# US 2009/0260313 A1 · Method for manufacturing floor panels and floor panel

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- Number: US 2009/0260313 A1
- Document ID: US20090260313A1
- Status: Published application
- Kind: A1
- Application number: 12/295,657
- Filed: 2007-04-04
- Published: 2009-10-22
- Earliest claimed: 2006-04-06
- Assignees: Flooring Industries, Ltd.
- Inventors: Martin Segaert
- Web page: https://patentgrep.com/patent/US20090260313A1

## CPC

- B44C 5/043: {containing wooden elements}
- B27M 1/00: Working of wood not provided for in subclasses B27B - B27L, e.g. by stretching
- E04F 15/02: Flooring or floor layers composed of a number of similar elements (of webs E04F15/16)
- E04F 15/02033: {Joints with beveled or recessed upper edges}
- E04F 2201/0115: with snap action of the edge connectors
- E04F 2201/0153: by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- B27M: WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)

## Abstract

Floor panel, of the type comprising at least a single- or multi-piece substrate, which at least partially consists of wood or wood-based material, wherein the floor panel, at least at two opposite sides, has profiled edge portions, which at least comprise coupling parts, as well as is provided, at least at one of these sides, with a chamfer, such that the floor panel shows at least a first surface formed by the actual upper side of the floor panel, a second surface formed by the surface of said chamfer, and a third surface formed by the portion of the profiled edge portion extending below said chamfer, wherein at the first, as well as at the second and third surface, coatings are present, a first coating, a second coating and a third coating, respectively, wherein at least one of said coatings is realized as a solidified substance.

## Claims

### Claim at position 1

1-37. (canceled)

### Claim 38

Floor panel, comprising a single or multi-piece substrate comprising wood or wood-based material, said panel at least at two opposite sides having profiled edge portions which at least comprise coupling parts, and at least at one of the sides having a chamfer, such that the floor panel includes at least a first surface formed by the actual upper side of the floor panel, a second surface formed by the surface of said chamfer, and a third surface formed by the portion of the profiled edge portion extending below said chamfer, wherein, on the first, second and third surfaces, a first, second and third coating, respectively, are provided wherein at least one of said coatings is in the form of a solidified substance.

### Claim 39 (depends on 38)

The floor panel of claim 38, wherein the first, second and third coatings each are separate coatings.

### Claim 40 (depends on 38)

The floor panel of claim 38, wherein the first and second coatings on the first and second surfaces are one and the same material, said material comprising partially the first and partially the second coating, and wherein said third coating is a separate cooling.

### Claim 41 (depends on 38, 39)

The floor panel of claim 38 or 39, wherein the first and second coatings are disposed in an overlapping manner.

### Claim 42 (depends on 38, 39)

The floor panel of claim 38 or 39, wherein the second and the third coatings are disposed in an overlapping manner.

### Claim 43 (depends on 38, 39)

The floor panel of claim 38 or 39, wherein said first coating comprises any of:
a laminate layer, comprising a resin, and optionally a laminate;
a foil;
a lacquer or varnish;
a polymer; or
an ink, optionally in the form of a print.

### Claim 44 (depends on 38, 39)

The floor panel of claim 38 or 39, wherein the second coating comprises any of:
a foil;
a transfer film;
a lacquer, varnish, or ink; or
a polymer.

### Claim 45 (depends on 38, 39)

The floor panel of claim 38 or 39, wherein the third coating comprises any of:
a foil;
a transfer film;
a lacquer, varnish, or ink;
a polymer; or
a moisture-repellent substance.

### Claim 46 (depends on 38)

The floor panel of claim 38, wherein the floor panel is a laminate floor panel having a top layer comprising a resin material, which top layer defines the first coating, and wherein the second and third coatings are formed as a unitary colorant layer.

### Claim 47 (depends on 38, 40)

The floor panel of claim 38 or 40, wherein the floor panel is a laminate floor panel, including a top layer comprising a resin, which top layer defines the first coating; wherein the second coating is a decorative layer, said second coating being optionally integral with the first coating; and wherein the third coating comprises a moisture-repellent layer, and partially overlaps said second coating.

### Claim 48

Floor panel, comprising at least a single- or multi-piece substrate and having a top layer at its upper side and two opposite sides having profiled edge portions which at least comprise coupling parts; and wherein said substrate at least partially comprises wood or wood-based material; and wherein the floor panel, on one or more of said profiled edge portions, has a transparent or translucent and moisture-repellent film-shaped coating, which covers all or part of the entire surface of the respective profiled edge portions and which extends from the surface of the respective profiled edge portion as far as onto said upper side of the floor panel.

