JP2008538131A - Flooring system with multiple alignment points - Google Patents

Abstract

  The laminate flooring plank includes a decorative motif, surface irregularities embossed by machining, a surrounding recess, and a locking mechanism. By placing the same plank next to each other in the horizontal and vertical directions, and placing multiple portions of the decorative motif along the edges of one flooring plank, it is larger than the individual planks, It is possible to form a periodic flooring pattern that covers a plurality of thick plates in both widths.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated material. Specifically, the present invention relates to a flooring system comprising a decorative motif and a seamed laminate material having surface irregularities on which the decorative motif has been embossed and transferred by machining.

2. Description of Related Art Due to the appearance and feel, conventional building materials and finished flooring materials such as high-grade wood, slate, granite, stone, brick, and concrete are generally consumer preferred. However, such conventional building materials and finished flooring materials tend to have high manufacturing and construction costs. For example, hardwood floors have a very luxurious and luxurious appearance, but the materials and labor required to construct such floors are prohibitively expensive.
There are many alternatives that can be used in place of traditional building materials and finished flooring materials, including laminates such as high pressure laminate (HPL), direct extrusion laminate (DPL), and continuous laminate (CPL). . However, such alternatives typically do not have the realistic appearance and irregularities of conventional building materials and finished flooring materials. For example, most alternative flooring materials that have an outer surface with a wood grain motif look imitation and can easily be identified as not real wood. Furthermore, although high quality HPL, DPL, or CPL boards look visually like wood, it is easy to see that these boards are not real due to the irregularities.

The problem with most of the alternatives to conventional building materials and finished flooring materials is that their surface irregularities do not match the decorative motif. For example, the visual appearance of the nodes of the alternative flooring material does not match the features of the irregularities on the surface of the nodes. Therefore, the attractiveness of these alternative flooring materials is greatly reduced.
One technique used to match the surface irregularities of alternative flooring materials to the decorative motifs of these flooring materials is a technique known as chemical embossing. In chemical embossing, the surface irregularities of the alternative material are formed by chemically reacting the ink that creates the decorative motif with a substance added to the layer below the surface. Although the finish is somewhat clean, the resulting surface irregularities lack the sharpness and three-dimensional features of conventional materials.

As an alternative to conventional building materials and finished flooring materials, the laminate can be mechanically embossed to form surface irregularities. See for example US patent application 09/903807 and US Pat. No. 6,401,415. The contents of these documents are hereby incorporated by reference. By such a method, an embossed transfer laminate material having a decorative motif and matching high-quality three-dimensional unevenness is manufactured. Embossed transfer laminates require high precision transfer of mechanical embossing and decorative motifs. The advantage of the embossed transfer laminate is that the appearance and feel of conventional products can be realistically reproduced.
Regardless of the type of flooring system used, the flooring material must be able to be easily moved to the work site and installed easily and quickly. For this reason, an assembly and locking mechanism can be incorporated into the flooring system to facilitate on-site construction. One type of assembly and locking mechanism is a tongue and groove system that is used to connect panels. Such tongue and groove systems are disclosed in US Pat. No. 2,057,135 by Cherry and US Pat. No. 2,046,593 by Urbain. For example, FIG. 1 can be considered to show a tongue and groove system 11 that uses clips 12 to secure the panels together.

Another type of assembly and locking mechanism is disclosed in US Pat. No. 3,946,529 to Chevaux, in which the flooring system 13 is shown in FIG. 2 with a tongue and groove system positioned under the flooring. Seems to be connected using.
Yet another assembly and locking mechanism is shown in US Pat. No. 5,295,341 by Kajiwara. In this case, a snap-fitting type locking method such as a groove-tongue piece joint is attached to the laminate board. As a result, the laminate board can be assembled without an adhesive. According to FIG. 3, a plurality of laminate boards are provided with locking means in the form of channel connectors 16 and tongue-shaped piece connectors 18. The groove-type connector 16 has a forward protruding groove 20, and the tongue-like piece 18 is provided with a pair of front side walls 22 and 24 separated by an elongated groove 26. These side walls include rear locking surfaces 28 and 36. These side walls are compressed together to realize a locking structure.

Another type of assembly and locking mechanism is the snap-fit locking joint proposed in US Pat. No. 6,101,778 to Martinsson. As shown in FIG. 4, the plurality of laminate boards are provided with locking means constituted by a groove 6 and a tongue piece 7 forming a tongue piece-groove assembly. The groove 6 and tongue 7 can be made of a watertight material and can be snap-fitted so that the portion 9 just fits in the slot 4.
Although the assembly and locking mechanisms described above have proved useful, these mechanisms have so far been such that embossed transfer decorative motifs or graphics are aligned across the seams between individual embossed transfer laminates. It was never used in an embossed transfer laminate system. This makes the visual impression of the system constituted by the embossed transfer laminate board and the impression of unevenness extremely worse. Accordingly, it would be advantageous to provide a new embossed transfer laminate system that allows visual and concavo-convex patterns to cross seams while maintaining the pattern transferred by embossing. Further advantageous is an embossed transfer laminating system comprised of seamed embossed transfer laminate boards in which the visual and concavo-convex patterns cross the seam while maintaining the pattern transferred by embossing.

Furthermore, the aforementioned flooring system has a relatively low wear resistance. If not bound by any particular theory, premature aging (wear) would begin at or near the peripheral edge and / or along the tongue and groove lines. Since the aforementioned flooring system has surface irregularities distributed at approximately the same height (level), the center and the periphery of each panel contact the user (eg, a pedestrian) by the same amount. However, the perimeter of each panel deteriorates first because it is substantially weaker than the center of the panel.
In addition, flooring systems typically do not have a decorative motif or pattern design that is longer than one plank. For example, in a flooring system designed to replicate a wood floor that includes wood pieces, the length of the wood piece pattern is typically less than or equal to the length of a single plank. This configuration is desirable in prior art flooring systems because the installer does not need to add more than one plank to a single plank being constructed.

  Therefore, there is a need for an effective method for producing alternative building materials or finished flooring materials in which the alternative material has the same appearance and feel as conventional products and has improved resistance to premature wear. The number of planks used can be minimized while maintaining the ability to form design motifs or pattern elements that are longer than the length of a single plank.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide an embossed transfer flooring system that substantially solves one or more of the problems due to limitations and deficiencies associated with the prior art.
One advantage of the present invention is to provide an embossed transfer flooring system that includes individual adjacent planks having an embossed transfer decorative motif, in which at least one of the surface irregularities and the decorative motif is adjacent to the flooring thickness. Nearly accurate alignment between the plates.

Another advantage of the present invention is to provide an embossed transfer flooring system in which flooring planks having an embossed transfer decorative motif are joined, wherein at least one of the surface irregularities and the decorative motif is for adjacent flooring. By being positioned almost accurately between the thick plates, a substantially continuous embossed transfer pattern is formed across the joined floor planks.
Another advantage of the present invention is that, for example, a depression is provided in the peripheral surface of each flooring plank so that the upper surface of the periphery of the flooring plank is below a portion of the upper surface of the flooring plank surrounded by the periphery. An embossed transfer flooring system is provided that can include a flooring plank that can be positioned on the floor.

Another advantage of the present invention is a plurality of edge patterns disposed in proximity to a plurality of sides defining a periphery and at least one first portion of the periphery, wherein at least two of the plurality of edge patterns are A plurality of edge patterns that are substantially the same, and at least one bulk pattern disposed adjacent to the plurality of edge patterns and adjacent to at least one second portion around the edge pattern, wherein the at least one bulk pattern and There is provided a plank including at least one bulk pattern in which adjacent edge patterns 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. In the present system, each plank is a plurality of edge patterns arranged in proximity to a plurality of sides constituting the periphery and at least one first portion of the periphery, and at least two of the plurality of edge patterns are A plurality of edge patterns that are substantially the same, and at least one bulk pattern disposed adjacent to the plurality of edge patterns and adjacent to at least one second portion around the edge pattern, wherein the at least one bulk pattern; One edge pattern adjacent to at least one bulk pattern and at least one bulk pattern forming a substantially continuous pattern, and the edge patterns of at least two planks form a substantially continuous pattern.
Yet another advantage of the present invention is to provide a floor panel that includes a plurality of sides forming a periphery and a surface having a decorative motif thereon, the decorative motif being adjacent to each of the plurality of sides of the panel. At least two edge patterns and at least one bulk pattern located inside the panel and adjacent to the edge pattern of each side, wherein at least one edge pattern along one side is along the opposite side The edge pattern at the corresponding position is substantially the same, and at least a part of the decorative motif along one side is significantly different from the corresponding part of the opposite decorative motif.

