Method of creating a soft-edged wood tile

Abstract

A method of manufacturing soft-edged wood tiles uses an abrading machine 100 adapted to receive wood planks 200 according to a feeding direction 210, said wood planks 200 comprising an upper face (201 figure 3) and at least one side face (202 figure 3) perpendicular to the upper face (201 figure 3), said faces forming an edge (203 figure 3) which runs in a longitudinal direction substantially parallel to the feeding direction 210. At least one of the rollers 102 is disposed at an angle other than substantially perpendicular to the feeding direction 210, thereby forming an angle X between the rotational axis 112 of the roller 102 and the longitudinal direction. The wood planks 200 are each fed through the abrading machine 100 in the feeding direction 210, each time constituting a pass. The wood planks 200 may be each inspected after at least one pass. The wood planks 200 may be fed through the abrading machine 100 a plurality of times. The abrading machine 100 may then be adjusted after said at least one pass. For example, the angle X could be changed and / or a distance (d figure 5) between the rotational axis 112 of a roller 102 and the upper face (201 figure 3) of the wooden plank 200 could be adjusted. In this manner a wood tile (300 figure 7) with a softened edge (303 figure 7) is obtained.

Description

Technical Field The present application relates to a method of producing a soft-edged wood tile. More particularly, the application relates to a method of abrading a wooden plank to form a wooden tile with a soft edge such that when said wooden tile is joined with similar wooden tiles the joints between the wooden tiles are smooth and visibly seamless. The present application also relates to a surface comprising a plurality of soft-edged wooden tiles. More particularly, the present application relates to a plurality of soft -edged wooden tiles joined together such that soft edges are adjacent to one another and create visibly seamless and smooth tile joint lines. Background Wood tiles are commonly used to create large surfaces, such as a floor. Said surfaces comprise a plurality of wood tiles laid adjacent to one another, resulting in joints between the tiles. Wood tiles are often selected due to the characteristics naturally found in the material, for example, the variation of tone throughout the wood and the unique features such as knots and grain patterns. The use of wood can add warmth to a space and, in some cases, give said space a rustic element. Due to natural-occurring variations in the wood, which provide many of the desirable characteristics, other issues may however arise. For example, due to natural variations in the material, additional steps are required to create a smooth joint between wood planks. In particular, when adjacent tiles are of different depths a lip is formed at the joint. Said lip is generally undesirable, both for cosmetic reasons and practical reasons. In particular, it can give the floor an uneven and haphazard appearance. The lip may also pose a trip hazard, or make it difficult to set other items, such as furniture, level. Accordingly, several solutions have been proposed to overcome this problem. One such solution is applying a bevel to the edges of the material. When a bevel is applied at the joint between two wood tiles, a V-shaped indent is typically formed between the two tiles. Whilst this solution may go someway to resolve the problem of the possible existence of a lip at the joint, V-shaped indents can create additional problems. In particular, V-shaped indents can gather dirt and be difficult to keep clean. This can be unhygienic and / or cosmetically unappealing. Bevelled tile joints can also cause real wood floors to appear artificial. As discussed above, a key aspect of selecting wood for a surface is the natural aesthetics that comes along with it. Therefore, a bevel may not provide the desired visual look. An alternative solution is obtained by sanding the wood edges flat. This solution involves sanding the finished surface such as to reduce the lip between planks, or tiles, and create a smooth surface. Whilst this solution also goes some way to solving the “lip” problem, as with the bevelled solution, additional problems may be introduced. Sanding, unlike bevels, preserves the natural appearance of the wood. However, an issue with this solution is that sanding cannot be carried out until the tiles are in situ. In many instanced wood tiles cannot, therefore, be factory-finished and require extensive post installation finishing. This can be time consuming and impractical, particularly if the tiles are to be laid in a large surface. In some environments, the process of sanding is also impractical due to the dust and waste produced. In any event, on-site sanding may add significantly to the overall cost of an installation. There is, therefore, a requirement for a method of producing wooden tiles which, when joined together to create a larger surface, do not have bevels and yet produce a smooth surface, with smooth joints between them, which maintains the natural appearance of the wood, in the absence of extensive post-installation finishing. Statement of Invention The present application sets forth an inventive solution to the problem of how to manufacture a factory-finished wood tile which, when placed adjacent further wood tiles manufactured in the same way, creates a smooth joint which maintains the natural appearance of the wood. As opposed to sanding described above, the present application discloses a method, and resultant products, which do not require post-installation finishing to create a smooth joint between wood tiles. Further, the present application sets forth a method of manufacturing a wood tile which does not require a bevel, or similar feature, which detracts from the natural appearance of wood, and may be used to provide a larger surface with smooth joints. Further, the joint between wood tiles manufactured according to the present disclosure do not gather dirt such as is gathered in the bevel between wood tiles manufactured according to conventional manufacturing methods. To create a soft edge on a wood tile it is necessary to provide an abrading machine. Said abrading machine comprises one or more abrasion rollers having respective rotation axes. The abrasion machine is adapted to receive wood planks according to a feeding direction. The wood planks comprise an upper face and at least one side face. Said side face is generally perpendicular to the upper face, such as to provide an edge which runs in a longitudinal direction which is substantially parallel to the feeding direction. At least one roller would normally be arranged so as to extend perpendicularly with respect to the feeding direction, so as to provide abrasion on the upper face of the plank. The present invention instead