WO2010082082A1

WO2010082082A1 - Element for covering a surface and covering obtained therewith, method for manufacturing an element for covering a surface and corresponding machine.

Info

Publication number: WO2010082082A1
Application number: PCT/IB2009/007930
Authority: WO
Inventors: Claudio Cadorin; Rita Cadorin
Original assignee: Cadorin Group S.R.L.
Priority date: 2009-01-15
Filing date: 2009-12-29
Publication date: 2010-07-22
Also published as: IT1392607B1; ITVI20090002A1; EP2376264A1

Abstract

The present invention concerns a method for manufacturing an element (1, 100, 200) for covering surfaces, preferably walking surfaces, comprising the following operations: positioning of a support element (2) that defines an upper surface (3) and a lower surface (4). This method for manufacturing the element (1, 100, 200) also comprises a pressing operation suited to press part of said upper surface (3). The invention includes also the corresponding machine for manufacturing the element (1, 100, 200) for covering the surface (3).

Description

ELEMENT FOR COVERING A SURFACE AND COVERING OBTAINED

THEREWITH, METHOD FOR MANUFACTURING AN ELEMENT FOR

COVERING A SURFACE AND CORRESPONDING MACHINE. FIELD OF APPLICATION OF THE INVENTION The present invention relates to the sector of furniture and the building construction sector.

In particular, the present invention relates to the field of elements for covering surfaces.

In particular, the present invention concerns a method for manufacturing an element for covering surfaces.

More particularly, the present invention concerns a method for manufacturing an element for covering surfaces, preferably walking surfaces. For this reason, the present invention is described here below with particular reference to the manufacture of parquet flooring elements. It should be noted, however, that the applications of the present invention are not limited to the manufacture of parquet flooring elements. On the contrary, the present invention can be advantageously applied whenever it is necessary to provide a surface having special technical and functional characteristics.

In fact, according to the present invention said method makes it possible to manufacture an element for covering a walking surface having special acoustic, mechanical and functional characteristics.

The present invention also concerns a machine suited to implement said method.

The present invention also concerns an element for covering surfaces.

The present invention also concerns a covering made with said element. DESCRIPTION OF THE STATE OF THE ART

As already known, in building construction and in particular in the sector of furniture various types of elements are used for covering surfaces like for example walls, ceilings and floors.

Said covering elements comprise a substantially flat support element in which it is possible to identify a lower surface suited to be placed in contact with the surface to be covered and an upper, exposed surface.

Said elements are intended to ensure that the surfaces they cover offer suitable resistance to mechanical stress and to chemical and atmospheric agents, as well as to finish said surfaces with satisfying aesthetical results. More particularly, the function of the coverings for indoor use is to finish and decorate the surfaces of walls and floors (consisting of the exposed surfaces of said elements), thus also facilitating cleaning operations.

The present invention can be especially but not exclusively applied for manufacturing an element for covering surfaces, preferably walking surfaces, and more precisely for making a so-called parquet flooring.

For this reason, the present invention is described here below with particular reference to the manufacture of parquet strips.

It should be noted, however, that the applications of the present invention are not limited to the manufacture of parquet strips. On the contrary, the present invention can be also advantageously applied whenever it is necessary to cover a surface with elements having special anti slip, acoustic, mechanical and functional characteristics.

As already known, parquet flooring is a type of flooring obtained by assembling individual covering elements made of wood, also called blocks, staves, strips or panels, which are positioned adjacent to one another (for example even by means of joints) and fixed to or laid on the rough floor surface.

The elements for making parquet flooring can be substantially divided in two types: unfinished elements and prefinished elements.

It is known that the prefinished elements, differently from the unfinished or polished ones, are supplied already treated with varnish, oil or wax and therefore do not need any further treatment after laying.

Even these prefinished elements substantially comprise a support element in which it is possible to identify an upper surface and a lower surface and are substantially divided into prefinished solid wood elements and prefinished multi- layer elements.

The prefinished solid wood elements are constituted by an element obtained as an individual body in one-layer solid wood that defines both the above mentioned surfaces, while the prefinished multi-layer elements are constituted by a support element having a stratified structure, of the multi-layer or laminate type, comprising a layer in a noble material that defines the upper exposed surface.

The remaining layers can consist of other layers in wood or another material.

It should be noted, in any case, that the elements for covering surfaces of the type described and the corresponding methods for manufacturing them pose several problems; for example, the mechanical and functional characteristics of the upper exposed surface are substantially the natural characteristics of the material (wood) used.

It is therefore evident from the above that there is the need to identify alternative solutions which are more functional than the known solutions. In consideration of the above, it is desirable to provide an element for covering surfaces as well as a corresponding method for manufacturing it which allow the drawbacks of the known art to be overcome or at least limited. Therefore, it is desirable to provide an element for covering surfaces and a corresponding method for manufacturing it which make it possible to overcome the drawbacks found in the elements described above.

The main object of the present invention is thus to solve or at least partially overcome the problems that characterize the solutions known in the state of the art.

In particular, it is one object of the present invention to provide a solution that makes it possible to manufacture an element for covering surfaces whose exposed side has special mechanical and functional characteristics. In greater detail, one object of the present invention is to provide a solution that makes it possible to vary the characteristics of said surface according to the need and more precisely according to the intended use of the covering element. It is another object of the present invention to manufacture an element for covering surfaces that can be preferably used for making indoor floors and surfaces, the covering obtained therewith, as well as a method for manufacturing said element and a corresponding machine. It is a further object of the invention to carry out a covering element and a surface characterized by excellent quality also from an aesthetic and decorative point of view.