Additional features and advantages of the invention will be apparent from the description that follows, and in part will be appreciated by the description that follows or by practice of the invention. These and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
The foregoing general description and the following detailed description are exemplary and explanatory, and are intended to explain the present invention as defined in the claims in further detail. I want you to understand.

The accompanying drawings, which are included herein and constitute a part of this specification for a better understanding of the invention, illustrate embodiments of the invention and, together with the detailed description, explain the invention. It is used to explain the principle of
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

FIG. 5 shows an overview of the components of a flooring plank according to the principles of the present invention.
As shown in FIG. 5, the embossed transfer flooring system includes, for example, at least one floor plank. In one embodiment of the present invention, each floor plank is made of a board material 34 made of a board material (for example, medium density or high density fiber board, chip board, etc.) and a board resin 34 impregnated with a predetermined resin. At least one base sheet 36 (for example, kraft paper sheet) disposed on and / or below the substrate and impregnated with a polymerizable resin (for example, phenol such as melamine) is disposed on the board substrate. The decorative paper sheet 38 having a thickness of about 0.15 mm and at least one protective overlay sheet 30 disposed on the decorative paper sheet 38 can be included. In one embodiment of the present invention, each protective overlay sheet 30 can be made of highly durable paper impregnated with a melamine resin solution containing corundum (Al ₂ O ₃ ), silica, and the like. In another aspect of the invention, different papers can be placed between the decorative paper sheet 38 and the board substrate 34. In one embodiment of the present invention, at least one protective overlay sheet 30 and base sheet 36 can be impregnated with resin. In another aspect of the present invention, the resin impregnated in at least one protective overburley sheet 30 and base sheet 36 may be different from the melamine resin used to impregnate the decorative paper sheet 38. it can.

  In one embodiment of the present invention, the plurality of floor planks in the flooring system can be made of substantially the same paper, resin, or the like. For example, a flooring plank in a flooring system can be made from the same paper processing machine with paper consisting of approximately the same paper fibers (eg, having approximately the same ash content, color, and orientation). Furthermore, multiple floor planks in a flooring system can be made using paper that emerges from a single continuous section of a processing spool. All of the aforementioned paper use constraints that can be used to make flooring planks for a flooring system ensure that the impregnated paper has approximately the same final dimensions after being pressed and cured. In one aspect of the present invention, the paper warehouse used to make the flooring planks in the flooring system maintains the time, temperature, and humidity of storing the paper and the flooring planks are uniform in size. It is possible to control so that the property is easily secured. In another aspect of the invention, the plurality of flooring planks in the flooring system can be made using a cellulose paste manufactured by the same manufacturer. In yet another aspect of the present invention, a plurality of floor planks in a flooring system can be made using a resin manufactured by the same manufacturer. In yet another aspect of the invention, the resin comprises powder supplied from substantially the same supplier, has approximately the same chemical and physical quality, and can be mixed in the same reactor. Furthermore, the plurality of floor planks in the flooring system can be made using a resin having a substantially constant solid component. All of the aforementioned resin usage constraints that can be used to make flooring planks ensure that the impregnated paper has approximately the same final dimensions after being pressed and cured. In yet another aspect of the invention, each of the plurality of flooring planks in the flooring system can be made using substantially the same impregnation process. For example, when various paper sheets are immersed in a melamine resin, the paper needs to uniformly absorb a certain melamine resin. Furthermore, since the various paper sheets affect the degree of resin absorption, it is necessary to accurately control the belt tension and vibration of the impregnation machine.

According to the principle of the present invention, an embossed transfer flooring system including a plurality of flooring planks assembled by assembling the above-described sheets and substrates can be obtained. In order to realize such a flooring system, emboss transfer of the decorative motifs arranged on the decorative paper sheet 44 is performed on each flooring plank using a press such as the press shown in FIG. Can do.
As shown in FIG. 6, the press can include, for example, a base 42, an upper press 54, and an upper press plate 56. In one aspect of the present invention, the upper press plate can include an embossed pattern (eg, a surface having three-dimensional irregularities). Thus, the embossed pattern can include, for example, any design of ridges, dots, dents, etc., which can be aligned with a decorative motif formed on the decorative paper sheet 44.

In accordance with the principles of the present invention, in order to enable emboss transfer to a flooring plank, the decorative impregnated paper sheet 44 disposed on the board substrate 40 is accurately aligned with the embossing pattern of the upper press plate. Must be aligned to In one aspect of the present invention, the alignment of the embossed pattern of the press plate and the decorative motif must be done reliably when the press is in the locked position and the board is pressurized. The required control accuracy varies depending on the decorative motif used. For example, in order to align a woodgrain embossed transfer motif across adjacent embossed transfer flooring planks, it is higher than the alignment of woodgrained embossed transfer motifs that are not aligned to adjacent flooring planks Alignment accuracy is required.
Alignment of the decorative motif on the decorative paper sheet 44 with the embossed pattern on the upper press plate 56 removes approximately 2-3 millimeters of material around the board substrate 40 by a milling process, resulting in several reference surfaces. This is possible by forming a board substrate (e.g., a board edge) and a precisely controlled dimension. Next, a decorative impregnated paper sheet 44 having an outer dimension smaller than the board substrate 40 by about 8 mm or 10 mm is placed on the board substrate 40. In one aspect of the present invention, the decorative impregnated paper sheet 44 can be placed on the board substrate 40 by using the board edge as an alignment means. In one embodiment of the present invention, the alignment mark can be disposed on the board substrate 40 and aligned with the alignment mark provided on the decorative paper sheet 44.

In one embodiment of the present invention, the decorative paper sheet 44 can be bonded to the board substrate 40 by static electricity. After bonding, the decorative paper sheet 44 and the board substrate 40 are placed on the carriage and fed into the press. The phenomenon that the decorative paper sheet 44 shifts from the board substrate 40 to some beat while the board substrate 40 is moved by the carriage due to static electricity can be substantially prevented. In one aspect of the present invention, the decorative paper sheet 44 is accurately placed on the board substrate 40 using, for example, a tweezer (not shown) by stopping the carriage just before entering the press. be able to. In another aspect of the present invention, a tweezer can be used to accurately place the decorative paper sheet 44 on the board substrate 40 placed on the lower press plate. In one aspect of the invention, the decorative paper sheet 44, the at least one protective overlay sheet 46, and the optional base sheet 48 can be placed on the board substrate 40 prior to placement in the press. After the decorative paper sheet 44 is placed on the board substrate 40, the carriage can be moved out of the press. The alignment system can then align the system of decorative paper sheet 44 / board substrate 40 to the embossed pattern of the upper press plate 56. In one aspect of the invention, the alignment system can align the decorative motif 44 with the embossed pattern on the upper press plate 56 almost accurately by using the board edge. The press can be operated after alignment is complete.
In one aspect of the present invention, the components shown in FIG. 5 are aligned in the press and aligned with the embossed pattern, and then various sheets and substrates are pressed and cured for a predetermined time until the resin conforms. Thus, a flooring plank having very high hardness and wearability can be produced. For example, after being inserted into a press and aligned with the embossed pattern, the board substrate 40, decorative paper sheet 44, protective overlay sheet 46, and optional base sheet 48 are heated at a temperature of about 160-220 ° C. , By applying a pressure of about 20 to 40 kg / cm ² for about 20 to 60 seconds. Therefore, the upper press 54 presses the emboss pattern of the upper press plate 56 to the structure of the decorative paper sheet 44 and the board substrate 40. By applying a combination of temperature and pressure, the decorative paper sheet 44 and the board 40 are fused. The alignment system ensures that the decorative paper sheet 44 is generally aligned with the embossed pattern of the upper press plate 56. Therefore, the melamine resin contained in various sheets can be cured, and an embossed transfer plank can be produced.

In one aspect of the invention, the porosity of the fused part can be minimized by slowly curing the resin (eg, melamine). Therefore, when lowering the processing temperature, the time for pressing various sheets inside the press is lengthened. In another aspect of the present invention, when the press plate 56 is heated to about 160-220 ° C., the embossed pattern contained in the press plate can be enlarged. Therefore, the embossed pattern on the press plate 56 can be provided so as to cancel out the expansion of the pattern. Accordingly, the dimensions of the emboss pattern are set so that these dimensions substantially correspond to the design of the decorative motif when the resin contained in the constituent elements of FIG. 5 is cured.
According to the principle of the present invention, the unevenness of the embossed surface can be pressed against individual floor planks having a decorative motif. In one embodiment of the present invention, the decorative motif is transferred to the unevenness of the embossed surface. Therefore, a thick plate for embossed transfer flooring can be produced. In another aspect of the invention, an embossed transfer flooring system can be formed by joining together a plurality of embossed transfer flooring planks. In yet another aspect of the present invention, at least a portion of the embossed transfer patterns of adjacent flooring planks are substantially accurately aligned with respect to each other, and the substantially continuous embossing transfer pattern straddling adjacent flooring planks in the flooring system. Can be formed.

