FLOORING SYSTEM HAVING LARGE FLOOR PATTERN

SYSTEME DE PLANCHER A MOTIFS DE GRANDE TAILLE

English Abstract

Laminated flooring planks (60) include decorative motifs (G) , mechanically
embossed-in-registration surface textures (A, B, C, D) , recessed perimeters,
and locking mechanisms (J) . By arranging portions of the decorative motifs
along edges of a flooring plank, "a" periodic flooring pattern larger than an
individual plank and that spans across both the length and width of a number
of planks may be formed by placing identical planks adjacent to one another in
a horizontal direction and adjacent in a vertical direction.

French Abstract

La présente invention a trait à des lames de parquet stratifiées comportant des motifs décoratifs, des textures de surface en relief mécaniquement superposées, des périmètres évidés et des mécanismes de blocage. Grâce à l'agencement des parties des motifs décoratifs le long des bords d'une lame de parquet, on obtient un motif de plancher périodique plus important que celui d'une lame individuelle et dont la portée s'étend sur la largeur et la longueur d'une pluralité de lames grâce à la mise en place de lames identiques adjacentes les unes aux autres dans une direction horizontale et adjacentes dans une direction verticale.

Claims

What is claimed is:


1. A system of forming a decorative pattern, the system comprising:
a first unit, the first unit comprising:

a first plurality of subunits having a pattern, wherein a subunit of the first

plurality of subunits includes a decorative motif substantially different from
the unit
pattern; and

a second unit adjacent the first unit, the second unit comprising:

a second plurality of subunits having the pattern, wherein a subunit of the
second plurality of subunits includes the decorative motif where the first
subunit and the
second subunit align with one another such that the decorative motifs of the
first subunit
and the second subunit align with one another thereby forming the decorative
pattern.

2. The system as recited in claim 1, the system further comprising:
a third unit, the third unit comprising:

a third plurality of subunits having the pattern, wherein a subunit of the
third plurality of subunits includes the decorative motif such that the
decorative motif of
the third subunit forms the decorative pattern with the decorative motif of
both the first
subunit and the second subunit.

3. The system as recited in claim 2, the system further comprising:
a fourth unit, the fourth unit having at least four subunits.



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4. The system as recited in claim 3, wherein the subunit of the first unit
having the
decorative motif is adjacent the subunit of the second unit having the
decorative motif.
5. The system as recited in claim 4, wherein an edge unit of the first unit
has the
decorative motif.

6. The system as recited in claim 4, wherein a subunit adjacent an edge unit
of the
second unit has the decorative motif.

7. The system as recited in claim 1, wherein the first unit includes at least
four
subunits.

8. The system as recited in claim 1, wherein the second unit includes at least
four
subunits.

9. The system as recited in claim 1, wherein the first unit and the second
unit are
laminate flooring planks having wood grain patterns.

10. The system as recited in claim 1, wherein the subunits comprise an
embossed
surface texture in registration with the decorative motif.

11. The system as recited in claim 1, the first unit comprising:

a tongue extending from a perimeter of one edge of the first unit; and



48



a groove running along a perimeter of an opposite edge of the first unit.
12. The system as recited in claim 11, the second unit comprising:

a tongue extending from a perimeter of one edge of the second unit; and

a groove running along a perimeter of an opposite edge of the second unit
where
any of the grooves are capable of receiving any of the tongues.

13. The system as recited in claim 9, wherein the pattern comprises an
embossed
surface texture.

14. The system as recited in claim 1, wherein the first and second units are
laminate
flooring planks having a ceramic tile surface pattern.

15. A method of forming a decorative pattern, the method comprising:

arranging a first unit, the first unit having a plurality of subunits with a
pattern
where a first subunit of the first plurality of subunits has a decorative
motif with a pattern
different from the subunit pattern; and

placing a second unit adjacent the first unit, the second unit having a
plurality of
subunits with the subunit pattern where one subunit of the second plurality of
subunits
has the decorative motif where the first subunit having the decorative motif
is adjacent
the second subunit having the decorative motif thereby forming the decorative
pattern.
16. The method as recited in claim 15, the method further comprising:



49



arranging a third unit adjacent the first unit or the second unit, the third
unit
having a plurality of subunits where one subunit of the third plurality of
subunits has the
decorative motif where the third subunit having the decorative motif is
adjacent one of
the first subunits having the decorative motif and the second subunit having
the
decorative motif.

17. The method as recited an claim 15, wherein the first unit has a tongue
extending
from a perimeter of a first edge and a groove at a perimeter of a second edge
opposite the
first edge.

18. The method as recited in claim 17, wherein the second unit has a tongue
extending from a perimeter of a first edge and a groove at a perimeter of a
second edge
opposite the first edge.

19. The method as recited in claim 18, further comprising:
interlocking the second unit tongue with the first unit groove.

20. The method as recited in claim 15, wherein the first unit and the second
unit are
laminate flooring planks having wood flooring planks.

21. The method as recited in claim 15, wherein the subunits comprise an
embossed
surface texture in registration with the decorative motif.






22. The method as recited in claim 20, wherein the pattern comprises an
embossed
surface texture.

23. The method as recited in claim 15, wherein the first and second units are
laminate
flooring planks having ceramic tile patterns.

24. The method as recited in claim 15, wherein both the first unit and the
second unit
include at least four subunits.

25. A system for forming a decorative pattern, the system comprising:

a first unit having a plurality of subunits where the first plurality of
subunits have
a pattern disposed thereon, one subunit of the first plurality of subunits
having a
decorative motif where the decorative motif is substantially different from
the subunit
pattern; and

a second unit having a plurality of subunits where the second plurality of
subunits
have the subunit pattern and one subunit of the second plurality of subunits
has the
decorative motif where the decorative motifs of the first subunit and the
second subunit
align with each other when the first unit is set offset relative to the second
unit wherein
the aligned decorative motifs form the decorative pattern.

26. The system as recited in claim 25, the system further comprising:

a third unit having at least four subunits, where one of the one subunits has
the
decorative motif such that when the third unit is set offset relative to both
the first and



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second units, the decorative motif of the third subunit aligns with the
decorative motifs
on the first subunit and the second subunit.

27. The system as recited in claim 25, the system further comprising:
a fourth unit having at least four subunits.

28. The system as recited in claim 25, wherein both the first unit and the
second unit
have at least four subunits.



52

Description

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BACKGROUND OF THE INVENTION

Field of the Invention

[0001] The present invention relates to laminated materials. More
particularly,
the present invention relates to a flooring system of interlocked laminated
materials
having decorative motifs and surface textures that are mechanically embossed
in
registration with their decorative motifs.

Discussion of the Related Art

[0002] Because of their look and feel, traditional building and finishing
flooring
materials such as fine woods, slate, granite, stones, brick, and concrete are
generally
preferred by consumers. However, such traditional building and finishing
flooring
materials tend to be expensive to produce and install. For example, while a
solid wood
floor has a highly valued luxurious appearance, the materials and labor
required to install
such floors can be prohibitively expensive.

[0003] Many alternatives to traditional building and finishing flooring
materials
are available, including laminates such as high-pressure laminates (HPL),
direct-pressure
laminates (DPL), and continuous-pressure laminates (CPL). However, such
alternatives
typically do not possess the realistic look and texture of the traditional
building and
finishing flooring materials. For example, most alternatives having an outer
surface with
a wood motif look fake and can readily be identified as something other than
authentic
wood. Furthermore, while high quality HPL, DPL, or CPL boards may visually
look like
wood, their textures readily reveal that they are not.

[0004] One problem with most alternatives to traditional building and
finishing
flooring materials is that their surface textures do not match their
decorative motifs. For
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example, visual depictions of wood knots in alternative flooring materials are
not
matched with surface textures characteristic of the wood knots. Accordingly,
the
attractiveness of these alternative materials is significantly reduced.

[0005] One approach used to match the surface texture of alternative flooring
materials to their decorative motifs includes a technique known as chemical
embossing.
In chemical embossing, the surface texture of the alternative material is
developed by
chemically reacting an ink that forms the decorative motif with an agent added
to a sub-
surface layer. While somewhat successful, the resulting surface texture tends
to lack the
textual sharpness and three-dimensional characteristics of traditional
materials.

[0006] As an alternative to the traditional building and finishing flooring
materials laminated materials may be mechanically embossed to produce a
surface
texture. See, for example U.S. Patent Application 09/903,807 and U.S. Patent
No.
6,401,415, which are hereby incorporated by reference. Such methods produce
embossed-in-registration laminated materials having decorative motifs and
matching
high-quality three-dimensional textures. Embossed-in-registration laminated
materials
require accurate registration of mechanical embossment and the decorative
motif. An
advantage of embossed-in-registration laminated materials is that they can
realistically
reproduce the look and feel of traditional products.

[0007] No matter what type of flooring system is used, the flooring system
must
be easily moved to a work site while being easy and quick to install. To this
end,
assembly and locking mechanisms may be incorporated within flooring systems to
facilitate on-site installation. One type of assembly and locking mechanism is
the tongue

and groove system used for connecting panels. It is understood that such
tongue and
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groove systems are disclosed in Cherry, U.S. Pat. No. 2,057,135, and in
Urbain, U.S. Pat.
No. 2,046,593. For example, Figure 1 can be interpreted to illustrate a tongue
and
groove system 11 that uses clips 12 to secure panels together.

