WO2009016446A2

WO2009016446A2 - Floor covering consisting of floor panels and method for manufacturing such floor panels

Info

Publication number: WO2009016446A2
Application number: PCT/IB2008/001822
Authority: WO
Inventors: Bernard Thiers; Laurent Meersseman
Original assignee: Flooring Industries Limited, Sarl
Priority date: 2007-07-31
Filing date: 2008-07-14
Publication date: 2009-02-05
Also published as: BE1018426A3; WO2009016446A3

Abstract

Floor covering, which is at least composed of floor panels with coupling means (6), wherein said coupling means (6) put the floor panels (2) during coupling in a coupled condition, and wherein gaps (10) are present at the surface (9) of the floor covering (1), said gaps (10) defining a varying space (S) between the respective sides (4-5) of said coupled floor panels (2). The invention also relates to a floor panel (2) with which such floor covering (1) can be formed, to a method for manufacturing such floor panels (2) and to a packaging unit comprising two or more of such floor panels (2).

Description

Floor covering, floor panel, packaging unit and method for manufacturing such floor panels.

This application claims the benefit under 35 USC §119(e) of U.S. Provisional Patent Application No. 61/071,311 filed on April 22, 2008.

This invention relates to a floor covering, as well as to the floor panels from which such floor covering can be composed. Further, the invention relates to a packaging unit which comprises two or more of such floor panels, and to a method for manufacturing such floor panels.

More particularly, the invention relates to floating floor coverings of the type which is composed of floor panels having mechanical coupling means at one or more pairs of opposite sides thereof, the coupling means allowing that these floor panels may accomplish a connection with another floor panel. Said coupling parts may or may not be made in one piece with the floor panel and may provide for a mutual locking of the floor panels in horizontal as well as in vertical directions, for example, as described in the international patent applications WO 94/26999, WO 97/47834, WO 01/98603, WO 2005/068747 and WO 01/96688.

With the examples of the above-mentioned type of floor panels existing in the market, mostly care is taken that a good mutual coupling of constant or quasi- constant quality can be obtained by means of said mechanical coupling means. To this aim, for example, the coupling means may be used which are known as such from WO 97/47834 and which enable a coupling without play, wherein the possible occurrence of gaps at the surface can be counteracted as good as possible.

The mechanical coupling means which are known as such from WO 94/26999 may also be applied in a floor covering of the above-mentioned type. The coupling means described there are characterized, amongst others, by a play incorporated, for technical reasons, in the connection itself. Due to the presence of this play, the panels possibly may be installed such that already from the start gaps, whether or not desired, are present between the individual floor panels at the surface of the floor covering. However, the panels may also be installed such that in the beginning, there are no gaps present at the surface. Even in this latter case, after a certain period of time, as a consequence of repeatedly shrinkage and/or expansion of the floor panels, gaps may form in the floor covering, which define a space between the upper edges of the floor panels, the size of which may vary in the floor covering. This variation in size of gaps, which possibly may impart a certain aged appearance to the floor, is left entirely to chance and/or to the person installing the floor.

In WO 2005/068747, mechanical coupling means are described, which provide for that a minimum gap always remains present between the individual floor panels in the floor covering. However, these floor panels, too, have an incorporated play, such that the size of the gaps in the floor covering then always is determined during installation by an action of the user and/or after installation as a consequence of shrinking and/or expansion of the floor panels. Here, too, a variation in size of the gaps is left to chance and/or to the person installing the floor.

In the above-described documents from the state of the art, the presence or absence of gaps in the floor covering and/or the size and/or the variation in size of such gaps is left to chance and/or to the person installing the floor.

From JP 8-109734, it is also known in the meantime to make floor panels with coupling means providing for that, when coupling to of such floor panels, a space of constant size is obtained between the upper edges of the floor panels. A floor covering composed of such floor panels has the disadvantage that said space has an artificial appearance.

The present invention offers an alternative floor covering, wherein, according to certain preferred embodiments thereof, one or more disadvantages from the state of the art are remedied. To this aim, the invention relates to a floor covering which is at least compOsedxff flow panels being-irτ aτrrutually coupled ϋoπditroπ,- wherein this coupled condition consists at least in that the floor panels, at the edges of at least a first pair of opposite sides, are coupled to each other by means of mechanical coupling means, wherein in said coupled condition of these floor panels, at the coupled sides concerned, a locking exists in a vertical direction perpendicularly to the plane defined by the coupled floor panels, as well as in a horizontal direction perpendicularly to the respective sides and in the plane of the coupled floor panels, with the characteristic that said coupling means, when coupling, put the floor panels in a coupled condition, wherein at the surface of the floor covering gaps are present, which define a varying space between the respective sides of said coupled floor panels. "Varying" has to be understood in the broadest sense and relates to the presence of unequal spaces in the floor covering. According to the invention and its preferred embodiments, which will be explained in the following, the presence and/or size and/or the variation in size of possible gaps is connected to the floor panels themselves, for example, to the coupling means or coupling parts themselves, such that, preferably inevitably, a variation in gap size is already obtained during installation. Moreover, according to certain embodiments, it is possible that such gaps appear natural. It is noted that it is not excluded that the person installing the floor, during installation, still has several possibilities of choosing in respect to the presence and/or the size and/or the variation in size of possible gaps. So, for example, the choice of the floor panels to be coupled together may be left to the person installing the floor.

Preferably, the gaps of the present invention, over the majority of the length thereof, show a depth which is larger than the width thereof, and/or a depth which is such that the user can not notice the possible bottom of such gap. Still better, a width-depth relation, which is smaller than 75 percent and still better is smaller than 50%, can be used over the majority of the length of the gaps. Possibly, for artificially creating a depth effect, a dark, for example, a dark brown, black or grey, coloration of said side walls and/or bottom of the gap may be used. In general, the gaps of the invention, over the majority of their length, preferably are deeper than 1 millimeter, and still better deeper than one and a half or 2 millimeters.

It is clear that the width of a gap corresponds to said space and preferably is determined as the distance between the upper edges of the floor panels, measured in a horizontal plane perpendicular to the respective side. The depth of the gap preferably is determined by the distance, measured in a vertical plane, of the upper edges of the floor panels to the deepest point of the gap concerned.

Preferably, the gaps of the present invention have steep, preferably substantially vertical, lateral walls over the majority of their length. It is also not excluded that walls are used which form an undercut of the floor panels. It is evident that said spaces preferably are at least present at said first pair of opposite sides.

