# US 12,747,596 B2 · Method and system for attaching an underlay element to a board element and an associated board element

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- Number: US 12,747,596 B2
- Document ID: US12747596B2
- Status: Granted
- Kind: B2
- Application number: 17/061,881
- Filed: 2020-10-02
- Published: 2021-04-08
- Granted: 2026-09-29
- Earliest claimed: 2019-10-04
- Assignees: Ceraloc Innovation AB
- Applicants: Ceraloc Innovation AB
- Inventors: Per Josefsson; Christoffer Nilsson; Niclas Hakansson
- Web page: https://patentgrep.com/patent/US12747596B2

## CPC

- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- E04F 15/0215: {specially adapted for being adhesively fixed to an underlayer; Fastening means therefor; Fixing by means of plastics materials hardening after application}
- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/14: characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/06: permitting easy separation
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 9/02: comprising animal or vegetable substances {, e.g. cork, bamboo, starch}
- B32B 9/042: {of wood}
- B32B 9/045: {of synthetic resin}
- B32B 13/04: comprising such {water setting} substance as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a glass layer B32B17/06)}
- B32B 13/045: {of foam}
- B32B 19/04: next to another layer of {the same or of} a {different material (next to a glass layer B32B17/067)}
- B32B 19/047: {of foam}
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/042: {of wood (B32B21/13 takes precedence)}
- B32B 21/047: {of foam}
- B32B 21/14: comprising wood board or veneer
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 37/0076: {characterised in that the layers are not bonded on the totality of their surfaces}
- B32B 37/1292: {selectively, e.g. in stripes, in patterns (B32B37/0076 takes precedence)}
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 37/22: involving the assembly of both discrete and continuous layers
- B32B 2250/02: 2 layers
- B32B 2260/026: Wood layer
- B32B 2260/046: Synthetic resin
- B32B 2262/067: Wood fibres
- B32B 2262/101: Glass fibres
- B32B 2264/067: Wood particles
- B32B 2264/10: Inorganic particles
- B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
- B32B 2266/0207: Materials belonging to B32B25/00
- B32B 2266/0221: Vinyl resin
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/025: Polyolefin
- B32B 2266/0264: Polyester
- B32B 2266/0278: Polyurethane
- B32B 2266/06: Open cell foam
- B32B 2266/08: Closed cell foam
- B32B 2307/538: Roughness
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/7246: Water vapor barrier
- B32B 2307/732: Dimensional properties
- B32B 2307/748: Releasability
- B32B 2309/72: For measuring or regulating, e.g. systems with feedback loops
- B32B 2419/00: Buildings or parts thereof
- B32B 2419/04: Tiles for floors or walls
- B32B 2479/00: Furniture
- B32B 2607/00: Walls, panels
- E04F 13/0885: {specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application}
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/105: {of organic plastics with or without reinforcements or filling materials}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- E04F 15/206: {Layered panels for sound insulation}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

A method for attaching an underlay element to a weight-reduced board element. The method includes providing a board element and an underlay element, wherein a rear side of the board element includes a groove portion and a remaining portion. The groove portion includes at least one groove. An adhesive is applied on at least a portion of the remaining portion and/or on at least a portion of a corresponding residual portion of the underlay element, and the underlay element is arranged on the rear side of the board element, such that the adhesive contacts the underlay element and the rear side.

## Claims

### Claim 1

A method for attaching an underlay element to a weight-reduced board element comprising a plurality of grooves, the board element being a panel per se or the board element being dividable into at least one panel, wherein the at least one panel is a floor panel or a wall panel, the method comprising:
providing the board element, wherein a rear side of the board element comprises a groove portion and a remaining portion, said groove portion comprising said plurality of grooves, and said remaining portion being provided in a horizontal plane (HP) extending along the rear side of the board element, wherein said remaining portion is located on a periphery of the groove portion, each of said plurality of grooves being a recess formed from an essentially planar surface on the rear side of the board element,
providing the underlay element, the underlay element being a foam or a cork sheet, wherein an upper side of the underlay element comprises a cover portion and a corresponding residual portion, which are configured to face and to be aligned with the groove portion and the remaining portion, respectively, when the underlay element is attached to the rear side,
applying an adhesive on at least a portion of said remaining portion and/or on at least a portion of the corresponding residual portion of the underlay element, such that the plurality of grooves is free of adhesive during application and the adhesive fully circumscribes the groove portion, and
arranging the underlay element on the rear side of the board element, such that the adhesive contacts the underlay element and the rear side, including between the remaining portion and the corresponding residual portion of the underlay element,
wherein the board element comprises at least one layer, said at least one layer comprising a thermoplastic material, and wherein the plurality of grooves at least partly penetrates the at least one layer, and
wherein the adhesive is applied at least on a peripheral portion of the rear side of the board element and/or on a peripheral portion of the upper side of the underlay element, wherein the applying of the adhesive is performed on at most 95% of said remaining portion and/or of the corresponding residual portion of the underlay element.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the method further comprises controlling said applying of the adhesive based on a characteristic of the plurality of grooves, wherein said controlling is based on data about the characteristic of the plurality of grooves.