[0008] Another type of assembly and locking mechanism is understood to be
disclosed in Chevaux, U.S. Pat. No. 3,946,529 where a flooring system 13
appears to be
connected using a tongue and groove system arranged underneath the flooring,
reference
Figure 2.

[0009] Still another assembly and locking mechanism is taught in Kajiwara,
U.S.
Pat. No. 5,295,341. There, it is understood that laminated boards are provided
with a
snap-together system such as a groove-tongue joint. As a result the laminated
boards can
be assembled without glue. Referring to Figure 3, the laminated boards are
provided with
a locking means in the form of a groove connector 16, and a tongue connector
18. The
groove connector 16 has forwardly protruding grooves 20, while the tongue 18
is
provided with a pair of forwardly diverging sidewalls 22 and 24 that are
separated by an
elongated groove 26. The sidewalls include rear locking surfaces 28 and 36.
The
sidewalls can be compressed together to enable locking.

[0010] Another type of assembly and locking mechanism is the snap-together
joint is suggested in Martensson, U.S. Pat. No. 6,101,778. As shown in Figure
4, it is
understood that laminated boards are provided with a locking means comprised
of a
groove 6 and a tongue 7 that form a tongue-groove assembly. The groove 6 and
tongue 7

may be made of water tight material and snapped together with a portion 9
fitting in a slot
4.

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[0011) While the aforementioned assembly and locking mechanisms have proven
useful, they have not been used with embossed-in-registration laminate systems
in which
embossed-in-registration decorative motifs or graphics align across joints
between the
individual embossed-in-registration laminates. This significantly detracts
from the visual
and textural impression of systems comprised of embossed-in-registration
laminate
boards. Therefore, a new embossed-in-registration laminate system in which the
visual
and textural patterns cross joints while retaining the embossed-in-
registration aspects
would be beneficial. Even more beneficial would be an embossed-in-registration
laminate system comprised of interlocking embossed-in-registration laminate
boards in
which the visual and textural patterns cross joints while retaining embossed-
in-
registration aspects.

[0012] Further, the aforementioned flooring systems have a relatively low
ability
to resist wear. While not wishing to be bound by any particular theory, it is
hypothesized
that premature aging (wear) begins at or near the perimeter edges and/or along
tongue
and groove lines. The aforementioned flooring systems have a substantially
even (level)
surface texture such that the center and perimeter of each panel contact users
(e.g.,
pedestrians) an equal amount. The perimeter of each panel, however, is
substantially
weaker than the center of the panel and therefore deteriorates first.

[0013] In addition, flooring systems typically do not have decorative motifs
or
pattern designs that are longer than the length of a plank. For example, in a
flooring
system designed to reproduce a wood floor having wood strips, the length of
the wood
strip pattern is typically equal to or shorter than the length of a single
plank. This is

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desirable in related art flooring systems because it does not require the
installer to plan
more than one plank beyond the plank being installed.

[0014] Accordingly, there is a need for a workable method of fabricating
alternative building or finishing materials where the alternatives have the
realistic look
and feel of traditional products and have an increased capacity to resist
premature wear,
and in which the minimum number of planks is used maintained while still being
able to
create design motifs or pattern elements with a length greater than that of a
single plank.
SUMMARY OF THE INVENTION

[0015] Accordingly, the present invention is directed to embossed-in-
registration
flooring system that substantially obviates one or more of the problems due to
limitations
and disadvantages of the related art.

[0016] An advantage of the present invention provides an embossed-in-
registration flooring system including individual adjacent flooring planks
having
embossed-in-registration decorative motifs where at least one of a surface
texture and

decorative motif is substantially aligned between adjacent flooring plank.

[0017] Another advantage of the present invention provides an embossed-in-
registration flooring system including interlocked flooring planks having
embossed-in-
registration decorative motifs where at least one of a surface texture and
decorative motif
is substantially aligned between adjacent flooring planks such that
substantially
continuous embossed-in-registration patterns are formed across the interlocked
flooring
planks.



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[0018] Another advantage of the present invention provides an embossed-in-
registration flooring system may, for example, include flooring planks wherein
a surface

of a perimeter of each individual flooring plank may be recessed such that an
upper
surface of the perimeter of the flooring planks is below a portion of an upper
surface of
the flooring planks surrounded by the perimeter.

[0019] Another advantage of the present invention provides a plank comprising
a
plurality of sides defining a perimeter; a plurality of edge patterns arranged
proximate at
least one first portion of the perimeter, wherein at least two of the
plurality of edge
patterns are substantially identical; and at least one bulk pattern arranged
adjacent the
plurality of edge patterns and proximate at least one second portion of the
perimeter,
wherein at least one bulk pattern and an edge pattern adjacent the at least
one bulk pattern
forms a substantially continuous pattern.

[0020] Another advantage of the present invention provides a flooring system,
comprising at least two planks adjacent each other along a predetermined
direction,
wherein each plank comprises: a plurality of sides defining a perimeter; a
plurality of
edge patterns arranged proximate at least one first portion of the perimeter,
wherein at
least two of the plurality of edge patterns are substantially identical; and
at least one bulk
pattern arranged adjacent the plurality of edge patterns and proximate at
least one second
portion of the perimeter, wherein at least one bulk pattern and an edge
pattern adjacent
the at one least bulk pattern forms substantially continuous pattern; herein
edge patterns
of the at least two planks form a substantially continuous pattern.

[0021] A further advantage of the present invention provides a floor panel,
comprising a plurality of sides defining a perimeter; a surface having thereon
a decorative
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motif, said decorative motif conlprising at least two edge patterns adjacent
each of the
sides of the panel and at least one bulk pattern in the interior of the panel
and adjacent the
edge pattern on each side, wherein at least one edge pattern along a side is
substantially
identical to the edge pattern in a corresponding position along an opposite
side; and
wherein at least one portion of the decorative motif along a side is
substantially different
from the corresponding portion of the decorative motif along an opposite side.

[0022] Additional features and advantages of the invention will be set forth
in the
description which follows, and in part will be apparent from the description,
or may be
learned 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.

[0023] It is to be understood that both the foregoing general description and
the
following detailed description are exemplary and explanatory and are intended
to provide
further explanation of the invention as claimed.

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BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings, which are included to provide a fiuther
understanding of the invention and are incorporated in and constitute a part
of this
specification, illustrate embodiments of the invention and together with the
description
serve to explain the principles of the invention.

[0025] In the drawings:

[0026] Figure 1 illustrates a related art assembly and locking mechanism;
[0027] Figure 2 illustrates another related art assembly and locking
mechanism;
[0028] Figure 3 illustrates yet another related art assembly and locking
mechanism;

[0029] Figure 4 illustrates still another related art assembly and locking
mechanism;

[0030] Figure 5 illustrates a perspective view of components in an embossed-in-

registration flooring plank according to the principles of the present
invention;

[0031] Figure 6 illustrates a press machine capable of fabricating embossed-in-

registration flooring planks in accordance with the principles of the present
invention;
[0032] Figure 7 illustrates an embossed-in-registration flooring plank in one
aspect of the present invention;

[0033] Figure 8 illustrates a top view of a system of embossed-in-registration
flooring planks in another aspect of the present invention;

[0034] Figure 9 illustrates a cross-sectional view along line 9-9 shown in
Figure
8;

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[0035] Figure 10 illustrates a top view of a system of embossed-in-
registration
flooring planks in yet another aspect of the present invention;

[0036] Figure 11 illustrates a cross-sectional view along line 11-11 shown in
Figure 10;

[0037] Figures 12A and 12B illustrate schematic views including a perimeter
surface portion of a flooring plank in accordance with the principles of the
present
invention;

[0038] Figures 13A and 13B illustrate a flooring system in still another
aspect of
the present invention;

[0039] Figures 14A-14C illustrate an exemplary plank of a flooring system in
still
another aspect of the present invention and

[0040] Figures 15A-15E illustrate an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention.

[0041] Figure 16 illustrates an exemplaiy method of forming patterns on a
flooring plank in accordance with the principles of the present invention;

[0042] Figure 17 illustrates an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention;

[0043] Figure 18 illustrates an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention;

[0044] Figure 19 illustrates an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention;

[0045] Figure 20 illustrates an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention;

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[0046] Figure 21 illustrates an exemplary method of forming patterns on a

flooring plank in accordance with the principles of the present invention; and

[0047] Figures 22A-22D illustrate an exemplary method of forming patterns on a
flooring plank in accordance with the principles of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0048] Reference will now be made in detail to embodiments of the present
invention, examples of which are illustrated in the accompanying drawings.

[0049] Figure 5 generally illustrates components of a flooring plank according
to
the principles of the present invention.

[0050] Referring to Figure 5, an embossed-in-registration flooring system may,
for example, include at least one flooring plank. In one aspect of the present
invention
each flooring plank may include a board substrate 40 made out of a substrate
material
(e.g., a medium or high density fiberboard, chipboard, etc.), at least one
base sheet 48
(e.g., a kraft paper sheet) impregnated with predetermined resins and arranged
over
and/or under the board substrate 40, a decorative paper sheet 44 about 0.15 mm
thick and
impregnated with a polymerizable resin (e.g., phenols such as melamine)
arranged over
the board substrate, and at least one protective overlay sheet 46 arranged
over the
decorative paper sheet 44. In one aspect of the present invention, each
protective overlay
sheet 46 may be formed from a highly resistant paper impregnated with a
melamine
solution containing corundum (A1203), silica, etc. In another aspect of the
present
invention, different papers may be arranged between the decorative paper sheet
44 and



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the board substrate 40. In one aspect of the present invention, the at least
one protective
overlay sheet 46 and the base sheet 48 may be impregnated with a resin. In
another

aspect of the present invention the resin impregnating the at least one
protective overlay
sheet 46 and the base sheet 48 may be different from the melamine resin used
to
impregnate the decorative paper sheet 44.

