Panel with restored decor

Abstract

Flooring substrates may include a core layer having: first and second long edges; and first and second short edges. The first and second long edges and the first and second short edges may form the perimeter of the core layer. The core layer may include first and second long edge bevels formed along each of the first and second long edges, respectively. Flooring substrates may include a decor layer overlaid on the core layer having an image. The image may include a first area indicative of a void along at least one of the first and second long edges. The first area indicative of a void is positioned on at least one of the first or second long edge bevels.

Description

PANEL WITH RESTORED DECORCROSS-REFERENCE TO RELATED APPLICATION

[0001] This invention claims priority from United States Provisional Patent Application Serial No. 63 / 698,961, filed September 25, 2024, which is incorporated by reference in their entirety herein.BACKGROUND

[0002] Some trendy designs use real restored wood planks with gaps in between. However, using real restored wood planks is expensive. What is needed are systems and methods that address the above issuesSUMMARY

[0003] In an aspect, the present disclosure is directed to flooring substrates or panels that utilize a combination of beveled edges with a decor top layer having corresponding images indicating a void to give an appearance of gaps when installed next to one another. Flooring substrates may include a core layer having: first and second long edges; and first and second short edges. The first and second long edges and the first and second short edges may form the perimeter of the core layer. The core layer may include first and second long edge bevels formed along each of the first and second long edges, respectively. Flooring substrates may include a decor layer overlaid on the core layer having an image. The image may include a first area indicative of a void along at least one of the first and second long edges. The first area indicative of a void is positioned on at least one of the first or second long edge bevels.

[0004] Flooring systems may include a first flooring substrate having: a first long edge; a second long edge; two first short edges; a first decor layer having a first image, where the first image may include a first area indicative of a void along the first long edge; a first core layer having a first bevel along the first long edge and a second bevel along the second long edge, where the first area indicative of a void is positioned on the first bevel; a first secure component along the first long edge; and a second secure component along the second long edge, where the second secure component is configured to lock with the first secure component. Flooring systems may also include a second flooring substrate having: a third long edge; a fourth long edge; two second short edges; a second decor layer having a second image, where the second image may include a second area indicative of a void along the fourth long edge; a second core layer having a third bevel along the third long edge and afourth bevel along the fourth long edge, where the second area indicative of a void is positioned on the fourth bevel; a third secure component along the third long edge, where the third secure component is similar to the first secure component; and a fourth secure component along the fourth long edge, where the fourth secure component is similar to the second secure component.

[0005] Methods may include receiving an image indicative of a decor layer. The image may include at least one area indicative of a void. Methods may include applying the image to a core layer. Methods may include separating the core layer into two or more planks. Each plank may include two long edges and two short edges. Each plank may include a portion of at least one area indicative of a void along at least one long edge. Methods may include pressing a bevel into the two long edges of the two or more planks. Methods may include pressing a micro bevel into the two short edges of the two or more planks. Other embodiments of this aspect include corresponding computer systems, apparatus, and computer programs recorded on one or more computer storage devices, each configured to perform the actions of the methods.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0007] Fig. 1 shows example floor substrates described herein.

[0008] Fig. 2A shows an example floor substrate described herein.

[0009] Fig. 2B shows an example floor substrate described herein.

[0010] Fig. 3 shows a diagram of an example floor substrate described herein.

[0011] Fig. 4 shows a diagram of an example floor substrate described herein.

[0012] Fig. 5 shows an example decor layer to be applied on example floor substrates described herein.

[0013] Fig. 6 shows an example flooring system described herein.

[0014] Fig. 7 shows an example flooring system described herein.

[0015] Fig. 8 shows example images of Versailles patterns utilized by the flooring system described herein.DETAILED DESCRIPTION

[0016] It should be appreciated that this disclosure is not limited to the systems, components, and methods described herein. It is also to be understood that the terminology used herein is for the purpose of describing certain embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims.

[0017] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Any systems, components, and methods similar or equivalent to those described herein can be used in the practice or testing of the present invention. All publications mentioned are incorporated herein by reference in their entirety.

