 and 161 can also be positioned adjacent to each other to create a plank pattern having a length equal to twice the length of the plank across either the top or bottom plank. Furthermore, since only the edge patterns need to be the same in this embodiment, the interior patterns of the complete long and short panels of the plank can be different, thereby providing a more natural looking floor.

The number of planks in the flooring system can be further reduced to two planks. Figure 16C shows another embodiment having two planks 181 and 182. The first plank 181 comprises a discontinuous pattern 183 configured as a seam, an upper edge pattern 184 corresponding to the top plank of the plank 181, and a lower edge pattern 185 on the opposite side of the lower plank. The second plank 182 includes an edge pattern 184 on the top plate strip of planks on the opposite edge from the location of the edge pattern 184 on the first plank 181. The discontinuous pattern 183 is located on the edge of the plank opposite the edge where the edge pattern 184 is located. The bottom strip of planks 182 includes edge patterns 185 on opposite edges of planks 181, with two adjacent discontinuous patterns located in the interior of the bottom strip between the edge patterns 185.

When the first and second planks are positioned adjacent each other in the horizontal direction such that the edge patterns 184 or 185 of the different planks are adjacent each other, the result is a staggered pattern of weighted wood strips having a length that is twice the length of the planks.

In another embodiment shown in FIG. 16D, the two planks 186 and 187 have an arrangement of edge patterns 184 and 185 and a discontinuous pattern 183 that is different from the arrangement of the two planks in FIG. 16C. Specifically, the first plank 186 has edge patterns 184 at both ends of the top plank with adjacent discontinuous patterns 183 therebetween, and edge patterns 185 at both ends of the bottom plank with adjacent discontinuous patterns 183 therebetween. The second plank 187 has a top panel with an edge pattern 184 at both ends and a bottom panel with an edge pattern 185 at both ends. The second panel 187 does not include any discontinuous pattern. By arranging planks 186 and 187 adjacent to or alternating with each other, the result is a flooring design with staggered wood planks that is twice as long as the planks. In addition, since the plank 187 does not have a discontinuous pattern in this embodiment, a plurality of planks 187 can be disposed adjacent to each other to extend the length of the plank strip to any multiple of the length of the plank.

It is understood that the edge patterns 184 and 185 may be the same or they may be different in the embodiments of fig. 16C and 16D. Further, it is understood that the planks need not have more than one plank as part of their design pattern. For example, FIG. 16E shows an embodiment having two planks 188 and 189, each plank having only a portion of one plank. The plank 188 has a discontinuous pattern 183 at a first end of the plank and a continuous edge pattern 184 at an opposite second end of the plank. The plank 189 has a discontinuous pattern 183 at a second end and a continuous edge pattern 184 at a first end of the plank. Thus, planks 188 and 189 can be positioned adjacent to each other in a horizontal direction to create a single plank design where the length of the plank is twice the length of the plank and the width of the plank is equal to the width of the plank.

A further exemplary embodiment shown in FIG. 17 includes planks 188 and 189 shown in FIG. 16E, however additionally including a third plank 190 and a fourth plank 191. The third plank 190 comprises a discontinuous pattern 183 along all the edges of the plank and the fourth plank 191 comprises a continuous edge pattern 184 at both ends of the plank.

With such four different planks, the flooring design can have slats having a length generally equal to the length of one plank, two planks, or three or more planks, depending on the number of repeating third planks disposed adjacent to each other. In one exemplary arrangement, the planks are arranged adjacent to each other in a plurality of rows in the order of first plank 188, second plank 189, fourth plank 191 and third plank 190.

Four planks 188-191 have the further advantage that the planks can be manufactured using decorative paper that is extruded and cut into planks that are then packaged into cartons for transport and sale. In decor papers that are wide enough to fit four planks, it is reasonable to have four different planks on a single decor paper. In this way, the planks are pressed onto the board, embossed, cut together into planks, and shipped together in the same carton.

Figure 18 shows an embodiment of the invention wherein the flooring system comprises four flooring planks. The flooring system includes four planks 200, 202, 204, and 206, each having a surface design pattern comprising long horizontal slats. Planks 200, 204, and 206 have a similar arrangement of slats. The single integral strip 205 has a discontinuous edge pattern 203 in the bottom of the plank, on both sides of the strip at the end of the plank. The specific pattern of the single integral slats 205A, C and D, e.g., wood grain pattern, on each plank 200, 204, and 206, respectively, can be the same or different.