It is another object of the present invention to provide an element for covering surfaces that can be preferably used for making floors and has anti slip properties. It is a further object of the present invention to provide an element for covering surfaces that can be preferably used for making floors and has better acoustic characteristics than the elements of known type.

It is another object of the invention to provide an element which makes it possible to obtain floors and surfaces with an attractive appearance, particularly elegant and refined, and which also has special characteristics that can be determined during manufacture, like for example opacity and/or brightness and/or gloss and/or reflection characteristics.

It is another object of the invention to implement a process that makes it possible to obtain the element described above ensuring structural characteristics, lightness, surface protection capacity equal and even superior to those of the elements of known type.

It is another object of the invention to implement a process that is simple and capable of obtaining the element of the invention in an efficient and safe manner. It is another, yet not the least object of the invention to carry out an element that may have any shape and is particularly valuable, attractive, easy to manufacture and to install, and suitable for mass production.

SUMMARY OF THE PRESENT INVENTION

The present invention is based on the general consideration that it is possible to vary the characteristics of the exposed surface by subjecting the material of which it is made to special treatments.

The present invention is also based on the further consideration that by subjecting the element to suitable processes it is possible to increase the hardness of the wood material of which the exposed surface is made (walking surface in the case of a parquet floor element) and it is possible to increase the resistance of the surface to walking.

The present invention is based on the further consideration that by subjecting the element to particular working processes it is possible to obtain an element whose exposed surface (walking surface in the case of a parquet floor element) has special anti slip properties. The invention is also based on the further consideration that by subjecting the element to special working processes it is possible to obtain an element with particular acoustic properties (with different sound absorption, capable for example of reducing echoes, etc.). The present invention is also based on the consideration that these processes do not require the removal of material (from the exposed surface), thus reducing processing residues.

A further consideration on which the present invention is based is that if the vegetable fibre (wood grain) that constitutes the wooden element to which the exposed surface belongs is not interrupted following the application of said processes, some characteristics (for example the above mentioned mechanical characteristics) are further improved.

Another consideration on which the present invention is based is that said results can be obtained by crushing, shaping and pressing the element without removing material from the exposed surface. A further consideration on which the present invention is based is that in order to lend the exposed surface the above mentioned technical characteristics, by working on the wooden element of which said exposed surface is made, it is possible to give said surface also a particular and predetermined acoustic and/or aesthetic characteristic that makes it different and special compared to the exposed surfaces of the elements of known type.

A further consideration on which the present invention is based is that said processes should give the exposed surface (walking surface) grip properties that reduce the risk of slipping (friction). A further consideration on which the present invention is based is that said processes should make it possible to vary said aesthetic and technical characteristics (grip, hardness, ecc.) as desired, according to the intended use of the manufactured element.

According to a first embodiment of the invention, the subject of the invention is a method for manufacturing an element for covering surfaces, preferably walking surfaces, comprising the following operations: preparing a support element that defines an upper and a lower surface; said method also comprising at least one pressing operation for pressing at least part of said upper surface. Said operation thus makes it possible to carry out particular finishing processes on the exposed surface, and in particular to compact the vegetable fibres. This makes it possible to considerably increase the hardness of the upper exposed surface (walking surface).

According to a preferred embodiment of the invention, said pressing operation is carried out by subjecting the exposed surface to such a pressure as not to break and/or cut the vegetable fibres that make up the wooden element to which the exposed surface belongs.

This solution thus makes it possible to improve the mechanical characteristics of the wooden element to which the exposed surface belongs (wood fibres are compacted), thus obtaining an exposed surface that is smooth and continuous to the touch (in fact, wood fibres are neither cut nor broken nor interrupted). According to a further embodiment of the invention, said pressing operation is carried out by means of a pressing element (mould) having at least one portion of its surface suited to come into contact with said exposed surface, said at least one portion having at least one part provided with grooves and/or lines and/or cuts and/or relief patterns and/or bas-relief patterns and/or engraved patterns suited to be impressed on said exposed surface. This advantageously makes it possible to obtain, at the designed depth, effective patterns and decorations, as well as to vary the mechanical and acoustic characteristics of the element. It is clear, in fact, that this solution allows any type of pattern (fancy patterns) to be reproduced on the exposed surface. The same solution makes it also possible to further vary said effects obtained on the exposed surface by varying also the pressure exerted by the pressing element (mould) on the various areas of the exposed surface (working at different depths on the exposed surface). According to a further preferred embodiment of the invention, the exposed surface is also subjected to further finishing processes and in particular to a varnishing and/or brushing and/or smoothing and/or a similar process. This makes it possible to obtain further special finishes of the exposed surface (coloured-decorated finishes, etc.). According to a further embodiment of the invention, the subject is an element for covering surfaces, preferably walking surfaces, comprising a support element that defines an upper and a lower surface, said element having at least some parts of said upper surface that present a certain roughness.

In particular, said predetermined roughness depends on the mechanical and acoustic characteristics and is obtained through pressing. The proposed solution advantageusly makes it possible to manufacture an element with an exposed surface that is more compact compared to the elements of known type. This advantageously makes it possible to obtain an exposed surface (walking surface in the case of parquet flooring) whose resistance to walking is higher than the natural resistance of the wood of which the surface is made.