disposes at least one roller at an angle. Advantageously, this allows abrasion of the edge of the wood plank as well as the upper surface of the wood plank. According to the present application, at least one of the one or more abrasion rollers is disposed at an angle other than perpendicular to the feeding direction, providing that angle X is formed between the rotational axis of said roller and the longitudinal direction. Advantageously, said roller may selectively abrade the side face of the wood planks, thereby providing said soft edge. The wood planks are fed through the abrasion machine according to said feed direction. The wood planks are abraded by at least one of the rollers. Angle X may be between 10 and 50 degrees. Angle X may be selected based on the desired soft-edge result. In some arrangements, angle X may be altered during the manufacturing process such as to gradually form the desired soft-edge result. The selected angle X may be based on previous experience and knowledge of the characteristics of the specific wood material being used. It will be understood that said angle X may advantageously be obtained while maintaining the relevant roller parallel or substantially parallel to the wood planks being fed through the abrading machine. In other words, the axis of the roller may lie in-plane with reference to a notional surface defined by the planks while fed through the abrading machine. The method set forth by the present disclosure may also comprise the step of setting a distance “d” wherein “d” is the distance between the rotational axis of the roller and an upper surface of the wood plank. In setting the distance “d”, the level of abrasion of the roller on the wood plank can be varied. For example, reducing distance “d” may result in abrasion of the wood plank having greater depth. Reducing distance “d” may result in the roller exerting greater pressure on the wood plank. Distance “d” may also be increased, to lessen the pressure on the wood plank or to reduce the depth of abrasion on the wood plank. In some arrangements, the method presently described may comprise setting a feed speed wherein the feed speed is the rate at which the wood planks pass through the abrading machine. Advantageously, this parameter also allows the abrasion of the wood planks to be altered. For example, a slower feed speed may result in each portion of the wood plank being in contact with the at least one roller for a longer period of time, consequently resulting in a greater level of abrasion. The method of the present disclosure may also comprise the step of setting a rotational speed of the at least one roller. Said speed may be constant and, when the abrading machine comprises a plurality of rollers, may be the same for each of the rollers. Alternatively, the abrading machine may comprise a first roller arranged to rotate at a first rotational speed and a second roller arranged to rotate at a second rotational speed. Both rollers may be simultaneously active on the same or different portions of the wood plank, such as its upper face or side face. In some methods of the present application, the wood plank may be fed through the abrading machine a plurality of times; each time the wood plank is fed through the abrading machine constitutes a “pass”. For example, a wood plank may be fed through the abrading machine many times before it has been manufactured into a (final) wood tile. Advantageously, this allows the user to gradually increase the abrasion of the wood plank, for example using a coarse grit sandpaper to remove an upper layer before creating a smoother surface with a finer grit sandpaper. Further, in completing several passes, there is an opportunity for inspection of the wood plank between passes and, accordingly, an opportunity to adjust parameters of the abrading machine depending on the end-result desired. For example, said inspection may result in changing the feed speed, rotational speed or distance d. The method described herein may comprise the additional step of inspecting the wood plank after at least one pass and may also comprise the step of adjusting the abrading machine between passes. For example, said adjustment may comprise at least one of increasing or decreasing distance d, changing the rotational speed of at least one roller, changing the rotation direction of at least one roller, changing the feed speed of the wood plank or changing the angle X of at least one roller. The abrading machine may comprise at least 2 two rollers. For example, the abrading machine may comprise 4 rollers. Said rollers may be arranged sequentially, in a direction parallel to the feeding direction. At least one of the plurality of rollers may comprise sandpaper. Optionally, the abrading machine may comprise a first roller comprising sandpaper having a first grit and a second roller comprising sandpaper having a second grit. Advantageously, this allows the user to expose the wood plank to a variety of sandpaper grits during a single pass. In some arrangements of the present disclosure, comprising the steps of inspecting and adjusting the abrading machine between passes, said adjustment may comprise changing the grit of the sandpaper of at least one of the rollers. In some alternative arrangements, at least one roller may be a brush comprising bristles. The bristles of the at least one roller may comprise a plastic material. Additionally or alternatively, the bristles of at least one roller may comprise a metallic material. In such an arrangement, wherein the method comprises the step of adjusting the rollers, said adjustment may comprise changing the bristles of at least one roller. In some arrangements, at least one roller may be arranged to oscillate relative to the plank, at an oscillation speed. Oscillation refers to back and forth movement, or up and down movement, of the roller in a regular fashion. Said oscillation may be in a direction perpendicular to the feed direction. Alternatively, said oscillation may be in a direction parallel to the rotation axis of the oscillating roller. In such a way, the roller may be arranged to pass across the width of the upper surface of the plank as the plank passes through the abrading machine. The at least one roller may rotate in a clockwise direction. Alternatively, the at least one rollers may rotate in an anti-clockwise direction. In some embodiments, wherein the abrading machine comprises a plurality of rollers, at least one roller may rotate in a clockwise direction and at least one roller may rotate in an anti-clockwise direction. The feed speed may be 1 linear metre per minute, or above. The linear speed may be varied between different passes of the plank. For example, the feed speed of a first pass may be L1 linear metres per minute. The feed speed may optionally be increased to L2 linear metres per minute for a second pass. The feed speed may optionally