It is clear that the cooperation of the coupling means of two or more coupled floor panels, according to the present invention, determine the space as well as the variation of this space when coupling the floor panels, and such preferably in an unambiguous manner. This means that two of such floor panels can be coupled to each other preferably without play or almost without play.

Further, it is clear that the coupled condition which is mentioned relates to the coupled condition immediately after composing the floor covering. This is without possible changes in temperature or air humidity having caused the floor panels to shrink and/or expand. Of course, it is possible that the dimensions of said space change to a certain extent after installation, for example, under the influence of changes in temperature and/or humidity. Limiting possible play in the connection leads to that such dimensional changes of the space afterwards remain restricted, or that at least the occurrence of these changes is counteracted, and that under normal climatologic circumstances always an acceptable result is maintained in the floor covering.

In other words, the floor covering offers a floor covering showing varying spaces already when being installed. Thus, by means of the present invention, it is possible to obtain a floor covering with an aged appearance already during the installation thereof, and such without having to resort to the creativity of the user; anyhow, the gaps and the variation thereof along the upper edges of the floor panels may be connected unambiguously, or almost unambiguously, to the floor panels, preferably, to the coupling means. An aged appearance is present, for example, also with old glued or nailed parquets, however, such a condition is achieved only after several years of use. The present invention allows obtaining such condition already when installing the floor panels. Further, it is clear that gaps, whether or not varying gaps, also can be present at a second or further pair of opposite sides. Moreover, the invention also offers the possibility to the manufacturer of such floor covering of taking over the design of these gaps or, in other words, of including the size, as well as the size and/or the kind of the variation thereof, into the design of the individual floor panels and leaving it no longer to chance and/or to the user. Preferably, mechanical coupling means are used which are provided industrially at the floor panel, such as mechanical coupling parts which are made in one piece with such floor panels or are integrated in such floor panels. However, according to the invention it is not excluded that one may use other mechanical coupling means, such as separate connection profiles, which can be provided between the respective sides to be coupled.

Said varying space can be of differing nature and may be obtained according to a plurality of possibilities.

According to a first possibility, said varying space is at least obtained in that the position of the upper edge in respect to the coupling means present at the respective side differs in two or more of such floor panels from the floor covering. In such case, the actual variation only shows when two or more of such floor panels are coupled together for forming the floor covering of the invention. It is noted that the size of the possible gaps, more particularly the width thereof, according to this possibility still at least partially is left to chance, as it depends, for example, on the respective combination of floor panels or their mutual position. However, a variation in the size of the obtained spaces is as good as inevitable when the floor panels are connected to each other at random, which increases the chance for obtaining a naturally aged appearance of the composed floor covering.

According to a second possibility, said varying space is obtained at least in that the position of the upper edge of one or more of the coupled floor panels in respect to the coupling means present at the respective side varies along the respective edge of the respective floor panel itself. According to this possibility, this thus pertains to an edge of which the position changes at least in the floor panel itself. Of course, such variation already shows when looking at each floor panel separately.

It is clear that said two possibilities for forming varying spaces can be mutually combined and that the present invention, in particular the varying character of the space, can also be performed on other, not specifically mentioned possibilities.

Further, it is clear that the upper edge, at one as well as at both opposite sides of the same pair of sides, can be realized at a different position or realized in a varying manner. For example, it is possible that the upper edge at the groove or at the tongue sides in the floor panels of the floor covering of the invention is made at the same position and/or without variations, whereas the upper edge at the other opposite side is made at different positions and/or with variations. Such embodiment restricts the complexity of manufacturing such floor panels.

Preferably, said space has somewhere in the floor covering a size which renders it visible to the user. Visible gaps can be obtained when the width of the obtained space is more than 0.2 millimeters between the upper edges of the floor panels. Preferably, such visible gap is obtained over at least 25 percent of the length of the coupled sides in the floor covering. However, the occurrence of visible gaps, when using oblong floor panels, may be concentrated to the coupled long sides thereof. So, for example, such visible gap may be observed over at least 35 percent of the length of the coupled long sides. Still better, such visible gap is observed over at least 65 percent of the length of the coupled long sides. From the above, it is clear that the floor panels of the floor covering of the invention at one and the same side may have gaps as well as portions closely adjoining the floor panel or floor panels coupled thereto.

Preferably, said space, seen in average over the floor covering, i.e., over the majority of the length of the gaps present, is smaller than three or smaller than two millimeters; still better, in such floor covering the space always, possibly with limited local exceptions, is kept smaller than three millimeters. Larger dimensions may lead to annoying effects, such as visible dust accumulation in said gaps.

As aforementioned, the floor covering of the invention can be composed of oblong rectangular floor panels, wherein said first pair of opposite sides is formed by the long sides of the floor panel concerned.

As aforementioned, the floor covering may be composed of floor panels having also a second pair of opposite sides, which are also provided with coupling means. In such case, it is preferred that in the coupled condition at the edges of this second pair of opposite sides preferably no visible gaps, less gaps and/or smaller gaps are present. This may relate, for example, to the short sides of oblong floor panels. Practically seen, the floor panels in the floor covering of the invention may have profiled edge regions at least at both sides of said first pair of opposite sides, and preferably also at both sides of a second pair, the profiling of which substantially is constructed of two zones, on the one hand, a first zone comprising at least a portion of the profile of the mechanical coupling means or coupling parts, and, on the other hand, a second zone extending above said first zone, however, situated beneath the upper surface of the floor panels, wherein said second zone comprises at least a portion of a side wall of said gap. In a preferred embodiment, the floor covering comprises parallel rows of said floor panels, wherein said first zones of floor panels of one and the same row are aligned with each other, whereas said second zones, in conjunction with the second zones of similar floor panels of an adjacent row, in said coupled condition form said gap defining said varying space. Of course, it is not excluded that the floor covering of the present invention is constructed otherwise than of parallel rows. For example, it is also possible to install such floor covering in herringbone, tile or diamond patterns.

It is clear that the invention also relates to a floor panel that can be applied for composing such floor covering. Further, the invention also relates to a packaging unit which comprises two or more of such floor panels, wherein then, when coupling these floor panels, a varying gap can be formed between the respective coupled sides. Preferably, such packaging unit comprises 5 to 10 of such floor panels, wherein a good handling of the packaging unit is obtained when 7 or 8 floor panels are packaged together. Preferably, such packaging unit comprises floor panels with which a varying space can be obtained at least by means of said first possibility, as well as floor panels with which a varying space can be obtained at least by means of said second possibility.