Furthermore, said roughness can be obtained by pressing with a pressing element whose pressing surface is provided with special grooves and/or lines and/or cuts and/or relief patterns and/or engraved patterns that are suited to be impressed on said exposed surface. This advantageously makes it possible to obtain an element and an exposed surface (walking surface in the case of parquet flooring) with special acoustic

(sound absorption) and/or anti slip characteristics.

According to a further embodiment of the invention, the subject is a covering for surfaces, comprising a plurality of elements for covering surfaces arranged side by side, at least one of said elements for covering surfaces being manufactured according to the description provided above.

According to another embodiment of the invention, the subject is a machine for manufacturing elements for covering surfaces, preferably walking surfaces, comprising a support element in which it is possible to identify an upper and a lower surface, said machine comprising conveyor means defining an advance direction, suited to receive one or more support elements, said machine also comprising means for pressing at least part of said upper surface.

Therefore, the above shows that the solutions proposed according to the present invention make it possible to achieve the set objects. Advantageous embodiments of the invention are described in the dependent claims.

Further advantageous embodiments of the present invention are described in detail in the dependent claims.

The above clearly shows that the proposed solution makes it possible to obtain elements whose walking surfaces have special technical characteristics and at the same time are valuable from an aesthetical point of view, thus ensuring effective aesthetical results for the covered surface.

Still advantageously, the solution proposed makes it possible to obtain an element and a surface that ensure excellent resistance and long life. Still advantageously, the element that is the subject of the invention can be properly treated and finished, for example through the application of varnishes, waxes, oils, glossy or opaque colouring agents.

Still to advantage, the proposed solution makes it possible to produce an element that can be laid on and applied to the underlying surface even with traditional procedures and that is simple and easy to maintain.

Still advantageously, the proposed solution makes it possible to produce an element that can be used to decorate interiors, to make decorative panels and to decorate pieces of furniture, for example table tops or mirrors or boiseries.

Still advantageously, the method for manufacturing the element that is the subject of the invention allows a large number of elements of the above mentioned type to be obtained per unit of time, ensuring reduced costs, short processing times and flexibility, by adjusting the element processing methods depending on the needs, in order to obtain finishes and decorations of various types. Still advantageously, the method and the machine proposed allow mass production of said elements, considerably reducing manufacturing costs. Still to advantage, the proposed solution makes it possible to produce prefinished elements that therefore do not need further processing once they have been laid and allow the laying time to be considerably reduced. Still advantageously, the proposed solution makes it possible to produce prefinished elements having a repeatable quality that can be obtained even with specific products, for example UV curing products, that cannot be used in case of finishing after laying.

Still advantageously, the proposed solution makes it possible to produce prefinished elements whose finish is more resistant to abrasion than that of the elements of known type.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, advantages, aims and characteristics, as well as preferred embodiments (described by way of non-limiting examples) of the present invention are defined in the claims and will be clarified below by means of the following description, in which reference is made to the attached drawings, wherein:

Figure 1 shows a perspective view of an element for covering surfaces carried out according to the present invention; - Figure Ia shows a perspective view of another element for covering surfaces carried out according to the present invention; Figure Ib shows a perspective view of a further element for covering surfaces carried out according to the present invention; each one of Figures from 2a to 2c shows a schematic perspective view of a corresponding number of operations included in the method for making an element for covering surfaces that is also the subject of the invention; Figures from 2d to 2h show a plan view of one part of an element used to implement the method of the invention; each one of Figures from 3 to 5 shows a schematic perspective view of a corresponding number of operations included in a variant of the method for making an element for covering surfaces that is also the subject of the invention; each one of Figures from 6 to 10, 11a and from 11 to 15 shows a schematic perspective view of the same number of examples of execution of some operations included in the method that is the subject of the invention;

Figure 16 shows a schematic side view of an example of a machine or system that is also the subject of the invention;

Figure 17 shows a schematic side view of another example of a machine or system that is also the subject of the invention;

Figure 18 shows a schematic perspective view of a covering (floor) that is also the subject of the invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION By way of introduction, it should be noted that in the drawings characteristics and/or parts or components corresponding or equivalent to the individual examples of embodiment of the present invention are identified by the same reference numbers. Furthermore, in the case of a change in the position of the parts that make up the invention, the position indications given in the individual examples must be transferred, according to logic, to the new position. It is also important to underline that, for a better understanding of the schematic diagrams attached hereto, some parts of the non-limiting examples of embodiment shown can be represented using dotted lines or other methods. Even if the following description corresponding to the figures illustrates some particular embodiments of the invention, it is clear that the invention is not limited to said particular embodiments. On the contrary, the embodiments described below and illustrated in the drawings clarify different aspects of the present invention, the object and scope of which are defined in the claims. The present invention relates to the sector of furniture and the building construction sector. In particular, the present invention relates to the field of elements for covering surfaces.

In greater detail, the present invention relates to the methods for manufacturing elements for covering surfaces, preferably walking surfaces (for making floors). In particular, the present invention concerns a method for manufacturing an element for covering a surface. The present invention can be usefully employed in particular but not exclusively in the field of flooring.

More particularly, the present invention concerns a method for manufacturing an element for covering surfaces, preferably walking surfaces (for making floors). According to the present invention, said method makes it possible to manufacture an element for covering a walking surface having special mechanical and functional characteristics.

The present invention also concerns a machine suited to implement said method.

The present invention also relates to an element for covering surfaces and a covering made using said element.