[0051) In one aspect of the present invention, flooring planks within a
flooring
system may be fabricated from substantially the same paper, resin, etc. For
example,
flooring planks within a flooring system may be fabricated using paper made
from
substantially the same paper fibers (having, for example, substantially the
same ash
content, color, and orientation) on the same on the same paper making machine.
Further,
flooring planks within a flooring system may be fabricated using paper
originating from a
single, contiguous section on the manufacturing spool. All of the
aforementioned paper
use restrictions that may be employed in fabricating flooring planks of a
flooring system
ensure that impregnated papers will always have substantially the same final
dimensions
after they are pressed and cured. In one aspect of the present invention, the
warehousing
of paper used to fabricated flooring planks within a flooring system may be
controlled
such that the time, temperature, and humidity in which the paper is stored is
maintained
to facilitate consistent flooring plank dimensions. In another aspect of the
present
invention, flooring planks within a flooring system may be fabricated using
cellulose
paste made from the same manufacturer. In yet another aspect of the present
invention,
flooring planks within a flooring system may be fabricated using resins made
from the
same manufacturer. In still another aspect of the present invention, the
resins may
contain powder originating from substantially the same source, have
substantially the

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same chemical and physical qualities, and be mixed in the same reactor.
Further, flooring
planks within a flooring system may be fabricated using resins have a
substantially
constant solids content. All of the aforementioned resin use restrictions that
may be
employed in fabricating the flooring planks ensure that impregnated papers
will always
have substantially the same final dimensions after they are pressed and cured.
In still
another aspect of the present invention, each of the flooring planks within a
flooring
system may be fabricated using substantially the same impregnation process.
For
example, when dipping the various sheets of paper into melamine resin, the
paper should
experience a constant, uniform melamine load. Further, a band tension and
oscillation of
the impregnation machine should be precisely controlled as they influence the
degree to
which the various paper sheets are impregnated with the resin.

[0052] According to the principles of the present invention, the
aforementioned
sheets and substrates may be fabricated into an embossed-in-registration
flooring system
including a plurality of interlocking flooring planks. To produce such a
flooring system,
a press machine, such as a press machine shown in Figure 6, may be used to

mechanically emboss each flooring plank in registration with a decorative
motif arranged
on the decorative paper sheet 44.

[0053] Referring to Figure 6, the press machine may, for example, include a
base
42, a top press 54, and an upper press plate 56. In one aspect of the present
invention, the
upper press plate may include an embossing pattern (e.g., a three-
dimensionally textured
surface). Accordingly, the embossing pattern may, for example, include
elevated ridges,
dots, depressions, etc., of any design capable of being aligned with a
decorative motif
formed on the decorative paper sheet 44.

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[0054] According to the principles of the present invention, the impregnated
decorative paper sheet 44 arranged on the board substrate 40 must be
accurately

positioned relative to the embossing pattern of the upper press plate to
enable an
embossed-in-registration flooring plank. In one aspect of the present
invention,
alignment between the embossing pattern of the press plate and the decorative
motif must
be ensured when the press is in a locked position and the board is under
pressure. The
degree of control required may vary depending on the type of decorative motif
used. For
example, alignment of a wood grain embossed-in-registration motif across
adjacent
einbossed-in-registration flooring planks requires a higher degree of
alignment than
alignment of a wood grain embossed-in-registration motif that is not aligned
with
adjacent flooring planks,

[00551 Alignment between the decorative motif on the decorative paper sheet 44
and the embossing pattern on the upper press plate 56 may be achieved by
removing
about 2 to 3 millimeters of material around the perimeter of the board
substrate 40 in a
milling process thereby yielding several reference planes (e.g., board edges)
and a board
substrate having tightly controlled dimensions. Next, an impregnated
decorative paper
sheet 44 having exterior dimensions about 8 or 10 mm smaller than the board
substrate
40 is arranged on the board substrate 40. In one aspect of the present
invention, the
impregnated decorative paper sheet 44 may be arranged on the board substrate
40 using
the board edges as alignment means. In one aspect of the present invention,
alignment
marks may be arranged on the board substrate 40 and be alignable with
alignment marks
provided on the decorative paper sheet 44.

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[0056] In one aspect of the present invention, the decorative paper sheet 44
may

be attached to the board substrate 40 via static electricity. After they are
attached, the
decorative paper sheet 44 and the board substrate 40 are arranged on a
carriage feeding
into the press machine. The static electricity may substantially prevent the
decorative
paper sheet 44 from being accidentally displaced as the board substrate 40 is
moved with
the carriage. In one aspect of the present invention, the carriage may be
stopped just
before it enters into the press machine such that the decorative paper sheet
44 may be
precisely arranged over the board substrate 40 using, for example, tweezers
(not shown).
In another aspect of the present invention, the tweezers may be used to
precisely arrange
the decorative paper sheet 44 over the board substrate 40 arranged on the
lower press
plate. In one aspect of the present invention, the decorative paper sheet 44,
the at least
one protective overlay sheet 46, and the optional base sheet 48 may be
arranged over the
board substrate 40 prior to being arranged within the press machine. After the
decorative
paper sheet 44 is arranged over the board substrate 40, the carriage may be
moved out of
the press machine. Next, an alignment system substantially aligns the
decorative paper
sheet 44/board substrate 40 system with the embossing pattern in the upper
press plate
56. In one aspect of the present invention, the alignment system may use the
board edges
to substantially align the decorative motif 44 with the embossing pattern on
the upper
press plate 56. The press machine may be operated after the alignment is
complete.

[0057] In one aspect of the present invention, after the components
illustrated in
Figure 5 are arranged within the press machine and aligned with the embossing
pattern,
the various sheets and substrate may be pressed and cured for predetermined
amount of
time until the resins set, yielding an extremely hard and wear resistant
flooring plank.

14


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
For example, after being inserted into the press machine and aligned with the
embossing
pattern, the board substrate 40, decorative paper sheet 44, protective overlay
sheet 46,

and optional base sheet 48 may be heated at a temperature of about 160-220 C
and
pressed together under a pressure of about 20-40 Kg/cm2 for about 20 to 60
seconds.
Accordingly, the top press 54 presses the embossing pattern of the upper press
plate 56
into the decorative paper sheet 44 and board substrate 40 structure. The
combination of
the applied heat and pressure fuses the decorative paper sheet 44 and the
board substrate
40 together. The alignment system ensures that the decorative paper sheet 44
is
substantially aligned with the embossing pattern in the upper press plate 56.

Accordingly, melamine resin within the various sheets may be cured and an
embossed-in-
registration plank may be produced.

[0058] In one aspect of the present invention, porosity within the fused piece
may
be minimized by slowly curing the resins (e.g., the melamine). Accordingly, as
the
operating temperature is reduced, the time during which the various sheets
within the
press machine are pressed is increased. In another aspect of the present
invention, as the
press plate 56 is heated to about 160-220 C the embossing pattern included
within the
press plate may expand. Accordingly, the embossing pattern on the press plate
56 may
be provided so as to compensate for the expansion of the pattern. Therefore,
the
dimensions of the embossing pattern are provided such that they substantially
correspond
to the design of the decorative motif when the resins within the components of
Figure 5
are cured.

[0059] According to the principles of the present invention, a mechanically
embossed surface texture may be imparted to an individual flooring plank
having a


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
decorative motif. In one aspect of the present invention, the mechanically
embossed
surface texture may be provided in registration with the decorative motif.
Accordingly,

an embossed-in-registration flooring plank may be fabricated. In another
aspect of the
present invention, a plurality of embossed-in-registration flooring planks may
be joined
together to form an embossed-in-registration flooring system. In yet another
aspect of the
present invention, at least a portion of embossed-in-registration patterns of
adjacent
flooring planks may be substantially aligned with each other to form
substantially
contiguous embossed-in-registration patterns across adjacent flooring planks
within the
flooring system.

[0060] While the embossed-in-registration process described above is suitable
for
embossed surface textures that are less than about 0.2 mm deep, deeper surface
textures
may be problematic. Embossing patterns capable of imparting deep surface
textures, for
example, require relatively large press plate protrusions that tend to disturb
the pressure
homogeneity applied across the board surface. This pressure disturbance can
cause
distortions in the final product. In one aspect of the present invention,
embossed surface
textures may be formed greater than about 0.2 mm deep by hollowing out the
board
substrate 40 at locations where deep surface textures are desired. In one
aspect of the
present invention, the hollowing out process may be performed before, during,
or after
the perimeter of the board substrate 40 is milled as described above. In
another aspect of
the present invention, the board edges may be used to locate the boundaries of
the
hollowed out portions of the board substrate 40.

[0061] Referring to Figure 7, an embossed-in-registration flooring plank 60,
fabricated according to the process described above may optionally include a
protective
16


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
padding layer 50 on one side. The mechanically embossed surface texture is
registered
with the decorative motif 68 of the decorative paper sheet 44. By
registration, it is meant
that the embossed surface texture is substantially aligned with the decorative
motif of the
decorative paper sheet 44. By providing an embossed-in-registration flooring
plank, a
realistic representation of a natural material may provided to individual
flooring planks.
While the decorative motif illustrated in Figure 7 realistically represents
the image and
texture of a wood grain, it should be appreciated that other embossed-in-
registration
designs such as ceramic planks, concrete, marble, etc., may be produced.

