Finishing profile for a floor covering and methods for manufacturing such finishing profile.

The present invention relates to a finishing profile for a floor covering, as well as to a method for manufacturing such finishing profile.

More particularly, the invention relates to finishing profiles that can be employed there, where an edge of a floor covering must be finished. Herein, this relates to any type of floor covering, however, preferably the finishing profiles of the invention are applied when finishing a floatingly installed floor covering, such as, for example, when finishing gluelessly installed flooring of the type known, for example, from the WO 97/47834, namely, laminate panels, prefabricated parquet, veneer parquet or solid parquet.

Profiles that allow finishing an edge of such floor covering are known from the state of the art, for example, from US 6,745,534. Usually, such finishing profile is performed as a decorative strip, whether or not consisting of several parts, or the like, which can be pressed on in a rail-shaped profile or holder by means of an attachment portion.

Currently, a difference is made between some three kinds of possible finishing modes and associated finishing profiles .

According to a first possibility, the finishing profile relates to a so-called expansion profile, which usually is applied for finishing a joint, said joint being intended, for example, as an expansion joint, between two floor coverings of an equal or similar type.

According to a second possibility, the finishing profile relates to a so-called transition profile, which usually is applied for forming a transition from one type of floor covering to another type of floor covering, such as, for example, a transition from a laminate flooring to a carpet or a transition between laminate floorings of different thicknesses.

According to a third possibility, the finishing profile relates to a so-called end profile, which usually is used for finishing an edge of a floor covering next to a wall. Generally, in the above by "floor coverings of another type", floor coverings are meant having a different thickness.

In the meantime, amongst others, from WO 01/20101 and US 6,860,074, finishing profiles are known that allow finishing several kinds of transitions. To this aim, according to these documents, they have to be composed from several portions to form different configurations, depending on the required kind of finishing.

In the Belgian patent application BE 2005/0015, filed by the present applicant, finishing profiles have already been described, which allow to finish several kinds of transitions. According to BE 2005/0015, different configurations of one and the same finishing profile may be obtained by separating one or more portions from the finishing profile. Herein, the separation may take place, amongst others, by cutting through a layer-shaped covering provided on the finishing profile. However, the inventor of the present invention has found that in certain cases, it remains difficult to form a well-cut edge at the layer-shaped covering, for example, when not using a knife designed in particular to this aim. Also with embodiments in which is intended to break off one

or more portions of the finishing profile instead of cutting them off, wherein the break line is realized also through the layer-shaped covering, the disadvantage is created that that the risk is rather high that the layer-shaped covering is damaged at the broken-off edge or is delineated in a rather un-esthetic manner. In order to remedy this, the present invention aims at a finishing profile in which, when separating a portion of this finishing profile, the risk of obtaining a top layer delineated in a less qualitative manner is minimized or excluded. To this aim, the invention relates to a finishing profile for a floor covering, wherein this finishing profile comprises a body with at least two portions made separable from each other, which, in the unseparated condition, are connected to each other by means of a break-off or cut-off zone, wherein, by whether or not removing one or more of the aforementioned two portions, various application possibilities of the remaining portion of the body are created, wherein, at least on the aforementioned two portions of the body, a layer-shaped covering is provided, with as a characteristic that said layer- shaped covering shows an interruption at least over part of the length of the finishing profile, at the height of the transition between said two portions, and preferably at the height of said break-off or cut-off zone.

Herein, by an "interruption" is meant that the layer- shaped covering as such is completely interrupted in the depth for at least a portion or portions of the length of the finishing profile, or, in other words, that the interruption extends across the material layer of the layer-shaped covering. However, this does not exclude that the layer-shaped covering, at the height of the interruption, may be composed of overlapping portions; according to the present invention, in such case the

layer-shaped covering also has to be considered interrupted.

With a finishing profile according to the present invention, a better result is achieved, in particular in relation to the quality of the remaining portion after a possible separation has taken place, whereas a universal utilization of the finishing profile still remains possible .

It is noted that the application of the finishing profiles of the invention is not restricted to the above-described utilization possibilities or to the application thereof for the above-described types of floor coverings, although they preferably allow for at least two of the above-described utilization possibilities, of which, still better, at least one utilization possibility relates to the application of said remaining portion as an expansion profile.

