IP Library Granted Patent US 12,065,839
Granted Patent B2
US 12,065,839 · App. 18/182,510 · Granted Aug 20, 2024

Floor board and method for manufacturing such floor boards

Inventors: Dieter D'Hondt (Sint-Andries, BE); Aaron Shaw (High Point, NC)
Assignee: UNILIN BV
E04F15/02038E04F15/102E04F15/107Y10T428/24777
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Quick Facts
Patent No.
US 12,065,839
App. No.
18/182,510
Granted
Aug 20, 2024
Kind
B2
Abstract

A floor board including a decorative surface layer applied to a substrate, where the substrate has MDF or HDF material at a side edge thereof, where the side edge is treated both with an impregnation agent and/or a sealing agent based on a superabsorbing material. Also a method for manufacturing such floor boards.

Claims (33)

1. A floor board comprising a decorative surface layer applied to a substrate, wherein said substrate comprises MDF or HDF material at a side edge thereof, wherein the side edge is coated with a coating agent; wherein the coating agent is based on a wax;

wherein said MDF or HDF material has an average density of more than 750 kg per cubic meter and comprises a higher density region at least near said decorative surface layer, wherein said higher density region has a density of 900 kilograms per cubic meter or more.

2. The floor board of claim 1 , wherein the coating agent comprises particles, wherein the particles of the coating agent have an average particle diameter of less than 100 micron.

3. The floor board of claim 1 , wherein an entire top half of a thickness of the side edge, or an entire thickness, is coated with the coating agent.

4. The floor board of claim 1 , wherein the coating agent forms a water tight layer on the side edge, or on part of it.

5. The floor board of claim 1 , wherein the coating agent has been applied immediately underneath the decorative surface layer, possible overlapping therewith.

6. The floor board of claim 1 , wherein said floor board at said side edge as well as on a side edge opposite thereto comprise mechanical coupling means allowing to couple said floor board at the respective edges with a similar floor board such that said floor board and said similar floor board become locked both in a direction perpendicular to said decorative surface layer, as well as in a direction perpendicular to said edge and in a plane formed by said decorative surface layer.

7. The floor board as in claim 6 , wherein the coating agent seals a joint between adjacent edges of said floor board and said similar floor board; wherein said coating agent creates a sealing between the adjacent edges of said floor board and said similar floor board at a height of the lateral edge of said surface layer, or less than 1 millimeter under said surface layer.

8. The floor board as in claim 7 , wherein said mechanical coupling means are basically shaped as a tongue-in-groove coupling provided with additional locking means for creating said locking in the direction perpendicular to said edge and in a plane of the floor boards, wherein said mechanical coupling means allow for creating a tension force pushing the coupled floor board towards each other, by means of a bent-out lower groove lip that pushes on said tongue.

9. The floor board of claim 1 ,

wherein the floor board comprises a first pair of opposite side edges and a second pair of opposite side edges;

wherein said first pair of opposite edges comprise mechanical coupling means allowing to couple said floor board at the respective edges with a similar floor board such that said floor board and said similar floor board become locked both in a direction perpendicular to said decorative surface layer, as well as in a direction perpendicular to said edge and in a plane formed by said decorative surface layer; wherein said mechanical coupling means are basically shaped as a tongue-in-groove coupling;

wherein said second pair of opposite edges comprise mechanical coupling parts allowing for a coupling by means of a downward motion of two such floor boards at their second pair of opposite edges, such that the two such floor boards become locked both in a direction perpendicular to said decorative surface layer, as well as in a direction perpendicular to said edge and in a plane formed by said decorative surface layer;

wherein the first pair of opposite side edges and the second pair of opposite side edges of said substrate are treated with the coating agent.

10. The floor board of claim 1 , wherein said decorative surface layer is a surface layer having a thickness less than 0.75 millimeter.