[0062] According to the principles of the present invention, each of the
individual
flooring planks may, for example, include at least one locking mechanism.

[0063] In one aspect of the present invention, locking mechanisms may be
incorporated within the board substrate 40 before the embossing pattern is
imparted to the
surface of the board substrate 40 in registration with the decorative motif.
Accordingly,
locking mechanisms may be fabricated within individual board substrates 40.
Next, the
locking mechanisms may be used to join individual board substrates together to
form a
plank structure. The plank structure may then be inserted into the press 54.
After the
embossing pattern is imparted to the plank structure and the fused components
are fused
together, the plank structure is removed from the press 54. Next, embossed-in-
registration flooring planks 60 within the fused plank structure are separated
by
unlocking the locking mechanisms. In one aspect of the present invention,
cutting tools
may be used to assist in the separation and to ensure the decorative motif is
not damaged.

[0064] In another aspect of the present invention, the locking mechanisms may
be
incorporated within the board substrate 40 after the embossing pattern is
imparted to the
17


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
surface of the board substrate 40 in registration with the decorative motif.
Accordingly, a
board substrate 40 having relatively large dimensions of, for example, 4'x8',
may be
embossed by the press 54. Next, the resulting embossed-in-registration
substrate may be
cut into a plurality of individual embossed-in-registration flooring planks
60. In one
aspect of the present invention, edges of the individual embossed-in-
registration flooring
planks 60 may have smooth edges and precise dimensions. In one aspect of the
present
invention, the cutting may be performed using shaping tools, milling tools,
cutting tools,
breaking tools, etc. In one aspect of the present invention, the board
substrate may be cut
by the press machine. Accordingly, the board substrate 40 may be cut into
units (e.g.,
strips) having dimensions of, for example, 300 x 300 mm, 400 x 400 mm, 600 x
600 mm,
1,200 x 300 mm, 1,200 x 400 mm, etc. Next, the locking mechanisms may be
incorporated within the individual embossed-in-registration flooring planks
60. In one
aspect of the present invention, the locking mechanisms may be hidden beneath
the

surface of the flooring planks or they may be visible.

[0065] According to the principles of the present invention, the locking
mechanisms may be incorporated within the individual embossed-in-registration
flooring
planks 60 by aligning the at least one of the board edges, alignment marks,
decorative
motifs, and surface textures of the flooring plank with a milling tool. By
aligning the
milling tool with any of the aforementioned alignable features, locking
mechanisms may
be milled into the sides of the board substrates 40 such that, when flooring
planks 60 are
joined together the at least a portion of the decorative motifs form a
continuous pattern
and at least a portion of the embossed-in-registration patterns form a
substantially
continuous surface texture across adjacent flooring planks.

18


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WO 2006/123245 PCT/IB2006/001618
[0066] According to the principles of the present invention, the embossed-in-
registration flooring plank 60 may include a locking mechanism 64 (e.g., at
least one of a
tongue and groove locking system, a snap-together locking system, etc.)
extending along

all four sides of the embossed-in-registration laminate 60. For example, a
snap-together
locking system may be added to all four sides of the embossed-in-registration
flooring
plank 60 and used to connect multiple embossed-in-registration flooring planks
60 into an
enibossed-in-registration flooring system 300 (as shown in Figure 8). The
number and
location of locking mechanisms may depend on the desired configuration of the
embossed-in-registration flooring system. For example, when an embossed-in-
registration flooring system abuts a corner, only two locking mechanisms are
required
(along the sides).

[0067] Referring to Figure 8, the embossed-in-registration flooring planks A
and
B may, for example, include locking mechanisms along four sides (e.g., along
joints J1,
J2, J3, and J4). Embossed-in-registration flooring planks C and D may, for
example,
include locking mechanisms along four sides (e.g., along joints J1, J2, J3,
and another
joint not shown).

[0068] Embossed-in-registration flooring planks including the aforementioned
locking mechanisms may be securely attached together with or without glue to
form an
embossed-in-registration laminate system 300. Multiple embossed-in-
registration
flooring planks may be joined together to obtain any desired shape for
flooring, planking,
or the like. The embossed-in-registration flooring planks may be joined to
each other
such that at least portions of embossed-in-registration patterns of adjacent
flooring planks

19


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
are substantially aligned with each other and form a substantially continuous
image and
embossed surface texture across flooring planks within a flooring system.

[0069] Figures 8 and 9 illustrate an exemplary embossed-in-registration
flooring
system 300 incorporating one type of locking mechanism on each of the
individual
embossed-in-registration flooring planks 60. Figure 9 illustrates an exemplary
embossed-
in-registration flooring system including flooring planks incorporating a snap-
type tongue
and groove locking mechanism. In one aspect of the present invention, the snap-
type
tongue and groove locking mechanism may be integrated into the sidewalls of
each
embossed-in-registration laminate 60 so as to ensure that embossed-in-
registration
patterns of adjacent flooring planks are substantially aligned with each other
and
substantially continuous within the flooring system.

[0070] Figure 9 illustrates a cross sectional view of Figure 8 taken along
line 9-9.
As shown, the locking mechanism may be fabricated by forming a groove 230, a
tongue
200, a channel 210, and a lip 220 along the edges of the embossed-in-
registration flooring
planks 60. The locking mechanisms on the embossed-in-registration flooring
planks 60
may be joined together by inserting the tongue 200 into the groove 230 of an
adjacent
embossed-in-registration flooring plank 60. Subsequently, the lip 220 is
secured within
channel 210, thereby joining adjacent embossed-in-registration flooring planks
60 into an
embossed-in-registration flooring system 300. In one aspect of the present
invention, the
embossed-in-registration flooring planks 60 labeled A, B, C and D may be
joined
together with or without glue. It should is appreciated that other types of
locking
mechanisms may be incorporated within the sides of the individual embossed-in-
registration flooring planks 60.



CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
[0071] Referring back to Figure 8, each of the embossed-in-registration
flooring
planks 60 may, for example, exhibit an embossed-in-registration ceramic plank
motif G1.
The ceramic plank motif may comprise a plurality of planks in the shape of
squares,
rectangles, triangles, circles, ovals, any other shape or design that are
separated by grout
lines. In one aspect of the present invention, widths of grout lines Wh, Wv,
and the
intraboard grout width W may be substantially equal. When incorporating the
snap-type
tongue and groove locking mechanism into the embossed-in-registration flooring
planks

60 the grout width adjacent the joints J 1, J2, J3, and J4 on each embossed-in-
registration
laminate A, B, C, and D are approximately one-half the intraboard grout width
W. For
example, the vertical plank grout width (Wv) across joint J1 is made up of
grout lines on
embossed-in-registration laminates A, B, C and D, such that when the embossed-
in-
registration laminates A, B, C, and D are joined at Jl the vertical grout
width (Wv) is
approximately equal to (W). Accordingly, the grout width on any individual
embossed-
in-registration flooring plank 60 adjacent a joint is one-half of intraboard
grout width
(W). In another aspect of the present invention, the horizontal and vertical
grout widths
Wh and Wv may be controlled such they are substantially equal to the
dimensions of the
intraboard grout width W. It should be appreciated, however, that the
dimensions of the
grout widths in the embossed-in-registration flooring planks depend on the
type of
locking mechanism incorporated and the decorative motif exhibited.

[0072] In addition to grout lines, many other decorative motifs may be used in
the
embossed-in-registration flooring system of the present invention. Referring
to Figures
and 11, a decorative motif exhibiting, for example, a wood grain surface G2
substantially aligned across joints J5 and J6 of adjacent flooring planks may
be provided.

21


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
According to the principles of the present invention, wood grain patterns
generally

include more elements (e.g., wood grain lines, wood knot 423, etc.) that
extend to the
perimeters of the flooring planks that need to be aligned than ceramic plank
motifs.
Accordingly, aligning the wood grain motif is generally more difficult than
aligning grout
line portions of the ceramic plank motifs. For example, aligning a first
portion of a wood
knot 423 on embossed-in-registration flooring plank E with a second portion of
the wood
knot 423 on embossed-in-registration flooring plank F is generally more
complex than
aligning grout line widths across joints of adjacent flooring planks.
Accordingly, when
fabricating a locking mechanism, consideration of all the graphic elements
(e.g., wood
grains lines and wood knots 423) must be considered to ensure a realistic
embossed-in-
registration flooring system 400. In one aspect of the present invention, at
least one
portion of the decorative motif may be used as an alignment marks ensuring
consistent
alignment of adjacent flooring planks.

[0073] In another aspect of the present invention, individual flooring planks
within the embossed-in-registration flooring system 400 may be joined together
with a
snap-type mechanical system as illustrated in Figure 11 depicting a cross
sectional view
of Figure 10 along line 11-11. Again, alignment techniques used in the
fabrication of the
locking mechanism such that the embossed-in-registration laminate system 400
has a
surface texture surface 423 that is substantially continuous across joints, J5
and J6.
Optionally, the embossed-in-registration laminates 60 have a protective
padding layer 70
under the base sheet 48.

[0074] Figures 12A and 12B illustrate schematic views of a flooring plank in
accordance with the principles of the present invention.