be reduced to L3 linear metres per minute for a third, and optionally final, pass. The rotation speed of the at least one roller may be between 10 revolutions per minute (rpm), or above. Where the abrading machine comprises a plurality of rollers, each roller may rotate at the same speed. Alternatively, the rollers may rotate at different speeds. For example, at least one roller may rotate at a first rotation speed R1 and at least one roller may rotate at a second rotation speed R2. The oscillation speed may be between 1 linear metre per minute, or above. Where the abrading machine comprises a plurality of rollers, each roller may oscillate at the same speed. Alternatively, the rollers may oscillate at different speeds. For example, at least one roller may oscillate at a first oscillation speed S1 and at least one roller may oscillate at a second speed S2. Further, the oscillation direction may be the same, or in principle at least, different between different rollers. Where the abrading machine comprises a plurality of rollers, two or more rollers may be disposed at the same angle X. Alternatively, the rollers may be disposed each at a different angle X. For example, a first roller may be disposed at a first angle X1 and a second roller may be disposed at a second angle X2. Drawings Figure 1 illustrates an abrading machine according to the present disclosure; Figure 2 illustrates a plurality of rollers as described herein; Figure 3 is a perspective view of a wood plank; Figure 4 is a top schematic view of an abrading machine according to the present disclosure; Figure 5 is a side view of an abrading machine also according to the present disclosure; Figure 6 is a flow diagram of a method of producing a soft-edge wood tile according to the present disclosure; and, Figure 7 illustrates a single surface comprising a plurality of soft-edge wood tiles, manufactured according to the present methods. Detailed Description The following provides a detailed description of a method of producing a soft edge 303 on a wood tile 300 manufactured from a wood plank 200. In this context, ‘soft edge 303’ refers to a rounded edge, optionally wherein a corner has been blunted, for example via sanding. The resultant wood tile 300 may, optionally, be arranged with a plurality of other wood tiles 300 to create a single surface 350. For example, a plurality of wood tiles 300 may be arranged to form a floor. In such a way said soft edge 303 may create a joint between wood tiles 300 which is smooth and maintains the natural aesthetic of the wood plank 200. An example is shown in Figure 6. Figure 1 shows an abrading machine (or abrasion machine) 100. The abrasion machine 100 comprises at least one roller 102. As shown in Figure 1, the abrasion machine 100 may comprise a plurality of rollers 102. For example, the abrasion machine 100 may comprise 2 or 4 rollers 102. The at least one roller 102 is arranged to rotate around a rotation axis 110. The abrasion machine 100 may also comprise a production line 104 extending in a first direction 110. The at least one roller 102 may be arranged above the production line 104. Wherein the abrasion machine 100 comprises a plurality of rollers 102, said rollers 102 may be arranged in a row running parallel to the production line 104, and optionally also parallel the first direction 110. In some embodiments, the rollers 102 may be arranged such that the rotation axes 106 of the respective rollers 102 are parallel to one another. The rollers 102 may be spaced equally, in that the distance between the rotational axes 106 of adjacent rollers 102 may be consistent. The abrasion machine 100 is arranged to receive the wood plank 200. Said wood plank 200 may be fed through the abrasion machine 100 in a feed direction 210. Said feed direction 210 may be parallel to the first direction 110. The wood plank 200 may be fed through the abrasion machine 100 on an upper work surface 103 of the production line 104. The wood plank 200 may be manually fed through the abrasion machine 100. Alternatively, the abrasion machine 100 may comprise automated means for feeding the wood plank through the abrasion machine 100. In some machines, the production line 104 may be a moving surface arranged to move the wood plank 200 relative to the rollers 102. The production line 104 may, for example, be a conveyor belt 105 or conveyor chain. The conveyor belt 105 may run in a direction parallel to the feed direction 210. The conveyor belt 105 may be arranged to carry the wood plank 200 from a feed point, wherein said feed point is the point at which the wood plank 200 enters the abrasion machine 100, to an end point, wherein said end point is the point at which the wood plank 200 exits the abrasion machine 100. Advantageously, the production line 104 provides an automated method of moving the wood plank 200 relative to the rollers 102, optionally at a constant speed. This minimises the manual input required by an operator and provides consistency between passes through the abrasion machine 100. Figure 2 shows a plurality of rollers 102. Said rollers 102 may comprise a core 106 and an outer abrasive layer 108 surrounding the core 106. The abrasive outer layer 108 may comprise sandpaper 109. The sandpaper 109 may be arranged so as to extend radially from the core 106. The sandpaper 109 may be of a relatively fine grit. Alternatively, the sandpaper 109 may be of a relatively course griti. Wherein the abrasion machine 100 comprises a plurality of rollers 102, each of the rollers 102 may comprise sandpaper 109 of different grit. Alternatively, at least one roller 102 may comprise sandpaper 109 of a first grit and at least one roller 102 may comprise sandpaper 109 of a second grit. In some embodiments two or more rollers 102 may comprise sandpaper 109 of the first grit. Additionally or alternatively one or more rollers 102 may comprise sandpaper 109 of the second grit. For example, the abrasion machine 100 may comprise two rollers 102 comprising sandpaper 109 of the first grit and a further two rollers 102 comprising sandpaper 109 of the second grit. The abrasion machine 100 may also comprise only rollers 102 comprising sandpaper 109 of the first grit. In such a way, the plurality of rollers 102 may be configured to abrade the wood plank 200 in a user selected order of sandpaper 109 grit. For example, the grit of the sandpaper 109 may increase with feed direction 210 such that a first roller 102 is arranged to provide coarse abrasion and a final roller 102 is arranged to provide fine abrasion. The first roller 102 may be the roller 102 closest to the entry point of the production line 104 and the final roller 102 may be the roller 102 closest to the end point of the production line 104. The abrasive outer layer 108 may comprise a brush. Said brush may comprise bristles which extend radially from the core 106. The bristles may comprise a