Laminate flooring with custom images

Abstract

A laminate floor with custom images and a method for making the same are disclosed. The individual planks that make up the laminate floor each contain a base layer, a backing layer, an impact layer, a design layer, and a protective layer, which are laminated together, and have tongues and corresponding grooves in the sides of each plank. The design layer of each individual plank is made of a paper substrate and has a distinct section of an image printed on it. The laminate floor is then created by assembling the planks in a predetermined order and alignment to recreate the image on the floor. To create the laminate floor, an image is selected and digitized. The digitized image is then formatted to the dimensions of the flooring area desired, enhanced to a desired quality level, and segmented into distinct sections so that each section will fit on a plank. A digital layout is then created by aligning all of the sections so that they fit on a piece of base material, with spaces left between the section to account for later cutting and machining operations, and the digital layout is printed. The printed digital layout is then used as the design layer on a laminate flooring sheet, the laminate flooring sheet is cut into individual planks, and tongues and grooves are machined into the planks. The planks are then assembled in a predetermined order and alignment to create the laminate floor with the image.

I claim:  
     
         1 . A laminate flooring plank, comprising: 
 a) a base layer, the base layer including a top surface, a bottom surface, and a first, second, third, and fourth side surfaces;    b) a design layer, having a top surface and a bottom surface, disposed on the top surface of the base layer, the design layer including a distinct section of an image on the top surface, wherein when multiple laminate flooring planks are assembled, the image is recreated on a floor; and    c) a protective layer, disposed on the top surface of the design layer, to provide protection to the laminate flooring plank;    d) wherein the base layer, the design layer, and the protective layer are laminated together to form the flooring plank.    
     
     
         2 . A laminate flooring plank, as recited in  claim 1 , wherein the base layer has a generally rectangular shape.  
     
     
         3 . A laminate flooring plank, as recited in  claim 1 , wherein the base layer includes a tongue disposed on the first and second side surfaces and a corresponding groove disposed on the third and fourth side surfaces, opposite the first and second side surfaces, wherein the tongues and grooves are used to connect multiple laminate flooring planks together.  
     
     
         4 . A laminate flooring plank, as recited in  claim 1 , further comprising a backing layer, disposed on the bottom surface of the base layer, to provide support to and control warping of the laminate flooring plank.  
     
     
         5 . A laminate flooring plank, as recited in  claim 1 , further comprising an impact layer, disposed between the top surface of the base layer and the bottom surface of the design layer, to provide shock absorption and dent resistance to the laminate flooring plank.  
     
     
         6 . A laminate flooring plank, as recited in  claim 1 , wherein the design surface is paper and the distinct section of the image is printed on the top surface of the design surface.  
     
     
         7 . A laminate flooring plank, comprising: 
 a) a base layer, the base layer having a generally rectangular shape and including a top surface, a bottom surface, first, second, third and fourth side surfaces, a tongue disposed on the first and second side surfaces, and a corresponding groove disposed on the third and fourth side surfaces, opposite the first and second side surfaces, wherein the tongues and grooves are used to connect multiple laminate flooring planks together;    b) a backing layer, disposed on the bottom surface of the base layer, to provide support to and control warping of the laminate flooring plank;    c) an impact layer, having a top surface and a bottom surface, disposed on the top surface of the base layer, to provide shock absorption and dent resistance to the laminate flooring plank;    d) a design layer, having a top surface and a bottom surface, disposed on the top surface of the impact layer, the design layer being made of paper and having a distinct section of an image printed on the top surface of the design layer, wherein when multiple laminate flooring planks are assembled, the image is recreated on a floor; and    e) a protective layer, disposed on the top surface of the design layer, to provide protection to the laminate flooring plank;    f) wherein the backing layer, the base layer, the impact layer, the design layer, and the protective layer are laminated together to form the flooring plank.    
     
     
         8 . A flooring system, comprising: 
 a) a plurality of flooring pieces, each flooring piece containing a distinct section of an image and a plurality of side surfaces;    b) wherein when all of the flooring pieces, containing all of the distinct sections of the image, are assembled in a predetermined order and alignment, the flooring system recreates the image.    
     