  The above-described embossing transfer process is suitable for embossed surface irregularities having a depth of less than about 0.2 mm, but problems arise when the surface irregularities are deeper than this. An embossing pattern capable of pressing deep surface irregularities requires, for example, relatively large press plate protrusions, and these protrusions tend to impair the uniformity of pressure applied to the entire board surface. Thus, deformation of the final product can occur due to the blockage of pressure. In one aspect of the present invention, the embossed surface irregularities can be formed deeper than about 0.2 mm by providing depressions in the board substrate 40 where deep surface irregularities are required. In one aspect of the present invention, the recess formation process can be performed before, during, or after milling the periphery of the board substrate 40 as described above. In another aspect of the invention, the board edge may be used to locate the boundaries of the indented portion of the board substrate 40.

As shown in FIG. 7, an embossed transfer flooring plank 60 made according to the process described above can optionally include a protective pad layer 50 on one side. The unevenness on the embossed surface is transferred to the decorative motif 68 of the decorative paper sheet 44. The term “registration” refers to the fact that the irregularities of the embossed surface are almost exactly aligned with the decorative motif of the decorative paper sheet 44. By providing the embossed transfer floor plank, natural materials can be realistically reproduced on the individual floor planks. Although the decorative motif shown in FIG. 7 realistically represents a woodgrain image and irregularities, it should be understood that other embossed transfer designs such as thick ceramic, concrete, and marble can be formed.
In accordance with the principles of the present invention, each individual floor plank can include, for example, at least one locking mechanism.

In one aspect of the present invention, the locking mechanism can be mounted in the board substrate 40 before pressing the embossed pattern against the surface of the board substrate 40 in accordance with the decorative motif. Therefore, the locking mechanism can be provided inside each board substrate 40. Next, individual board substrates can be spliced together using a locking mechanism to form a plank structure. The thick plate structure can then be inserted into the press 54. After pressing the embossed pattern against the plank structure and fusing the fusion components together, the plank structure is removed from the press 54. Next, the thick plate 60 for embossed transfer flooring inside the fused thick plate structure is separated by releasing the locking mechanism. In one embodiment of the present invention, a cutting tool can be used to facilitate separation, and the decorative motif can be reliably prevented from being damaged.
In another aspect of the present invention, the locking mechanism can be installed in the board substrate 40 after pressing the embossed pattern against the surface of the board substrate 40 in accordance with the decorative motif. Accordingly, for example, the board substrate 40 having a relatively large size of 4 ′ × 8 ′ can be embossed by the press 54. The resulting embossed transfer substrate can then be cut to create a plurality of individual embossed transfer flooring planks 60. In one aspect of the invention, the edges of the individual embossed transfer floor planks 60 can have smooth edges and precise dimensions. In one aspect of the invention, the cutting can be performed using a shaping tool, a milling tool, a cutting tool, a separation tool, and the like. In one embodiment of the present invention, the board substrate can be cut by a press. Therefore, the board substrate 40 can be cut to produce a plurality of wood units (for example, wood strips) having dimensions of 300 mm × 300 mm, 400 mm × 400 mm, 600 mm × 600 mm, 1, 200 mm × 300 mm, 1, 200 mm × 400 mm, and the like. The locking mechanism can then be attached to each embossed transfer flooring plank 60. In one aspect of the present invention, the locking mechanism can be arranged to be hidden or visible under the surface of the flooring plank.

In accordance with the principles of the present invention, the locking mechanism is configured by aligning at least one of the board edges, alignment marks, decorative motifs, and surface irregularities of the floor plank with the milling tool. The embossed transfer flooring thick plate 60 can be attached. By aligning the milling tool with the aforementioned alignable mechanism, the locking mechanism can be milled on the side of the board substrate 40, so that when the floor planks 60 are spliced together, a decorative motif At least a portion of the embossed transfer pattern forms an uneven surface that is substantially continuous across adjacent flooring planks.
In accordance with the principles of the present invention, the embossed transfer flooring plank 60 is provided with a locking mechanism 64 (e.g., tongue and groove locking system, snap-fitting type engagement along all four sides of the embossed transfer laminate 60). At least one of the stopping methods). For example, the snap-fitting type locking method can be attached to all four sides of the embossed transfer flooring plank 60, and a plurality of embossed transfer flooring planks 60 are connected to form one embossed transfer flooring system 300. Can be used (shown in FIG. 8). The number and location of locking mechanisms is determined by the desired configuration of the embossed transfer flooring system. For example, if the embossed transfer flooring system touches a corner, only two locking mechanisms are required (along the side).

As shown in FIG. 8, the embossed transfer floor planks A and B can include locking mechanisms along, for example, four sides (eg, along seams J1, J2, J3, and J4). . The embossed transfer floor planks C and D can include locking mechanisms along, for example, four sides (eg, along seams J1, J2, J3, and other seams not shown).
Embossed transfer flooring slabs including the aforementioned locking mechanisms can be rigidly attached to each other with or without adhesive to form an embossed transfer laminate system 300. Multiple embossed transfer flooring planks can be spliced together to obtain any desired shape for flooring or blanking. By seaming embossing transfer floor planks to each other, at least a portion of the embossing transfer pattern of adjacent flooring planks is generally aligned with respect to each other so that substantially continuous images and embossed surface irregularities are present in the flooring system. It is formed across a plurality of flooring planks.

8 and 9 show an exemplary embossed transfer flooring system 300 that includes a type of locking mechanism attached to each individual embossed transfer flooring plank 60. FIG. 9 shows an exemplary embossed transfer flooring system that includes a flooring plank with a snap-fit tongue and a groove locking mechanism attached. In one aspect of the present invention, the snap-fitting type tongue-like piece and the groove locking mechanism are provided on the side wall of each embossing transfer laminate material 60 to ensure that the embossing transfer patterns of adjacent flooring planks are substantially relative to each other. It can be aligned and substantially continuous in the flooring system.
FIG. 9 shows a cross-sectional view of FIG. 8 along line 9-9. As shown in the figure, the locking mechanism can be provided by forming the groove 230, the tongue-like piece 200, the passage 210, and the edge 220 along the edge of the embossed transfer flooring plank 60. The locking mechanism of the embossed transfer flooring plank 60 can be spliced together by inserting the tongue piece 200 into the groove 230 of the adjacent embossed transfer flooring plank 60. Next, by fixing the edge 220 in the passage 210, the adjacent embossed transfer flooring planks 60 can be joined together to form one embossed transfer flooring system 300. In one aspect of the invention, the embossed transfer flooring plank 60 indicated by the symbols A, B, C, and D can be spliced together with or without an adhesive. It should be understood that other types of locking mechanisms can be attached to the sides of individual embossed transfer flooring planks 60.

  Again, according to FIG. 8, each of the embossed transfer flooring planks 60 can have, for example, an embossed transfer plank ceramic motif G1. The slab ceramic motif can include a plurality of slabs of square, rectangular, triangular, circular, elliptical, any other shape or design, and these slabs are separated by a grout line. In one aspect of the present invention, the widths of grout lines Wh, Wv and the in-board grout width W can be made substantially equal. When attaching the snap-fitting type tongue-like piece and the groove locking mechanism to the thick plate 60 for embossed transfer flooring, the joints J1, J2, J3, and J4 on the embossed transfer laminate materials A, B, C, and D are provided. The width of the adjacent grout is approximately half of the in-board grout width W. For example, the grouting width (Wv) of the vertical plank straddling the joint J1 is constituted by the grouting line on the embossed transfer laminate materials A, B, C, and D, so that the embossed transfer laminate materials A, B , C, and D are spliced at J1, the vertical grout width (Wv) is approximately equal to (W). Accordingly, the grout width on any embossed transfer flooring plank 60 adjacent to the seam is half of the in-board grout width (W). In another aspect of the invention, the horizontal grouting width Wh and the vertical grouting width Wv can be controlled such that these widths are approximately equal to the size of the in-board grouting width W. However, it should be understood that the grout width dimension of the embossed transfer flooring plank will vary depending on the locking mechanism attached and the type of decorative motif being represented.