The invention also relates to a method for manufacturing such floor panel, with the characteristic that this floor panel, at least at both sides of said first pair of opposite sides, is provided with profiled edge portions, the profiling of which is constructed at least, and preferably substantially, of two zones, on the one hand, a first zone in which at least a portion of the profile of the mechanical coupling means is formed, and, on the other hand, a second zone, which is located above said first zone, however, situated beneath the upper surface of the floor panels, and wherein in said second zone at least the profile of a side wall of said gap is formed. Preferably, said second zone is formed independently of said first zone. This means that said second zone, in respect to the first zone, can be formed at two or more different lateral positions, or, in other words, that the method preferably is applied for manufacturing two or more floor panels, wherein said second zone of these floor panels is made such that a varying gap can be obtained in the floor covering. It is noted that such varying gap, as also described above, can be obtained according to various possibilities.

It is clear that said second zone preferably comprises the upper edge of the respective floor panel. Such second zone may extend downward to a location where, when coupling two of such floor panels, a contact surface can be formed, which prevents or restricts the horizontal movement of the respective floor panels towards each other.

Preferably, the first as well as the second zone is formed by means of a machining treatment with a mechanical tool, wherein the position and/or orientation of the mechanical tool forming said second zone is variable in relation to the floor panel, whereas the mechanical tool or instrument forming said first zone preferably is fixedly installed in respect to the floor panel.

Instead of working with a mechanical tool, one may also work with a tool such as a laser or any other technique.

The variability of the respective tool, whether or not a mechanical tool is concerned, preferably is obtained in that this tool can be displaced automatically, whereas floor panels are presented to the respective, for example, machining treatment. This may take place, for example, in a controlled manner, such as by means of cams and/or by means of spindles and/or gearwheels, the rotation of which is controlled. According to the invention, it is not excluded that mechanisms are used which can effect any displacement or turning of the respective tool or instrument.

Automatically, whether or not random, displacing a tool or instrument may be obtained, for example, by means of a computer and associated software, which then controls the respective mechanism or the drive thereof. Possibly, one may also work with codes or other markings or recognition marks on the floor panels, wherein these codes or marks then can be supplied to the respective software in order to perform a suitable control of the mechanism. Amongst others, in the case of floor panels with a printed decor, for example, this decor itself can be applied as a recognition mark, and one may work, for example, with panel recognition by means of cameras or other sensors.

In a preferred embodiment of the method, the position and/or the orientation of the mechanical tool or instrument forming said second zone is altered in respect to the floor panel, whereas the orientation and/or position of the mechanical tool or instrument forming said first zone remains unaltered. Said alteration substantially can be performed in two manners. A first possible manner relates to manufacturing said floor panels successively, wherein said alteration in position and/or orientation of said mechanical instrument forming the second zone is performed at least between the manufacture of both floor panels. This means that the alteration is performed at least at a moment when the respective instrument is not in contact with said floor panels. As a deviating variant of this manner of manufacturing, the floor panels may also be manufactured in groups, wherein the adjustment of the respective instrument then occurs at least in between the manufacture of the groups. In this deviating variant, it is preferred to keep the position and orientation of the instruments constant during the manufacture of the same group of floor panels. A second possible manner relates to manufacturing said floor panels successively, wherein said alteration in position and/or orientation of said mechanical instrument forming the second zone is performed at least during the manufacture of at least one of both floor panels. This means that the alteration in position and/or orientation is performed at least at a moment when this instrument is in contact with at least one of said floor panels. It is noted that both possible manners of performing the alteration in position and/or orientation can be combined.

It is clear that, when the first manner of altering the position and/or orientation is applied, the obtained floor panels, when being coupled, may have a varying space which is obtained according to said first possibility and that, when the second manner of altering the position and/or orientation is applied, the obtained floor panels, when being coupled, may have a varying space which is obtained according said second possibility. Of course, the combination of both manners may lead to floor panels having, when coupled, a varying space obtained according to the combination of the first and the second possibility. It is noted that the invention in particular relates to laminate floor coverings, wherein the floor panels substantially consist of a substrate and a top layer on the basis of synthetic material, said top layer having a printed decor and being provided on this substrate. Said decor may be printed directly on the substrate, whether or not by the intermediary of primer layers. However, the decor may also be provided on a material sheet, such as a paper sheet, which is taken up in said top layer. Further, the top layer may also comprise a protective layer, which is situated above the printed decor and which comprises, for example, wear-resistant particles, such as aluminum oxide. It is not excluded that this protective layer also comprises a material sheet, such as a paper sheet. Such laminate floor panel may be manufactured, for example, according to a DPL (Direct Pressure Laminate) or a HPL (High Pressure Laminate) technique. In the case of a DPL technique, one or more material sheets provided with resin, together with the substrate, are brought into a press device, where, under the influence of increased pressure and temperature, they are connected to each other as well as to the substrate. In the case of a HPL technique, the top layer is formed separately on the basis of two or more material sheets provided with resin, before the obtained top layer is provided on the substrate, for example, by gluing.

It is clear that the invention is not limited to laminate floor coverings, but relates to any kind of floor covering. For example, it may also be applied for floor coverings composed of floor panels with a wooden top layer, such as veneer parquet, so- called "engineered wood", or solid parquet.

With the intention of better showing the characteristics of the invention, hereafter, as an example without any limitative character, several preferred embodiments are described, with reference to the accompanying drawings, wherein:

Figure 1 in perspective represents a floor covering with the characteristics of the invention;

Figure 2, also in perspective, but on a larger scale, represents a view onto the region indicated by F2 in figure 1 ;

Figure 3, at a larger scale, represents a cross-section according to the line Ill-Ill indicated in figure 1 ;

Figure 4, at a still larger scale, represents a view onto the region indicated by F4 in figure 3;

Figures 5 and 6, in a view similar to that of figure 4, represent variants;

Figure 7, in a view similar to that of figure 3, represents a variant;

Figure 8, at a larger scale, represents a view on the region indicated by F8 in figure 7;

Figures 9 to 12 represent examples of floor panels with the characteristics of the invention;

Figure 13 schematically represents several steps in a method according to the present invention; Figures 14 to 17, respectively, represent views according to the lines XIV-

XIV, XV-XV, XVI-XVI and XVII-XVII indicated in figure 13; and

Figures 18 to 19 for various variants represent a view similar to that of figure 17; and

Figure 20, in the same view as figure 18, represents another variant.

