Patent ID: 8268110

Claim:
A method comprising the steps of : putting together a first piece, wherein the first piece is comprised of a wear layer, a pattern layer, and a base layer, with the wear layer, the pattern layer, and the base layer arranged in a sandwich manner, such that the wear layer is on top of the pattern layer, the pattern layer is on top of the base layer, and the pattern layer is in between the wear layer and the base layer; and removing portions of the first piece to form a first floor plank, such that the first floor plank includes a part of the wear layer of the first piece but not all of the wear layer of the first piece; wherein the first floor plank has a length, a width, and a thickness, such that the length is substantially greater than the width and the thickness; wherein the step of removing portions of the first piece to form a first floor plank forms a first vertical channel; wherein the first vertical channel has a left side wall, a right side wall, and a bottom, which together form a first U-shape, such that each of the left side wall and the right side wall of the first vertical channel is substantially perpendicular to the length of the first floor plank, and the bottom of the first vertical channel is substantially parallel to the length of the first floor plank; and wherein each of the left side wall and the right side wall extends from the bottom of the first vertical channel towards the part of the wear layer of the first piece, which is included in the first floor plank; wherein the step of removing portions of the first piece to form a first floor plank forms a second vertical channel; wherein the second vertical channel has a left side wall, a right side wall, and a bottom, which together form a second U-shape, such that each of the left side wall and the right side wall of the second vertical channel is substantially perpendicular to the length of the first floor plank, and the bottom of the second vertical channel is substantially parallel to the length of the first floor plank; and wherein each of the left side wall and the right side wall of the second vertical channel extends from the bottom of the second vertical channel toward the part of the wear layer of the first piece, which is included in the first floor plank; and wherein each of the left side wall and the right side wall of the second vertical channel extends from the bottom of the second vertical channel to the bottom of the first vertical channel.