Abstract:
The present invention relates to a floor panel and a flooring with a preferably continuous and unbroken front face, which is at least partially light transmitting and which has a light pattern/sign at the front face.

Description:
BENEFIT 
     The present application claims the benefit of U.S. Provisional Application No. 60/757,892, filed in the United States on Jan. 11, 2006, the entire contents of which are hereby incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention relate to a flooring and a floor panel with a continuous and unbroken front surface, which is at least partially light transmitting, providing for a light sign or pattern at the front face. 
     BACKGROUND 
     Embodiments of the invention may concern a laminate floor panel comprising a mechanical locking system, formed at least at two opposite edges and with a continuous and unbroken front surface, which is at least partially light transmitting. The following description of known techniques, problems of known systems and objects and features of embodiments of the invention will above all, as a non-restrictive example, be aimed as the field of the application. It should be emphasised that embodiments of the invention may be used in any floor panel and it could be combined with all types of known locking systems, for example, where the floor panels are intended to be joined using a mechanical locking system connecting the panels in the horizontal and vertical directions on at least two adjacent sides. Embodiments of the invention may also be applicable to, for example, solid wooden floors, parquet floors with a core of wood or wood-fibre-based material and a surface of wood or wood veneer and the like, floors with a printed and preferably also varnished surface, floors with a surface layer of plastic or cork, linoleum, rubber. Even floors with hard surfaces such as stone, tile and similar may be included and floorings with soft wear layer, for example, needle felt glued to a board. The invention can also be used for building panels, which preferably contain a board material, for example, wall panels, ceilings, furniture components and similar. 
     It is known that an illuminated floor can be assembled of wooden panels comprising illumination devices mounted through holes of the wooden panels, for example, as described in U.S. Pat. No. 5,095,412. 
     It is also known that an illuminated floor can be achieved by panels of glass or plastic assembled above illumination devices, for example, as described in DE 200 04 992 U1. 
     The illuminated floor panels known up to now have several disadvantages. There are apertures and notches at the front surface, due to the broken surface, which collect dust and moisture, and which apertures also lower the impact strength and the wear resistance. Alternatively, the panels comprise a surface of plastic or glass, which is a poor material for a floor panel with low strength and wear resistance. The known floor panels are also not aesthetically pleasing since they do not look like a normal panel and therefore do not blend in to a normal floor. Another disadvantage is that the known panels are difficult to assemble and disassemble, which is of great importance for a floor panel with a lighting means, since the lighting device must be possible to repair or exchange. 
     OBJECTS AND SUMMARY 
     Embodiments of the present invention may include a floor panel or flooring with a light means, in particular a laminate floor panel, which provides for new embodiments according to different aspects offering respective advantages. A useful area for the floor panels are public flooring, e.g. in stores, restaurants, ships, hotels and airports, for information signs or decoration. 
     According to a first aspect, embodiments of the invention provides for a laminate floor panel, which is at least partly light transmitting, comprising a front face, a rear face, a surface layer of resin-impregnated sheets and a wood-based core. The light transmitting is preferably obtained by removing parts of the core or even parts of the surface layer to such an extent that a light source located under the floor surface is visible at the front face. 
     According to a preferred embodiment of this first aspect there is an aperture at the rear face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The aperture is preferably formed by mechanical working, e.g. drilling and chipping. 
     Laminate flooring usually comprises a core of a 6-9 mm fibreboard, a 0.2-0.8 mm thick upper decorative surface layer of laminate, preferably comprising sheet material impregnated with thermosetting resins and a 0.1-0.6 mm thick lower balancing layer of laminate, plastic, paper or like material. The surface layer provides appearance and durability to the floorboards; and preferably contains at least one layer imprinted with a pattern, for example a wood pattern printed on a paper layer. The core provides stability, and the balancing layer keeps the board plane when the relative humidity (RH) varies during the year. The floorboards are generally laid floating, i.e. without gluing, on an existing subfloor. 