Figure 1 represents a floor covering 1 , which is composed of floor panels 2 being in a coupled condition. The figure clearly shows that this coupled condition consists at least in that the floor panels 2 at the edges 3 of at least a first pair of opposite sides 4-5, in this case at the long sides 4-5 of the oblong floor panels 2, are coupled to each other by means of mechanical coupling means 6. Of course, it is preferred that the floor panels 2 also are coupled at the second pair of opposite sides 7-8 by means of such or other mechanical coupling means 6. In the example, in this coupled condition, for example at the long sides 4-5 and/or at the short sides 7-8, there exists a locking in a vertical direction V1 as well as in a horizontal direction H1 between the coupled floor panels 1.

The particularity of the invention consists in that gaps 10 are present at the surface 9 of the floor covering 1 , in this case at least along the long sides 4-5 of the coupled floor panels 2, said gaps 10 defining a varying space S between the respective sides 4-5 of said coupled floor panels 2. In figure 1 is shown clearly that such varying gaps 10 can be formed by coupling floor panels 2, the upper edge 11 of which is locally disturbed, as well as by coupling floor panels 2, the upper edge 11 of which gradually varies along the floor panel 2 in position in respect to the coupling means 6. It is also possible to form such varying gaps S by providing for that the, possibly straight, upper edges 11 of coupled-together floor panels 2 are not aligned with each other, for example, in that the upper edges 11 of the long sides 5, when two of such floor panels are coupled to each other at their short sides 7-8, adopt another lateral position P1-P2 in respect to the coupling means 6, at least at the height of the corner points 12. Figure 2 represents an example of this last-mentioned possibility. Of course, as represented here by means of figure 1 , combinations between these three possibilities are not excluded.

In the example represented by means of figure 1 , in the coupled condition of the floor panel 2, at the second pair of opposite sides 7-8, namely, in this case the short sides, no gaps 10 or only smaller, possibly invisible, gaps 10 are present. Of course, according to the invention it is not excluded that at the opposite short sides 7-8 similar gaps 10 are provided as at the opposite long sides 4-5.

Figures 2 and 3 illustrate that the floor panels 2 of the floor covering 1 from figure 1 have profiled edge portions 13, the profiling of which is constructed at least of two zones Z1-Z2.

In a first zone Z1, at least a portion of said coupling means 6 and in this case the entire coupling means 6 are formed. In this case, the coupling means 6 or coupling parts are substantially formed as a tongue 14 and a groove 15, wherein the groove 15 is bordered by means of a lower lip 16 and an upper lip 17 and wherein this tongue 14 and groove 15 further are provided with locking means or locking parts 18, such that by means of these coupling means 6 a locking between two of such floor panels 2 can be obtained in a vertical direction V1 as well as in a horizontal direction Hl

In a second zone Z2, which extends above said first zone Z1, but which is situated beneath the upper surface 9 of the floor panels 2, at least the profile of a side wall 19 of said varying gaps 10 is formed.

As already became clear from figure 1, figure 2 also shows that the floor panels 2 of the example, amongst others, can be composed to a floor covering 1 in substantially parallel rows 20. Herein, said first zones Z1 of floor panels 2 from the same row 20 are aligned with each other, whereas said second zones Z2, in cooperation with the second zones Z2 of similar floor panels 2 of an adjacent row 20, in said coupled condition form said gap 10 defining said varying space S, and thus these second zones Z2 mutually are not aligned or at least not all of them are aligned. Figure 3 also shows this latter.

Further, figure 3 clearly shows the construction of a floor panel 2 of the figures 1 and 2. This relates to a floor panel 2 with a core 21 with a top layer 23 situated at the upper side 22 thereof. At the underside 24 of the floor panel 2, as represented, preferably also an underlying layer 25 or backing layer is provided. The top layer 23 and/or backing layer 25 may have been produced in different manners. For example, this may relate to layers of veneer, HPL (High Pressure Laminate), DPL (Direct Pressure Laminate) or foil.

The top layer 23 represented in figure 3 shows the typical construction of a DPL laminate floor panel, wherein this top layer shows at least a decorative layer 26 with at least a print and comprises a protective layer 27 or overlay with hard particles, such as aluminum oxide or the like. Preferably, these layers 26-27 comprise a carrier sheet, for example, a paper sheet, which is provided with a synthetic resin, such as melamine. In the case of a DPL, as it is the case here, these layers 26-27 are connected to each other and to the core 21 by means of one and the same press treatment. This is contrary to a HPL, wherein first the top layer 23 is separately made by means of a press treatment, after which it is provided on a core 21 , for example, by gluing this top layer 23 on the core 21. The underlying layer 25 represented in figure 3 also relates to a carrier sheet provided with resin, more particularly a paper sheet, which in the same press treatment is connected to the core, when forming the DPL top layer.

As figure 3 shows, the aforementioned coupling means 6, at least at said first pair of opposite sides 4-5, however, preferably at both pairs of opposite sides 4-5-7-8, are made in one piece with the floor panel 2, more particularly in one piece with the respective side and in particular in one piece with the core 21 of the floor panel 2. In the example, this relates to a core 21 of wood-based material, more particularly of finely ground wood, which is kept together with a binding agent, such as MDF or HDF (Medium Density Fiberboard or High Density Fiberboard). Other examples of such materials are various kinds of chipboards or OSB (Oriented Strand Board).

By means of the floor panels 2 represented at the right hand side of figure 3 in dashed line, it is illustrated that the coupling means 6 allow that two of such floor panels 2 can be coupled at the respective sides 4-5-7-8 to each other in a manner known as such. As illustrated, this may be performed by bringing the one floor panel 2 with a substantially horizontal shifting movement T laterally into the other floor panel 2, wherein use is made of a so-called click- or snap-effect, or by turning the one floor panel 2 by means of a relative turning movement W around the respective upper edges 11 into the other, wherein also a click- or snap-effect may occur. However, the invention is not restricted to coupling means 6 allowing both above-described manners of coupling, but also relates to floor panels 2 with coupling means 6 allowing at least one of the above-mentioned coupling manners, and/or which allow at least another coupling manner, such as coupling by means of a substantially downward translation movement, also denominated "push-lock", wherein also a click- and/or snap-effect may occur.