metal, optionally steel. The bristles may alternatively comprise a plastics material. Wherein the abrasion machine 100 comprises a plurality of rollers 102, said rollers 102 may comprise a variety of abrasive outer layers 108. For example, at least one of the rollers 102 may comprise plastic bristles and another of the at least one rollers 102 may comprise metal bristles. In some embodiments the abrasion machine 100 may comprise at least one roller 102 comprising sandpaper 109 and at least one roller 102 comprising a brush. The abrasion machine 100 may comprise rollers 102 comprising a variety of grits of sandpaper 109 and a variety of bristle materials. The rollers 102 may be arranged to rotate clockwise and anti-clockwise around their respective rotation axis 110. The rollers 102 may be positioned at a distance, “d”, from a wood plank 200 positioned on the production line 104. Distance d may define the distance between an upper surface 201 of the wood plank 200 and the rotational axis 112 of the roller 102. The distance d may be approximately equal to a radius of at least one roller 102. Alternatively, distance d may be less than the radius of at least one roller 102. In such a configuration, the abrasive outer layer 108 of the roller 102 may be arranged to cut into the upper surface 201 of the wood plank 200. In some embodiments, the distance d may be reduced. For example, wherein at least one roller 102 has become worn, distance d may be reduced to achieve the desired abrasion. Figure 3 illustrates the wood plank 200. The wood plank 200 comprises an upper surface 201 and may comprise a plurality of side surfaces 202 approximately perpendicular to the upper surface 201. At least one edge 203 may be formed between the upper surface 201 and at least one side surface 202. The wood plank 200 may comprise oak, pine or mahogany wood. The wood plank 200 may be of a standard size. The wood plank 200 may extend in the feeding direction 210. Said extension may define a length of the plank 200. The length of the plank 200 may be between 300mm, or more. The plank 200 may comprise a width, said width may be 50mm, or more. The plank 200 may comprise a thickness. The thickness of the plank 200 may be 10mm, or more. In some embodiments of the present invention, the thickness of the plank 200 may be accurately measured prior to the plank 200 being received by the abrasion machine 100. Accordingly, the abrasion machine 100 may be adjusted for particular plank 200 thickness. For example, the height of at least one of the rollers 102 may be selected based on the plank 200 thickness and a desired distance d. In such a way, the present invention may be applied to planks 200 of a variety of thicknesses. Figure 4 illustrates a top view of a set-up of the abrasion machine 100 according to the present description. In the shown arrangement, the wood plank 200 is arranged such that the length of the plank 200 is approximately parallel to the feeding direction 210. In the arrangement shown, the feeding direction 210 is also parallel to the first direction 110. As shown, the at least one roller 102 is arranged at an angle X wherein the angle X is the angle between the rotational axis 112 of the roller 102 and a line 113 perpendicular to the first direction 110. It will be appreciated that the roller 102 will still lie on a plane substantially parallel to the working surface on the abrading machine 100. In some alternative arrangements, wherein the abrasion machine 100 comprises a plurality of rollers 102, two or more rollers 102 may be arranged at the angle X. The angle X may vary between rollers 102. Optionally, the abrasion machine 100 may comprise at least one roller 102 arranged perpendicular to first direction 110. Further, the abrasion machine 100 may comprise at least one roller 102 arranged broadly perpendicular to the first direction 110 and at least one roller 102 arranged at the angle X. As shown in Figure 4, the at least one roller 102 may extend in a direction parallel to the respective rotation axis 112. Said extension may be greater than the width of the plank 200. The at least one roller 102 may comprise a first end 101 and a second end 103 wherein the extension of the roller 102 is the distance between the first 101 and second 103 end. The extension of the roller 102 may be such that when said roller 102 is disposed at the angle X the width of the plank 102 lies between the first 101 and second end 103. In other words, the extension of the roller 102 is sufficient that the entire width of the plank 200 may be abraded by the at least one roller 102 when the at least one roller 102 is arranged at the angle X. Advantageously, in being disposed at the angle X, wherein the wood plank 200 interacts with the roller 102, the roller 102 is able to abrade both the upper surface 201 of the wood plank 200, and at least one edge 203 between the upper surface 101 and a side surface 202. In such a way, the roller 102 disposed at the angle X is arranged to abrade the edge 203 to create a soft edge 303. The angle X may be selected and adjusted based on a variety of factors such as the type of wood of the plank 200 and the desired finish of the wood tile 300. Figure 5 illustrates a side view of a further set-up of the abrasion machine 100 according to the present description. Distance d is shown as the distance between the upper surface 201 of the plank 200 and the rotational axis 112 of the roller 102. Distance d may be equivalent to distance “r” wherein distance r is equivalent to the distance from the rotational axis 106 of the roller to an outer edge 107 of the abrasive outer layer 108 when the roller 102 is at rest and is not in contact with the upper surface 201 of the plank 200. The rotational axis 112 of the roller 102 may run centrally through the core 106 of the at least one roller 102. Distance d may be less than distance r. For example, the roller 102 may be brought towards the plank 200 such that the plank 200 acts upon the roller 102 to reduce distance r at a point of contact between the upper surface 201 the plank 200 and the roller 102. The roller 102 may therefore be compressed by reducing distance d. In such a way, the force applied by the roller 102 on the plank 200 may be varied by varying d. Where d is less than r, the abrasive outer layer 108 of the roller 102 may be arranged to press into the upper surface 201 of the wood plank 200. Figure 6 illustrates an example method of creating a soft edge wood tile 300, according to the present disclosure. As shown in Figure 6, the abrasion machine 100 according to the description above is provided 401. A wood plank 200 according to the description above is also provided 402. The rollers 102 are set 403 in a first configuration. Said first configuration may be dependent on the wood plank 200 provided. For example, for a given wood type, such as oak or pine, a standard set-up