The examples of embodiment of the invention described below refer to an element for covering floors and in particular for making parquet floors.

It is clear, however, that the element described can be used to cover any type of surface, indoors and outdoors, like for example walls or ceilings, or even to cover parts of any type of object.

Analogously, the method and the machine described above are suitable for manufacturing elements to be used for making any type of covering, and preferably for making elements for parquet flooring (strips).

An element for covering surfaces, preferably walking surfaces, that is the subject of the present invention, is represented in Figure 1, where it is indicated as a whole by 1.

It comprises a support element 2 that defines an upper surface 3 (also called exposed surface) and a lower surface 4.

In the non-limiting example shown herein, the body 2 is a body made of solid wood.

The surface 3 presents a predetermined degree of roughness, schematically shown in Figure 1 with rectangles 3r.

Said roughness 3r is obtained by pressing the upper surface 3, as will be better illustrated below, and is preferably carried out by means of a pressing element having a suitably shaped surface.

This advantageously makes it possible to predetermine the mechanical characteristics of hardness and friction of the surface 3 of the element 1 according to its intended use.

More particularly, the different shapes impressed on the surface mainly vary the grip characteristics of the surface itself. Varying the pressing force mainly means varying the hardness of the surface.

Advantageously, said shapes are reproduced in negative on the upper surface 3 of the element 1 following the pressing operation. Said shapes can be of any type, and in particular they can reproduce the form of known things, like for example animal tracks, the outline of a flower, a knurl (which increases the grip of the surface), etc.

This gives the element 1 also special aesthetic characteristics.

According to a preferred embodiment of the invention, said pressing operation is carried out so that the vegetable fibres making up the upper surface 3 are not interrupted or cut or broken, thus lending the surface 3 special mechanical characteristics.

The above clearly shows that said pressing operation (changing the shape of the pressing element and the pressure force exerted by it on the surface 3) is also carried out in such a way as to give the element 1, and in particular the surface 3, special aesthetic characteristics and/or characteristics that can be felt to the touch.

Furthermore, in some preferred embodiments of the invention, the surface 3 can be smoothed and/or brushed.

A further embodiment of the covering element of the invention is described here below with reference to Figure Ia, wherein the parts, components and/or characteristics already described with reference to the previous figure are indicated by the same reference numbers.

In the embodiment shown in Figure Ia, the element 100 is differentiated from the previous one owing to the fact that at least one part of said upper surface 3

(exposed surface) is provided with at least one layer 5 of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material (schematically shown in said figure with lines indicated by 5).

In other words, the layer of material 5 may cover the entire upper surface 3 or part of it, as shown in the example of Figure Ia.

More generally, the surface 3 of the body 2 may have, on some parts or on its entire surface, a layer of material that gives the surface of the element 100 special qualities in terms of brightness and/or reflection and/or refraction and/or iridescence and/or gloss and/or opacity.

The refracting and/or reflecting and/or iridescent and/or glossy material preferably comprises natural or synthetic materials. More precisely, said material may comprise powders or bodies in a vitreous material or a metal or a mineral or an organic material.

More particularly, according to some preferred embodiments of the invention, the above mentioned vitreous material may comprise glass or silica powders or equivalent materials, while the metal powders or bodies may comprise a precious or non precious metal, characterized by a certain gloss or light reflection capacity.

More particularly, the precious metal may preferably comprise gold and/or platinum and/or silver and/or alloys of these metals. As an alternative, the metal may preferably comprise aluminium and/or tin and/or copper and/or metal alloys like for example brass or bronze, etc.

Always according to the invention, the mineral material may comprise parts or powders of stones (also of metals) like for example quartz, as well as parts or powders of precious stones like for example diamond or ruby or amethyst or sapphire, etc. As regards the organic material, it may comprise for example a synthetic or natural material like mother of pearl, that is renowned for its iridescence. Always according to the invention, to obtain different characteristics in terms of gloss or reflection or refraction or iridescence, the upper surface 3 may also be brushed (for example with rollers provided with projecting elements) and/or smoothed and/or treated with steel wool and/or scraped and/or sandblasted at least in one part where said material 5 is used. It is also clear that the upper surface 3 may belong to a natural or composite wooden body or a body in a similar material. A further embodiment of the element of the invention is described here below with reference to Figure Ib, wherein the parts, components and/or characteristics already described with reference to previous figures are indicated by the same reference numbers.

More particularly, in said Figure Ib the element is indicated as a whole by 200 and is differentiated from the element shown in Figure 1 due to the fact that the body 2 is stratified (of the so-called multi-layer or laminate or sandwich or plywood type).

More precisely, the body 2 comprises a first layer 21 made of noble wood like for example oak, walnut, etc, a second layer 22 made of plywood (or solid wood that can even be a noble wood) and a third layer 23 made of a material identical to the material used for the first layer 21 or having flexibility and/or resistance and/or thermal expansion substantially equivalent to those of the first layer 21.

This particular embodiment is also called counterbalanced element, since the two layers 21 and 23 are made of the same material/using the same system.

It is clear, however, that in other embodiments the body 2 may be of the multi- layer or laminate or sandwich type.

It is also clear that the body 2 may comprise any number of layers and that these may be made of any material.

In particular, it should be noted that some layers may also be made of a synthetic material, Even in this case it is possible to apply a layer 5 of a material as described in the example of embodiment of Figure Ia.