In the upper part of the plank are two incomplete slats 208 and 209, which are adjacent to each other, separated by a discontinuous pattern 207 simulating a seam or joint. The particular pattern of incomplete panels 208A, C and D and incomplete panels 209A, C and D, respectively, on each plank 200, 204, and 206, for example, the wood grain pattern, can be the same or different. At some portion of the edge or end of the plank where the incomplete slats 208 and 209 meet the end of the plank is a continuous edge pattern 201 that is the same across all four planks 200, 202, 204, and 206. The continuous edge pattern 201 is contiguous or continuous with the overall or body pattern of the slats 208 and 209, however, the continuous edge pattern is the same, although the body pattern of the incomplete slats 208A, 208C, 208D, 209A, 209C and 209D may be different. In this way, when any one plank 200, 202, 204, and 206 is disposed adjacent to one another, the continuous edge patterns of adjacent incomplete slats, e.g., 209A and 208C, of the different planks align to create the appearance of a single, complete slat across the upper portion of more than one plank.

The discontinuous pattern 207 may be the same as the discontinuous pattern 203, it may be similar to two discontinuous patterns 203 disposed adjacent to each other, or it may be completely different from the discontinuous pattern 203. The planks 200, 204, and 206 differ in horizontal position along the discontinuous pattern 207 of the upper portion of the planks. In other words, the length of the incomplete slat pairs 208 and 209 may vary in each of the planks 200, 204, and 206. For example, the length of the incomplete slats 208C and 209C of the plank 204 is different from the length of the incomplete slats 208D and 209D of the plank 206. Thus, although the planks 200, 204, and 206 have the same arrangement of continuous edge pattern 201, discontinuous edge pattern 203, incomplete and complete panels 208 and 209, the lengths of those incomplete panels are different. In this way, a floor formed from planks 200, 202, 204, and 206 will appear to have a more random and natural appearance due to the different lengths of the complete planks formed by placing incomplete planks adjacent to each other.

As shown in fig. 18, the flooring system may also include a plank 202 having one complete plank 205B surrounded by a discontinuous edge pattern 203 at the ends of the plank in the bottom of the plank 202 and a single incomplete plank 210 containing a continuous edge pattern 201 of portions near the edges of the plank therein in the upper portion of the plank 202. The plank 202 can be used to extend the apparent length of the incomplete strip by one plank length. For example, if planks 200, 202, and 204 are placed adjacent to each other, they will create the appearance of: one long full slat is provided above three full slats of equal length. Furthermore, because the placement of the discontinuous pattern 207 is different in planks 200 and 204, the length of the long complete plank will not equal a multiple of the plank length.

Figure 19 shows another alternative embodiment of the present invention wherein the flooring system comprises four planks 220 and 223. Three 221-223 of the plank each include a discontinuous pattern 224 at different locations in their decorative pattern, thereby forming two incomplete slats 226A and 227A, 226B and 227B, and 226C and 227C, respectively. The length of the incomplete slats 226 and 227 varies among planks due to the different arrangement of the discontinuous pattern 224. The plank 220, which is one of the planks, does not include the discontinuous pattern 224 and therefore has a decorative pattern that forms only a single incomplete plank. A portion of the decorative pattern near the edges of the planks forms a continuous edge pattern 225 that is the same on both sides of all four planks 220-223 in the flooring system. The continuous edge pattern is continuous and is part of the overall decorative pattern on the plank that seamlessly continues from one plank to the next when disposed adjacent to another edge pattern on another plank. Using a flooring system having four different planks as shown in fig. 19, a flooring pattern may be created in which the plank bars may have various lengths, including lengths greater than one or two plank lengths, but may not be multiples of a plank length.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Claims (21)

1. A flooring system comprising:

a first thick plate;

a second thick plate;

a first decorative edge pattern located on a portion of a first edge of the first plank and a portion of a second opposite edge of the second plank;

a second decorative edge pattern located on a portion of the second edge of the first plank and a portion of the first edge of the second plank;

a first decorative body pattern comprising a majority of the first slab interior region, the first decorative body pattern abutting the first decorative edge pattern and the second decorative edge pattern; and

a second decorative body pattern comprising a majority of the second slab interior region, the second decorative body pattern abutting the first decorative edge pattern and the second decorative edge pattern, the first decorative body pattern being substantially different from the second decorative body pattern;

wherein the first and second planks are placed adjacent to each other with the first decorative edge pattern of the first plank aligned with the first decorative edge pattern of the second plank, the decorative floor pattern being uninterrupted from the first plank to the second plank, thereby achieving the appearance of a single plank.

2. The flooring system of claim 1, further comprising:

a second decorative edge pattern also at a portion of the first edge of the first plank generally opposite the portion of the second edge of the first plank having the second decorative edge pattern.

3. The flooring system of claim 2, further comprising:

a first decorative edge pattern also at a portion of the second edge of the first plank generally opposite the portion of the first edge of the first plank having the first decorative edge pattern.

4. The flooring system of claim 2, further comprising:

a discontinuous pattern at an interior region of the first plank, the interior region being between a second decorative edge pattern at a first edge portion of the first plank and a second decorative edge pattern at a second edge portion of the first plank.