22


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
[0075] Referring to Figures 12A and 12B, an upper surface at the perimeter, P,
of
each embossed-in-registration flooring plank may be recessed below an upper
surface at
the portions of the flooring plank surrounded by the perimeter. An object
O(e.g., a users
shoe, a wheel, etc.) contacting the major surface, Ms, of a flooring plank
does not

generally contact the surface of the perimeter, Ps, due to the perimeter's
recessed surface.
In one aspect of the present invention, the perimeter may include a portion of
the flooring
plank extending from the edge of the flooring plank approximately 3.175 mm
toward the
center of the flooring plank. In another aspect of the present invention, the
depth to

which the surface of the perimeter of the flooring plank is recessed is
approximately
0.794 mm. In another aspect of the present invention, the surface of at least
one portion
of the perimeter of a flooring plank may not be recessed, as will be discussed
in greater
detail below with reference to Figure 13.

[0076] Accordingly, the embossed-in-registration pattern may be provided to
the
edges of the flooring plank and may be aligned with embossed-in-registration
patterns
formed on adjacent flooring planks while the edges of each individual flooring
plank may
be prevented from prematurely wearing.

[0077] Although it has been shown in Figures 8 and 10 that individual flooring
planks within a flooring system are substantially the same size and shape and
are joined
to each other such that each side of each flooring plank is joined to only one
adjacent
flooring plank, it should be appreciated that individual flooring planks
within a flooring
system may vary in size (e.g., width and/or length) and shape (e.g.,
rectangular, square,
triangular, hexagonal, etc.). In one aspect of the present invention,
individual flooring
planks may have complementary shapes capable of being assembled similar to a
puzzle

23


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
or mosaic. Further, one aspect of the present invention contemplates that
sides of
individual flooring planks may contact more than one adjacent flooring plank.

[0078] In accordance with the principles of the present invention, flooring
planks
within a flooring system may be arranged such that at least one side of each
plank
includes at least one sub-panel adjacent at least two other sub-panels. In
another aspect
of the present invention, each plank may include, either entirely or
partially, at least one
sub-panel, as will be described in greater detail below.

[0079] In Figure 13A, for example, partial sub-panel 134A of plank 130A may be
a complementary sub-panel with respect to neighboring partial sub-panel 136B
of plank
130B, adjacent plank 130A. With this arrangement, the partial sub-panels 134A
and
136B may be made to appear as one unitary sub-panel.

[0080] Still referring to Figure 13A, each of the planks 130A-F may comprise
at
least three sub-panels wherein at least one of the sub-panels is a unitary sub-
panel and at
least two of the sub-panels are partial sub-panels. For example, 132A is a
unitary sub-
panel and 134A and 136A are partial sub-panels.

[0081] In one aspect of the present invention, the unitary sub-panel 132A may
provide a complete decorative motif with or without an embossed surface
texture that
may or may not be in registration with the decorative motif. In another aspect
of the
present invention, the partial sub-panels 134A and 136A of a plank may provide
separated, incomplete decorative motifs with or without embossed surface
textures that
may or may not be in registration with the decorative motifs. In one aspect of
the present
invention, neighboring partial sub-panels of adjacent planks may be
complementary to
each other such that they provide a substantially complete decorative motif
and/or surface

24


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
texture and appear as a substantially continuous, unitary sub-panel. In one
aspect of the
present invention, complementary partial sub-panels may have complementary
decorative
motifs and/or embossed surface textures. Accordingly, when complementary
partial sub-
panels of adjacent planks are properly aligned, a substantially continuous
(i.e., complete)
decorative motif and/or embossed surface texture may be formed across
neighboring
complementary partial sub-panels. In one aspect of the present invention, sub-
panels
within a plank may or may not comprise substantially the same decorative motif
and/or
embossed surface texture.

[0082] Figure 13B illustrates a schematic view of an exemplary plank 130 such
as
that shown in Figure 13A.

[0083] In one aspect of the present invention, portions of the perimeter
surface of
each plank may be recessed at locations where neighboring sub-panels are not
complementary. In another aspect of the present invention, portions of the
perimeter
surface of each plank may be non-recessed at locations where neighboring sub-
panels are
complementary. Referring to Figure 13B, portions of the upper surface of the
perimeter
"P" of each of the planks 130 indicated by reference numeral 138a may be
slightly
recessed compared to the major surface of each of the planks (see also Figure
12B) to
prevent premature wear of each of the planks. Further, portions of the upper
surface of
the perimeter of each of the planks 130 indicated by reference numeral 138b
may be non-
recessed and substantially coplanar with the major surface of the sub-panels.
Recessing
only portions of the perimeter surface of each of the planks at positions not
occupied by
the decorative motifs and/or embossed surface textures of partial sub-panels
of a plank
allows complementary partial sub-panels to appear as a part of a unitary sub-
panel while



CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
not significantly detracting from the overall durability of each of the
planks. In yet

another aspect of the present invention, portions of the surface of each plank
may be
recessed at locations where sub-panels of a plank are adjacent one another.
Referring to
Figure 13B, portions of the upper surface of each of the planks 130 indicated
by reference
numeral 138c may be slightly recessed compared to the major surface of each of
the

planks (see also Figure 12B) to provide a visual and textural effect that each
of the sub-
panels of the plank are not a part of the same plank.

[0084] Figures 14A-14C illustrate an exemplary plank of a flooring system in
still
another aspect of the present invention.

[00851 Referring to Figures 14A-14C, similar to the plank shown in Figures 13A
and 13B, portions of the upper surface of the perimeter "P" of each of the
planks 130
indicated by reference numeral 13 8a may be beveled to prevent premature wear
of each
of the planks. Further, portions upper surface of the perimeter of each of the
planks 130
indicated by reference numeral 138b may not be beveled such that they are
substantially
coplanar with the major surface of the sub-panels. Beveling the perimeter
surface of each
of the planks at positions corresponding to the decorative motifs and/or
embossed surface
textures of partial sub-panels of a plank allows complementary partial sub-
panels to
appear as a part of a unitary sub-panel while not significantly detracting
from the overall
durability of each of the planks. In yet another aspect of the present
invention, portions
of the surface of each plank may be provided with a groove at locations where
sub-panels
of a plank are adjacent to one another.

[0086] Figures 14B and 14C illustrate cross-sectional views of plank 130 taken
across lines I-F and I1-II', respectively. Referring to Figures 14B and 14C,
portions of
26


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
the upper surface of each of the planks 130 indicated by reference numeral
138c may be
beveled to form a groove. This groove may also prevent premature wear of each
of the
planks. Thus, the groove provides a visual and textural effect that sub-panels
of a plank
are separate. In one aspect of the present invention, the bevel at 138c may
produce a
groove having a substantially V-shaped groove. It is appreciated, however,
that the bevel
may produce other groove topographies (e.g., U-shaped grooves, etc.). In one
aspect of
the present invention, the beveling of each of the planks 130 at perimeter
surface portion
138a creates a groove between adjacent planks. Accordingly, the groove formed
between
adjacent ones of the planks, via beveling at 138a, has substantially the same
width and
topography as grooves formed within the planks, via beveling at 138c.

[0087] The motif and/or surface texture present at the recessed surface of the
perimeter of each plank may or may not correspond to the motif/surface texture
present at
the main surface of a corresponding plank. Thus, a substantially continuous
motif and/or
surface texture may or may not be present across the surfaces of the perimeter
and the
interior of any individual plank. Aligmnent marks or markings (not shown) can
be used
to self-align a decorative motif on the planks. In one aspect of the present
invention, the
embossed in-registration pattern may be a free form or custom design. It is to
be
understood that substantially any embossed-in-registration pattern and any
decorative
motif may be realized by applying the principles of the present invention. In
one aspect
of the present invention, alignment of the planks may be done visually upon
joining them
together. Accordingly, alignment of the planks 130 may be performed using the
decorative motif and/or embossed surface texture of each of the planks.

27


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
[0088] While it has been illustrated that the planks in Figures 13A, 13B, and
14A-
14C are substantially rectangular, the principles of the present invention
allow the planks
within the flooring system to have other shapes and sizes (e.g., geometric,
freeform, etc.)

or different or similar dimensions such that the flooring planks may be
assembled in a
"mosaic"-type arrangement or other regular, semi-repetitious, or random
arrangement of
panels. Further, while it is illustrated that each plank comprises an
identical sub-panel
layout, the principles of the present invention allow the planks within the
flooring system
to have other sub-panel layouts (e.g., other sub-panel shapes, sizes, etc.)
The individual
planks within the flooring system may be cut from a board such that joints
between the
flooring panels of the flooring system are not visible. Further, the planks
within the
flooring system illustrated in Figures 13 and 14 may be joined together with
or without
glue. Still further, while it has been discussed that the embossed surface
texture is
substantially aligned with an underlying decorative motif, it is to be
understood that
substantially any embossed surface texture may be imparted to the planks of
the present
invention, regardless of the underlying decorative motif. Still further, the
decorative
motifs and/or the embossed surface texture of one plank may not be aligned or
even be
remotely similar in appearance and/or texture to decorative motifs and/or
embossed
surface textures of adjacent planks.

[0089) According to the principles of the present invention, any of the
aforementioned decorative motifs and/or embossed surface textures that may or
may not
be embossed in registration with the decorative motifs (collectively referred
to herein as
"patterns") may be applied to any of the aforementioned planks to form a
substantially
continuous pattern across adjacent planks arranged along a predetermined
direction by

28


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
forming each of the plank patterns using at least one bulk pattern and at
least one edge
pattern.