[0018] The use of the terms “a,” ‘"an,” “the,” and similar referents in the context of describing the presently claimed invention (especially in the context of the claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.

[0019] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

[0020] Use of the term "about" is intended to describe values either above or below the stated value in a range of approx. + / - 10%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / - 5%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / - 2%; in other embodiments the values may range in value either above or below the stated value in a range of approx. + / - 1%. The preceding ranges are intended to be made clear by context, and no further limitation is implied. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as’') provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0021] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present systems, components, and methods are disclosedand described, it is to be understood that this disclosure is not limited to the specific systems, components, and methods disclosed unless otherw ise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0022] Described herein are systems, methods for creating panels (planks, pieces, etc.) to look like restored wood, and the panels themselves. The panels may comprise floor substrate. The panels may comprise gaps (voids, blank space, etc.). The gaps may be faux gaps and may only exist on a decor layer. The decor layer can be a film and / or paper on which an image with the gaps is printed. Printing may include digital printing or traditional printing. Printing may comprise using a rotogravure. In some aspects, the decor layer includes images of restored wood planks. In other aspects, the image can comprise wood Versailles paneling, a wood parquet pattern, a chevron pattern, a herringbone pattern, tile mosaic, or other images of flooring patterns with edges between the flooring (e.g., tile, etc.). The absence of actual gaps may prevent dirt and debris from falling in between planks, while still providing the look of flooring that has gaps. The panels described herein increase cleanability over existing solutions.

[0023] Real restored wood planks with the gaps in between may be scanned using a large scanner. The scanned images may be modified (edited, adjusted, fixed, etc.) to meet requirements and / or preferences. After the scanned image is modified, the modified image may be printed on a film and / or paper to form the decor layer. The printed film and / or paper may be coupled (applied, attached, affixed, etc.) to a core layer. In an embodiment, the decor layer may be directly printed onto a surface of the core layer with or without primer and / or ink adherence layer therebetween. The combined decor layer and core layer may be pressed at the edges and separated into panels - creating individual panels with a pressed bevel appearance along the long edges. The short edges may have other types of bevels, but particularly in one example, the short edges may have a micro-bevel. Having pressed bevel long edges and micro-bevel short edges cause the faux gaps in installed panels to appear real. The difference in real size of the micro-bevel on the short end versus the bevel associated with the simulated void along the long end provides further visual suggestion of simulated faux gaps betw een the planks. The small size of the micro-bevels compared to the larger pressed bevels along the long ends of planks is a part of a trompe 1'oeil illusion - appearing to have a true, natural edges along the planks. In addition, the beveling along the long edge results in an indentation, which enhances the appearance of a gap along the long edges. Usinga micro-bevel may help mitigate quality issues associated with ledging over wood. In some embodiments, the short edges may comprise a 90-degree angle instead of a micro-bevel.

[0024] Prior to separation into panels, a sheet can include a decor layer which may comprise images of several panels, wherein the panels may be separated by the faux gaps. In some aspects, the faux gaps can take the form of black stripes that separate panels. In additional aspects, adjacent the black stripes / gaps, a transitional color that is lighter than the black stripes but darker that the color of the majority of the remainder of the images (e.g., a darker wood coloring than that of the majority of the wood panel image). The combined decor layer and core layer may be pressed and separated into panels somewhere, splitting or being pressed along the gaps. The pressing and separation into individual panels may be such that no two adjacent panels will have more than a combined threshold of combined faux gap and no individual panel will have more than an individual threshold of the faux gap. The combined threshold may range approximately between 4 to 5 millimeters (mm). The individual threshold may range approximately between 2 to 2.5 mm.

[0025] The faux gap on a panel may or may not extend the full length of the panel’s edge after pressing. The width of the faux gap may be inconsistent along the length of the panel’s edge. At least a portion along the edge of a panel may have a faux gap and the faux gap may vary in width in the portion along the edge of the panel. The width of the faux gap may be less than the individual threshold at every location along the portion. As such, when panels are interconnected, adjacent panels may together form a combined faux gap that extends at least a portion of the length of the panels. The width of the combined faux gap may vary but will be less than the combined threshold.