In addition to grout lines, many other decorative motifs can be used in the embossed transfer flooring system of the present invention. As shown in FIGS. 10 and 11, for example, a decorative motif can be provided that represents a woodgrain surface G2 that is generally aligned across the seams J5 and J6 of adjacent floor planks. In accordance with the principles of the present invention, the woodgrain pattern typically includes elements located in the periphery (eg, woodgrain lines, nodes 423, etc.) that require alignment of the flooring plank rather than the plank ceramic motif. Including many. Therefore, the alignment of the woodgrain motif is generally more difficult than the alignment of the grout line portion of the thick plate ceramic motif. For example, aligning the first part of the node 423 on the embossing transfer flooring plank E with the second part of the node 423 on the embossing transfer flooring plank F is generally done by adjacent flooring. It is more complicated to align the grout line width across the seam of the plank. Thus, when providing a locking mechanism, all of the graphic elements (eg, wood grain lines and nodes 423) need to be taken into account in order to reliably implement a realistic embossed transfer flooring system 400. In one aspect of the present invention, by using at least a part of the decorative motif as an alignment mark, accurate alignment with an adjacent flooring plank can be reliably performed.
In another aspect of the present invention, the individual floor planks in the embossed transfer flooring system 400 are snap-fit locking as shown in FIG. 11, which represents a cross-sectional view of FIG. 10 along line 11-11. Can be spliced together by the method. Again, by using the alignment method to provide the locking mechanism, the embossed transfer laminate system 400 has surface irregularities 423 that are substantially continuous across the seams J5 and J6. Optionally, the embossed transfer laminate 60 has a protective pad layer 70 under the base sheet 48.

12A and 12B show schematic views of a flooring plank according to the principles of the present invention.
As shown in FIGS. 12A and 12B, a depression can be formed on the upper surface of the periphery P of each embossed transfer flooring plank below the upper surface of the portion surrounded by the periphery of the flooring plank. An object O (for example, a user's shoes, wheels, etc.) that comes into contact with the main surface Ms of the flooring plank is usually not in contact with the surface of the peripheral Ps because the peripheral surface is recessed. In one aspect of the invention, the perimeter can include a portion of the flooring plank that extends approximately 3.175 mm from the edge toward the center. In another aspect of the invention, the depth of the recess in the surface around the floor plank is about 0.794 mm. In another aspect of the present invention, it is not necessary to provide a depression in the surface of at least a portion of the periphery of the flooring plank, which will be discussed in further detail below with reference to FIG.
Therefore, the embossed transfer pattern can be provided on the edge of the flooring plank, and can be aligned with the embossed transfer pattern formed on the adjacent flooring plank, and further, the individual flooring plank It is possible to prevent a phenomenon that the edges of the metal wear at an early stage.

8 and 10, the individual floor planks in the flooring system have approximately the same size and shape, and each side of each joined floor plank is spliced to only one adjacent floor plank. Although understood, it is understood that the size (eg, width and / or length) and shape (eg, rectangle, square, triangle, hexagon, etc.) of each flooring plank within the flooring system can vary. I want. In one aspect of the invention, the individual floor planks can have complementary shapes that can be assembled in the same way as puzzles or mosaics. Furthermore, in one aspect of the invention, the sides of each flooring plank can be in contact with more than one adjacent flooring plank.
In accordance with the principles of the present invention, flooring planks in a flooring system can be arranged such that at least one side of each plank includes at least one subpanel adjacent to at least two other subpanels. . In another aspect of the invention, all or part of each plank can include at least one sub-panel, which will be described in further detail below.

In FIG. 13A, for example, the partial sub-panel 134A of the thick plate 130A can be a sub-panel complementary to the adjacent partial sub-panel 136B of the thick plate 130B adjacent to the thick plate 130A. This arrangement allows partial subpanels 134A and 136B to appear as one integrated subpanel.
Still referring to FIG. 13A, each of the planks 130A-F can include at least three subpanels, at least one of which is an integral subpanel, and at least two of these subpanels. One is a partial subpanel. For example, 132A is an integral subpanel and 134A and 136A are partial subpanels.

  In one aspect of the present invention, the integrated subpanel 132A can display a complete decorative motif with or without an embossed surface, which may or may not be transferred to the decorative motif. May be. In another aspect of the present invention, the slab partial sub-panels 134A and 136A can display isolated, incomplete decorative motifs with or without irregularities on the embossed surface. The irregularities may or may not be transferred to the decorative motif. In one aspect of the invention, adjacent partial subpanels of adjacent slabs are complementary to each other so that these partial subpanels provide a substantially complete decorative motif and / or surface irregularities and are substantially continuous in one piece. Appears like a sub-panel. In one aspect of the invention, the complementary partial subpanel can have complementary decorative motifs and / or embossed surface irregularities. Thus, when adjacent partial sub-panels of adjacent planks are correctly aligned, the generally continuous (ie, complete) decorative motif and / or embossed surface irregularities will straddle adjacent complementary partial sub-panels. It is formed. In one aspect of the invention, the partial subpanel within one plank may or may not include substantially the same decorative motif and / or embossed surface irregularities.

FIG. 13B shows a schematic diagram of an exemplary plank 130 as shown in FIG. 13A.
In one aspect of the invention, a depression may be provided in a portion of the peripheral surface of each plank at a location where adjacent subpanels are not complementary. In another aspect of the invention, no depression may be provided in a portion of the peripheral surface of each plank where adjacent subpanels are complementary. According to FIG. 13B, a portion of the upper surface of the perimeter “P” of each slab 130 indicated by reference numeral 138a is slightly recessed from the major surface of each of these slabs (see also FIG. 12B). A depression can be provided to prevent early wear of each thick plate. Furthermore, a recess is not provided in a part of the upper surface around each of the thick plates 130 indicated by the reference numeral 138b, and they can be substantially flush with the main surface of the sub-panel. The overall durability of each plank is greatly reduced by providing indentations only on the peripheral surface of each plank only in the part not covered by the decorative motif and / or embossed surface irregularities of the partial subpanel of one plank. Without reduction, the complementary partial subpanel groups can appear as if they were part of an integral subpanel. In yet another aspect of the present invention, a recess may be provided in a portion of the surface of each plank at a location where one plank sub-panel is adjacent to each other. According to FIG. 13B, a portion of the upper surface of each plank 130 indicated by reference numeral 138c is provided with a depression slightly recessed from each major surface of the plank (see also FIG. 12B). Visual and rugged effects can be provided such that each of the sub-panels is not part of the same plank.

14A-14C illustrate an exemplary plank of a flooring system in yet another aspect of the present invention.
14A-14C, similar to the plank shown in FIGS. 13A and 13B, chamfer a portion of the upper surface of each perimeter “P” of plank 130 indicated by reference number 138a to prematurely wear each plank. Can be prevented. Furthermore, a portion of the upper surface around each of the planks 130 indicated by reference numeral 138b may not be chamfered, and they may be substantially flush with the main surface of the subpanel. By chamfering each peripheral surface of the plank at a position corresponding to the decorative motif and / or the embossed surface irregularities of the partial subpanel of one plank, the overall durability of each plank is greatly reduced Rather, complementary partial subpanel groups can appear as if they are part of an integral subpanel. In yet another aspect of the present invention, a groove can be provided in a portion of the surface of each plank adjacent to one plank subpanel.

14B and 14C show cross-sectional views of the plank 130 along line II ′ and line II-II ′, respectively. As shown in FIGS. 14B and 14C, a portion of the upper surface of each plank 130 indicated by reference numeral 138c can be chamfered to form a groove. This groove can also prevent each of the planks from wearing out too quickly. Thus, the groove can provide a visual effect and unevenness effect as if one thick plate sub-panel is a separate panel. In one embodiment of the present invention, a substantially V-shaped groove can be formed by chamfering 138c. However, it should be understood that other groove structures (eg, U-shaped grooves, etc.) can be formed by chamfering. In one aspect of the present invention, a groove is formed between adjacent planks by chamfering the position of each peripheral surface portion 138a of plank 130. Accordingly, a groove formed between adjacent thick plates by chamfering 138a has substantially the same width and structure as a groove formed in the thick plate by chamfering 138c.
The recessed surface motifs and / or surface irregularities around each plank may or may not correspond to the corresponding major surface motifs / surface irregularities of the planks. Thus, the substantially continuous motif and / or surface irregularities may or may not straddle the peripheral and internal surfaces of any individual plank. One or more alignment marks (not shown) can be used to self-align a decorative motif on the plank. In one aspect of the invention, the embossed transfer pattern can be a free pattern or a custom design. Here, it should be understood that nearly all embossed transfer patterns and all decorative motifs can be realized by applying the principles of the present invention. In one aspect of the present invention, the positioning of the planks can be done visually by splicing the planks together. Therefore, the alignment of the plank 130 can be performed using the decorative motif and / or the embossed surface irregularities of each plank.