11. The floor board of claim 1 , wherein said decorative surface layer is formed from at least one or more paper layers treated with a thermosetting resin; or at least one or more wood veneer layers.

12. The floor board of claim 1 , wherein an upper edge of a first and/or a second pair of opposite side edges are formed with a lowered edge surface.

13. The floor board of claim 12 , wherein said lowered edge surface is in the form of a square edge, a beveled edge or a chamfered edge.

14. The floor board of claim 12 , wherein the lowered edge surface is provided with the same decorative surface layer as a remainder of an upper surface of the floor board.

15. The floor board of claim 12 , wherein the lowered edge surface is provided with a decoration separate from the decorative surface layer of the remainder of the upper surface of the floor board.

16. The floor board of claim 12 , wherein the lowered edge surface comprises a surface of said substrate and is free from decoration.

17. The floor board of claim 1 , wherein the wax is a microwax.

18. The floor board of claim 1 , wherein said MDF or HDF material comprises wood fibers glued by means of urea formaldehyde glue or melamine urea formaldehyde glue.

19. The floor board of claim 1 , wherein the coating agent forms a water tight layer on the side edge, or on a part thereof;

wherein the coating agent is applied immediately underneath the decorative surface layer, or at least overlapping therewith;

wherein an upper edge of a first and/or a second pair of opposite side edges are formed with a lowered edge surface;

wherein said lowered edge surface is in the form of a square edge, a beveled edge or a chamfered edge; and

wherein the lowered edge surface is provided with the same decorative surface layer as a remainder of an upper surface of the floor board.

20. The floor board of claim 1 , wherein the coating agent forms a water tight layer on the side edge, or on a part thereof;

wherein the coating agent has been applied immediately underneath the decorative surface layer, or at least overlapping therewith;

wherein an upper edge of a first and/or a second pair of opposite side edges are formed with a lowered edge surface;

wherein said lowered edge surface is in the form of a square edge, a beveled edge or a chamfered edge;

wherein the lowered edge surface is treated with the coating agent and is provided with a separate decoration differing from a remainder of an upper surface of the panel.

Assignments (8)
NUNC PRO TUNC ASSIGNMENT Recorded Mar 18, 2024
From: FLOORING INDUSTRIES LIMITED, SARL
To: UNILIN BV
Reel/Frame 066805/0445 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 15, 2023
From: ALADDIN MANUFACTURING CORPORATION
To: MOHAWK FLOORING INVESTMENTS, LLC
Reel/Frame 063644/0943 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 15, 2023
From: MOHAWK FLOORING INVESTMENTS, LLC
To: MOHAWK INTERNATIONAL HOLDINGS (DE), LLC
Reel/Frame 063644/0967 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 15, 2023
From: MOHAWK INTERNATIONAL HOLDINGS (DE), LLC
To: MOHAWK GLOBAL INVESTMENTS S.À.R.L.
Reel/Frame 063645/0028 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 15, 2023
From: MOHAWK GLOBAL INVESTMENTS S.À.R.L.
To: MOHAWK INTERNATIONAL HOLDINGS S.À.R.L.
Reel/Frame 063645/0049 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 15, 2023
From: MOHAWK INTERNATIONAL HOLDINGS S.À.R.L.
To: FLOORING INDUSTRIES LIMITED, SARL
Reel/Frame 063645/0336 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 13, 2023
From: UNILIN NORTH AMERICA, LLC
To: ALADDIN MANUFACTURING CORPORATION
Reel/Frame 062963/0615 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 13, 2023
From: D-HONDT, DIETER; SHAW, AARON
To: UNILIN NORTH AMERICA, LLC
Reel/Frame 062963/0683 →
Continuity (5)
Continuation 17504787 · Oct 19, 2021
Continuation 16808745 · Mar 4, 2020
Continuation 15571576
Provisional Application 62160283 · May 12, 2015
Related Publication 20230212865A1 · Jul 6, 2023
Cited By (8)
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