may be applied. The thickness of the plank 200 may also be accurately measured. Said measurement may inform the first configuration. For example, a height of the at least one roller 102 may be selected based on a desired distance d and the thickness of the plank 200. Similarly, the abrasive outer layer 108 of the rollers 102 may be selected based on the wood plank 200. For example, rollers 102 having an outer abrasive layer 108 comprising sandpaper 109 of a coarser grit may be configured for a wood plank 200 requiring substantial abrasion and rollers 102 having an outer abrasive layer 108 comprising sandpaper 109 of a finer grit may be configured for a wood plank 200 requiring less substantial abrasing. Further, the rotational speed of the at least one roller 102 may be informed by the wood type of the plank 200 or the desired finish of the wood tile 300. The first configuration may comprise a plurality of rollers 102, at least one of said rollers 102 being arranged at the angle X. The first configuration may comprise 4 rollers 102. Alternatively, the first configuration may comprise 6 or 8 rollers 102. The angle X may be between 10 and 50 degrees. The plurality of rollers 102 may comprise at least one roller 102 comprising a sandpaper 109 abrasive outer layer 108. Additionally or alternatively, the plurality of rollers 102 may comprise at least one roller 102 comprising bristles. Said bristles may be plastic or, optionally, metal. In an arrangement, the first configuration comprises four rollers 102 each having an abrasive outer later 180 comprising sandpaper 109. Wherein the first configuration comprises a plurality of rollers 102, said rollers 102 may be arranged such that the rollers 102 are in a row wherein said row runs parallel to the first direction 110. The at least one roller 102 may be arranged such that the rotational axis 112 of the at least one roller 102 lies across the width of the wood plank 200. In other words, the first end 101 and the second end 103 of the at least one roller 102 may be located at opposite sides across the width of the wood plank 200, as shown in Figure 2. The first configuration may be arranged based on existing knowledge, which may comprise trial and error. For example, for certain types and sizes of wood plank 200 a standard first configuration may be known and selected. A first set-up may, for example, comprise four rollers 102. Of said four rollers 102, two rollers 102 may comprise a first sandpaper 109 and the further two rollers 102 may comprise a second sandpaper 109. A second set-up may comprise four rollers 102. Of said four rollers 102, two rollers 102 may comprise a third sandpaper 109 and the further two rollers 102 may comprise a fourth sandpaper 109. Following the set-up of the at least one roller 102, parameters of the abrasion machine 100 may also be set 404. In particular, said parameters may include one or more of: feed speed of the wood plank 200, height of the at least one roller 102 and rotational speed of the at least one roller 102. The feed speed may refer to the rate at which the wood plank 200 is fed through the abrasion machine 100. The feed speed of the wood plank 200 may be controlled via altering the speed of the production line 104. The wood plank 200 may be fed through the abrasion machine 100 manually. Alternatively, said production line 104 may comprise a conveyor belt 105. The wood plank 200 may be placed upon said belt 105. The wood plank 200 may enter the abrasion machine 100 at the entry point and exit the abrasion machine 100 at the end point. The production line 104 may run in a straight line from the entry point to the end point. In such a way, the production line 104 may be arranged to carry the wood plank 200 passed each of the rollers 102 in turn, in such a way that the wood plank 200 interacts with at least one of the rollers 102 and is abraded by at least one of the rollers 102. Where the wood plank 200 is passed through the abrasion machine 100 a plurality of times, the feed speed may be altered between passes. The feed speed may be between 1 linear metre per minute, or more. The feed speed selected may also be dependent upon wood type of the wood plank 200 and desired finish of the wood tile 300. For example, the feed speed selected for a pine wood plank 200 may be different to the feed speed selected for an oak wood plank 200. The rotation speed of the at least one roller 102 may also be set. The rotation speed of the roller 102 refers to the speed at which the at least one roller 102 rotates about its respective rotation axis 112. Each roller 102 may have a different rotation speed, alternatively the rollers 102 may have the same rotation speed. The rotation speed may also be adjusted between passes of the wood plank 200 through the abrasion machine 100. Said adjustment may be informed by existing knowledge, for example from trial and error, or alternatively by an inspection of the wood plank 200. The at least one roller may also be arranged to oscillate relative to the first direction 110. For example, at least one roller 102 may be arranged to oscillate across the width of the wood plank 200, optionally in a direction parallel to the rotation axis 112 of at least one roller 102. Oscillation refers to the movement of the roller 102 back and forth along a singular axis in a regular fashion. Said oscillation may be in the direction perpendicular to the first direction 110. In such a way the rollers 102 may abrade the wood plank 200 in the direction perpendicular to the first direction 110, due to the oscillation, and in the first direction 110, due to the movement of the wood plank 200 through the abrasion machine 100 along the production line 104. Said abrasion may therefore be carried out in both directions simultaneously. Wherein the abrasion machine 100 comprise a plurality of rollers 102, at least one of the rollers 102 may oscillate and at least one of the rollers 102 may not oscillate. Optionally, all of the rollers 102 of the abrasion machine 100 may oscillate. Further optionally, none of the rollers 102 of the abrasion machine 100 may oscillate. The rollers 102 may be configured to oscillate at an oscillation speed. Said oscillation speed may refer to the speed at which the roller 102 moves in a direction perpendicular to the first direction 110. The oscillation speed may be constant and may be the same for all oscillating rollers 102. Alternatively, the oscillation speed may be different for individual rollers 102. The oscillation speed may be 1 oscillation per minute, or more. The oscillation speed may also be altered between passes of the wood plank 200 through the abrasion machine 100. Following the initial set up 403 of the roller 102 configuration and setting 404 of the abrasion machine 100 operational parameters the wood plank 200 may be fed 405 through the abrasion machine 100. The wood plank 200 may be