[0026] The panels described herein may be manufactured using a device that presses a bevel shape onto the panels, allowing the decor layer to extend to the edges of the panels. The bevels along the long edges of a panel may be pressed. The micro-bevels along the short edges of a panel may be cut. Short bevels may break up a pattern, giving a panel a more realistic look. Irregular plank edges may be printed on a short edge of a panel. The systems and methods described herein may use continuous lamination processing to couple a decor layer to a core layer. The systems and methods described herein may use a hot press to couple a decor layer to a core layer, to apply bevels and / or micro-bevels to the panels, and / or to separate the panels. The systems and methods described herein may use a punch cut method to separate the panels. The systems and methods described herein may create a seamless blend of edges of panels. A size of faux gaps (black edges) may be large enough to be present after a decor layer is coupled to a core layer of a panel.

[0027] The bevels and the decor layer may combine dimension and print to give a false illusion of gaps without gaps being present. The systems and methods described herein may include adding a marking on a decor layer to align correctly with a punch cut.

[0028] The systems and methods described herein may comprise aligning a decor layer with a core layer within a hot press. An infrared device may be used to align the decor layer and the core layer. A wear layer, a Polyvinyl chloride (PVC) decor film, and a vinyl layer may be laminated together in the hot press to create a luxury vinyl tile (LVT) topper. The LVT topper may be coupled (glued, affixed, etc.) to a core (wood polymer composite (WPC) core, foamed and rigid PVC core, etc.) to create a whole sandwich. Multiple panels may be punch cut with the hot press from one sheet (e.g., the whole sandwich). Five panels may be cut from one sheet. An infrared device may be used to align a punch cut line in an area associated with a shadowing effect. When five panels are cut, there may be six gaps, wherein each panel, when cut, will have a void (gap, black area, etc.) along at least a portion of both long edges. When five panels are cut, there may be four gaps, wherein the middle panel will have a void along at least a portion of both long edges, and the remaining four panels will each have a void along at least a portion of one long edge. Having a panel with a long edge without a void may allow for tolerance in creating panels. If during lamination or cutting an alignment adjusted up to a tolerance amount, such as the individual threshold, to accommodate a void on one long edge of a panel, then having no void on the other long edge of the panel means that the other long edge will not have a void with too large of a faux gap to maintain the illusion of the gap. Having the panel designed with a void along only one long edge allows for the pattern to shift in one direction to accommodate a long edge with the void without an equal and opposite shift to a void on the other long edge that would overaccentuate the void on the other long edge, possibly ruining the illusion of the gap. Having a panel with a long edge without a void may break up a view. A profile (locking system, etc.) along the edges may be added after the sheet is cut into panels. Micro-bevels may be added along the short edges of the panels after the sheet is cut into panels.

[0029] The systems and methods described herein may use a trompe 1'oeil technique. The systems and methods described herein may be used to create a tile look. The systems and methods described herein may be used to create a false edge look. The systems and methods described herein may be used to create a Versailles pattern.

[0030] A first area representing a void along a first long edge of a first panel combined with a second area representing a void along a second adjacent long edge of a second adjacent panel may form a combined area representing a void. The combined area representing a void maybe no more than wider than the combined threshold. The combined area representing a void may be 0 mm to as wide as the combined threshold. The first area representing a void and the second area representing the void may be different from each other. The first area representing a void and / or the second area representing the void may be randomly created, such that at no point does a width of the combined area exceed the combined threshold. The first area representing a void and / or the second area representing the void may be randomly- created, such that at no point does a width of the either the first or second area representing the void exceed the individual threshold. The first area representing a void and / or the second area representing the void may be created irregularly, so as to look realistic and natural, similar to the scanned images of real restored wood planks. A medium of a decor layer maycause variation of areas representing a void. For example, film may expand or contract. The decor layer may comprise a shadowing effect between an image of a wood plank and an area representing a void. The shadowing effect may add a false impression of a dimension to a panel. The shadowing effect may give an illusion of size and / or dimension to an otherwise two dimensional visual. The combination of the shadowing effect and an actual indentation along edges may create the trompe 1'oeil effect and fool a viewer into thinking apparent edges and voids are real.