     
         9 . A flooring system, as recited in  claim 8 , wherein each flooring piece includes a means for connecting the flooring piece to other flooring pieces.  
     
     
         10 . A flooring system, as recited in  claim 9 , wherein the means for connecting the flooring pieces comprises a tongue disposed on at least one of the plurality of side surfaces and a corresponding groove disposed within another of the plurality of side surfaces, opposite the tongue, on each flooring piece.  
     
     
         11 . A flooring system, as recited in  claim 8 , wherein the plurality of flooring pieces are laminate flooring planks.  
     
     
         12 . A flooring system, comprising: 
 a) a plurality of laminate flooring planks, each plank including a distinct section of an image, a plurality of side surfaces, a tongue disposed on one of the plurality of side surfaces, and a corresponding groove disposed within another of the plurality of side surfaces, opposite the tongue;    b) wherein when all of the planks, containing all of the distinct sections of the image, are assembled in a predetermined order and alignment, the flooring system recreates the image.    
     
     
         13 . A method for preparing an image for use on a laminate floor, comprising the steps of: 
 acquiring a digital image;    segmenting the digital image into a plurality of sections, wherein each section is sized to fit on a laminate flooring plank and contains a distinct portion of the digital image;    creating a digital layout using all of the plurality of sections; and    printing the digital layout.    
     
     
         14 . A method for preparing an image for use on a laminate floor, as recited in  claim 13 , wherein acquiring the digital image comprises the steps of scanning an image and saving the scanned image into a digital format.  
     
     
         15 . A method for preparing an image for use on a laminate floor, as recited in  claim 13 , wherein creating the digital layout comprises the steps of arranging the plurality of sections so that they fit on a sheet of base material and there are predetermined spaces between each section.  
     
     
         16 . A method for preparing an image for use on a laminate floor, as recited in  claim 13 , further comprising the steps of formatting the digital image and enhancing the digital image.  
     
     
         17 . A method for preparing an image for use on a laminate floor, as recited in  claim 16 , wherein formatting the digital image includes the step of resizing the digital image to the dimensions required to fit a flooring area.  
     
     
         18 . A method for preparing an image for use on a laminate floor, as recited in  claim 16 , wherein enhancing the digital image includes the step of sharpening the digital image to obtain a desired image quality.  
     
     
         19 . A method for creating a laminate floor, comprising the steps of: 
 acquiring a digital image;    segmenting the digital image into a plurality of sections, wherein each section is sized to fit on a laminate flooring plank and contains a distinct portion of the digital image;    creating a digital layout using all of the plurality of sections;    printing the digital layout;    securing the printed digital layout to a sheet of base material;    dividing the sheet of base material, with the printed digital layout secured thereon, into a plurality of flooring planks; and    assembling the plurality of flooring planks in a predetermined order and alignment to reproduce the digital image on the laminate floor.    
     
     
         20 . A method for creating a laminate floor, as recited in  claim 19 , wherein acquiring the digital image comprises the steps of scanning an image and saving the scanned image into a digital format.  
     
     
         21 . A method for creating a laminate floor, as recited in  claim 19 , wherein creating the digital layout comprises the steps of arranging the plurality of sections to fit on the sheet of base material with predetermined spaces between each section.  
     
     
         22 . A method for creating a laminate floor, as recited in  claim 19 , further comprising the steps of formatting the digital image and enhancing the digital image.  
     
     
         23 . A method for creating a laminate floor, as recited in  claim 22 , wherein formatting the digital image includes the step of resizing the digital image to the dimensions required to fit a flooring area.  
     
     
         24 . A method for creating a laminate floor, as recited in  claim 22 , wherein enhancing the digital image includes the step of sharpening the digital image to obtain a desired image quality.  
     
     
         25 . A method for creating a laminate floor, as recited in  claim 19 , wherein securing the printed digital layout to the sheet of base material comprises the step of laminating the printed digital layout to the sheet of base material.  
     
     
         26 . A method for creating a laminate floor, as recited in  claim 19 , wherein dividing the laminated sheet of base material into a plurality of floor planks comprises the steps of cutting the laminated sheet of base material into a plurality of floor planks, machining a tongue into one side of each floor plank, and machining a corresponding groove into a second side of each floor plank, opposite the tongue.