While the planks of FIGS. 13A, 13B, and 14A-14C have been illustrated with a generally rectangular configuration, in accordance with the principles of the present invention, planks in a flooring system may have other shapes and sizes (e.g., geometric Structure, free shape, etc.), or different or similar dimensions, so that the flooring slabs are arranged in a “mosaic” manner or otherwise regular, semi- Panels can be arranged repeatedly or randomly. Further, although each plank is illustrated as having the same sub-panel layout, according to the principles of the present invention, planks in a flooring system may have other sub-panel layouts (eg, other sub-panel shapes, sizes, etc.). Can have. Individual planks in the flooring system can be cut from a single board so that the seams between the flooring panels of the flooring system are not visible. Furthermore, the planks in the flooring system shown in FIGS. 13 and 14 can be spliced with or without an adhesive. Furthermore, although the case where the unevenness of the embossed surface is almost accurately aligned with the underlying decorative motif has been discussed, almost any unevenness of the embossed surface can be used regardless of the underlying decorative motif. It should be understood that it can be pressed against a plank. Furthermore, the decorative motifs and / or embossed surface irregularities of one plank do not need to be aligned, or in some cases, the neighboring motif decorative motifs and / or embossed surface irregularities and / or appearances and / or The unevenness does not have to be similar.
In accordance with the principles of the present invention, any of the embossed surface irregularities (collectively referred to herein as “patterns”) that may or may not be embossed transferred to the aforementioned decorative motif and / or decorative motif. Is applied to any of the aforementioned planks, and each of the plank patterns is formed using at least one bulk pattern and at least one edge pattern, thereby adjacent thickness disposed along a predetermined direction. A substantially continuous pattern across the plate can be formed.

In one aspect of the invention, each edge pattern can be provided on a perimeter that extends along at least a portion of at least one edge of each plank. In another aspect of the invention, each edge pattern can span only a predetermined distance (eg, about 1 millimeter, about 1 inch, etc.) from the periphery of the plank to the interior. In another aspect of the present invention, the at least one bulk pattern may be disposed adjacent to the at least one edge pattern, and in this case, the pattern provided on the edge of the bulk pattern adjacent to the edge pattern is an edge. A visual / concave pattern can be formed that is substantially continuous with the pattern provided on the edge of the pattern adjacent to the bulk pattern.
In one aspect of the invention, the patterns of individual planks arranged adjacent to each other along a predetermined direction in a flooring system are adjacent if the edge patterns of adjacent planks form a substantially continuous pattern. Can be complemented (that is, a substantially continuous pattern can be formed across adjacent thick plates). When the above-described flooring system includes a plurality of adjacent planks arranged along a predetermined direction, and the edges of each plank are arranged adjacent to the edge pattern of other planks along a predetermined direction, The edge patterns of adjacent planks are the same or nearly the same. When the edge patterns of adjacent thick plates are the same or substantially the same, one continuous pattern can be formed across the adjacent thick plates.

For example, as shown in FIG. 15A, the exemplary plank pattern of plank 150 includes two edge patterns 152 and a bulk pattern 154 that are substantially the same as each other. As shown in FIG. 15A, two edge patterns 152 that are substantially the same are provided in the periphery of the plank 150, are located at a part of the edges on both sides of the plank, and extend a predetermined distance toward the inside of the plank 150. It extends. Further, as shown in FIG. 15A, the pattern provided on the edge adjacent to the edge pattern 152 of the bulk pattern 154 forms a pattern that is substantially continuous with the pattern provided on the edge adjacent to the bulk pattern of the edge pattern 152. To do.
Next, as shown in FIG. 15B, by arranging a plurality of thick plates 150A, 150B, 150C, etc. as shown in FIG. 15A adjacent to each other along a predetermined direction in the flooring system, An edge is arranged adjacent to the edge of another plank along a predetermined direction (for example, one edge of plank 150A is adjacent to one edge of plank 150B and one edge of plank 150C Is adjacent to one edge of the plank 150D). As described above, since the bulk pattern 154 is aligned with the edge pattern 152 almost accurately, a substantially continuous pattern across the individual planks 150 can be formed.

In one embodiment of the present invention, the predetermined direction in which the thick plate is arranged is based on the adjacent edge pattern 152 of the thick plate, so that the pattern to be formed is continuous only by arranging the thick plate in the predetermined direction, And it has a natural appearance. In this embodiment, the discontinuous pattern is formed by reversing the plank or turning the plank over. However, in another embodiment, the edge pattern along a portion of the perimeter is such that the pattern is not broken by reversing, flipping or repositioning the plank, i.e. the pattern is continuous. You can choose.
In another embodiment, the predetermined direction is determined based on an interlocking mechanism that splices adjacent planks and does not mesh properly if the planks are placed in a direction other than the predetermined direction. Like that. An example of such an interlocking mechanism is a tongue-and-groove locking system that does not use an adhesive, in which the tongue-shaped piece is formed along at least one edge of the plank and the groove is It is formed along the opposite edge. In yet another embodiment, the predetermined direction is determined based on both the edge pattern 152 and a locking mechanism that does not use adhesive.

In accordance with the principles of the present invention, the bulk patterns 154A-154F may or may not be the same. In one aspect of the invention, each of the bulk patterns 154 in the flooring system can be unique. Furthermore, according to the principles of the present invention, the edge patterns of the individual planks can be substantially the same. Therefore, the edge pattern of adjacent planks in which almost continuous patterns are formed along a predetermined direction in the flooring system is substantially the same. The substantially continuous pattern can be provided across the plank 150A because the bulk pattern 154A and the edge pattern 152A are aligned with each other to form a substantially continuous pattern. The substantially continuous pattern can be provided so as to individually traverse the thick plates 150B, 150C and the like. This is because these respective bulk patterns 154B, 154C, etc., and edge patterns 152B, 152C, etc. are similarly aligned with each other to form a substantially continuous pattern.
Since the edge patterns of the planks 150A to 150F in the flooring system shown in FIG. 15B are the same, the edge pattern 152A forms a substantially continuous pattern together with the edge pattern 152B, and the edge pattern 152C forms a substantially continuous pattern as the edge pattern 152D. In the same manner, the remaining edge patterns are formed in a substantially continuous pattern. Therefore, a substantially continuous pattern straddles the thick plates 150A and 150B, straddles the thick plates 150C and 150D, and the remaining thick plates are formed in the same manner. The boundary or seam between the edge pattern 152A and the edge pattern 152B is hardly visible in appearance, or its presence is minimized. Similarly, the boundary or seam between the edge pattern 152C and the edge pattern 152D is hardly visible in appearance, or its presence is minimized. The edge pattern 152E, the edge pattern 152F, and the boundary or seam are hardly recognized in appearance, or their presence is minimized.

In an embodiment of the present invention in which all of the edge patterns 152 are substantially the same, the thickness is maintained while maintaining a state in which a substantially continuous pattern is formed across the planks arranged adjacent to each other along a predetermined direction. Any of the plates 150A-150F can be placed in place of any other plank in the flooring system. This is because all the bulk patterns of one plank are almost exactly aligned with their respective edge patterns, and a nearly continuous pattern is formed in the plank, and all planks adjacent to each other in the flooring system This is because the edge pattern is the same, and a substantially continuous pattern is formed across the adjacent thick plates along the predetermined direction.
In another embodiment, the adjacent right and left edge patterns 152 of the plank can be substantially the same, but the opposite left and right edge patterns 152 are not the same.