### Claim 49 (depends on 48)

The floor panel of claim 48, wherein the film-shaped coating extends over the entire surface of the respective profiled edge portion.

### Claim 50 (depends on 48, 49)

The floor panel of claim 48 or 49, wherein the floor panel has a film-shaped coating on all sides or profiled edge portions, said coating extending from the respective side or from the respective profiled edge portion as far as onto said upper side of the floor panel.

### Claim 51 (depends on 48, 49)

The floor panel of claim 48 or 49, wherein the film-shaped coating is formed by a substance that has solidified from a liquid during or after application.

### Claim 52 (depends on 48, 49)

The floor panel of claim 48 or 49, wherein the film-shaped coating is a water-tight or substantially water-tight layer.

### Claim 53 (depends on 48, 49)

The floor panel of claim 48 or 49, wherein the film-shaped coating, with or without a moisture-repellent or waterproof top layer at the upper side of the floor panel and with or without a moisture-repellent or water-tight layer at the underside of the floor panel, constitutes an entirely complete moisture-repellent or water-tight encapsulation of the panel.

### Claim 54

Floor panel, comprising at least a one- or multi-piece substrate, substrate comprising wood or wood-based material, wherein the floor panel, at least at two opposite sides, has profiled edge portions which comprise coupling parts configured so as to enable mechanically coupling two of such floor panels to each other; wherein, in coupled condition, there is a locking in vertical and horizontal directions; wherein the floor panel, at least at the actual upper side, is provided with a top layer covering a first surface; wherein, viewed in cross-section, next to at least one of said sides, the top layer terminates at a first location; said floor panel further comprising a second surface extending from said first location at least over a portion of the edge portion; wherein, viewed in cross-section, at the second surface at least two different coatings, including a first coating and a second coating, are applied and which cover mutually differing, and optionally overlapping, zones; wherein, viewed along the contour of a side, the second coating extends farther downward than the first coating; wherein the first and the second coating are made layer-shaped; wherein the first and second coating together cover only a portion of the contour of the edge portion, with the second coating extending downward as far as a second location, said second location, in the coupled condition of two of such floor panels, being in contact with the other floor panel.

### Claim 55 (depends on 54)

The floor panel of claim 54, wherein the two coatings adjoin each other, optionally overlapping each other, and wherein on the edge portions of said sides exclusively layer-shaped coatings are applied.

### Claim 56 (depends on 54, 55)

The floor panel of claim 54 or 55, wherein the coating of an uppermost zone is made as a strip of narrow width.

### Claim 57 (depends on 54, 55)

The floor panel of claim 54 or 55, wherein the floor panel, viewed in cross-section, has a chamfer next to said first location and wherein the first coating extends at least partially over the chamfer, and wherein the second coating is at least partially disposed on a panel side wall located below the chamfer.

### Claim 58 (depends on 54, 55)

The floor panel of claim 54 or 55, wherein a lower edge of the first coating is disposed on a panel side wall or at the first location where the side wall starts, such that the first coating extends at least up to said first location where the floor panels abut against each other or almost against each other.

### Claim 59

Floor panel, comprising at least a single- or multi-piece substrate upon which a top layer is disposed, wherein the substrate at least partially comprises wood or wood-based material; wherein the floor panel, at least at two opposite sides, has profiled edge portions, which comprise actual side walls as well as coupling parts configured so as to enable two of said floor panels to be coupled mechanically to each other; wherein the coupling parts, in coupled condition of two of such floor panels, effect a locking in vertical as well as horizontal directions, and provide for an intentional gap between the actual side walls of the floor panels, or at least enable the floor panels to be coupled in such a manner that such intentional gap is created; the gap having side walls that are formed at least partially by the substrate; wherein the side walls of said gap, at the bottom, extend up to each other; and wherein at least on said side walls, a fixed coating is provided, such that the gap is not closed by the coating; and wherein the coating covers at least a portion of the wall of the substrate in the gap.

### Claim 60

Method for manufacturing floor panels having at least a single- or multi-piece substrate and having, at least at two opposite sides, profiled edge portions, which at least comprise coupling parts, wherein said substrate at least partially comprises wood