Preferably, said interruption of the layer-shaped covering is provided locally, and still better, the two portions of the layer-shaped covering, these are the portions at opposite sides of the aforementioned interruption, adjoin closely and/or is the distance between both portions of the layer-shaped covering smaller than one millimeter. In this way, it is obtained that, in the case that in the desired configuration or utilization possibility of the finishing profile, the respective separable portions of the body do not have to be separated, this interruption is hardly apparent.

It is noted that according to the invention, a layer- shaped covering of any kind can be applied. So, for example, may the layer-shaped covering consist of a film, laminate, veneer, lacquer, ink or similar. When a

finishing profile according to the invention comprises a layer-shaped covering consisting of a laminate, all difficulties imparted by a possible breaking-off or cutting-off of this laminate are avoided. So, for example, is it known that such laminate comprises a resin-immersed layer that may have abrasion-resistant features. These abrasion-resistant features are mostly obtained in that hard particles, such as aluminum oxide or the like, are incorporated in the laminate. The application of such laminate for a finishing profile of the invention is of particular importance, in view of the fact that in this case, too, a good result may be obtained in a simple manner.

In the most preferred embodiments of the invention, said two portions of the body are integrally connected to each other at the location of said break-off zone, still better the two portions as such, including the break-off zone, are performed in one piece and/or the entire body is made in one piece. According to these preferred embodiments, it is obtained that separate and/or integrated connection elements between said two portions are not necessary, which may result in a simple and/or inexpensive manufacture of the finishing profiles of the invention.

As will become evident from the further introduction and the description, the invention is not limited to finishing profiles with a body, of which latter solely two portions are made mutually separable. When the body comprises three or more separable portions and/or is provided with two or more break-off or cut-off zones where these portions may be separated from each other, the layer-shaped covering preferably, at least over a portion of the length of the finishing profile, comprises an interruption at the height of each of the

transitions between said three portions, and preferably at the height of each of the aforementioned break-off or cut-off zones.

It is noted that the aforementioned interruption, interruptions, respectively, may extend, whether continuously or not, over the entire length of the finishing profile. It is clear that the presence of such, whether or not continuous, interruptions over the entire length of the finishing profile yields an optimum result with a possible separation of a portion of the body.

The finishing profiles of the invention may be manufactured in any manner. However, the present invention also relates to two inventive possibilities for realizing such finishing profile.

According to a first possibility, the invention relates to a method for manufacturing such finishing profile, starting from a carrier from which said body is formed and which is provided, at least partially, with said layer-shaped covering, with as a characteristic that said layer-shaped covering is provided as a single whole on the aforementioned two mutually separable portions and that said interruption, interruptions, respectively, is effected after providing the layer-shaped covering. This first possibility offers an inexpensive and/or simple manufacturing mode for such finishing profile.

In a particular case, wherein the layer-shaped covering shows a printed pattern or other pattern and the interruption is relatively thin or is local, it is obtained, according to this first possibility, in a simple manner that the aforementioned pattern still extends, practically seen, continuously over the

interruption. It is noted that the pattern does not necessarily have to be obtained artificially, for example, by printing, however also may relate to a natural pattern, such as it is the case, for example, when veneer is applied as a layer-shaped covering. Preferably, the aforementioned pattern is adapted to the floor covering with which the finishing profile has to cooperate, and possibly may represent a wood pattern or a stone pattern.

According to a second possibility, the invention relates to a method for manufacturing such finishing profile, starting from a carrier from which said body is formed and which is provided, at least partially, with said layer-shaped covering, with as a characteristic that said layer-shaped covering is provided separately on each of the aforementioned two mutually separable portions. By applying a method according to this second possibility, a separate processing in order to provide said interruption is not necessary. Also, by means of this method, a close adjoining between both portions of the layer-shaped covering may be obtained in a simpler manner, such that the interruption may be performed in such a manner that it is hardly visible.

According to a first preferred form of embodiment of both possibilities, said body is formed from said carrier after the layer-shaped covering has been applied.

According to a second preferred form of embodiment of both possibilities, said body or said carrier, from which the body is obtained, is formed by extrusion prior to applying the layer-shaped covering.