Figure 3 also illustrates that the coupling means 6, in a coupled condition of two of such floor panels, provide for a locking in vertical direction V1 perpendicular to the plane defined by coupled floor panels 2, as well as in horizontal direction H1 perpendicular to the respective sides 4-5-7-8 and in the plane of the coupled floor panels 2. The locking in vertical direction V1 is obtained by means of a tongue 14 and a groove 15, which, during coupling, are brought into each other, wherein said groove 15 is bordered by means of a lower lip 16 and upper lip 17. The locking in horizontal direction H1 is obtained by locking means 18 which are present at the coupling means 6. In this case, the locking means or locking parts 18 relate to an upright locking element 2 at said lower lip 16 and a cooperating-therewith locking element 29 at the underside 30 of said tongue 14. In the coupled condition of the floor panels 2, the coupling means 6 at the coupled sides 4-5-7-8 preferably have cooperating contact surfaces 31-32 at the height of said locking means or locking parts 18. It is noted that in this case the upper lip 17 of the groove 15 is free from locking means 18 which contribute to said locking in horizontal direction H1.

Further, it is clear from figure 3 that the coupling means 6 bring the floor panels 2 into a coupled condition in which gaps 10 are present at the surface of the floor covering 1.

Preferably, the floor covering 1 of the present invention also shows the feature illustrated by means of figure 1 that for floor panels 2 of the same row 20, and preferably for all floor panels 2 of the floor covering 1 , the distance D, measured in the horizontal plane, between the contact surfaces 31-32, which are formed in the coupled condition at the locking means or locking parts 18 of opposite sides 4-5-7- 8 of the same floor panel 2, is constant. Preferably, this distance D is at least constant for the opposite sides 4-5, where said gap 10 is present. In the example of figure 1 , this thus relates at least to the long sides 4-5 of the floor panels 2.

As clearly shown on figure 3, it is possible that above the coupling means 6, however, beneath said second zone Z2, also a contact surface 33 is formed between the coupled floor panels 2. Said contact surface 33 prevents a movement of the floor panels 2 towards each other in said horizontal direction H1. Preferably, the floor covering of the invention is composed of floor panels which, in said coupled condition, such as in the example of figure 3, are free from play, or at least are almost free from play. This means that preferably a freedom of movement is applied in the horizontal direction H1 of two coupled floor panels, which is smaller than 0.2 millimeters. Of course it is possible according to the invention that, when coupling two floor panels, there is no freedom of movement at all in the horizontal direction Hl

Preferably, such gap 10 is formed by removing material at the respective edge 3 and/or upper edge 11 by means of any technique. However, other techniques for providing such gap 10 are not excluded. For example, such gap 10, or at least the lateral walls 19 of such gap 10, can be formed by thermically deforming the respective upper edge 11.

Figure 4 shows that the gaps 10 in this case show substantially vertical lateral walls 19 over the majority of their length L, which then preferably adjoin to a gap bottom 34 formed at the respective side 4-5-7-8 or a portion 35 thereof formed at that location. Preferably, the floor panels 2 adjoin each other at the height of or beneath said gap bottom 34.

According to the invention, a different geometry for the gaps 10 than the one represented in figure 4 is not excluded. For example, lateral walls 19 comprising convexly or concavely bent surfaces, or inclined walls, can be applied, wherein the lateral walls 19 then adjoin or not adjoin to a portion 35 of the gap bottom 34 formed at the respective side 4-5-7-8 and wherein the floor panels 2 preferably adjoin each other at the height of or beneath said gap bottom 34. Figure 5 shows an example, wherein the inclination A of the lateral gap walls 19 varies along the upper edges 11 of the floor panels 2, such that in this manner the varying space S required by the invention is obtained. Of course, gaps 10 of different geometry can be combined with each other in the same floor covering 1 and/or in the same floor panel 2. Therefore, it is possible, for example, that the two lateral gap walls 19 have a differing geometry. Thus, the one lateral wall 19 of the gap 10 may have an inclination A, whereas the other is made bent or vertical. It is noted that in the case of inclined walls 19, preferably substantially vertical walls are used, or at least inclinations A which, over the majority of the length L of the gap 10, are larger than 70° and still better are larger than 80°, such that the gap 10, towards the surface 9 of the floor panel 2, varies in width only in a limited manner and/or that the gap 10 does not appear to be a chamfer or a so-called V-groove. Of course, the inclination A preferably is also limited to 90° or the vertical. However, it is not excluded that lateral gap walls 19 are used which undercut the panel surface 9, wherein in other words lateral walls 19 are applied with an inclination A of more than 90°. Figure 6 shows an example thereof. By such undercuts, particular depth effects can be obtained. In combination therewith, figure 6 also shows that said gap bottom 34 does not necessarily have to be flat and/or horizontal. Of course, such gap bottom 34 can also be applied without said undercutting lateral walls 19.

Figure 7 shows that it is possible to combine the gaps 1 of the invention with other edge finishes, such as chamfers 36 provided at the height of one or more upper edges 11. In the represented example, this relates to a chamfer 36 in the form of a bevel, which is applied at least at two opposite sides 4-5 of the floor panel 2. In such case, the gap 10 of the invention is applied beneath the chamfer 10 and the space S is defined between the upper edge 11 lowered by the bevels or other chamfers 36.

Figure 8 shows another such combination, wherein said chamfer 36 is provided only at one of two opposite sides 5, in this case at the side with the groove 15.

It is clear that the surfaces 37 of such chamfers 36 preferably are covered with a decorative layer 38 matching the general appearance of the floor panel 3.

Possibly, this decorative layer 38 may be continued downward on the lateral gap walls 19 and possibly, however, not necessarily, up to the gap bottom 34.

It is noted that in a preferred embodiment of the present invention, the lateral gaps 19 and preferably also the bottom 34 of the gap 10 are treated at least partially and preferably entirely with a water-repellent agent, or are provided with a layer which hinders or prevents the penetration of water into the floor panel 2 and/or the core 21 thereof.

Further, it is noted that it is already known as such to form chamfers 36 at the upper edges 11 of floor panels 2, wherein these chamfers 36 are performed with a geometry varying along the respective sides 4-5 of the floor panel 2. To this aim, for further information reference is made to the patent documents PCT/IB2007/0001583, WO 2006/066776 and EP 1 808 311. Although in this last- mentioned document, bevels are mentioned of which the inclination may vary between 15° and 89°, it is clear that this does not concern gaps in the meaning of the present patent application, as according to EP 1 808 311 it is desired to form a visible inclined wall, or chamfer, over the major part of the length of the sides at the floor panel, the inclination of which, on average, will be around 40°. A possible inclination of 89° in this case may occur only sporadically and can not lead to the gaps of the present invention, which preferably are performed over the majority of the length L of the respective coupled sides 4-5-7-8 with a preferably substantially vertical lateral wall 19.