For example, in FIG. 15C, the pattern of the integrated subpanel 132 of the plank 150 can be formed by the bulk pattern 154G, the pattern of the partial subpanel 134 can be formed by the bulk pattern 154I and the edge pattern 152, and the partial subpanel 136. These patterns can be formed by the bulk pattern 154H and the edge pattern 152. In this case, the bulk patterns 154G to 154I may be the same or different. However, as described above, the edge patterns 152 provided around the partial subpanel portions 134 and 136 of the plank 150 and extending along a part of the edge of the plank 150 are the same. Accordingly, in the view of FIG. 13A, for example, when the planks 130A and 130B are arranged adjacent to each other along a predetermined direction, the edge patterns 152 of the complementary partial sub-panels 134A and 136B are substantially the same as each other and substantially continuous. The pattern can be formed across adjacent planks, in which case the bulk pattern of complementary partial sub-panels becomes part of a substantially continuous pattern and looks like an integral sub-panel and / or integral Shows unevenness like a sub-panel.
Further, referring to FIGS. 15C and 15D, the method described above with reference to FIGS. 15A and 15B should be applied to a flooring system using thick plates such as those shown in FIGS. Thus, a substantially continuous pattern can be provided across the planks arranged adjacent to each other along the predetermined direction. FIG. 15D shows a plank having a woodgrain pattern in the arrangement shown in FIG. 15B. Since the edge pattern 152A is substantially the same as the adjacent edge pattern 152B, the planks 150A and 150B have a substantially continuous woodgrain pattern appearance, and this pattern includes the edge pattern 152A and the edge pattern 152B of the adjacent plank. It extends across the boundary or seam between them and does not break.

Further, 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 in the portion corresponding to the height of the partial board in the lower half of these planks. The pattern does not continue across the border between the planks 150A and 150B across the portion of the upper half of the plank corresponding to the full board height.
As described above, within the flooring system using the planks shown in FIGS. 13A-14C and 15C, the bulk patterns inside the plank sub-panels may be the same or different. In one aspect of the invention, each of the bulk patterns in the flooring system can be a unique pattern.

FIG. 15E shows an embodiment of the invention in which the plank edge pattern is the same (or nearly the same) for all planks. Specifically, FIG. 15E shows four planks 150A, 150B, 150C, and 150D, with plank 150A adjacent to the left edge of plank 150B and adjacent to the upper edge of plank 150C. Yes. The thick plate 150D is adjacent to the right edge of the thick plate 150C and is adjacent to the lower edge of the thick plate 150B.
In this embodiment, each plank decal paper has a wood grain design. However, in the present invention, other natural material designs other than wood grain can be used. The wood grain design of plank 150A includes, for example, a complete board or wood strip 155A in the upper half of the board, a short incomplete board 151A, and a long incomplete board 153A. Each of these boards has a woodgrain pattern. Further, the short imperfect board 151A and the long imperfect board 153A have an edge pattern 152 extending along a portion corresponding to the width of the imperfect boards 151A and 153A in the periphery of the thick plate, and these edge patterns are They can extend inside these boards by a short distance (eg, 1 centimeter). The edge patterns 152 of the incomplete boards 151A and 153A are the same. The edge pattern 152 does not have to bite into the inside of the board.

Similarly, planks 150B, 150C, and 150D have full boards 155B, 155C, and 155D that extend the length of the plank, respectively, and are short boards adjacent to long boards 153B, 153C, and 153D, respectively. 151B, 151C, and 151D. Each of these short and long boards has the same edge pattern 152 along the portion of the perimeter of the plank that corresponds to the width of these short and long boards.
All short boards 151A-D, long boards 153A-D, and full boards 155A-D have woodgrain patterns that are different from each other or partly quite similar to each other. Only these imperfect board edge patterns 152 are the same in this particular embodiment. Furthermore, the edge pattern and internal woodgrain pattern of each incomplete board form a continuous pattern. That is, despite the fact that these edge patterns 152 are the same, a continuous woodgrain pattern as a whole is formed on each of the short imperfect board and the long imperfect board that are all different from each other.

As shown in FIG. 15E, when the thick plates 150A and 150B are arranged adjacent to each other, the complete boards 155A and 155B are adjacent to each other, and the long board 153A and the short board 151B are adjacent to each other. Because the adjacent edges of the complete boards are different, the complete boards 155A and 155B have the appearance of separate boards, and the woodgrain pattern is discontinuous across these boards. Since the edge pattern 152 of the long board 153A and the short board 151B is the same, the unique woodgrain pattern of 153A and 151B is a single continuous board with a unique woodgrain pattern extending across the planks 150A and 150B. Has the appearance of being formed. Furthermore, the complete continuous board has the appearance of a unique woodgrain pattern that extends across these planks to the boards 153A and 151B, thereby minimizing the visibility or appearance of the boundaries or seams between the planks. Similarly, the woodgrain pattern across the boards 153C and 151D is continuous.
In yet another embodiment, the planks 150A, 150B, 150C, and 150D may have surface irregularities that are embossed onto the decal paper grain design. The edge pattern 152 is part of the wood grain design and can be the same or nearly the same in all planks, so that the embossed surface irregularities are along imperfect boards in adjacent planks as described above. Appear to be continuous. In yet another embodiment, the unevenness of the embossed transfer surface can include a chamfer that simulates the seam between the boards, so in the plank 150A, for example, the complete board 155A is replaced by the board 155A and the incomplete boards 151A and 153A. And a chamfer extending along the periphery of the board including the boundary between them. The incomplete boards 151A and 153A have chamfered portions at positions where the boards are adjacent to each other, but the incomplete boards have chamfered portions along the portion where the edge pattern 152 is located in the periphery of the thick plate 150A. Absent. In this way, the continuous woodgrain pattern and the unevenness of the corresponding embossed transfer surface can be continuously extended across the thick plates 150A and 150B without being interrupted by the chamfered portion. This further makes the boundary between the planks less noticeable.

By making all the edge patterns 152 the same, the edge patterns 152 are always aligned to form the appearance of a continuous woodgrain pattern that extends across adjacent long and short boards of two thick plates. The invention allows all planks to be combined with each other in a predetermined direction such that a long board 153 is adjacent to another short board 151 of another plank. For example, when the positions of the thick plates 150A and 150B are reversed (thus the thick plate 150B is adjacent to the upper edge of the thick plate 150C), the edge pattern 152 of the long board 153B matches the edge pattern of the short board 151A. Alternatively, a continuous wood grain pattern is formed on the boards 153B and 151A across the thick plates 150B and 150A in alignment with the edge pattern of the short board 151A.
Since any of the thick plates may be arranged adjacent to each other in a predetermined direction, the present invention reduces the complexity of stretching the laminate floor. The pattern will match. In yet another embodiment, the plank 150 has an adhesive in which a tongue is formed on two adjacent peripheral edges of the plank and a groove is formed on two adjacent peripheral edges on the opposite side. Is used so that the long board 153 is combined with the short board 151 only in the direction of alignment, for example at the position where the edge pattern 152 coincides.
In the exemplary embodiment described above, decorative motifs and design pattern elements such as wood strips extend across separate adjacent planks. However, since the wood strip motif has a length equal to the length of the plank, the plank can be replaced, and the boarding is surely facilitated.

Reference is now made to FIG. FIG. 16 shows a floor having a floor pattern 500 formed by patterns 500a-500d according to one embodiment of the present invention. A floor 501 is defined by a plurality of flooring units having a decorative motif 512 on the upper surface. Specifically, the plurality of flooring units includes flooring units 504, 506, 508 and 510, which are more clearly shown in FIGS. 17A-17D.
FIG. 17A is an embodiment of the present invention showing a flooring unit 504 that includes subunits 504a-504d. The subunits 504a to 504d form the flooring unit 504 so that one thick plate is formed. In the embodiment shown in FIG. 17A, subunit 504 c has a decorative motif 512. Note that in another embodiment of the invention, subunit 504b, not subunit 504c, has a decorative motif 512.

FIG. 17B illustrates a flooring unit 506 according to one embodiment of the present invention. The flooring unit 506 includes subunits 506a to 506d. In this embodiment, none of the subunits 506a to 506d includes the decorative motif as the flooring unit 504 shown in FIG. 17A has.
FIG. 17C is one embodiment of the present invention showing a flooring unit 508. The flooring unit 508 includes subunits 508a to 508d. Note that subunit 508 a has a decorative motif 512. However, according to some embodiments of the present invention, subunit 508d may include a decorative motif 512 instead of subunit 508a.

FIG. 17D shows a flooring unit 510 according to one embodiment of the invention. The flooring unit 510 includes subunits 510a-510d each having a decorative motif 512. According to one embodiment of the present invention, the flooring unit 510 includes ceramic tiles, similar to the flooring units 504, 506, and 508. In addition, the flooring units 504, 506, 508 and 510 can be any material used for flooring applications such as wood, cork, marble and the like. The flooring units 504, 506, 508 and 510 have four subunits as described above (eg, 504a-504d). However, the flooring units 504, 506, 508 and 510 may have any number of subunits in accordance with the present invention, as will be described below.
In the floor pattern 500 shown in FIG. 16, the flooring units 504, 506, 508 and 510 are aligned with each other such that the decorative motif 512 forms the floor pattern 500. As previously described, each flooring unit 504, 506, 508 and 510 includes four subunits. In this embodiment, the flooring units 504, 506, 508 and 510 are aligned such that the decorative motifs 512 disposed on the flooring units are aligned with each other.