For the body of the finishing profiles of the invention, use can be made of any material, such as, for example, composite material consisting of wood particles and a binding agent, MDF or HDF (Medium Density Fiberboard or High Density Fiberboard) , plywood, paper pulp, synthetic material, metal, such as aluminum, or the like.

Various other preferred forms of embodiment of finishing profiles and methods for the manufacture thereof are possible. In this respect, reference is made to the detailed description and appended claims.

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 cross-section represents a finishing profile according to the invention;

Figure 2 represents an application or utilization possibility of the finishing profile from figure 1; Figures 3 and 4 represent a variant of a finishing profile according to the invention and an application thereof;

Figure 5 represents another application of the finishing profiles from figures 1 and 3; Figures 6 to 8, at a larger scale, represent the part indicated by F6 in figure 1; Figure 9 represents another variant of a finishing profile according to the invention;

Figures 10 and 11, in perspective view, represent further variants of the finishing profile, as well illustrate methods for manufacturing finishing profiles according to the invention;

Figures 12 and 13 show another variant of a finishing profile according to the invention, wherein figure 13, at a larger scale, represents the part indicated by F13 in figure 12; Figures 14 to 16 represent other variants, wherein figures 15 to 16, at a larger scale, represent the part indicated by F15 in figure 14.

Figure 1 represents a finishing profile 1 with the characteristics of the invention. The finishing profile 1 consists of a body 2, which is provided with a layer- shaped covering 3. Said body 2 comprises, on the one hand, a flange-shaped portion 4 with an attachment portion 6 situated at the bottom side 5, with which attachment portion it can be fixedly pressed into a holder 7, and, on the other hand, a nose portion 8 extending downward from the flange-shaped portion 4.

The finishing profile 1 of figure 1 shows the typical global form of a so-called end profile 9. To this aim, the nose portion 8 has a relatively steep lateral decorative side 10. As represented in figure 2, such finishing profile 19 usually is applied for finishing an edge 11 of a floor covering 12 next to a wall 13, wherein the aforementioned lateral decorative side 10 then is intended for adjoining against said wall 13.

The variant of figure 3 also comprises a body 2 with such flange-shaped portion 4 and a nose portion 4, which, in this case, extends laterally and downward from the flange-shaped portion 4, however, rather has the typical global form of a so-called transition profile 14. To this aim, the nose portion 8 has a lateral decorative side 10, which, in comparison to the nose portion 8 of figure 2, globally is less steep. As represented in figure 4, such finishing profile 1-14

usually is applied with a transition from one type of floor covering 12A to another type of floor covering 12B, such as here, for example, a transition between a laminate flooring 12a and a fitted carpet 12B, wherein the nose portion 8 with said lateral decorative side 10 is intended for bridging-over the height difference between both types of floor covering 12A-12B caused, in this case, by their differing thickness.

In the example of figures 1 and 2 as well as in the example of figures 3 and 4, the flange-shaped portion 4 and the respective nose portion 8 are made separable from each other, wherein, by removing the nose portion 8, a different utilization possibility of the remaining portion 15 of the body 2, in this case, the flange- shaped portion 4, is created. In both examples, the flange-shaped portion 4-15 as such may be applied as a so-called expansion profile 16. As represented in figure 5, such flange-shaped portion 4 or remaining portion 15 of the finishing profile 1 may be applied for finishing a joint 17 between two floor coverings 12. Herein, the flange-shaped portion 4 adjoins with the bottom side 5 of its two flanges against the respective floor coverings 12.

As represented in figures 6 to 8, the mutual separability of the respective portions 4-8 of the finishing profiles of the present invention, as in the examples of figures 1 to 4, has been obtained in that they, in the unseparated condition, are connected to each other by means of a break-off or cut-off zone 18. To this aim, both portions 4-8 in this case are connected to each other solely by a limited material portion 19 of the body 2.