placed directly on to the production line 104. In some arrangements the production line 104 may be a conveyor belt 105. The wood plank 200 may enter the abrasion machine 100 at the entry point. The wood plank 200 may be fed through a guide wherein said guide is arranged to align the wood plank 200 with the production line 100. The wood plank 200 travels through the abrasion machine 100 according to the feed speed which was set previously. The wood plank 100 may interact with a first roller 102 wherein the first roller 102 is the roller 102 positioned closest to the entry point. The wood plank 200 may travel along the production line 104 from the entry point to the end point. Between the entry and end points the wood plank 200 may be abraded by at least one roller 102. Where the wood plank 200 interacts with the first roller 102, the abrasive outer layer 108 may abrade at least one surface of the wood plank 200. Said abrasion may remove material from the surface of the wood plank 200, for example the upper surface 201 of the wood plank 200. The abrasion of the surface may depend on a variety of factors, including the distance d and the grit of the sandpaper 109 of the rollers 1020. For example, a roller 102 comprising sandpaper 109 having a coarser grit value may remove more material than is removed by a roller 102 comprising sandpaper 109 of a finer grit value. Abrasion carried out by a roller 102 comprising sandpaper 109 having a finer grit value may provide a smoother surface. Said first roller 102 rotates about a rotation axis 112. Said rotation axis 112 may be perpendicular to the production line 104. Alternatively, the rotation axis 112 may be arranged at the angle X relative to the production line 104. Additionally or alternatively, the first roller 102 may be arranged to oscillate relative to the wood plank 200. The roller 102 may therefore rotate around its respective rotation axis 112 while simultaneously oscillating across the width of the wood plank 200. Said first roller 102 abrades at least the upper surface 201 of the wood plank 200 as it passes below the roller 102. Wherein the roller 102 is positioned at the angle X relative to the production line 104, a soft edge 303 is to be created from at least one edge of the wood plank 200. A soft edge 303 is created from at least one edge 203 wherein said at least one edge 203 is defined by a joint between the upper surface 201 of the wood plank 200 and at least one side surface 202 of the wood plank 200. Wherein the roller 102 is at the angle X, the roller 102 abrades the edge 203 in such a way as to remove material from the edge 203. In doing so, the abrasion machine 100 creates a rounded surface, or soft edge 303, at the joint of the upper surface 201 of the wood plank 200 and the at least one side surface 202 of the wood plank 200. The soft edge 303 may be created gradually through a plurality of interactions with at least one roller 102. Optionally, said interactions may comprise passing once under a plurality of rollers 102. Further optionally said interactions may comprise passing under a single roller 102 a plurality of times. Alternatively said interactions may comprise passing under a plurality of rollers 102 a plurality of times. Following interaction with the first roller 102, the wood plank 200 may have further interactions with additional rollers 102 as it is transported on the product line 104. Said rollers 102 may comprise sandpaper 109 of different grit. Additionally or alternatively, the abrasion machine 100 may comprise at least one roller 102 having bristles. Said bristles may comprise metal or plastic. The abrasion machine 100 may comprise at lease one roller 102 having metal bristles and at least one roller 102 having plastic bristles. The abrasion machine 100 may comprise a plurality of rollers 102 comprising bristles and a plurality of rollers 102 comprising sandpaper 109. The abrasion machine 100 may also comprise a plurality of rollers 102 disposed at the angle X. Said angle X may be the same for each of the rollers 102. Alternatively, at least one of the rollers 102 may be disposed at angle X which is different to the angle X at which a further roller 102 is disposed. Where the wood plank 200 has travelled from the entry point to the end point of the abrasion machine 100, where said entry point and said end point are at opposite ends of the production line 104, a pass is completed. Following the first pass, an inspection 406 of the wood plank 200 may be carried out. The wood plank 200 may be inspected 406 for one or more of colour, smoothness, texture and thickness. Said inspection 406 may be a visual inspection or may comprise equipment. For example, the thickness of the wood plank 200 may be measured using callipers. The texture of the wood plank 200 may be assessed by running a hand across the wood plank 200. Following the first pass, the rollers 102 may also be inspected. For example, the rollers 102 may be inspected for cleanliness and wear. Where the sandpaper 109 or bristles of a roller 102 have become worn, the roller 102, or the abrasive outer layer 108 of the roller 102, may be removed and, optionally, replaced. The inspection 406 may identify 407 a need for an additional pass, alternatively the inspection 406 may identify that no further abrasion is required and the wood plank 200 has successfully been manufactured 408 into a soft edge wood tile 300. Where a further pass is required, the inspection 406 and existing knowledge may identify 409 a need for roller 102 adjustment 410. For example, existing knowledge may comprise trial and error which has informed standard set ups for at least one of wood type, wood thickness, wood hardness or desired finish. The roller 102 adjustment 409 may comprise changing the sandpaper 109 of at least one of an existing roller 102 to a different grit. Alternatively or additionally, the material of the outer abrasive layer 108 of at least one of the rollers 102 may be changed. For example, a roller 102 comprising sandpaper 109 may be replaced by a roller 102 comprising bristles, or vice versa. A roller 102 comprising plastic bristles may be replaced by a roller 102 comprising metal bristles, or vice versa. In such a way, the abrasion machine 100 provides an extremely flexible set up which can be tailored to requirements of individual wood planks 200 and wood tiles 300 and allows for amendments to be made to the set up, during the manufacturing process. Additionally, or alternatively, the distance d may be altered between passes, optionally due to an inspection finding. For example, wherein greater pressure is required to be exerted on the wood plank 200 by the roller 120, distance d may be reduced. Greater pressure may be required, for example, wherein the sandpaper 109 of the roller 102 is worn, or wherein deeper abrasion is desired on the wood plank 200. Alternatively, the distance