In order to form the pattern 500 a of the floor pattern 500, the subunit 504 c of the flooring unit 504 is aligned with the subunit 508 a of the flooring unit 508 along the X axis of the floor 501. Specifically, in order to form the pattern 500a, the subunit 504c of the flooring unit 504 is aligned with the subunit 508a of the flooring unit 508 to form the pattern 500a. Similarly, both subunit 508a and subunit 504c align with subunit 510a of flooring unit 510 to form pattern 500a. The pattern 500c is formed similarly to the pattern 500a according to an embodiment of the present invention.
In the embodiment shown in FIG. 16, the subunit 510 d is aligned with the subunit 510 a of another flooring unit 510 along the Y axis of the floor pattern 500, thereby being disposed on the two flooring units 510. The decorative motif 512 is aligned along the Y axis. In addition, in this embodiment, the subunit 508a of the second flooring unit 508 is aligned with the subunit 510d of the second flooring unit 510, thus forming the pattern 500b as shown. In this embodiment, the pattern 500d is formed in the same manner as the pattern 500b. In addition, the flooring unit 506 is disposed inside the floor pattern 500, and the subunit 506a is adjacent to the subunit 504d of the flooring unit 504 that forms the pattern 500a.

As shown in FIG. 16, a subunit located at the end of the flooring unit 508 (eg, subunit 508a or 508d) is aligned with a subunit at the end of the flooring unit 506 (eg, 506a or 506d). Furthermore, in the embodiment shown in FIG. 16, the flooring units 504, 506, 508 and 510 have four subunits. However, the flooring units 504, 506, 508, and 510 can have any number of subunits. For example, a flooring unit can include six subunits, as shown in FIGS. 19A-19D.
FIG. 19A shows a flooring unit 514 having subunits 514a-514f according to one embodiment of the invention. The flooring unit 514 also includes a decorative motif 512 on the subunit 514e. FIG. 19B is an embodiment of the present invention showing a flooring unit 516. The flooring unit 516 includes subunits 516a to 516f. FIG. 19C shows a flooring unit 518 having subunits 518a-518f. In addition, the flooring unit 518 has a decorative motif 512 disposed on the subunit 518a. The flooring unit 520 shown in FIG. 19D includes subunits 520a to 520f each having a decorative motif 512 on the upper surface. Flooring units 514, 516, 518 and 520 may be used to form a floor pattern 522 of the floor 500 as shown in FIG.

In one embodiment of the present invention shown in FIG. 18, the flooring units 514, 516, 518, and 520 form a pattern 522 that includes patterns 522a-522d. In this embodiment, as illustrated, the subunits 514e, 518a and 520a form a pattern 522a. Similarly, the pattern 522c is formed by the same method as the pattern 522a. In addition, as shown, the subunits 520a to 520f and the subunit 518a form patterns 522b and 522d.
As shown in FIGS. 16 and 18, the pattern of the floor 501 has a decorative motif on the subunit located at the end of the flooring member, the subunit directly adjacent to the end subunit, and all the subunits of the flooring unit. Formed by decorative motifs placed on the flooring unit. In addition, a flooring unit that does not include a decorative motif is also used to form the pattern of the floor 501. Thus, a flooring unit having at least three subunits can be used to form a pattern on the floor according to the present invention.

In addition, in one embodiment of the present invention where the flooring unit includes four subunits, three flooring units can be used as shown in FIG. In this embodiment, one flooring unit includes a decorative motif on all subunits, such as flooring unit 510, for example. The second flooring unit, like the flooring unit 504 or 508, has a decorative motif in any one of the subunits. All subunits of the third flooring unit do not have a decorative motif, as does the flooring unit 506. In FIG. 20, the subunits 508a and 510a form patterns 513a and 513c of the pattern 513. In addition, the flooring unit 510 and the subunit 508a form patterns 513b and 513d of the pattern 513.
In a further embodiment, one flooring unit includes 5 subunits and has patterns 531a-531d using four flooring units 524, 526, 528 and 530, as clearly shown in FIG. A pattern 531 can be formed. As shown in FIGS. 22A-22D, flooring units 524, 526, 528, and 530 include five subunits. The flooring unit 524 includes subunits 524a to 524e. The flooring unit 526 includes subunits 526a-526e that all have a decorative motif 512. The flooring unit 528 includes subunits 528a to 528e. Here, the subunit 528d has a decorative motif 512. The flooring unit 530 includes subunits 530a to 530e, and the subunit 530c has a decorative motif 512.

As shown in FIG. 21, a pattern 531a is formed by the subunits 526a and 528d. The flooring unit 526 also forms patterns 513b and 531d. Further, a pattern 531c is formed on the floor 501 by the subunits 526e and 530c.
As shown in FIGS. 23 and 24, patterns 534 and 536 are formed using flooring units 504, 506, 508 and 510 or flooring units 514, 516, 518 and 520 according to some embodiments of the present invention. In addition, many kinds of patterns such as patterns 500 and 522 can be formed on the floor 501.

Further, in one embodiment of the present invention, the subunits can be offset from each other such that the subunit 508a is aligned with the subunit 504c in FIG. In some embodiments where the subunits are offset from each other, four flooring units (eg, flooring units 504, 506, 508, and 510) can be used regardless of the number of subunits.
FIG. 23 illustrates another embodiment of the present invention. FIG. 23 shows four planks 1000, 1002, 1004 and 1006 (before machining the tongues and groove edges of each plank) having different patterns. Each of these planks can be divided into four equal subunits a, b, c and d. The embodiment of FIG. 23 includes a decorative motif having a width that is less than the width of one subunit.

As shown in FIG. 23, the plank 1000 does not include a decorative motif. The plank 1002 includes a decorative motif only in a part of one of the four subunits. In this example, the height of the decorative motif (in the direction parallel to the length of the plank) is approximately equal to half the height of the subunit. The plank 1004 has a decorative motif on another subunit of the plank. That is, the subunit having the decorative motif of the plank 1004 is different from the subunit having the decorative motif of the plank 1002.
Finally, plank 1006 has a decorative motif that runs over the full length of the plank but only a portion of each subunit. For example, the decorative motif can have a width equal to half the width of the plank (a direction parallel to the short side of the plank) and can be arranged over the entire length of the plank. In other embodiments, or another aspect of this embodiment, the decorative motif can have a different width that is less than the width of the entire plank.

After processing a predetermined edge on a plank, the flooring system according to this embodiment requires at least seven different planks. However, if the slab bonding system has the same coupling mechanism or profile on both sides of the slab, this flooring system only requires four slabs as described above.
Since the decorative motif is included only in a part of each subunit, when the subunits are arranged adjacent to each other, when the entire subunit is adjacent to the whole subunit, as shown in FIG. The flooring system includes the same plank 1000 as shown in FIG. 23, a plank 1002 similar to that shown in FIG. 23, and a plank 1004 similar to that shown in FIG. However, a thick plate 1003 similar to that obtained by rotating the thick plate 1004 by 180 degrees is further included. By arranging the plank 1003 adjacent to the planks 1006 and 1002, the decorative motifs of adjacent planks can be aligned. Furthermore, a thick plate 1005 similar to the one obtained by rotating the thick plate 1002 by 180 degrees is included. By arranging this thick plate 1003 adjacent to the thick plate 1003, a decorative motif extends over adjacent subunits of these thick plates. Line up in a row. Further, the flooring system includes a plank 1007 similar to plank 1006 rotated 180 degrees. Therefore, this flooring system having the thick plates 1000, 1002, 1003, 1004, 1005, 1006 and 1007 can form the flooring pattern shown in FIG. 24, and the height of the flooring pattern is equal to two planks ( Or, each plank contains 4 subunits, so the width is equivalent to 9 subunits), but the decorative motif is arranged only in part of the width of planks 1006 and 1007. As a result, the actual width of the decorative motif is equivalent to eight planks. However, nine planks are required to make this width.

