초록

Floorboards comprising a core and a surface layer with curved edge portions, which are formed by a compression of the core.

대표청구항 ▼

1. A method of making a floorboard, comprising: affixing a surface layer on a wood fiber based core to form a floor element, thencutting the floor element into floor panels, such that each floor panel includes an edge portion formed by an edge part of the core and an edge part of the surface layer a

1. A method of making a floorboard, comprising: affixing a surface layer on a wood fiber based core to form a floor element, thencutting the floor element into floor panels, such that each floor panel includes an edge portion formed by an edge part of the core and an edge part of the surface layer affixed to the core's edge part, wherein a top face of the surface layer forms a floor surface lying in a horizontal plane, thenapplying pressure on a portion of the top face defined by the surface layer's edge part with a compression tool having a predetermined profile such that the core's edge part is compressed and said surface layer's edge part is permanently bent out of said plane, wherein said edge portion of said floor panel obtains an edge profile corresponding to the predetermined profile of the compression tool, with said portion of said top face defined by the surface layer's edge part being disposed under said plane, and thenforming a mechanical locking system at the edge of the floorboard,wherein the surface layer extends to an outer edge of the compressed edge part,wherein an edge groove is formed at the edge of the floor panel before compression. 2. The method as claimed in claim 1, wherein the surface layer comprises paper sheets impregnated with a thermosetting resin. 3. The method as claimed in claim 1, wherein the surface layer is a wood veneer. 4. The method as claimed in claim 1, wherein the core is made of HDF. 5. The method as claimed in claim 4, wherein the edge portion is pressed under heat exceeding 100 degrees C. 6. The method as claimed in claim 4, wherein the edge portion is pressed under heat exceeding 160 degrees C. 7. The method as claimed in claim 1, wherein the outer edge of the compressed edge part is a vertical, planar surface. 8. A method of making a building panel, comprising: affixing a surface layer on a wood fiber based core to form a building element, thencutting the building element into building panels, such that each building panel includes an edge portion formed by an edge part of the core and an edge part of the surface layer affixed to the core's edge part, wherein a top face of the surface layer forms a panel surface lying in a plane, thenapplying pressure on a portion of the top face defined by the surface layer's edge part with a compression tool having a predetermined profile such that the core's edge part is compressed and said surface layer's edge part is permanently bent out of said plane, wherein said edge portion of said building panel obtains an edge profile corresponding to the predetermined profile of the compression tool, with said portion of said top face defined by the surface layer's edge part being disposed under said plane, and thenforming a mechanical locking system at the edge of the building panel,wherein the surface layer extends to an outer edge of the compressed edge part,wherein the surface layer comprises paper sheets impregnated with a thermosetting resin. 9. A method of making a floorboard, comprising: affixing a surface layer comprising a paper laminate on a wood fiber based core to form a floor element, thencutting the floor element into floor panels, such that each floor panel includes an edge portion formed by an edge part of the core and an edge part of the surface layer affixed to the core's edge part, wherein a top face of the surface layer forms a floor surface lying in a horizontal plane, thenapplying pressure on a portion of the top face defined by the surface layer's edge part with a compression tool having a predetermined profile such that the core's edge part is compressed and said surface layer's edge part is permanently bent out of said plane, wherein said edge portion of said floor panel obtains an edge profile corresponding to the predetermined profile of the compression tool, with said portion of said top face defined by the surface layer's edge part being disposed under said plane, andafter compressing the core's edge part, forming a mechanical locking system at the edge of the floor panel,wherein the paper laminate comprises paper sheets impregnated with a thermosetting resin, and an upper part of the core under the surface layer is impregnated with a material to increase the flexibility of the paper laminate. 10. The method as claimed in claim 9, wherein the outer edge of the compressed edge part is a vertical, planar surface. 11. The method as claimed in claim 9, further comprising applying the surface layer directly to the wood fiber based core and pressing them together under pressure and heat, and without any gluing. 12. The method as claimed in claim 9, wherein the upper part of the core under the surface layer is impregnated with melamine. 13. The method as claimed in claim 9, wherein the upper part of the core under the surface layer is impregnated with glue. 14. The method as claimed in claim 9, further comprising the step of making the paper laminate in a separate step, wherein the paper laminate is a high pressure laminate made in a separate operation where a plurality of sheets of paper impregnated with a thermosetting resin are compressed under high pressure and at a high temperature, and then affixed to the core. 15. The method as claimed in claim 9, wherein the step of affixing the paper laminate comprises both manufacture of the paper laminate and the fastening to the core take place in one and the same manufacturing step, wherein one or more papers impregnated with a thermosetting resin are applied directly to the core and pressed together under pressure and heat without any gluing. 16. A method of making a building panel, comprising: affixing a surface layer comprising a paper laminate on a wood fiber based core to form a building element, thencutting the building element into building panels, such that each building panel includes an edge portion formed by an edge part of the core and an edge part of the surface layer affixed to the core's edge part, wherein a top face of the surface layer forms a panel surface lying in a plane, thenapplying pressure on a portion of the top face defined by the surface layer's edge part with a compression tool having a predetermined profile such that the core's edge part is compressed and said surface layer's edge part is permanently bent out of said plane, wherein said edge portion of said building panel obtains an edge profile corresponding to the predetermined profile of the compression tool, with said portion of said top face defined by the surface layer's edge part being disposed under said plane, andafter compressing the core's edge part, forming a mechanical locking system at the edge of the building panel;wherein the paper laminate comprises paper sheets impregnated with a thermosetting resin, and an upper part of the core under the surface layer is impregnated with a material to increase the flexibility of the paper laminate. 17. The method as claimed in claim 16, further comprising applying the surface layer directly to the wood fiber based core and pressing them together under pressure and heat, and without any gluing. 18. The method as claimed in claim 16, wherein the upper part of the core under the surface layer is impregnated with melamine. 19. The method as claimed in claim 16, wherein the upper part of the core under the surface layer is impregnated with glue. 20. The method as claimed in claim 16, further comprising the step of making the paper laminate in a separate step, wherein the paper laminate is a high pressure laminate made in a separate operation where a plurality of sheets of paper impregnated with a thermosetting resin are compressed under high pressure and at a high temperature, and then affixed to the core. 21. The method as claimed in claim 16, wherein the step of affixing the paper laminate comprises both manufacture of the paper laminate and the fastening to the core take place in one and the same manufacturing step, wherein one or more papers impregnated with a thermosetting resin are applied directly to the core and pressed together under pressure and heat without any gluing.