Figure 9 represents two oblong floor panels 2 according to the invention, which are coupled at the short sides 7-8, wherein the position P1-P2-P3-P4 of the upper edge 11 at the long opposite sides 4-5 of these floor panels 2 mutually differs in respect to the coupling means 6 present at these sides. It is clear that the actual variation of the position of the upper edge 11 , in this case, becomes clearly visible only when two or more of such floor panels 2 are coupled together. When, as represented here, a third floor panel 2A is connected to the long sides 4-5 of the two floor panels 2, a floor covering 1 can be obtained having the gap 10 required according to the invention. The thus obtained varying space S between the upper edges 11 of the first two floor panels 2 and the third floor panel 2A fulfills the first possibility thereof mentioned in the introduction. Further, it is noted that in the example no or only smaller, possibly invisible, gaps are present at the short coupled sides 7-8 of the floor panels 2. Figure 10 represents another oblong floor panel 2, wherein several of such floor panels 2 can form a floor covering 1 in which varying gaps 10 are situated, wherein these gaps 10 are obtained according to the second possibility mentioned in the introduction. To this aim, the position of the upper edge 11 of the floor panel 2 varies in respect to the coupling means 6 present at the respective side along the respective edge 3 concerned. The variation thus relates to a variation along the edge 3 of the floor panel 2 itself. From the figure, it is clear that the upper edges 11 at least at one long side 4, and preferably at both long sides 4-5, deviate from the direction determined by the coupling means 6 at the respective sides 4-5 of the floor panel 2. The upper edges 11 at the pair of long sides 4-5 of the floor panel 2 from the example are made straight, however, deviate in their direction from the direction determined by the coupling means 6.

Figure 11 shows an example of a floor panel 2, wherein the upper edges 11 at the pair of long sides 4-5 vary in direction in the floor panel 2 itself. Herein, the upper edges 11 preferably show a curvature. Still better, this curvature is such that over the length of the upper edges 11 only one local extreme 39, either a minimum or a maximum, occurs in the space between the upper edge 11 and the coupling means 6 at the respective side 4-5. In such case, the impression of a warped floor panel 2 can be conveyed.

Figure 12 shows an example wherein the curvature is such that several local extremes 39 are situated within the space between the upper edge 11 and the coupling means 6. Hereby, an excellent imitation of aged, worn floors can be obtained.

It is clear that where in the above passages a curvature is mentioned, also an upper edge 11 can be used which is composed of several straight pieces with a differing direction, wherein these straight pieces then commonly approach such curvature.

Figure 13 schematically represents how the floor panels 2 of the invention can be manufactured. In this case, this relates to oblong floor panels 2, wherein at the opposite long sides 4-5 as well as at the opposite short sides 7-8 machining treatments are performed by means of mechanical tools 40, in this case rotating milling tools. To this aim, the floor panels 2 in the example are transported through two edge treatment machines 41 and successively moved at their sides 4-5-7-8 over a number of milling tools, whereby these sides are provided with profiled edge regions 13. Herein, the floor panels 2 are directed with their underside 24 upward and the upper side 9 of the floor panels is used as a reference for the treatments. According to the invention, it is not excluded that the floor panels are transported through the edge treatment machines 41 with their upper side 9 directed upward.

Figure 14 shows that the floor panels 2, when performing the machining treatments at the height of their edges 3, preferably are supported at both flat panel sides, for example, by means of pressure shoes 42 and a chain 43. As figure 14 shows, the profiling of the edge portions 13 may comprise, for example, a smoothing step S1 , in which a portion 44 of the surplus material 45 is machined off.

Figure 15 shows that the profiling can comprise a step S2, in which a portion of the tongue 14, which extends beyond the upper edge 11, is formed.

Figure 16 shows that the underside 30 of the tongue 14, in other words, a portion of the tongue 14 which is located beneath the upper surface 9 of the floor panel 2, can be formed in a separate step S3.

Figure 17 shows that the upper edge 11 of the floor panel 2, with the inclusion of a lateral wall 19 of said gap 10, can be formed in a separate step S4.

It is noted that figures 14 to 17 illustrate that the profiling of the profiled edge portions 13 is constructed at least, and preferably substantially, from two zones Z1-Z2. On the one hand, there is the first zone Z1 in which the profile of the mechanical coupling means 6 is formed, and, on the other hand, there is the second zone Z2 in which the profile of a side wall 19 of said gap 10 is formed. This second zone Z2 is situated on top of said first zone Z1 , however, beneath the upper surface 9 of the floor panel 2.

As figure 17 illustrates, said second zone Z2 can be formed independently from said first zone Zl To this aim, the tool 40 or the milling cutter forming said lateral wall 19 is made with a variable position and/or orientation. In the represented example, the orientation and/or the position of the tool 40 or the milling cutter forming said second zone 22 can be altered in respect to the floor panel 2, whereas the position and/or the orientation of the mechanical tool forming said first zone Z1, as represented in figures 14 to 16, preferably is fixedly arranged in respect to the floor panel 2. The alteration of position and/or orientation of the tool 40 forming a lateral wall 19 of the gap 10, illustrated by means of figure 17, relates to a rotation R of the tool 40 around an axis O extending parallel or almost parallel to the passage direction 46 of the floor panel 2 through the machine 41 , or, in other words, in this case extends parallel to the longitudinal direction of the coupling means 6. It is noted that the passage direction 46 is shown clearly by means of figure 13.

Figure 18 shows another possibility for an alteration in position and/or orientation of the tool 40. Here, this relates to a translation movement H of the milling tool 40 in the plane of the floor panel 2. In this case, such translation movement H corresponds to a translation movement in the plane of the milling tool 40. In general, according to the invention any translation movement can be applied.

Figure 19 shows still another possibility for an alteration in position and/or orientation of the tool 40. This also relates to a translation movement V of the milling tool 40, however, in this case a translation movement V out of the plane of the floor panel 2. More particularly, the translation movement V occurs in a direction transverse, and here even perpendicularly, to the surface 9 of the floor panel 9.

It is clear that according to the invention, one may also work with other instruments or tools 40 than milling tools. Preferably, however, use is made of machining treatments, for example, by means of mechanical tools, such as planing, milling and/or sawing tools. It is not excluded that one or more lasers or other tools are applied. For the use of laser cutting for manufacturing floor panels with coupling means, reference is also made to WO 2006/090287, where such treatment is applied for cutting straight upper edges. It is evident that this kind of treatment can be applied here, too, for obtaining upper edges, the position of which is varying in respect to the coupling means. This may be realized, for example, when the position of the laser beam is varied in respect to these coupling means. Preferably, in such case at least a portion of the profile of a gap wall is formed by means of the laser cut.