Figures 2a and 2b schematically illustrate a method for making an element for covering surfaces, preferably walking surfaces, carried out according to the present invention. According to this method, a support element 2, in the example an element of the type shown in Figure Ib, is prepared so that it can be machined, said support element 2 being provided with an upper surface 3 (also called exposed surface) and a lower surface 4, and at least one pressing operation is carried out in order to press at least one part of said upper surface 3 (schematically shown in Figure 2b) and to obtain the desired roughness 3r.

In other words, following the pressing operation predetermined geometrical shapes 3r are impressed on the upper surface 3, thus giving the surface 3 particular roughness values.

It should be noted that, as already explained, said geometrical shapes can be of any type. For example, they can reproduce the form of living and non-living things, like animal tracks, flowers, landscapes, etc., ensuring that the obtained element has particular aesthetic characteristics.

This pressing operation makes it possible to increase the compactness and/or hardness of the material with which said surface 3 is made. More particularly, the different shapes impressed on the surface mainly change the grip characteristics of the surface itself. Varying the pressing force mainly means varying the hardness of the surface.

According to another preferred embodiment of the invention, at least one pressing operation is carried out by subjecting the exposed surface 3 to such a pressure as not to break and/or cut the vegetable fibres that make up the wooden element 21 to which said exposed surface 3 belongs.

In other words, said pressing operation is carried out in a controlled manner, in order to obtain the above mentioned roughness and in particular in such a way as not to interrupt the grain of the vegetable fibre that makes up the element 21 to which said upper exposed surface 3 belongs.

This pressing operation is carried out using a pressing element 8 (mould), schematically shown in Figure 2c, having at least one portion 8s of its surface suited to come into contact with said exposed surface 3 provided with shapes (shapes/patterns in relief and/or engraved) and/or grooves and/or lines and/or cuts and/or hollows and/or undulations suited to be impressed on said upper exposed surface 3 during the pressing operation.

Said cuts or patterns present on the surface 8s of the pressing element 8 may have any geometrical shape. By way of example, Figures from 2d to 2h show some possible shapes (changing said shapes means obtaining different surface characteristics).

In particular, in Figure 2d the grooves have a substantially triangular shape. In Figure 2e the grooves have a substantially circular shape. In Figure 2f the grooves have a substantially polygonal shape, and in particular, in the preferred non-limiting example of embodiment illustrated therein, the shape of an hexagon.

In Figure 2g the surface is provided with substantially square grooves that, properly pressed on the upper surface 3, produce the same shapes in negative, thus pressing the fibres (and increasing hardness) and obtaining the desired surface roughness. In Figure 2h the grooves consist of a series of parallel broken lines (substantially called a snake shape).

Again, as previously explained, said shapes can reproduce any element, even of a decorative nature. In particular, said shapes can reproduce, for example, the shape of living and non-living objects, like animal tracks, flowers, landscapes etc., thus ensuring that the obtained element has particular aesthetic features.

The above clearly shows that in any case these shapes can be of any type and that they can be chosen according to the particular roughness characteristics to be obtained on the upper surface 3 of the element 1 being treated (for example according to its intended use). According to a preferred embodiment of the invention, the pressing operation can be carried out in such a way as to exert different pressures on the various parts of said upper surface 3.

In this way more or less compact areas are obtained on the upper surface 3 of the element. In this case, therefore, the element obtained will clearly have an exposed surface 3 in which it is possible to identify areas having different technical/functional characteristics.

This may be obtained even using more than one pressing element 8 (mould), even at the same time. This makes it possible to obtain rough areas having different shape and depth, The pressing operation can be advantageously carried out with a cold or hot process.

In particular, the hot pressing process can be a dry or steam process.

It is worth noting that in the particular example shown in Figure 2a the support element 2 consists of a stratified structure of the type described and represented in Figure Ib, comprising three layers 21, 22 and 23.

Each one of the elements 1, 100, 200 can also be varnished with an opaque varnish (for example an oil or wax varnish).

A further method for manufacturing an element for covering surfaces includes, in addition to the pressing operation, also the following operation: - applying to at least part of the upper surface 3 at least one layer 5 of refracting and/or reflecting and/or iridescent and/or bright and/or glossy and/or opacifying material of the type described above.

It is worth noting that in the particular example shown in Figures from 3 to 5 the support element 2 consists of a stratified structure of the type described and represented in Figure Ib, comprising three layers 21, 22 and 23.

It is clear, however, that the same operations can be carried out for any type of support element 2 of the type described above (for example in solid wood).

It should be noted that in the case where the surface 3 belongs to a body made of a wood material and more generally in the case where the surface is porous, the material 5, once applied, tends to get into the pores, advantageously sticking to the surface 3.

As regards the application of at least one layer 5 of material, it preferably includes glueing a sheet or foil of said material onto at least part of the upper surface 3. In the example represented herein, the material is a metallic material comprising gold and the foil is constituted by a film.

More particularly, in the non-limiting example schematically shown in Figures 6 and 7, the glueing operation includes the following steps:

- spreading on at least one part of the upper surface 3 a bonding agent 6, as schematically shown in Figure 6 (in the example the surface 3 has already been pressed and presents the roughness 3r); laying a film or a foil 51 of metallic material as schematically shown in Figure 7. Always according to the invention, as shown in particular in Figure 8, the method of the invention may also include a further operation for pressing the film 51 against the upper surface 3, carried out for example with another pressing means 8.