[0090] In one aspect of the present invention, each edge pattern may be
present at
a perimeter portion of the plank extending along at least a portion of at
least one edge of
each plank. In another aspect of the present invention, each edge pattern may
extend to a
predetermined distance (e.g., about one millimeter, about one inch, etc.) into
the interior
of the plank, away from the perimeter of the plank. In another aspect of the
present

invention, at least one bulk pattern may be arranged adjacent at least one
edge pattern,
wherein a pattern present at the edge of the bulk pattern adjacent the edge
pattern may
form a substantially continuous visual/textural pattern with a pattern present
at the edge
of the edge pattern adjacent the bulk pattern.

[0091] In one aspect of the present invention, patterns of individual planks,
arranged adjacent each other along a predetermined direction within a flooring
system,
may complement patterns of adjacent planks (i.e., form substantially
continuous patterns
across adjacent planks) when edge patterns of the adjacent planks form a
substantially
continuous pattern. Where the flooring system described above comprises a
plurality of
adjacent planks arranged along the predetermined direction, and where the
edges of each
plank are arranged adjacent to edge patterns of other planks along the
predetermined
direction, edge patterns of adjacent planks are identical or substantially
identical. The
identical or substantially identical edge patterns of adjacent planks enable a
continuous
pattern to be formed across the adjacent planks.

[0092] For example, referring to Figure 15A, an exemplary plank pattern of
plank
150 may comprise two edge patterns 152 substantially identical to each other
and a bulk
29


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
pattern 154. As shown in Figure 15A, the two substantially identical edge
patterns 152

are present at a perimeter portion of the plank 150, extend along a portion of
the opposite
edges of the plank, and extend a predetermined distance into the interior of
the plank 150.
Still referring to Figure 15A, the pattern present at the edge of the bulk
pattern 154
adjacent the edge patterns 152 forms a substantially continuous pattern with
the pattern
present at the edge patterns 152 adjacent the bulk pattern.

[0093] Referring now to Figure 15B, a plurality of planks 150A, 150B, 150C,
etc., such as those illustrated in Figure 15A may be arranged adjacent each
other within a
flooring system along a predetermined direction such that edges of each plank
are
arranged adjacent to the edges of other planks along the predetermined
direction (e.g., an
edge of plank 150A is adjacent an edge of plank 150B, an edge of plank 150C is
adjacent
an edge of plank 150D, etc.). As mentioned above, a substantially continuous
pattern
may be formed across an individual plank 150 because the bulk pattern 154 is
substantially aligned with the edge patterns 152.

[0094] In an embodiment of the invention, the predetermined direction in which
the planks are arranged is based on the adjacent edge patterns 152 in the
planks, such that
only by arranging the planks in the predetermined direction will the pattern
formed be
continuous and natural-looking. In this embodiment, reversing a plank or
flipping a
plank over will result in a discontinuous pattern. However, it is understood
that in
another embodiment, the edge patterns along a portion of the perimeter may be
selected
such that reversing, flipping or otherwise rearranging planks does not disrupt
the pattern,
i.e. the pattern is continuous.



CA 02597133 2007-08-28
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[0095] In another embodiment, the predetermined direction is based on the
interlocking mechanism that joins adjacent planks, such that the planks will
not fit

together properly if they are arranged in a direction other than the
predetermined
direction. One example of such a interlocking mechanism is a glueless tongue
and
groove system, in which the tongue is formed along at least one edge of the
plank and the
groove formed along the opposite edge. In yet another embodiment, the
predetermined
direction is based on both the edge patterns 152 and the glueless locking
mechanism.

[0096] According to the principles of the present invention, bulk patterns
154A-
154F may or may not be the same. In one aspect of the present invention, each
of the
bulk patterns 154 within a flooring system may be unique. Further, according
to the
principles of the present invention, edge patterns of individual planks may be

substantially identical. Therefore, edge patterns of adjacent planks in a
flooring system,
across which a substantially continuous pattern is formed along the
predetermined
direction, are also substantially identical. A substantially continuous
pattern may be
provided across plank 150A because bulk pattern 154A and edge patterns 152A
are
aligned with each other to produce a substantially continuous pattern.
Substantially
continuous patterns may be individually provided across planks 150B, 150C,
etc.,
because their respective bulk patterns 154B, 154C, etc., and edge patterns
152B, 152C,
etc. are similarly aligned with each other to produce a substantially
continuous pattern.

[0097] Because the edge patterns of planks 150A-150F within the flooring
system
illustrated in Figure 15B are identical, edge pattern 152A forms a
substantially
continuous pattern with edge pattern 152B, edge pattern 152C forms a
substantially
continuous pattern with edge pattern 152D, and so on. Accordingly, a
substantially

31


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continuous pattern may be formed across planks 150A and 150B, across planks
150C and
150D, and so on. The boundary or joint between the edge pattern 152A and the
edge
pattern 152B is substantially not visible, or the appearance of the presence
of the

boundary or joint is minimized. Similarly, the boundary or joint between the
edge pattern
152C and the edge pattern 152D is substantially not visible, or the appearance
of the
presence of the boundary or joint is minimized. The boundary or joint between
the edge
pattern 152E and the edge pattern 152F is substantially not visible, or the
appearance of
the presence of the boundary or joint is minimized.

100981 In one embodiment of the present invention, in which the edge patterns
152 are all substantially identical, any of the planks 150A-150F may replace
any other
plank within the flooring system while still maintaining the presence of a
substantially
continuous pattern across planks arranged adjacent each other along the
predetermined
direction. This is because all bulk patterns of a plank are substantially
aligned with their
respective edge patterns to form substantially continuous patterns within a
plank and
because all edge patterns of planks adjacent each other within a flooring
system are
identical, forming form substantially continuous patterns across planks
adjacent each
other along the predetermined direction.

[0099] In another embodiment, planks may have adjacent right and left edge
patterns 152 substantially identical, while opposite left and right edge
patterns 152 are
not.

[00100] For example, in Figure 15C, the unitary sub-panel 132 of plank
150 may have a pattern provided by a bulk pattern 154G, partial sub-panel 134
may have
a pattern provided by bulk pattern 1541 and edge pattern 152, and partial sub-
panel 136

32


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may have a pattern provided by bulk pattern 154H and edge pattern 152, wherein
the bulk
patterns 154G-154I may or may not be the same. As mentioned above, however,
the

edge pattern 152, present at the perimeter of the partial sub-panel portions
134 and 136 of
the plank 150 and extending along a portion of the edges of the plank 150, are
identical to
each other. Accordingly, in view of Figure 13A, when, for example, planks 130A
and
130B are arranged adjacent each other along a predetermined direction, edge
patterns 152
of complementary partial sub-panels 134A and 136B are substantially identical
to each
other and a substantially continuous pattern may be formed across adjacent
planks,
wherein the bulk patterns of the complementary partial-sub panels become a
part of a
substantially continuous pattern, appearing, visually and/or texturally as a
unitary sub-
panel.

[00101] Furthermore, referring now to Figures 15C and 15D, flooring
systems incorporating planks such as those illustrated in Figures 13A-14C may
be
provided with substantially continuous patterns across planks adjacent each
other along
predetermined directions by applying the techniques described above with
reference to
Figures 15A and 15B.. Figure 15D shows the planks having a wood grain pattern
in the
arrangement shown in Figure 15B. Because the edge pattern 152A is
substantially
identical to the adjacent edge pattern 152B, planks 150A and 150B have the
appearance
of a substantially continuous wood grain pattern running uninterrupted across
the
boundary or joint between edge pattern 152A and edge pattern 152B of the
adjacent
plank.

[001021 In addition, because the edge patterns 152A and 152B do not run
along the entire length of the boundary or joint between planks 150A and 150B,
but only
33


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along the portion corresponding to the height of the partial board on the
bottom half of

the planks, the pattern is not continuous across that portion of the boundary
between
planks 150A and 150B corresponding to the height of the complete boards on the
top half
of the planks.

[00103] As mentioned above, within the flooring system incorporating the
planks illustrated in Figures 13A-14C and 15C, the bulk patterns within the
sub-panels of
the planks may or may not be the same. In one aspect of the present invention,
each of
the bulk patterns within the flooring system may be unique.

[00104] Fig. 15E shows an embodiment of the invention in which the edge
patterns of the planks are identical (or substantially identical) in every
plank.
Specifically, Fig. 15E shows four planks, 150A, 150B, 150C, and 150D arranged
such
that plank 150A is adjacent the left edge of plank 150B and adjacent to a top
edge of
plank 150C. Plank 150D is adjacent to the right edge of plank 150C and
adjacent to the
bottom edge of 150B.

[00105] In this embodiment, the decor paper of each plank has a wood
design. However, it is understood that other natural looking designs other
than wood are
contemplated by this invention as well. The wood design in plank 150A
includes, for
example, a complete board or strip 155A on a top half of the board, a short
incomplete
board 151A and a long incomplete board 153A. Each of the boards has a wood
grain
pattern. In addition, the short and long incomplete boards 151A and 153A have
an edge
pattern 152 running along a portion of the perimeter of the plank
corresponding to the
width of the incomplete boards 151A and 153A, and may extend a small distance
(such
as one centimeter, for example) into the interior of the boards. The edge
patterns 152 of

34


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WO 2006/123245 PCT/IB2006/001618
incomplete boards 151A and 153A are identical. The edge patterns 152 may also
not
extend into the interior of the boards.