Further, it is clear that such tool 40 must not necessarily be located substantially in the plane of the floor panel 2, as it was the case in the examples from figures 17 to 19. For forming the upper edge 11 , also tools 40, for example, milling tools, can be applied, which form an angle with the floor panel 2. In such case, it is clear that for the alteration of the position and/or the orientation of this tool 40 both a translation movement H in the plane of the floor panel 2, as well as a translation movement in the plane of the tool, wherein these translation movements in the present case in fact define different directions, or any other translation movement can be applied. Of course, alterations in position and/or orientation by any rotation movement R remain possible.

It is noted that according to the invention, it is preferred that the coupling means 6, locking means 18 and other portions of the coupling means 6 and/or coupling parts are made in one piece with the floor panel 2, preferably are made in one piece with the substrate 21 of the floor panel 2. The same is valid for the walls of said gap 10.

Further, it is noted that the present invention can be applied to any kind of floor panels 2. For example, this may relate to laminate floor panels, such as floor panels 2 with a DPL top layer 23 on a MDF or HDF substrate 21 , wooden floor panels 2, such as solid parquet, composed floor panels 2, such as so-called

"engineered wood", veneer parquet. Preferably, this relates to floor panels 2 with a wooden top layer 23 or a top layer 23 at least representing wood. In this latter case, this may relate, for example, to a printed pattern in the form of a wood pattern.

It is clear that the method of the invention is particularly useful when such floor panels are treated at their edges in a continuous process. By such technique, it is possible to obtain passage speeds which are higher than 100 m/min and may even be up to 300 m/min. Altering, as aforementioned, the orientation and/or the position of the tool forming said second zone, and thus at least the profile of a gap wall, remains possible, even when the highest aforementioned passage speeds are used.

Figure 20 shows another particular variant of two coupled floor panels 2 with the characteristics of the invention. In this variant, the gaps 10, just as in figures 7 and 8, are combined with another edge finish, namely, in this case chamfers 36 provided at the height of both adjacent upper edges 11. This relates to chamfers 36 in the form of bevels. The gap 10 of the invention is applied beneath the chamfers 36 and the space S is defined between the upper edges 11 lowered by the bevels. The particularity of the embodiment represented here is that the gap 10 applied beneath the chamfers 36 has inclined lateral walls 19. In the example, the lateral walls 19 have an inclination of approximately 70 degrees. Of course, any slope of 60° or more can suffice. One may even work with slopes which are larger than 90°, such that in fact an undercut of the upper edges 11 can be obtained.

The embodiment of figure 20 further clearly shows that the gap bottom 34 does not necessarily has to be made as a surface, but may also consist of a whether or not straight line over a portion of the length of the gap 10. In this embodiment, the line is obtained by means of an acutely tapered gap 10.

Figure 20 further also shows that one or more treatments and/or colorations of the chamfers 36 and/or the lateral gap walls 19 and the possible bottom surface 35 can be applied.

In the example, at least the major part of the surface, if not the entire surface, of the chamfers as well as of the lateral gap walls 19 is treated with a water-repellent matter, or provided with a layer 47 hindering or preventing the penetration of water into the floor panel 2 and/or the core 21 thereof. Such treatment can be performed, for example, by means of techniques known as such, such as by means of sputter heads, which can be of the type which is known as such from DE 92 02 976 U1 , and wherein, for example, excessively applied substance can be drawn off again immediately.

On said water-repellent layer 47, then, at least at the height of the surface 37 of the chamfers 36, a decorative layer 38 is provided. Such decorative layer 38 preferably is made matching the upper side 9 or decorative side of the floor panel 2 and may consist of a lacquer, a film, a print or the like. As already mentioned in connection with figures 7 and 8, such decorative layer 38 possibly can be continued downwardly on the lateral gap walls 19 and possibly up to or onto the gap bottom 34. In the example, this decorative layer is continued at least up to beneath the upper edge 11. It is noted that the decorative layer 38 also can be located entirely beneath said water-repellent layer 47 or can be made complementary thereto and/or overlapping at the edges. Further, it is noted that the decorative layer 38 mentioned here does not necessarily have to be combined with a water-repellent layer 47.

In the example, the lateral gap walls 19 as such are also provided with a separate decorative layer 48. Preferably, this relates to a coloration with a color that is darker than the general color of the upper side 9 of the floor panel 2. In this manner, the gap 10 can render an extra deep impression. In the represented example, the separate decorative layer 48 is made complementary to the decorative layer 38 provided on the surface 37 of the chamfers 36. However, this is not necessarily the case. Namely, overlaps may occur, for example, at the edges thereof. Such separate decorative layer may also be provided entirely on a portion of the decorative layer 38 which continues beneath the upper edges of the floor panel 2.

Such separate layer 48 on the lateral gap walls 19 does not necessarily have to be provided in a constant manner over the entire length of the gap 10. A certain variation in color or position of this layer 48, such as a variation in the position of the highest point 49 of this layer 48, may lead to an optical effect, which can be interpreted as a variation of the gap width S, even when this width S in fact is constant.

It is clear that possibly also the separate layer 48 of the lateral gap walls 19 can be situated beneath said water-proofing or water-repellent layer 47. Here is noted, too, that the separate decorative layer 48 does not necessarily have to be combined with a water-repellent layer 47 and/or a decorative layer 38 on the chamfers 36.

Preferably, such separate layer 48 is obtained by means of a print, such as by means of an inkjet print. However, it is not excluded that for the separate layer 48 a lacquer or a foil, such as a transfer foil, is applied.

It is noted that by means of figure 20, various inventive aspects are illustrated which are independent from the fact whether the gaps 10 define a varying or a fixed space S between the coupled sides of the floor panels 2. Preferably, indeed a connection without play with a horizontal and a vertical locking is obtained.

Said independent inventive aspects concern in particular: - the independent aspect that a gap 10 is realized with inclined, possibly acutely tapered lateral walls 19, which either are not are not combined with edge finishes, such as chamfers, and/or with contact surfaces 33, where the floor panels 2 adjoin each other and which are located beneath the gap bottom 34; - the independent aspect that a gap 10 is realized of which the gap bottom

34 is made as a line at least over a portion of the length of gap 10;

- the independent aspect that at least a portion of the surface of the lateral gap walls 19 is colored with a separate decorative layer 48, wherein this either may or may not vary, for example, in position and/or color; - the independent aspect that at least a portion of the surface of the lateral gap walls 19 is colored by means of a print, such as an inkjet print or a transfer print. Of course, also a method for obtaining such floor panels 2 is considered an independent aspect;

- the independent aspect that the surface of the lateral walls 19 of the gap 10 and/or the gap bottom 34 and/or the possible chamfers 36 are provided with a water-proofing or water-repellent layer 47, which can be applied by means of a sputtering technique;

- the independent aspect that the surface of the lateral walls 19 of the gap 10 and/or the gap bottom 34 and/or the possible chamfers 36 are provided with two or more covering layers provided at least partially over each other.