### Claim 3 (depends on 2)

The method according to claim 2, wherein the characteristic is a shape of the plurality of grooves and/or an extension of the plurality of grooves in a first (X) and/or a second (Y) horizontal direction of the board element.

### Claim 4 (depends on 2)

The method according to claim 2, wherein the characteristic is:
a position of the plurality of grooves in the rear side and/or a distance between at least one pair of grooves of the plurality of grooves in the first (X) and/or the second (Y) horizontal direction, or
a distance between at least one pair of groove arrangements in the first (X) and/or the second (Y) horizontal direction, each groove arrangement comprising at least one groove of the plurality of grooves.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the method further comprises controlling said applying of the adhesive based on a characteristic of the plurality of grooves, and retrieving data about the characteristic of the plurality of grooves for controlling said applying of the adhesive.

### Claim 6 (depends on 5)

The method according to claim 5, wherein said data is obtained by scanning the rear side of the board element by a scanner.

### Claim 7 (depends on 6)

The method according to claim 6, wherein a position of the adhesive applied during the applying is based on the retrieved data.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the peripheral portion of the rear side of the board element comprises a peripheral portion of the at least one floor or wall panel, into which the board element is configured to be divided and/or wherein the peripheral portion of the upper side of the underlay element comprises a peripheral portion of at least one underlay unit, into which the underlay element is configured to be cut.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the adhesive is applied in a pattern arrangement.

### Claim 10 (depends on 1)

The method according to claim 1, wherein at least two grooves of the plurality of grooves are discontinuous grooves which have been discontinuously formed, and wherein said applying of the adhesive comprises:
applying the adhesive between the discontinuous grooves, and/or
applying the adhesive between corresponding cover portions of the underlay element.

### Claim 11 (depends on 1)

The method according to claim 1, further comprising:
cutting said underlay element into at least one underlay unit along at least one cutting portion, and/or
dividing said board element into the at least one floor or wall panel, along at least one dividing portion.

### Claim 12 (depends on 1)

The method according to claim 1, further comprising controlling the applying of the adhesive such that no, or substantially no, adhesive is applied on a rear-side portion of the board element and/or an upper-side portion of the underlay element configured to be further processed.

### Claim 13 (depends on 1)

The method according to claim 1, further comprising controlling said applying of the adhesive such that no, or substantially no, adhesive is applied in at least one cutting portion and/or at least one dividing portion.

### Claim 14 (depends on 1)

The method according to claim 1, further comprising controlling said applying of the adhesive such that no, or substantially no, adhesive is applied:
in a rear-side portion where a locking system, is configured to be formed, and/or
in an upper-side portion of the at least one underlay unit configured to be provided along said rear-side portion.

### Claim 15 (depends on 1)

The method according to claim 1, further comprising separating material elements removed from the underlay element and the board element during or after processing of the board element and the underlay elements.

### Claim 16 (depends on 1)

The method according to claim 1, is applied by roller coating.

### Claim 17 (depends on 1)

The method according to claim 1, wherein the adhesive substantially covers an entire extent of the rear side of the board element between the plurality of grooves.

### Claim 18 (depends on 1)

The method according to claim 1, wherein the essentially planar surface on the rear side of the board element includes a surface roughness.

### Claim 19 (depends on 1)

The method according to claim 1, wherein the essentially planar surface on the rear side of the board element is smooth.

### Claim 20 (depends on 1)

The method according to claim 1, wherein the peripheral portion of the rear side comprises the essentially planar surface.