5. The flooring system of claim 1, wherein the first decorative edge pattern is a discontinuous pattern.

6. The flooring system of claim 4, further comprising:

a discontinuous pattern at an interior region of the first plank, the interior region being between a first decorative edge pattern at a first edge portion of the first plank and a first decorative edge pattern at a second edge portion of the first plank.

7. The flooring system of claim 1, wherein the first decorative edge pattern further comprises at least a portion of a decorative pattern continuous with the first and second decorative body patterns.

8. The flooring system of claim 7, wherein the decorative pattern of the first decorative edge pattern is a wood grain pattern.

9. The flooring system of claim 1, further comprising a third plank, wherein the third plank has, the first decorative edge pattern extending along one portion of both edges of the third plank, and the second decorative edge pattern extending along another portion of both edges of the third plank,

wherein the third thick panel comprises a third decorative body pattern comprising a majority of the third thick panel interior region, the third decorative body pattern being contiguous with the first decorative edge pattern and the second decorative edge pattern, the third decorative body pattern being different from the first and second decorative body patterns.

10. The flooring system of claim 9, further comprising:

a fourth flooring plank having the first decorative edge pattern along a portion of both edges of the fourth plank that is different from the portion where the second decorative edge pattern on the third plank is located;

wherein the fourth thick panel comprises a fourth decorative body pattern comprising a majority of the fourth thick panel interior region, the fourth decorative body pattern being contiguous with the first decorative edge pattern and the second decorative edge pattern, the fourth decorative body pattern being different from the first, second, and third decorative body patterns.

11. The flooring system of claim 1, wherein the first decorative edge pattern and the second decorative edge pattern are different from each other.

12. The flooring system of claim 1, further comprising a recessed edge extending along at least a portion of a perimeter of each of the first and second planks.

13. A building panel system, comprising:

a plurality of different planks having an interior decorative pattern;

each of the planks having a first edge and a second edge opposite the first edge;

a first continuous decorative edge pattern on at least a portion of the first edge of at least two planks of the plurality of different planks;

a second continuous decorative edge pattern on at least a portion of the second edges of at least two planks of the plurality of different planks;

a first discontinuous decorative edge pattern on at least a portion of the first edge of at least two of the plurality of different planks;

a second discontinuous decorative edge pattern on at least a portion of the second edge of at least two of the plurality of different planks;

a first decorative body pattern making up a majority of an interior region of a first slab of the plurality of slabs, the first decorative body pattern being continuous and contiguous with the first and second continuous decorative edge patterns and the first and second discontinuous decorative edge patterns;

a second decorative body pattern constituting a majority of an interior region of a second slab of the plurality of slabs, the second decorative body pattern being continuous and contiguous with the first and second discontinuous decorative edge patterns, the first decorative body pattern being substantially different from the second decorative body pattern;

wherein when the first and second planks are placed adjacent to and aligned with each other, the first continuous decorative edge pattern of the first plank is aligned with the second continuous decorative edge pattern of the second plank such that the decorative flooring pattern is continuous and uninterrupted from the first plank to the second plank, thereby forming a single plank appearance across at least a portion of the first and second planks.

14. The building panel system of claim 13, wherein the building panel system is a flooring system and the plank is a flooring plank, the interior decorative pattern being a natural wood grain pattern.

15. The building panel system of claim 13, further comprising a recessed edge extending along at least a portion of a perimeter of each of the plurality of different planks.

16. A flooring system comprising:

a first plank having a first decorative pattern;

a second slab having a second decorative pattern, the second decorative pattern being different from the first decorative pattern;

a third slab having a third decorative pattern, the third decorative pattern being different from the first and second decorative patterns;

wherein each of the first, second, and third planks comprises a first edge and a second edge, the second edge opposite the first edge;

a continuous decorative edge pattern extending along an entirety of each of the first and second edges of each of the first, second and third planks, wherein the continuous decorative edge pattern is continuous and contiguous with each of the first, second and third decorative patterns; and

wherein any of the first, second and third planks can be placed adjacent to each other edge-to-edge such that the continuous decorative edge pattern of one plank is aligned with the continuous decorative edge pattern of another plank to give the appearance of a continuous decorative flooring pattern across a plurality of planks.

17. The flooring system of claim 16, further comprising a fourth plank having a fourth decorative pattern, the fourth decorative pattern being different from the first, second, and third decorative patterns,

the fourth plank has a continuous decorative edge pattern extending along the entire first edge and second edge, the first edge being opposite the second edge.

18. The flooring system of claim 17, further comprising a discontinuous pattern at different locations on each of the second, third and fourth decorative patterns, thereby creating the appearance of gaps between planks.

19. The flooring system of claim 17, wherein each of the first, second, third and fourth planks comprises a recessed edge extending along at least a portion of the perimeter of each plank.

20. The flooring system of claim 17, wherein the continuous decorative edge pattern extends to the recessed portion.

21. The flooring system of claim 16, wherein the continuous decorative edge pattern and the first, second, and third decorative patterns are natural wood grain patterns.