It should also be noted that the layer of material 5 can be obtained also by spraying solid particles of said material. More particularly, said material can, for example, consist of bright powder (for example gold, silver, precious metals) which is sprayed (applied) onto the upper surface 3 and fixed thereto by means of a bonding agent.

Always according to the invention, the method that is the subject of the invention may also comprise a drying stage, carried out for example in a furnace or in the air.

A further preferred embodiment of the method of the invention, schematically represented in particular in Figure 9, is differentiated from the previous ones due to the fact that said application consists in the application of at least one layer of varnish or oil or wax comprising powders or particles of the above mentioned material.

More precisely, the varnish used may be for example a metalized or mica varnish or a varnish comprising suspended particles of a refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above. Said varnish can be applied, for example, by means of sprayers indicated as a whole by number 10 in Figure 9.

As regards the support element and more particularly the upper surface 3, according to a preferred embodiment of the invention and as explained above, it belongs to a wooden body already subjected to pressing. According to a preferred embodiment, the method may also comprise the following operation: at least partial removal of said at least one layer of material 5, preferably in order to let at least one part of the upper surface 3 of the body 2 emerge.

This advantageously makes it possible to obtain an element having an exposed surface with particular brightness, gloss, luminosity thanks to the application of the layer 5 in addition to the intrinsic characteristics of the surface 3.

This removal stage preferably comprises at least one of the following operations: brushing and/or smoothing and/or scraping and/or sandblasting and/or scratching and/or rubbing and/or chemical etching, More particularly, the brushing operation, as shown in detail in Figure 10, is carried out with a generically rotary brush having a cylindrical or circular shape.

The brush 30 is preferably constituted by a series of bristles 31 made for example of a metallic, synthetic or natural material, according to the more or less aggressive action to be exerted on the surface. As an alternative, the brush may be of the ragged paper or Scotch-Brite type.

As schematically shown in the non-limiting example of Figure 11a, smoothing may be carried out with a body having an abrasive surface 41 like for example a roller 40 or a disc or a brush or a sandpaper strap with grain varying according to the result to be obtained on the surface. As schematically shown in Figure 11, the steel wool treatment is carried out with steel wool 70 or an abrasive cloth or a sponge. Steel wool preferably comprises threads of metallic or synthetic material, twisted at random.

As schematically shown in Figure 12, scraping is carried out with a scraping tool

80 generally constituted by sharp, preferably metallic elements 81 that cut the material 5, removing it at least partially. More particularly, said elements 81 are moved at random in order to obtain cuts with substantially random shape, dimension and characteristics.

As schematically shown in Figure 13, sandblasting is substantially carried out by using an abrasive component 91 (sand, metal gravel, sodium bicarbonate, ecc) ejected at very high pressure by a specific machine called sandblasting machine.

Scratching, very similar to scraping, is substantially carried out by cutting the surface with sharp elements or bodies in order to remove the above mentioned material at least partially.

As an alternative, the material can be removed by etching, the so-called pickling process, with acid or another chemical, natural or synthetic substance. The above clearly shows that it is possible to obtain different surface effects depending on the characteristics of the abrasives used or the processing parameters adopted for the operations described above. It is clear, therefore, that these parameters can be any and must be understood as part of the present invention.

A further preferred embodiment of the method of the invention is differentiated from the previous one due to the fact that at least one layer of refracting and/or reflecting and/or iridescent and/or bright and/or opacifying and/or glossy material of the type described above is applied only to some parts of the upper exposed surface previously subjected to a pressing operation.

This means that in this case application of the material is limited only to some areas, thus advantageously reducing the quantity of material 5 applied to the exposed surface, and reducing the production costs of the element. Said application of the refracting and/or reflecting and/or iridescent and/or bright and/or glossy material can be carried out, for example, by spraying, as schematically shown in Figure 14. In this case the spraying means 99 can be activated alternately or can be moved at random over the element 2. In this way spraying is carried out on specific areas. Alternatively, according to the proposed method it is possible to apply a film of material, for example metallic material, provided with some through openings 12, as schematically shown in Figure 15.

This advantageously makes it possible to obtain an element having an exposed surface with particular characteristics, which successively can undergo also the different processing operations described above. A further preferred embodiment of the method of the invention is differentiated from the previous ones due to the fact that, before pressing of the surface 3 and/or application of said at least one layer of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above, it comprises at least one of the following operations: cleaning at least one part of the upper surface 3 of the element 2.

These operations make it possible to enhance some of the characteristics of the material of which the upper surface 3 is made.

More particularly, the cleaning operation may comprise at least one sandblasting operation and/or steel wool treatment and/or brushing and/or smoothing and/or scraping operation of the type described above. A further preferred embodiment of the method of the invention is differentiated from the previous ones due to the fact that, before pressing of the surface 3 and/or application of said at least one layer of opacifying and/or refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above, a colouring substance and/or a varnish and/or an oil and/or a wax is applied to at least part of said upper surface 3.

This allows further special surface effects to be obtained.

More particularly, application of a colouring substance and/or a varnish is preferably carried out by spraying or French polishing or with a brush or roller or water wash or sponge. Said substance, furthermore, may be distributed uniformly or not on the surface 3, thus obtaining other different chromatic effects.

A further preferred embodiment of the method of the invention is differentiated from the previous ones due to the fact that, after pressing of the surface 3 and/or application of said at least one layer of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above, said at least one layer is fixed.

More particularly, said fixing operation is carried out by applying at least one preferably transparent layer of varnish and/or oil and/or wax.