     The front surface of the floor panel according to the first aspect of the invention may be a wear resistant material, covering any object under the panel, and is continuous and also a natural floor material. A first advantage is that there are no dust or moisture collecting apertures or notches at the front surface. A second advantage is that when the lighting means is turned of, the floor panel looks just like a normal floor. A third advantage is that the floor panel has a high wear and impact resistance. 
     Preferably, a mechanical locking system is formed at least at two opposite edges of the floor panel, which facilitates the joining of a similar floor panel or a normal floor panel, which is not partly light-transmitting. Mechanical locking system joined by angling are for instance known from WO 94/26999, which is especially advantageous at the long sides of a rectangular floor, and another locking system especially advantageous at the short sides, particularly when combined with an angling locking system like the one described in WO 94/26999, are described in PCT/SE2005/001 586, owner Valinge Innovation AB. Other shapes of floor panels are also possible. One advantage in providing an illuminated floor panel with a mechanical locking system is that when you want or need to change an illuminated floor panel, due to failure of lighting means or a desire to have another light sign/symbol, it is simple to disassemble such floor panels and to change the illuminated panels. The above mentioned combination of locking systems make it possible to join floorpanels by several methods, preferably with a single action method where the long edge is installed with angling and the short edge, which is provided with a flexible tongue, with vertical folding. This combination is also very easy to disassemble. Other mechanical locking system are also known, and possible to use, which are joined by Angling-Angling, Angling-Snapping or Snapping-Snapping. Floorboards with a mechanical locking system are generally laid floating, i.e. without gluing, on an existing subfloor. 
     Evidently it is also possible to use a tongue and a groove joint; usually combined with gluing or nailing or other fastening means. 
     According to an embodiment of the first aspect, the wood based core is made of MDF or HDF. 
     According to another embodiment, lighting means is mounted into the aperture. It is also possible to connect a conductor to the lighting means and in the same or another aperture a battery cell and/or a receiver and/or a control unit. The aperture is preferably filled with a filling material, preferably light transmitting. 
     The thickness of the transmitting layer is adapted to the power of the lighting means, with the aim of facilitating light to transmit through the transmitting layer. The transmitting layer preferably comprising substantially the surface layer or the surface layer and a part of the core under the surface layer. 
     According to a second aspect, embodiments of the invention provide for a floor panel comprising a light-transmitting core of plastic or glass and a surface layer of resin-impregnated sheets, which is also at least partly light transmitting. It is feasible to mount a light means under the floor panel, preferably in a subfloor or into an aperture. An advantage with this system is that it is easier to mount, connect and control the lighting means; the draw back is that the subfloor normally has to be worked or changed. It is also possible to combine a floor according to the first aspect with such a sub-floor comprising a lighting means, provided that if there is a filler, the filler is light transmitting. 
     According to a first embodiment of the second aspect, only a part is light transmitting. Before attaching the surface layer to the light-transmitting core the rear side of the surface layer is worked, chemically or mechanically, forming a thinner part with a light-transmitting layer. Preferably, the space between the transmitting layer and the core is filled with a light transmitting filler, e.g. resin. An advantage of this embodiment is that it is possible to create a light pattern with only one lighting means. 
     According to second embodiment of the second aspect, the whole surface layer is light transmitting and the light pattern at the front surface is formed by the lighting means solely. Another possibility is that there is a second layer between the surface layer and the core, which is partly light transmitting, or the attaching means has various light transmitting properties-forming the light pattern at the front surface. 
     In both embodiments the attaching means also is preferably light transmitting, at least at the transmitting layer. The thickness of the transmitting layer, respectively in the first embodiment and of the surface layer in the second embodiment, is adapted to the power of the lighting means, with the aim of facilitating light to transmit. 
     Preferably, a mechanical locking system is formed at the edges, alike as in the first aspect, resulting in the same advantages. 
     In the first and second aspect of the invention the resin impregnated sheets could be replaced with a wood veneer, preferably treated with oil or varnish. 