d may be increased. Wherein a worn roller 102 has been replaced with a new roller 102, it may be necessary to increase distance d to achieve the same pressure on the wood plank 200. Alternatively, distance d may be reduced in order to reduce the pressure exerted on the wood plank 200 by the roller 102. The distance d may also be adjusted to achieve greater abrasion of at least one edge 203 of the wood plank 200. Additionally, or alternatively, where at least one roller 200 is arranged at the angle X, the angle X may be adjusted to achieve further abrasion of at least one edge 203 of the wood plank 200. Alternatively, the roller 200 arranged at the angle X may be adjusted to be perpendicular to the feed direction 210 or replaced by a roller 102 perpendicular to the feed direction 210. All of the adjustments described above may be applied to a single roller 102, a plurality of rollers 102 or, optionally, all the rollers 102 of the abrasion machine 100. Each roller 102 may be adjusted independently of the other rollers 102. In addition to roller 102 adjustment 400, the inspection 406 may inform adjustment 412 of parameters of the abrasion machine 100. Such parameters may include, but are not limited to, the feed speed of the wood plank 200, the rotational speed of the rollers 102 or the oscillation speed of the rollers 102. In such a way, the abrasion machine 100 may be tailored to suit a wide variety of wood planks 200, and desired wood tiles 300. Further, the abrasion machine 100 may be adapted 410, 412 during the manufacturing process. Said adaptations may be informed by inspections 406 carried out between passes of the wood plank 200 through the abrasion machine 100. In some arrangements, the wood plank 200 may complete a plurality of passes without any adjustments to the rollers 102 or the parameters of the abrasion machine 100. Following the completion of the inspection 406 and, optionally, any adjustments 410, 412 the wood plank 200 may be fed 413 through the abrasion machine 100 for a further pass. Once the further pass has been completed, a further inspection 406 and optionally, further adjustments 410, 412 may be made. In some embodiments, the wood plank 200 may complete at least three, four or 5 passes through the abrasion machine 100. Optionally, an inspection 406 is carried out between each pass. Further optionally, adjustments 410, 412 to the roller 102, the abrasion machine 100 parameters or both are carried out between each pass. In other embodiments, said adjustments may be carried out between some passes, and not others. Where an inspection 406 identifies no further passes are required, a wood tile 300 comprising a soft edge 303 is manufactured. Said wood tile 300 may be arranged with a plurality of additional wood tiles 300 to form a single surface 350. Said surface 350 may, for example, be a floor. The plurality of wood tiles 300 may be arranged such that the soft edge 303 of a first wood tile 300 is adjacent to the soft edge 303 of a second wood tile 300. The soft edge 303 allows the wood tiles 300 to sit adjacent to one another without creating a lip between the wood tiles 300. Further, due to the removal of the sharp edge 203 of the wood plank 200 during the process according to the present disclosure, the joint between the wood tiles 300 is smoother than those created by conventional methods such as the bevel method. Further, the joints created between soft edges 303 are more cosmetically appealing compared with conventional methods. For example, wherein the join between wood tiles 300 comprises a beveled edge, the resulting appearance can be artificial. The beveled edge can therefore detract from the natural appearance of the wood plank 200. The wood tile 300 manufactured according to the present invention instead maintains the natural appearance of the wood plank 200. Further, where bevel edges are prone to gathering dirt, due to the indent created between the two wood tiles, the joint between two soft-edge wood tiles 300 is smooth and therefore does not create such an indent. Advantageously, the wood tiles 300 manufactured according to the present disclosure may be factory finished, wherein factory finished refers to the wood tiles 300 not requiring further processing, such as sanding, during or after installation. Figure 7 illustrates a single surface 350 comprising wood tiles 300 manufactured according to the present disclosure. The single surface 350 may, optionally, be a floor. As can be seen in Figure 7, the single surface 350 comprises a plurality of soft-edge wood tiles 300 positioned adjacent to one another. The joins between the wood tiles 300 are smooth, and do not require post install manufacturing. Further, the joints do not comprise a bevel and so have maintained the natural aesthetic of the wood plank 200 used to manufacture the wood tile 300. Further, the floor is substantially levelled, and no lip is present. The present disclosure has therefore provided a method of manufacturing wood tiles 300 which, when joined together to create a larger surface 350, produce smooth joints between them which maintain the natural appearance of the wood plank 200 without requiring extensive post-installation finishing. The singular terms “a” and “an” should not be taken to mean “one and only one”. Rather, they should be taken to mean “at least one” or “one or more” unless stated otherwise. The word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated features but does not exclude the inclusion of one or more further features. The above implementations have been described by way of example only, and the described implementations are to be considered in all respects only as illustrative and not restrictive. It will be appreciated that variation of the described implementations may be made without departing from the scope of the disclosure. It will also be apparent that there are many variations that have not been described, but that fall within the scope of the appended claims. List of reference numerals used in the description and drawings: 100 Abrasion machine 101 First end 102 Roller 103 Second end 104 Production line 105 Conveyor belt 106 Core 107 Outer edge 108 Abrasive outer layer 109 Sandpaper 110 First direction 112 Rotational axis 113 Line 200 Wood plank 201 Upper surface 202 Side surface 203 Edge 210 Feeding direction 300 Wood tile 303 Soft edge 350 Single surface 401 Provide abrasion machine 402 Provie wood plank 403 Set roller(s) in first configuration 404 Set abrasion machine operational parameters 405 Feed wood plank for first pass 406 Inspect wood plank and rollers 407 Identify if further pass required 408 Wood tile created 409 Identify if roller adjustment is required 410 Adjust roller configuration 411 Identify if abrasion machine operational parameter adjustment is required 412 Adjust operational parameters of abrasion machine 413 Feed wood plank for further pass