More precisely, according to a preferred embodiment of the invention, said varnish is preferably shiny or matt.

Always according to a preferred embodiment of the invention, said varnish is also of the electrically insulating type.

A further preferred embodiment of the method of the invention is differentiated from the previous ones due to the fact that, before said fixing operation, it comprises a stage of oxidation of said at least one layer 5 of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above.

This allows a further special surface finish to be obtained.

It is clear that all the operations described above can be advantageously carried out while the support element 2 moves along a preferably rectilinear advance direction, as shown also in some of the figures mentioned above.

This makes it possible to obtain a method that can be applied to continuous production lines, thus ensuring lower manufacturing costs for each individual element. It is clear, however, that all and/or some of the operations described above can be carried out even manually by an operator, in particular when the material, more precisely the metal used is precious, for example gold and/or silver and/or platinum.

It should also be noted that according to a further preferred embodiment of the invention all the operations described with reference to the schematic figures from 9 to 15 are carried out before the pressing operation schematically shown in Figure 8. In other words, always according to the invention, pressing and creation of the roughness 3r can be performed, for example, after application of the material 5. A machine (substantially complete with all the working stations) for making elements for covering surfaces, preferably walking surfaces, subject of the present invention is schematically represented in Figure 16, where it is indicated as a whole by 500. It comprises conveyor means 501 defining an advance direction 502 and suited to receive one or more support elements 2.

According to the invention, the machine or system 500 comprises means 50Op suited to press the surface 3 and comprising a pressing roller (the machine may, however, include a press of the type schematically shown in Figure 2c; and in this case the advance of the machines would be by steps). Furthermore, the system comprises means 505 suited to apply a refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above to at least part of the upper surface 3 of the support element 2. It should be noted that in the example shown herein the material is constituted by a film of a precious material. More particularly, the conveyor means 501 comprise transport means constituted by at least a first transport line equipped with a first conveyor belt 503. In the example shown herein, the above mentioned means 505, suited to apply a refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type previously described, comprise a unit 506 for distributing a bonding agent 6 on the surface 3 of the body 2 and a unit 507 suited to lay a metallic film 51 on the surface 3 and a pressing roller 508.

In the example illustrated, the machine also comprises at least one unit for distributing a fixing material, arranged above the conveyor means 501 downstream of the means 505. Said distributing means can be of the sprayer or doctor blade type, and more generally of the type suited to spread a uniform film of varnish or oil or wax on said elements 2.

Figure 17 shows another example of a system or machine suited to implement one of the methods described above. In the machine it is possible to identify the various processing stations indicated as a whole by numbers 60Op, 601, 602, 603,

604, 605, 606.

Said stations 60Op, 601, 602, 603, 604, 605, 606 schematically represent some examples of equipment that carry out the operations described with reference to the above mentioned methods subject of the invention, More particularly:

- the station 60Op comprises a pressing station of the steam type (also in this case said press may be of the type shown in Figure 2c; in this case the advance of the machine would be by steps);

- the station 601 comprises a spray varnish and/or oil and/or wax treatment station (alternatively the station may also be of the roller type), if necessary followed by a drying station, not represented herein;

- the second station 602 consists of a brushing and/or sandblasting and/or smoothing station;

- the third station 603 comprises a station for application of the layer of opacifying and/or refracting and/or reflecting and/or iridescent and/or bright and/or glossy material of the type described above, constituted in the example by a metallic film; in the example shown herein the third station 603 comprises a unit 603 a suited to spread a layer of bonding agent, and a unit 603b for unwinding and applying a metallic film to the body 2, equipped with a pressing roller 603c;

- the fourth station 604 comprises a drying station and includes a furnace;

- the fifth station 605 consists of a brushing station;

- the sixth station 606 comprises a fixing station including, in the non- limiting example illustrated herein, a station for spraying a varnish or an oil or a wax.

It is clear that in other embodiments the system may or not comprise one or more of the above mentioned six processing stations indicated by numbers 601, 602, 603, 604, 605, 606, as described above with reference to the method that is the subject of the invention. More particularly, by way of example, it is worth noting that other systems, in addition to the station 60Op, may comprise:

- exclusively the third station 603 or the following combinations:

- the second station 602 and the third station 603; - the first station 601 , the second station 602 and the third station 603 ;

- the first station 601, the second station 602, the third station 603 and the fourth station 604;

- the first station 601, the second station 602, the third station 603, the fourth station 604 and the fifth station 605; - the first station 601, the second station 602, the third station 603, the fourth station 604, the fifth station 605 and the sixth station 606. In other words, the system may substantially comprise all the possible combinations, however including at least the station 60Op for pressing the surface 3 of the body 2 in each of them. Obviously, also the sequence of the operations described above may be different from that indicated in the examples, provided that it is suited to make elements with analogous characteristics.

In particular it should be noted that the pressing station 60Op (shown in Figures 16 and 17 as first station) can also be the last working station (see for example the station 60Op shown with broken lines in Figure 16).

Figure 18 shows a covering 700 comprising a plurality of elements for covering surfaces arranged side by side, wherein at least one of said elements for covering surfaces, indicated by 1 in the figure, is of the type that is the subject of the present invention. It should be noted in particular that the covering shown is a floor made up of elements that are all level.

As regards application and in particular laying of the element of the invention, it should be noted that it can simply rest on the surface to be covered or can be fixed to it by mechanical means, like for example screws or nails, or glued onto it.