[00106] Similarly, planks 150B, 150C, and 150D have complete boards
155B, 155C, and 155D, respectively, running the length of the plank, and short
boards
151B, 151C, and 151D which are adjacent to long boards 153B, 153C, and 153D,
respectively. Each of the short and long boards may have an identical edge
pattern 152
along a portion of the perimeter of the plank corresponding to the width of
the short and
long boards.

[00107] All short boards 151A-D, long boards 153 A-D, and complete
boards 155A-D have wood grain patterns that are different from each other or
some
identical to each other. Only the edge patterns 152 in the incomplete boards
are identical

in this particular example. Furthermore, the edge pattern and interior wood
grain pattern
of each incomplete board form a continuous pattern. In other words, there is a
continuous overall wood grain pattern on each of the short boards and long
boards that
are all different from one another, despite the fact that the edge patterns
152 are the same.

[00108] When planks 150A and 150B are placed adjacent to one another as
shown in Fig. 15E, complete boards 155A and 155B will be adjacent to each
other, and
long board 153A and short board 151B will be adjacent. Complete boards 155A
and
155B appear as separate boards and the wood grain pattern is discontinuous
across them,
because the adjacent edges of the complete boards are different. But because
the edge
patterns 152 in long board 153A and short board 151B are the same, the unique
wood
grain patterns of 153A and 151B appear to form a single continuous board with
a unique
wood grain pattern running across the planks 150A and 150B. Furthermore, the



CA 02597133 2007-08-28
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appearance of a complete and continuous board with a unique wood grain pattern
running
in boards 153A and 151B across the planks minimizes the visibility or
appearance of the
joint or boundary between the planks. Similarly, the wood grain pattern across
boards
153C and 151 D is continuous.

[00109] In a further embodiment, the planks 150A, 150B, 150C, and 150D
may have a surface texture that is embossed in registration with the wood
design on the
decor paper. Because edge patterns 152 are part of that wood design and may be
the
same or substantially identical in every plank, the embossed surface texture
will appear to
be continuous along the incomplete boards of adjacent planks in the manner
discussed
above. In still another embodiment, the embossed in registration surface
texture may
include bevels to imitate searns between boards, such that in plank 150A, for
example,
the complete board 155A would have a bevel running along its perimeter,
including the
boundary between board 155A and incomplete boards 151A and 153A. The
incomplete
boards 151A and 153A would have a bevel where they are adjacent, but the
incomplete
boards would not have a bevel along the portion of the perimeter of the plank
150A
where the edge patterns 152 are located. In this way, a continuous wood grain
pattern
and corresponding embossed in registration surface texture can run
continuously across
planks 150A and 150B uninterrupted by a bevel. This would further reduce the
appearance of the boundary between planks.

[00110] By having all edge patterns 152 to be identical, the present
invention allows any planks to be fit together in the predetermined direction
in which a
long board 153 is adjacent a short board 151 of another plank, because the
edge patterns
152 will always line up to form the appearance of a continuous wood grain
pattern

36


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WO 2006/123245 PCT/IB2006/001618
running across the adjacent long and short boards of the two planks. For
example, if the
positions of planks 150A and 150B were reversed (such that plank 150B was
adjacent a

top edge of plank 150C), the edge pattern 152 of long board 153B would match
or be
aligned with the edge pattern of short board 151A, forming a continuous wood
grain
pattern in the boards 153B and 151A across planks 150B and 150A.

[00111] The present invention reduces the complexity involved in installing
a laminated floor, because it does not matter which planks are placed adjacent
to one
another in the predetermined direction. The patterns will be aligned. In a
further
embodiment, the planks 150 are provided with a glueless interlocking tongue
and groove
system in which the tongue is formed on two adjacent perimeter edges of the
plank and
the groove is formed in the opposite two adjacent perimeter edges so that the
planks can
only be fit together in the direction that will align long boards 153 with
short boards 151,
for example, where edge patterns 152 meet.

[00112] In the exemplary embodiment discussed above, the decorative
motifs and design pattern elements such as wood strips run across separate
adjacent
planks. However, the wood strip motif has a length equal to that of the length
of the
plank, in order to allow for the interchangeability of planks, ensuring an
easy installation.

[00113] Now making reference to Figure 16, Figure 16 illustrates a floor
501 having a floor pattern 500 formed by patterns 500a through 500d in
accordance with
an embodiment of the present invention. A plurality of flooring units having a
decorative
motif 512 disposed thereon define the floor 501. In particular, the plurality
of flooring
units includes flooring units 504, 506, 508 and 510, as more clearly shown
with reference
to Figures 17A through 17D.

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[00114] Figure 17A is an embodiment of the present invention illustrating
the flooring unit 504 which includes subunits 504a through 504d. The subunits
504a
through 504d form the flooring unit 504 such that a plank is formed. In the
embodiment
shown in Figure 17A, the subunit 504c has the decorative motif 512. It should
be noted
that in an alternative embodiment of the present invention, the subunit 504b
may include
the decorative motif 512 instead of the subunit 504c.

[00115] Figure 17B illustrates the flooring unit 506 in accordance with an
embodiment of the present invention. The flooring unit 506 includes subunits
506a
through 506d. In this embodiment, the subunits 506a through 506d do not
include a
decorative motif, as discussed with reference to Figure 17A and the flooring
unit 504.

[00116] Figure 17C is an embodiment of the present invention showing the
flooring unit 508. The flooring unit 508 has subunits 508a through 508d. Here,
the
subunit 508a has the decorative motif 512. Nonetheless, in accordance with
embodiments of the present invention, the subunit 508d may include the
decorative motif
512 instead of the subunit 508a.

[00117] Figure 17D illustrates the flooring unit 510 in accordance with an
embodiment of the present invention. The flooring unit 510 includes subunits
510a
through 510d each having the decorative motif 512. In accordance with an
embodiment
of the present invention, the flooring unit 510, along with the flooring units
504, 506 and
508, includes ceramic tiles. In addition, the flooring units 504, 506, 508 and
510 may be
any material used in flooring applications, such as wood, cork, marble or the
like. It
should be noted that the flooring units 504, 506, 508 and 510 have been
described as
having four subunits (e.g., subunits 504a through 504d). However, the flooring
units

38


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WO 2006/123245 PCT/IB2006/001618
504, 506, 508 and 510 may have any number of subunits in accordance with the
present
invention, as will be discussed further on.

[00118] Returning attention to Figure 16 and the floor pattern 500 shown
therein, the flooring units 504, 506, 508 and 510 are aligned with respect to
one another
such that the decorative motifs 512 form the floor pattern 500. As previously
mentioned,
each of the flooring units 504, 506, 508 and 510 comprise 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 504, 508 and 510 align with one
another.
[00119] In order to form the pattern 500a of the floor pattern 500, the

subunit 504c of the flooring unit 504 aligns with the subunit 508a of the
flooring unit 508
along an X-axis of the floor 501. More specifically, in order to form the
pattern 500a, the
subunits 504c of the flooring unit 504 align with the subunits 508a of the
flooring unit
508 to form the pattern 500a. Likewise, both the subunit 508a and the subunit
504c align
with the subunit 510a of the flooring unit 510 thereby forming the pattern
500a. It should
be noted that the pattern 500c is formed in a manner similar to the pattern
500a, in
accordance with an embodiment of the present invention.

[00120] In the embodiment shown with reference to Figure 16, the subunit
510d aligns with the subunit 510a of a second flooring unit 510 along a Y axis
of the
floor pattern 500 such that decorative motifs 512 disposed on the first and
second
flooring unit 510 align along the Y axis. Additionally, in this embodiment, a
subunit
508a of a second flooring unit 508 aligns with the subunit 510d of the second
flooring
unit 510 thereby forming the pattern 500b as shown. It should be noted that in
this
embodiment, the pattern 500d is formed in a manner similar to that described
with

39


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
reference to the pattern 500b. In addition, the flooring units 506 are
disposed within the
floor pattern 500 such that the subunit 506a is adjacent the subunit 504d of
the flooring

unit 504 that forms the pattern 500a.

[00121] As may be seen with reference to Figure 16, an endmost subunit
(e.g., the subunit 508a or 508d) of the flooring unit 508 aligns with a
subunit adjacent an
endmost subunit (e.g., the subunit 506a or 506d) of the flooring unit 506.
Furthermore, in
the embodiment shown in Figure 16, the flooring units 504, 506, 508 and 510
have four
subunits. Nonetheless, the flooring units 504, 506, 508 and 510 may have any
number of
subunits. For example, flooring units may have six subunits, as shown in
Figures 19A
through 19D.

[00122] Figure 19A illustrates a flooring unit 514 having subunits 514a
through 514f in accordance with an embodiment of the present invention. The
flooring
unit 514 also includes the decorative motif 512 on the subunit 514e. Figure
19B is an
embodiment of the present invention showing a flooring unit 516. The flooring
unit 516
has subunits 516a through 516f. Figure 19C shows a flooring unit 518 having
subunits
518a through 518f. In addition, the flooring unit 518 has the decorative motif
512
disposed on the subunit 518a. Flooring unit 520, shown in Figure 19D, includes
subunits
520a through 520f each having the decorative motif 512 disposed thereon. The
flooring
units 514, 516, 518 and 520 may be used to form a floor pattern 522 for the
floor 500 as
shown in Figure 18.