As represented in figure 7, the break-off or cut-off zone 18 applied according to the invention preferably allows an easy separation of the respective portions 4- 8. By an easy separation is meant that the respective portions 4-8 may be separated without using a tool or possibly by means of simple manual tools, such as a knife. As represented in figure 7 by arrow R, the separation simply takes place by rotating the nose portion 8 in respect to the flange-shaped portion 4. It is clear that the separation may also be obtained by performing the rotation R towards this attachment portion 6 instead of, as shown, away from the attachment portion 6. A separation, such as in figure 7, is possible, for example, when the material 19 of the break-off zone 18 can easily be torn off or split, for example, when the material relates to MDF or HDF. It is known that MDF or HDF offers only a limited resistance against splitting forces. Also other materials which are easy to split may be used to this aim. It is noted that also materials, which are more resistant against splitting forces, can be used. Possibly, notches may be provided in the break-off zone 18, with the intention of promoting the splitting or tearing.

As represented in figure 8, it is possible that after separation, a rough surface 20 remains on the separated portions 4-8. These surfaces 20 possibly may be treated in a simple manner, for example, with abrasive paper. Preferably, the break-off zone or cut-off zone 18, irrespective of how it is implemented, globally shows a maximum section S, which is smaller than 3 millimeters, and still better is two millimeters or smaller. By limiting the maximum section S of the break-off zone or cut-off zone 18, it is achieved that the size of the aforementioned rough surface 20 is restricted and/or that the respective portions 4-8 can be separated from

each other more easily. For example, a rough surface 20 may be very disturbing when it remains on the aforementioned remaining portion 15 of the finishing profile 1.

The particularity of the finishing profiles 1 of the present invention lies in the fact that said layer- shaped covering 3 shows an interruption 21 at the height of the transition 22 between the portions that are made separable, in this case, between the flange-shaped portion 4 and the nose portion 8. In the example of figure 1, a preferred form of embodiment is concerned, in which the interruption 21 is also situated at the height of said break-off or cut-off zone 18. As aforementioned, a qualitatively better result can be obtained by applying the interruption 21 after the separation of the respective portions 4-8, in particular in respect to the quality of the edge of the layer- shaped covering 3 itself.

According to the invention, said interruption 21 of the layer-shaped covering 3 at the height of the transition 22 preferably is provided locally. Herein, the distance O between two portions of the layer-shaped covering 3 preferably is smaller than one millimeter. By the close adjoining of both portions of the layer-shaped covering 3 is obtained that the interruption 21 of the layer- shaped covering 3 is experienced as less disturbing by the user of such finishing profile 1, whereas still a good result is obtained with a possible separation of the respective portions 4-8.

In figures 6 and 8, in dashed line a variant is represented in which the interruption 21 is rendered hardly visible.

Figure 9 represents another particular variant of a finishing profile ^' 1 according to the invention. The respective finishing profile 1 comprises a body 2 with three portions 4-8A-8B, amongst which, on the one hand, a flange-shaped portion 4 with an attachment portion 6 situated at the bottom side 5, and, on the other hand, two nose portions 8A-8B extending, at opposite sides of the flange-shaped portion 4, downward and/or laterally of said flange-shaped portion 4. The two nose portions 8A-8B relate to, on the one hand, a nose portion 8A similar to the nose portion 8 represented in figure 1, and, on the other hand, a nose portion 8B similar to the nose portion 8 represented in figure 3. The flange- shaped portion 4 and the two nose portions 8A-8B of figure 9 are connected to each other in a mutually separable manner via a break-off or cut-off zone 18. At the height of each of the transitions 22 between said three portions 4-8A-8B, the layer-shaped covering 3 provided on the body 2 locally shows interruptions 21. It is clear that by separating one or more of the portions 8A-8B, various utilization possibilities are created, for example, those represented in figures 2, 4 and 5.

Figure 10 represents an example of a finishing profile according to the invention, wherein the layer-shaped covering 3, at the height of said transition 22 or break-off zone 18, transitions 22 or break-off zones 18, respectively, shows an interruption 21, interruptions 21, respectively, over the entire length L of the finishing profile 1.

Figure 11 represents another example of a finishing profile 1 according to the invention, wherein the layer- shaped covering 3, at the height of said transition 22 or break-off zone 18, transitions 22 or break-off zones

18, respectively, shows an intermittent interruption 21, interruptions 21, respectively, over the entire length L of the finishing profile 1.

It is evident that according to the invention, the interruption 21 of the layer-shaped covering 3 may also be performed solely over a part of the length L of the finishing profile 1.

It is noted that figures 10 and 11 also represent methods for manufacturing a finishing profile 1 of the invention according to the first possibility, mentioned in the introduction, of such methods.