It is also clear that the body 2, as well as the element 1, may have any geometrical shape and dimensions.

Finally, the edges of the element 1 may be provided with seats and/or projections suited to house/fit in corresponding projections/seats of analogous elements suited to be positioned adjacent to it. This makes it possible to match the various elements during application to the surface to be covered.

It should therefore be noted that the scope of the present invention is defined by the claims, including all forms equivalent to those claimed.

It should also be observed, as already explained, that the sequence of the various operations described above, comprising at least one pressing operation on the upper surface 3, may vary according to the type of result to be obtained (for example, the material 5 may be applied before pressing the surface 3, etc.).

Each one of the elements 1, 100, 200 can furthermore be subjected to a varnishing treatment with matt varnishes or to oil, wax and similar treatments, or be left raw.

The above clearly shows that the proposed solution allows the set objects to be achieved.

Even though the invention has been described making reference to the attached drawings, in the construction stage changes can be made that shall all be considered protected by the present patent, provided that they fall within the scope of the inventive concept expressed in the following claims.

It is also worth noting that where the characteristics mentioned in the following claims are followed by reference signs, these are used merely to facilitate the readability of the claim itself and shall not be seen as limiting its interpretation in any way.

Claims

1) Method for manufacturing an element (1, 100, 200) for covering surfaces, preferably walking surfaces, comprising the following operations:

- positioning of a support element (2) that defines an upper surface (3) and a lower surface (4), characterized in that it also comprises at least one pressing operation for pressing at least part of said upper surface (3).

2) Method according to claim 1), characterized in that said at least one pressing operation is carried out in such a way as to increase the hardness of the material of which said surface (3) is made.

3) Method according to claims 1) or 2), characterized in that said at least one pressing operation is carried out by exerting on said visible surface (3) such a pressure as not to interrupt the vegetable fibres that make up the wooden element to which said visible surface (3) belongs. 4) Method according to claims 1) or 2) or 3), characterized in that said at least one pressing operation is carried out in such a way as to exert different pressures on the various parts of said upper surface (3).

5) Method according to any of the preceding claims, characterized in that said at least one pressing operation is carried out with at least one pressing element (8) having at least one portion of its upper surface (8s) suited to come into contact with said visible surface (3), at least one part of said at least one portion being provided with shapings and/or grooves and/or scores and/or cuts (8c) suited to be impressed on said visible upper surface (3).

6) Method according to any of the preceding claims, characterized in that the pressure exerted on said visible surface isn't constant on the entirety of said surface, so that more/less compact areas are obtained on the element to which said visible surface belongs.

7) Method according to any of the preceding claims, characterized in that it also comprises at least one of the following operations: - finishing; painting; application of at least one layer of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material (5) to at least some parts of said upper surface (3); - brushing and/or scraping and/or sandblasting and/or polishing and/or steel wool treatment.

8) Method according to claim 7), characterized in that it also comprises the following operation: at least partial removal of said at least one layer of material (5). 9) Method according to any of the preceding claims, characterized in that, before the pressing of said at least one layer of material, it comprises at least one of the following operations: cleaning and/or smoothing and/or polishing and/or brushing at least part of said upper surface.

10)Method according to any of the claims from 1) to 8), characterized in that said pressing operation is carried out and said surface is produced after performing all the other operations. l l)Method according to any of the preceding claims, characterized in that at least one of said operations is carried out while said support element moves along a preferably rectilinear advance direction. 12)Machine (500, 600) for manufacturing elements (1, 100) for covering surfaces, preferably walking surfaces, comprising a support element (2) in which it is possible to identify an upper surface (3) and a lower surface (4), said machine comprising conveyor means (501) defining an advance direction (502) and suited to receive one or more support elements (2), characterized in that it comprises means (505, 603) for pressing said at least one part of said upper surface (3).

13)Machine according to claim 12), characterized in that it also comprises at least one station for:

- applying a refracting and/or reflecting and/or iridescent and/or bright and/or glossy material (5), said station being:

- a spray painting station (601) and/or an oiling station and/or a waxing station and/or a roller coating station;

- a brushing and/or polishing and/or sandblasting and/or scraping and/or scratching station; - a drying station;

- a fixing station (606), preferably comprising a station for spraying a paint or oil or wax.

14)Machine according to claim 12) or 13), characterized in that it is designed to implement the method according to any of the claims from 1) to 11). 15)Element (1, 100) for covering surfaces, preferably walking surfaces, comprising a support element (2) defining an upper surface (3) and a lower surface (4), characterized in that it is manufactured in accordance with a method as per any of the claims from 1) to 11).

16)Element (I₅ 100) for covering surfaces, preferably walking surfaces, comprising a support element (2) defining an upper surface (3) and a lower surface (4), characterized in that at least some parts of said upper surface (3) present predetermined roughness.

17)Element according to claim 16), characterized in that said roughness is obtained by means of a pressing operation. 18)Element according to claim 17), characterized in that at least one part of said upper surface (3) is provided with at least one layer of refracting and/or reflecting and/or iridescent and/or bright and/or glossy material (5).

19)Covering (700) comprising a plurality of elements for covering surfaces (1,

100, 200) arranged side by side, characterized in that at least one of said elements (1, 100, 200) for covering surfaces is carried out according to any of the claims from 15) to 18).

20)Method or element or machine or covering according to any of the preceding claims, wherein said upper surface (3) belongs to a wooden body.