     According to a third aspect, embodiments of the invention provide for a floor panel comprising a solid wood body, an aperture at the rear face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The aperture is preferably formed by mechanical working, e.g. drilling and chipping and the front surface preferably treated with oil or varnish. 
     Preferably, a mechanical locking system is formed at the edges, alike as described in the first aspect, resulting in the same advantages. 
     According to another embodiment of the third aspect a lighting means is mounted into the aperture. It is also possible connect a conductor to the lighting means and in the same or another aperture a battery cell and/or a receiver and/or a control unit. The aperture is preferably filled with a filling material, preferably light transmitting. Another solution is to mount a light means under the floor panel, as described in the second aspect, resulting in the same advantages. 
     The thickness of the transmitting layer is adapted to the power of the lighting means, with the aim of facilitating light to transmit through the transmitting layer. 
     According to a second object, embodiments of the invention provide for a flooring comprising at least one of the floor panels above in the first object, joined to one or more similar floor panels or one or more normal floor panels, which are not partly light-transmitting. 
     Preferably—the flooring is joined on a sub-floor comprising a lighting means mounted in e.g. an aperture or recess of the sub-floor. 
     A preferred lighting means is a light emitting diode, due to the low heat generation and small size. 
     In view of the above, an objective of embodiments of the invention is to solve or at least reduce the problems discussed above. 
     In particular, an objective of embodiments of this invention is to provide a floor panel with a light pattern/sign, which when an accompanying light means is turned off looks like a normal floor panel, and due to the front face of the floor panel being of a normal floor material the wear resistance is high. There are also no dust and moisture collecting apertures and recesses at the front face. 
     An advantage of forming a mechanical locking system at the edges of the floor panel is that it is easy to assemble and also disassemble and change the floor panel with the light pattern/sign. 
     All references to “a/an/the [element, device, component, means, step, etc]” are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIGS. 1   a - b  are a schematic top plan view and a schematic bottom view respectively of a floor panel according to one embodiment of the invention, 
         FIG. 2  shows a view whereby panels are joined by a single-action, angling at one edge and vertical folding at an adjacent edge. 
         FIGS. 3   a - d  show in cross-section different embodiments of the invention. 
         FIGS. 4   a - c  show in cross-section different embodiments of a floor panel mounted on a sub-floor with a lighting means. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     As represented in  FIGS. 1 and 2 , embodiments of the invention relate to a floor panel and a flooring, provided with a light sign or pattern. The sign or pattern is preferably not visible when a related lighting means is turned off, and in that state the floor panel or the flooring looks just like a normal floor and all the features related to the lighting are covered. The lighting means is mounted in the floor panel or in a sub-floor. 
     According to a first aspect of the invention, a laminate floor panel  1 , at least partly light transmitting, may comprise a front face  2  and a rear face  3  and a light sign or a decoration  9  is provided at the front face. The floor panel may further comprise, as shown in  FIGS. 3   a - c , surface layer  33  of resin impregnated sheets or a wood veneer, a wood based core  35 , an aperture  31  at the rear-face of the floor panel and a transmitting layer between the bottom of the aperture and the front face. The thickness of the transmitting layer is adapted to the power of an accompanying lighting means  36 , aiming at facilitating light to transmit through the transmitting layer. The sign or decoration  9  is preferably only visible when the related lighting means is turned on and the lighting means it self and the aperture is preferably never visible from the front face. In one alternative, the transmitting layer  32  only comprises the surface layer  33  and in a second alternative the transmitting layer  32 ′ also comprises the core  35 . The aperture  32  is at least partly preferably filled with a filler  37 , preferably light transmitting. 
     Preferably a mechanical locking system  6 ,  6 ′ is formed at least at two opposite edges  5   a ,  5   b  or  4   a ,  4   b . The most preferred mechanical locking system comprising a flexible tongue, which results in a very simple assemble and disassemble operation, facilitating the change of the floor panel with the light sign. The floor panel  1  in  FIG. 2  is joined along a first edge  5   b  to a to a second edge of an adjacent floor panel  1 ′, with a mechanical locking system  6 ′ comprising a flexible tongue  10 , by vertical folding, and along a third edge  4   b  to the fourth edge  4   a  of another adjacent floor panel  1 ″, with a mechanical locking system  6 , by angling. The whole panel  1  is joined in a single action. Other known mechanical locking systems for floor panels are also possible to use. 