FIG. 24 shows a flooring pattern formed using seven planks of this flooring system, the decorative motif of which is different from the motif occupying the entire subunit as shown in the above embodiment. Only occupies a part of one subunit of the plank. Thus, since the decorative motif is shifted in each subunit, this flooring system can make the physical connection between adjacent planks using this flooring system inconspicuous. Specifically, in FIG. 24, since the thick plate 1003 is disposed adjacent to the thick plate 1006, the second subunit of the thick plate 1003 shown as the subunit 1003b becomes the first subunit of the thick plate 1006. Adjacent to subunit 1006a. Similarly, the subunit 1005d is adjacent to the subunit 1003b of the thick plate 1003. Thus, the planks 1003 and 1005 are offset by a distance of two subunits or by half of the total length of the plank, while the plank 1003 is only one subunit from the plank 1006. Or by a quarter of the length of the plank. The difference between the displacement of the thick plates 1006 and 1003 and the displacement of the thick plates 1003 and 1005 makes the physical coupling between adjacent thick plates inconspicuous.
By repeating the arrangement of the thick plates 1003 and 1005 as described above, a flooring pattern having a variable width can be generated. The width of the entire pattern in this embodiment corresponds to the width of the plank of the number of planks 1003 and 1005 arranged adjacent to each other plus one, which is the portion of the decorative motif on the plank 1006 The decorative motif portion of the thick plate 1007 is added to the overall width of the decorative motif from This is because in this embodiment, the width of the decorative motif corresponds to half the width of the thick plate. In this way, in FIG. 24, seven thick plates 1003 and 1005 (four thick plates 1003 and three thick plates 1005) between the thick plates 1006 and 1007 have a width corresponding to the width of eight thick plates. The decorative motif of the flooring pattern which has is formed, and the flooring pattern itself is physically formed of nine flooring planks.

  Furthermore, the height of the flooring pattern can be made an arbitrary multiple of the length of the planks by simply adding the planks 1006 adjacent to each other in the vertical direction. The vertical direction is parallel to the length of the plank. Therefore, by adding the thick plates 1006 adjacent to each other on one side and adding the thick plates 1007 adjacent to each other on the other side, the height of the entire flooring pattern can be extended. This is further illustrated in FIG. FIG. 25 shows a height corresponding to the length of three thick plates formed by adjoining three planks 1006 on one side and adjoining three planks 1007 on the other side. Having a flooring pattern. In order to complete this flooring pattern, 13 planks are required in the width direction, and the width of the flooring pattern corresponds to 12 planking planks. Furthermore, the minimum flooring pattern that can be formed by the flooring pattern of the present embodiment has a height corresponding to the length of one thick plate and a width corresponding to the width of four thick plates in the width direction. It is necessary to arrange five planks adjacent to each other, and in particular, the planks 1006, 1005, 1003, 1005 and 1007 are required to form this flooring pattern.

  Various other embodiments are possible, in which the width of the decorative motif is smaller than the overall width of the plank and not equal to half the width of the plank, and the height of the decorative motif is a subunit. Unlike the overall height and not equal to half the subunit height. Furthermore, more or less planks are required in the flooring system to form floors with flooring patterns of varying widths and heights, depending on the width of the decorative motif flooring motif.

2 shows an assembly and locking mechanism according to the related art. Fig. 5 shows an assembly and locking mechanism according to another related art. Fig. 6 shows an assembly and locking mechanism according to still another related technique. Fig. 6 shows an assembly and locking mechanism according to still another related technique. It is a perspective view of the component of the thick board for embossing transfer flooring by the principle of this invention. 1 shows a press machine having the function of producing a thick plate for embossed transfer flooring in accordance with the principles of the present invention. The thick board for emboss transfer flooring in one mode of the present invention is shown. It is a top view of the thick board system for emboss transfer flooring in another aspect of the present invention. FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. It is a top view of the thick board system for emboss transfer flooring in another aspect of this invention. FIG. 11 is a cross-sectional view taken along line 11-11 of FIG. A and B are schematic views including a peripheral surface portion of a flooring plank according to the principle of the present invention. A and B show a flooring system in still another aspect of the present invention. AC illustrate exemplary planks of a flooring system in yet another aspect of the present invention. A through E illustrate exemplary methods of forming a pattern on a flooring plank in accordance with the principles of the present invention. 2 illustrates an exemplary method for forming a pattern on a flooring plank in accordance with the principles of the present invention. 3 illustrates another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention. Figure 4 illustrates yet another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention. Figure 4 illustrates yet another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention. Figure 4 illustrates yet another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention. Figure 4 illustrates yet another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention. AD illustrate yet another exemplary method of forming a pattern on a flooring plank in accordance with the principles of the present invention.

Claims (28)

A system for forming a decorative pattern,
A first plurality of subunits having a pattern, wherein one subunit has a first plurality of subunits having a decorative motif substantially different from the pattern of the units, And a plurality of second subunits having a pattern, wherein one subunit comprises the first subunit and the second subunit by aligning the first subunit and the second subunit with each other. A system comprising a second unit adjacent to the first unit, having a second plurality of subunits, comprising a decorative pattern in which the decorative motifs are formed in alignment with each other. Furthermore, a third unit is provided, and the third unit is
A plurality of third subunits having a pattern, wherein one subunit forms a decorative motif formed by a decorative motif of the third subunit together with a decorative motif of both the first subunit and the second subunit The system of claim 1, comprising a third plurality of subunits. The system of claim 2 further comprising a fourth unit having at least four subunits.   4. The system of claim 3, wherein the subunit of the first unit having a decorative motif is adjacent to the subunit of the second unit having a decorative motif.   The system of claim 4, wherein the edge unit of the first unit has a decorative motif.   The system according to claim 4, wherein the subunits adjacent to the edge unit of the second unit have a decorative motif.   The system of claim 1, wherein the first unit includes at least four subunits.   The system of claim 1, wherein the second unit comprises at least four subunits.   The system of claim 1, wherein the first unit and the second unit are laminate flooring planks having a woodgrain pattern.   The system of claim 1, wherein the subunits include surface irregularities by embossing with a decorative motif transferred. The first unit is
The system of claim 1, comprising a tongue extending from the periphery of one edge of the first unit, and a groove running along the periphery of the opposite edge of the first unit. The second unit
A tongue extending from the peripheral edge of one edge of the second unit, and a groove running along the peripheral edge of the opposite edge of the second unit, the groove capable of receiving the tongue in either 12. The system of claim 11, comprising:   The system of claim 9, wherein the pattern has embossed surface irregularities.   The system of claim 1, wherein the first and second units are laminated floor planks having a ceramic tile surface pattern. A method of forming a decorative pattern,
A first plurality of subunits having a pattern, wherein the first subunit has a first plurality of subunits having a decorative motif substantially different from the pattern of the subunits A plurality of second subunits having a subunit pattern, wherein one subunit includes a first subunit having a decorative motif and a second subunit having a decorative motif Disposing a second unit having a second plurality of subunits comprising a decorative pattern formed by aligning the units with each other adjacent to the first unit.   Further comprising disposing a third unit adjacent to the first unit or the second unit, wherein the third unit has a third plurality of subunits, one of these subunits being 16. The method of claim 15, wherein the decorative motif comprises a third subunit having a decorative motif adjacent to a first subunit having a decorative motif and a second subunit having a decorative motif.   The method according to claim 15, wherein the first unit has a tongue extending from the periphery of the first edge and a groove provided in the periphery of the second edge opposite to the first edge.   18. The method of claim 17, wherein the second unit has a tongue extending from the periphery of the first edge and a groove provided in the periphery of the second edge opposite the first edge. The method of claim 18, further comprising securing the tongue of the second unit and the groove of the first unit to each other.   The method according to claim 15, wherein the first unit and the second unit are laminated floor planks having a woodgrain pattern.   The method according to claim 15, wherein the subunits include surface irregularities by embossing to which a decorative motif is transferred.   21. The method of claim 20, wherein the pattern comprises embossed surface irregularities.   The method according to claim 15, wherein the first unit and the second unit are laminated floor planks having a pattern of ceramic tiles.   The method of claim 15, wherein both the first unit and the second unit comprise at least four subunits. A system for forming a decorative pattern,
A first unit having a first plurality of subunits on which one decoration pattern is arranged, wherein one of the subunits has a decoration motif substantially different from the pattern of the subunits , And a second unit having a second plurality of subunits having a subunit pattern, wherein one of the subunits is first when the first unit is arranged offset from the second unit. A system comprising a second unit, wherein a decorative motif of the subunits of the second and second subunits includes a decorative motif formed in alignment with each other, and the decorative motif forms a decorative pattern. A third unit having at least four subunits, wherein one of the subunits is arranged with the third unit offset from both the first and second units. 26. The system of claim 25, further comprising a third unit having a decorative motif such that the decorative motif is aligned with the decorative motif on the first subunit and the second subunit. 26. The system of claim 25, further comprising a fourth unit having at least four subunits.   26. The system of claim 25, wherein both the first unit and the second unit have at least four subunits.

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