[00123] Figure 18 illustrates an embodiment of the present invention where
the flooring units 514, 516, 518 and 520 form a pattern 522 including patterns
522a
through 522d. In this embodiment, subunits 514e, 518a and 520a form the
pattern 522a



CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
as shown. Likewise, pattern 522c is formed in a manner similar to that used
for the

pattern 522a. In addition, subunits 520a through 520f and subunits 518a form
the
patterns 522b and 522d as illustrated.

[00124] As may be seen with reference to Figures 16 and 18, the patterns of
the floor 501 are formed with decorative motifs disposed on the following: an
edge most
subunit of a flooring member, a subunit immediately adjacent an edge most
subunit, and

a flooring unit having decorative motifs disposed on all subunits of the
flooring unit.
Additionally, a flooring unit which does not include decorative motifs is also
used in
forming the patterns of the floor 501. Therefore, flooring units having at
least three
subunits may be used to form patterns on a floor in accordance with the
present
invention.

[00125] In addition, in an embodiment of the present invention where a
flooring unit includes four subunits, three flooring units may be used as
illustrated in
Figure 20. In this embodiment, one flooring unit includes a decorative motif
on all of the
subunits, such as the flooring unit 510. A second flooring unit has a
decorative motif on
any one of the subunits, such as either the flooring unit 504 or 508. The
subunits of the
third flooring unit are all devoid of the decorative motif similar to the
flooring unit 506.
In Figure 20, the subunits 508a and 510a form patterns 513a and 513c of
pattern 513. In
addition, the flooring unit 510 and the subunits 508a from patterns 513b and
513d of the
pattern 513.

[00126] In a further embodiment, where a flooring unit includes five
subunits, four flooring units 524, 526, 528 and 530 may be used as more
clearly
illustrated in Figure 21 to form the pattern 531 having patterns 531a through
531d.

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WO 2006/123245 PCT/IB2006/001618
Making reference to Figures 22A through 22D, the flooring units 524, 526, 528
and 530
include five subunits. The flooring unit 524 includes subunits 524a through
524e. The
flooring unit 526 has subunits 526a through 526e where all the subunits
include the
decorative motif 512. The flooring unit 528 has the subunits 528a through
528e. Here,
the subunit 528d has the decorative motif 512. The flooring unit 530 includes
subunits
530a through 530e where the subunit 530c has the decorative motif 512.

[00127] Returning attention to Figure 21, the subunits 526a and 528d form
the pattern 531a. The flooring unit 526 also forms the patterns 531b and 531d.
Furthermore, the subunits 526e and 530c form the pattern 531c such that the
pattern 531
is formed on the floor 501.

[00128] It should be noted that in accordance with embodiments of the
present invention, many types of patterns for the floor 501, such as the
patterns 500 and
522, may be formed using either of the flooring units 504, 506, 508 and 510 or
the
flooring units 514, 516, 518 and 520, as shown in Figures 23 and 24 where
patterns 534
and 536 are formed.

[00129] Furthermore, in one embodiment of the present invention, the
subunits may be staggered from one another, as more clearly shown in Figure 16
where
the subunit 500a aligns with the subunit 504c. In embodiments where the
subunits are
offset from one another, four flooring units, (e.g., the flooring units 504,
506, 508 and
510) may be used irrespective of the number of subunits.

[00130] Figure 23 illustrates a further embodiment of the present invention.
Figure 23 illustrates a flooring system having four (prior to milling the
tongue and groove
edges of each plank) distinctly patterned planks 1000, 1002, 1004 and 1006,
each

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WO 2006/123245 PCT/IB2006/001618
divisible into four equal subunits a, b, c, and d). The embodiment in Figure
23 includes a
decorative motif that has a width less than the width of a subunit.

[00131] As illustrated in Figure 23, plank 1000 does not include the
decorative motif. Figure 1002 includes the decorative motif on only a portion
of one of
the four subunits of the plank 1002. In this example, the decorative motif has
a height
(the direction parallel to the length of the plank) substantially equal to
half of the height
of a subunit. Plank 1004 includes the decorative motif on a different subunit
of the plank.
In other words, the subunit of plank 1004 that includes the decorative motif
is different
from the subunit of plank 1002 that includes the decorative motif.

[00132] Finally, plank 1006 includes the decorative motif running the
entire length of the plank but only in a portion of each of the subunits. For
example, the
decorative motif may have a width (the direction parallel to the short side of
the plank)
equal to half the width of the plank, but runs the entire length of the plank.
In other
embodiments or other aspects of this embodiment the decorative motif may have
a
different width, that width being less than the total width of a plank.

[00133] After the planks are milled with the profiled edges, at least seven
different planks are required in the flooring system according to this
embodiment.
However, if the planks have a joint system in which the joining mechanism or
joint
profile on opposite edges of the planks are the same, then only the four
planks discussed

above are required for this flooring system.

[00134] Because the decorative motif is on only a portion of each subunit,
if the subunits are placed adjacent to one another such that entire subunits
are adjacent to
an entire subunit, then, as illustrated in Figure 24, the flooring system will
include a plank
43


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WO 2006/123245 PCT/IB2006/001618
1000 which is the same as that illustrated in Figure 23, a plank 1002 which is
similar to
that illustrated in Figure 23, and a plank 1004 which is similar to that
illustrated in Figure
23. However, there are also additional planks, including plank 1003, which is
the same
as plank 1004 rotated 180 . Plank 1003 may be placed adjacent to planks 1006
and 1002
such that the decorative motif on the adjacent planks are aligned. There is
also a plank
1005, similar to the plank 1002 rotated 180 , that may be placed adjacent to
plank 1003
such that the decorative motif lines up across adjacent subunits of the
planks.
Furthermore, the flooring system includes plank 1007 which is similar to plank
1006
rotated 180 . Thus the flooring system having planks 1000, 1002, 1003, 1004,
1005,
1006 and 1007 is able to create a flooring pattern illustrated in Figure 24
which has a
height equal to the length of two planks (or eight subunits in which each
plank had a total
of four subunits and a width of nine planks, however, because the decorative
motif is
only on a portion of the width of the planks 1006 and 1007, the actual width
of the
decorative motif is eight planks wide, although it requires a total of nine
planks to create
the pattern.

[00135] Figure 24 illustrates a flooring pattern created using the seven
planks of this flooring system in which the decorative motifs occupy only on a
portion of
a subunit of the plank rather than the entirety of the subunit as was
illustrated in
embodiments discussed earlier. Because the decorative motif is offset within
each
subunit in this fashion, this flooring system is able to disguise the physical
joints between
adjacent planks using this flooring system. More specifically, in Figure 24,
plank 1003 is
placed adjacent to plank 1006 such that the second subunit of plank 1003,
identified as
subunit 1003b, is adjacent to the first subunit 1006a of plank 1006.
Similarly, subunit

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1005d is adjacent to subunit 1003b of plank 1003. In this way, planks 1003 and
1005 are
offset from each other by a distance of two subunits, or half of the total
length of the

plank, whereas, plank 1003 is offset from plank 1006 by a distance of only one
subunit or
a quarter of the length of the plank. This difference in offsets between
planks 1006 and
1003 and 1003 and 1005 further aids in disguising the physical joints between
adjacent
planks.

[00136] The arrangement of planks 1003 and 1005 discussed above may be
repeated to create a flooring pattern having a variable width. The width of
the overall
pattern in this embodiment is equal to the total number of planks 1003 and
1005 placed
adjacent to one another plus one plank width which is the total decorative
motif width
from the portion of the decorative motif on plank 1006 plus the portion of the
decorative
motif on plank 1007. This is the case because, in this example, the width of
the
decorative motif equals one half the width of a plank. Thus, in Figure 24
there are seven
planks 1003 and 1005 (four of plank 1003 and three of plank 1005) between
planks 1006
and 1007 to create a decorative motif in a flooring pattern having a width
equal to eight
plank widths even though the flooring pattern itself is created with nine
physical flooring
planks.

[00137] Furthermore, the height of the flooring pattern may be extended to
any multiple of plank lengths simply by running additional planks 1006
adjacent to one
another in the vertical direction - the vertical direction being parallel to
the length of the
plank. Therefore, by adding additional planks 1006 adjacent to one another on
one side
and additional planks 1007 adjacent to one another on the opposite side, the
height of the
overall flooring pattern may be extended. This is further illustrated in
Figure 25 which


CA 02597133 2007-08-28
WO 2006/123245 PCT/IB2006/001618
has a flooring pattern with a height equal to three plank lengths created by
three planks
1006 adjacent to one another on one side and three planks 1007 adjacent to one
another

on the other side. The flooring pattern has a width equal to the width of
twelve flooring
planks even though thirteen planks are required to complete the flooring
pattern in the
width direction. Furthermore, with the flooring system of the embodiment
currently
discussed, the smallest flooring pattern that may be created is a flooring
pattern having a
height equal to the length of one plank and a width equal to the width of four
planks and
requires five planks placed adjacent to one another in the width direction,
specifically
planks 1006, 1005, 1003, 1005 and 1007 to create this flooring pattern.

[00138] It is understood that the various additional embodiments in which
the decorative motif has a width less than the total width of a plank and not
equal to half
the width of the plank, and in which the height of the decorative motif is
some height
other than the total height of the subunit and different from half the height
of the subunit.
Furthermore, it is understood that depending on the width of the flooring
motif of the
decorative motif greater or fewer planks may be required in the flooring
system to enable
the creation of floors having flooring patterns of various widths and heights.

[00139) DC:50311317.1

46

Representative Drawing