Figure 10 shows that according to this first possible manufacturing method, it is started from a carrier that has already been provided with a layer-shaped covering 3, said carrier being represented in dashed line 24, from which carrier said body 2 is formed or is being formed. Herein, the layer-shaped covering 3 originally has been provided on the portions 4-8A-8B, which are made in a separable manner, of the body 2. As represented, the aforementioned interruption 21 at the height of the transition 22 or break-off zone 18 is obtained by performing an incision in the layer-shaped covering 3, for example, by means of a knife or other cutting element 25. According to a particular variant, the incision is made by means of a cutting beam, such as a laser beam. This particular variant may result in a very accurate cut or interruption 21, which hardly is visible to the user.

It is clear that the finishing profile 1 of figure 10 as such may be obtained according to said first possibility as well as according to said second possibility of methods for manufacturing such finishing profiles 1.

However, a pattern 26 extending practically continuously over the interruption 21 or transition 22, as in this case, can be obtained more easily according to the first possibility illustrated here.

Figure 11 shows that according to a variant of this first possibility an intermittent interruption 21 may be obtained, for example, by employing a cutting element 25 in the form of a serrated cutting wheel. Here, too, according to a particular variant a cutting beam, such as a laser beam, may be utilized. It is clear that this beam then preferably is controlled in a pulsating manner. It is noted that in this example, also a pattern 26 is obtained that extends practically continuously over the interruption 21 or transition 22.

The variant of figure 12 relates to a finishing profile 1 with a body 2, which latter can be obtained, for example, by extrusion. Here, the mutual separability of the nose portion 8 and the flange-shaped portion 4 has been obtained in that the body 2, at the height of said break-off or cut-off zone 18, is provided with recesses 27. Further, the particularity of this variant is that the break-off or cut-off zone 18, instead of being provided directly beneath the layer-shaped covering 3, is provided closer to the attachment portion 6 of the flange-shaped portion 4. It is noted that, according to the invention, the break-off or cut-off zone 18 may be situated at any location and may be performed in any manner. Thus, for example, it is not excluded that a nose portion 8 also is connected or solely is connected to an attachment portion 6 situated at the bottom side 5 of a flange-shaped portion 4. In such connection, the portions 4-8 may be interconnected, for example, via a break-off or cut-off zone 18 situated at a lateral wall 28 of the respective attachment portion 6.

Figure 13 shows another variant, wherein the layer- shaped coverings 3 of the separable-made portions 4-8 are made overlapping. Hereby, it is achieved that the interruption 21 of the layer-shaped covering 3 is almost invisible to the user. In dashed line 29, a further variant is represented, wherein the layer-shaped covering shows an inwardly-folded portion 30.

Figure 14 shows a variant of a finishing profile 1 according to the invention, wherein the aforementioned interruption 21, contrary to the examples from figures 1 to 13, is not situated at the height of the break-off or cut-off zone 18, however, is provided at a certain vertical distance D from this break-off or cut-off zone 18.

Figure 15 shows still a further variant of the finishing profile 1 represented in figure 14. The finishing profile 1 allows that the flange-shaped portion 4 in use forms a contact surface 31 with the nose portion 8. The respective contact surface 31 may be created, for example, as a result of the nose portion 8, when the finishing profile 1 is subjected to a load or after the finishing profile 1 has been fixedly pressed into the holder 7, being slightly turned in respect to the flange-shaped portion 4. Further, it is clear from figure 15 that optionally a notch 32 may be provided at the height of the break-off or cut-off zone 18, which notch, as also mentioned above, promotes the separation of the nose portion 8.

Figure 16 shows a variant, wherein the contact surface

31 is formed on a support portion 33 provided in particular to this aim. Preferably, for forming this contact surface, only a small turning, and still better

no turning at all, of the nose portion 8 in respect to the flange-shaped portion 4 must be performed.

It is noted that for manufacturing the bodies of the finishing profiles from figures 12 to 16, preferably a technique such as extrusion is applied.

The present invention is in no way limited to the forms of embodiment described by way of example and represented in the figures, on the contrary may such finishing profiles 1 and methods for the manufacture thereof be performed according to various variants, without leaving the scope of the invention.