     One alternative is to attach the lighting means into the aperture and connect it with a conductor  39  and via the conductor control the lighting means by a control unit C. A battery cell B and a receiver R is also possible to connect via the conductor. A second alternative is to mount the lighting means and a battery cell in the same aperture, together with preferably a receiver R and a control unit C. The conductor is preferably attached into a recess of the floor panel and covered with a filler, e.g. resin. One example of a lighting-means is a light emitting diode and another example is fibre optic. If fibre optic: is used, the conductor is a fibre optic cable. 
     The wood-based core is preferably a particle, MDF or HDF board. 
     According to a second aspect of the invention, represented in  FIGS. 4   b - c , the floor panel comprising a core made of a light transmitting material  40 , such as plastic or glass and a surface layer  33  of resin impregnated sheets or wood veneer, which are at least partly light transmitting. The floor panels are mounted on a sub-floor  41 , comprising a lighting means  36 , preferably a light emitting diode, mounted into an aperture  43  of the sub-floor. One alternative is to connect the lighting means with a conductor  39  mounted into a recess  42  of the subfloor and via the conductor control the lighting means by a control unit C. A battery cell B and a receiver R is also possible to connect via the conductor. A second alternative is to mount the lighting means and a battery cell in the same aperture, together with preferably a receiver R and a control unit C. Also the floor panel according to the second aspect is preferably joined by a mechanical locking system, alike as described above. 
     In one embodiment, see  FIG. 4   b , the surface layer has at least one area comprising a thinner and light transmitting layer, which is mechanically or chemically worked. A space  44  between the core  40  and the transmitting layer is preferably filled with a light transmitting filler. 
     In a second embodiment, see  FIG. 4   c , the whole surface layer  33  is light transmitting. The pattern or sign at the font face is in this embodiment formed by the formation of the lighting means  36 . Is it also possible to form the light pattern or the sign at the front face by an additional layer between the surface layer and the core or by the attaching means used for attaching the surface layer to the core. The additional layer could be punched or could have a printed pattern, which is at least partly visible from the front face. In this case, the additional layer and the attaching means has light-transmitting properties, which varies over the front surface. The design of the whole floor panel could be changed if the surface is light transmitting. The appearance of several panels in a floor could for example be varied over time by changing the light intensity in individual floor panes. This will create a new design element which could be very attractive in for example show rooms, shops etc. 
     A third aspect of the invention; represented in  FIG. 3   d , is a partly light-transmitting floor panel, comprising a body  38  of solid wood, an aperture, a lighting means  36 , and a transmitting layer  32 ″ between the bottom of the aperture and the front face. The aperture is preferably, at least partly, filled with a filler. The features-described above for the first aspect and related to the mechanical locking, the lighting means, the battery cell, the receiver and the control unit are applicable also to a floor panel according to the third aspect.  FIG. 4   a  shows that it is also possible to mount a floor panel according to the first and third aspect on a sub-floor comprising a lighting means. 
     The thickness of the transmitting layer, described above in the different aspects of the invention, is preferably in the range of 0.05-1 mm and most preferably in the range of 0.3-0.7 mm. The thickness depends of the power of the lighting means and the light transmitting properties of the material, and to some extent also the strength of the material. Most materials suitable for flooring could be light transmitting if they are made thin enough. Stone, tiles and a lot of different plastic and wood based materials are possible to use. In metal surfaces for example micro openings which are not visible from the surface could be made and preferably filled with a light transmitting material 
     A second object of embodiments of the invention is a flooring comprising at least one of the floor panels above, joined to one or more similar floor panels or one or more normal floor panels, which are not partly light-transmitting. 
     Embodiments of the invention have mainly been described above with reference to a few embodiments. However, as is readily appreciated by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended claims. 
     Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein.