Patent ID: 8215078

Claim:
A floorboard comprising: a locking system, a wood fiber based core, and a surface layer comprising a paper laminate arranged on an upper side of the core, outer flat parts of the surface layer constituting a floor surface in a horizontal plane, a plane perpendicular to the horizontal plane and at the outer edge of the surface layer constituting a vertical plane, the floorboard has an edge portion with a curved edge profile defining a curved edge surface which is located under the horizontal plane, the curved edge surface at the vertical plane is at a distance from the horizontal plane which distance constitutes an edge depth exceeding the thickness of the surface layer, wherein the curved edge surface is an upper surface of the edge portion, wherein the floor surface and the edge surface are made in one piece of the same material, wherein the edge portion includes at least a compressed portion of the core defining the curved edge profile such that a part of the core in the edge portion under the curved edge surface adjacent to the vertical plane and at a vertical distance from the curved edge surface, has a higher density than a part of the core under the floor surface adjacent to the edge portion and at the same vertical distance from the floor surface, further wherein the density of the core beneath the curved edge surface is greatest adjacent the curved edge surface and progressively decreases along a distance in a downward direction away from the curved edge surface, and wherein said surface layer comprising a paper laminate comprises one or more papers impregnated with a thermosetting resin, applied directly to the board and pressed together under pressure and heat without any separate glue layer between the one or more papers and the board, wherein the formation and fastening of the paper laminate takes place in the manufacturing step.