Claims

1. Method of manufacturing soft-edged wood tiles, the method comprising the steps of: providing an abrading machine comprising one or more abrasive rollers having5 respective rotation axes, the abrading machine being adapted to receive wood planks according to a feeding direction, said wood planks comprising an upper face and at least one side face perpendicular to the upper face, said upper face and at least one side edge forming an edge which runs in a longitudinal direction substantially parallel to the feeding direction;disposing at least one of the rollers at an angle other than substantially perpendicular10 to such feeding direction, such that an angle X is formed between the rotational axis of the roller and said longitudinal direction; and,feeding each wood plank through the abrading machine according to said feeding direction a plurality of times, wherein each time constitutes a pass, wherein the method further comprises:15 inspecting at least one of the wood planks after at least one pass; andadjusting the abrading machine after said at least one pass.LO CXI2. The method of claim 1, wherein the angle X is between 10 and 50 degrees.^^20 3. The method of claim 1 or 2, further comprising the step of setting a distance d, wherein d isthe distance between the rotational axis of the roller and the upper face of the wooden plank.CXI4. The method of claim 1, 2 or 3, further comprising the step of setting a feed speed, wherein the feed speed is the rate at which the wood planks pass through the abrading machine;25 preferably wherein said feed speed is 1 linear metre per minute or above.

5. The method of any one of claims 1 to 4, further comprising the step of setting a rotational speed of the at least one roller; preferably, wherein said rotational speed is 10 rpm, or above.30 6. The method of claim 2, wherein said adjusting the abrading machine after the at least onepass comprises changing the angle X.

7. The method of claim 3, wherein said adjusting the abrading machine after the at least one pass comprises increasing or decreasing the distance d.35 8. The method of claim 4, wherein said adjusting the abrading machine after the at least onepass comprises changing the feed speed.27 01 259. The method of claim 5, wherein said adjusting the abrading machine after the at least one pass comprises changing the rotational speed of at least one of the rollers.

10. The method of any one of claims 6 to 9, wherein said adjusting the abrading machine after 5 the at least one pass comprises changing the rotation direction of at least one of the rollers.

11. The method of any preceding claim, wherein the abrading machine comprises at least 2 rollers; optionally 4 rollers.1012. The method of claim 11, wherein the rollers are arranged sequentially in a direction parallel to the feeding direction.

13. The method of any preceding claim, wherein at least one of the rollers comprises 15 sandpaper.

14. The method of claim 13 and 11, wherein a first roller comprises sandpaper having a first grit and a second roller comprises sandpaper having a second grit.20 15. The method of claim 13 or 14, wherein said adjusting the abrading machine after at leastone pass comprises changing the grit of the sandpaper of at least one of the rollers.

16. The method of any preceding claim wherein at least one of the rollers comprises a brush comprising bristles.2517. The method of claim 16, wherein said bristles are made of plastics.

18. The method of claim 16, wherein the bristles are made of metal.30 19. The method of claim 16, 17 or 18, wherein said adjusting the abrading machine after atleast one pass comprises changing the bristles of the at least one brush.

20. The method of any preceding claim, wherein the at least one roller is adapted to oscillate relative to the plank, at an oscillation speed; preferably, wherein said oscillation speed is 10 35 rpm, or above.

21. The method of claim 20, wherein the at least one roller is adapted to oscillate in a direction perpendicular to the feed direction.

22. The method of claim 20 or 21, wherein the at least one roller is adapted to oscillate in a 5 direction parallel to the rotation axis of the at least one roller.

23. The method of claim 20, 21 or 22, wherein said adjusting the abrading machine after at least one pass comprises altering the oscillation speed of the at least one roller.1027 01 25

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