It is clear that these inventive aspects or preferred embodiments thereof can be mutually combined in an unrestricted manner and that such floor panels 2 may show in particular one or more of the features illustrated by means of figure 20.

Further, it is clear that within the scope of the present invention, the upper edge can be defined as the visible edge of the upper surface of the floor panel. In the case of an upper surface with visible chamfers, the upper edge thus is located beneath this chamfer.

The present invention is in no way limited to the embodiments described by way of example and represented in the figures, on the contrary may such floor coverings, floor panels, packaging units and methods be realized according to various variants, without leaving the scope of the invention.

So, for example, the invention is not limited to floor panels which are installed in a floating manner. It may also find application with floor panels that are anchored to an underlying substrate, for example, by means of glue, nails or other attachment means. In such floor coverings, too, it may be interesting to obtain a varying gap already during installation.

Further, the coupling means which as such are described in BE 2007/0154, can also be applied in combination with the present invention. The coupling means described there are particularly useful because they can accommodate a limited expansion of the floor covering.

Claims

Claims.

1.- Floor covering, wherein this floor covering (1) is at least composed of floor panels (2) being in a coupled condition, wherein this coupled condition consists at least in that the floor panels (2), at the edges (3) of at least a first pair of opposite sides (4-5), are coupled to each other by means of mechanical coupling means (6), wherein in said coupled condition of these floor panels (2), at the coupled sides (4-5) concerned, a locking exists in a vertical direction (V1) perpendicularly to the plane defined by the coupled floor panels (2), as well as in a horizontal direction (H1) perpendicularly to the respective sides (4-5) and in the plane of the coupled floor panels (2), characterized in that said coupling means (6), when coupling, put the floor panels (2) in a coupled condition, wherein gaps (10) are present at the surface of the floor covering (1), said gaps defining a varying space (S) between the respective sides (4-5) of said coupled floor panels (2).

2.- Floor covering according to claim 1, characterized in that said varying space (S) is obtained at least in that the position (P1-P2) of the upper edge (11) of one or more of the coupled floor panels (2) in respect to the coupling means (6) present at the respective side (4-5) varies along the respective edge (3).

3.- Floor covering according to claim 1 or 2, characterized in that said varying space (S) is obtained in that the position (P1-P2) of the upper edge (11) in respect to the coupling means (6) present at the respective side (4-5) differs at two or more of such floor panels (2).

4.- Floor covering according to any of the preceding claims, characterized in that said space (S), seen in average, is smaller than 3 millimeters.

5.- Floor covering according to any of the preceding claims, characterized in that it is at least composed of oblong rectangular floor panels (2), wherein said first pair of opposite sides (4-5) is formed by the long sides of the respective floor panel (2).

6.- Floor covering according to any of the preceding claims, characterized in that said floor panels (2) have a second pair of opposite sides (7-8), which are also provided with coupling means (6), wherein, in the coupled condition, preferably no gaps or only a smaller gap (10) are present at the edges (3) of this second pair of opposite sides (7-8).

7.- Floor covering according to any of the preceding claims, characterized in that said floor panels (2), at least at both sides (4-5) of said first pair of opposite sides, have profiled edge portions (13), the profiling of which is at least constructed of two zones (21 -Z2), on the one hand, a first zone (Z1) in which the profile of the mechanical coupling means (6) is formed, and, on the other hand, a second zone (Z2) extending above said first zone (Z1), however, situated beneath the upper surface (9) of the floor panels (2), wherein the profile of a side wall (19) of said gap (10) is formed in said second zone (Z2).

8.- Floor covering according to claim 7, characterized in that this floor covering (1) comprises rows (20) of said floor panels (2), wherein said first zones (Z1) of floor panels (2) of one and the same row (20) are mutually aligned, whereas said second zones (Z2), in conjunction with the second zones (Z2) of similar floor panels (2) of an adjacent row (20) in said coupled condition form said gap (10), which defines said varying space (S).

9.- Floor panel, characterized in that it can be applied for forming a floor covering (1) with the characteristics of any of the preceding claims.

10.- Packaging unit, wherein such packaging unit comprises two or more floor panels (2) with the characteristics of claim 9.

11.- Method for manufacturing a floor panel, wherein this method is applied for manufacturing floor panels (2) with the characteristics of claim 9, characterized in that this floor panel (2), at least at both sides of said first pair of opposite sides (4- 5), is provided with profiled edge portions (13), the profiling of which is constructed at least of two zones (Z1-Z2), on the one hand, a first zone (Z1) in which at least a portion of the profile of the mechanical coupling means (6) is formed, and, on the other hand, a second zone (Z2), which is located above said first zone (Z1), however, is situated beneath the upper surface (9) of the floor panels (2), and wherein in said second zone (Z2) at least the profile of a side wall (19) of said gap (10) is formed.

12.- Method according to claim 11, characterized in that said second zone (Z2) is formed independently from said first zone (Z1).

13.- Method according to claim 11 or 12, characterized in that the first zone (Z1) as well as the second zone (Z2) is formed by means of a machining treatment with a mechanical tool (40), wherein the position and/or orientation of the mechanical tool (40) forming said second zone (Z2) is variable in relation to the floor panel (2), whereas the position and/or orientation of the mechanical tool (40) forming said first zone (Z1) preferably is fixedly installed in respect to the floor panel (2).

14.- Method according to any of the claims 11 to 13, characterized in that it is applied for manufacturing at least two floor panels (2) with the characteristics of claim 9, and that the position and/or the orientation of the mechanical tool (40) forming said second zone (Z2) is altered in respect to the floor panel (2), whereas the orientation and/or position of the mechanical tool (40) forming said first zone (Z1) remains unaltered.

15.- Method according to claim 14, characterized in that said floor panels (2) are manufactured successively and that said alteration in position and/or orientation of said mechanical tool (40) forming the second zone (Z2) occurs at least between the manufacture of both floor panels (2).

16.- Method according to claim 14 or 15, characterized in that said floor panels (2) are manufactured successively and that said alteration in position and/or orientation of said mechanical tool (40) forming the second zone (Z2) occurs at least during the manufacture of at least one of both floor panels (2).