[0031] Fig. 1 shows example floor substrates lOa-lOe (panels, planks, etc.) described herein. A sheet 20 may be cut along a first target line 202a, a second target line 202b, a third target line 202c, and a fourth target line 202d creating the floor substrates 10a- lOe. A first sheet edge 204a and a second sheet edge 204b may comprise an area indicative of a void. The sheet 20 may comprise an image comprising the target lines 202a-202d and sheet edges 204a-204b. The second target line 202b and the third target line 202c may also comprise an area indicative of a void. The result may be that the floor substrate 10a and the floor substrate lOd comprise an area indicative of a void along a left long edge, the floor substrate 10b and the floor substrate lOe comprise an area indicative of a void along a right long edge, and the floor substrate 10c comprises areas indicative of a void along both long edges. Alternatively or additionally, the first target line 202a may comprise an area indicative of a void, resulting in the floor substrates 10a and 10b comprising areas indicative of a void along both long edges. Alternatively7or additionally, the fourth target line 202d may comprise an area indicative of a void, resulting in the floor substrates lOd and lOe comprising areas indicative of a void along both long edges.

[0032] A floor substrate, such as the floor substrate 10b after the sheet 20 is cut, may comprise a core layer 102, as shown in Figs. 1, 2A-B, and 3. A floor substrate, such as thefloor substrate 10b after the sheet 20 is cut, may comprise a decor layer 104. A cut floor substrate 10b may comprise a first long edge 106. The first long edge 106 may comprise an area indicative of a void 118. A cut floor substrate 10b may comprise a second long edge 108. The second long edge 108 may or may not comprise an area indicative of a void 118. A floor substrate, such as the floor substrate 10b after the sheet 20 is cut, may comprise a first short edge 110 and a second short edge 112. The first long edge 106, the second long edge 108, the first short edge 110, and the second short edge 112 may form a perimeter 115 of a floor substrate for a cut floor substrate 10b. A floor substrate, such as the floor substrate 10b after the sheet 20 is cut, may comprise a length 114 and a width 116.

[0033] Figs. 2A and 2B show an example floor substrate 10 described herein. The example floor substrate 10 may be a cut floor substrate 10, which includes a core layer 102. The floor substrate 10 may comprise a first bevel 120. The first bevel 120 may be along a long edge, such as the long edge 106, comprising the area indicative of the void 118. The first bevel 120 may comprise the area indicative of the void 118. The first bevel 120 may comprise a width of or about 3.5 mm. The first bevel 120 may comprise a depth of or about 1 mm. In an aspect, a shadowing effect may be added to the bevel 120.

[0034] Fig. 3 shows a diagram of an example floor substrate 10 described herein. The diagram may show a front view of a first short edge 110 of the floor substrate 10, wherein a first long edge 106 is on the right side of the figure and a second long edge 108 is on the left side of the figure. The first long edge 106 may comprise a first bevel 120. The second long edge 108 may comprise a second bevel 122. The first bevel 120 may comprise a width of or about 3.5 mm. The first bevel 120 may comprise a depth of or about 1 mm. The second bevel 122 may comprise a width of or about 3.5 mm. The second bevel 122 may comprise a depth of or about 1 mm.

[0035] Fig. 4 shows a diagram of an example floor substrate 10 described herein. The diagram may show a front view of a first long edge 106 of the floor substrate 10, wherein a first short edge 110 is on the left side of the figure and a second short edge 112 is on the right side of the figure. The first short edge 110 may comprise a first micro-bevel 124. The second short edge 112 may comprise a second micro-bevel 126.

[0036] Fig. 5 shows an example decor layer to be applied on example floor substrates described herein. The example decor layer may comprise a first segment 104a, a second segment 104b, a third segment 104c, a fourth segment 104d, and a fifth segment 104e. Each of the first segment 104a of the decor layer, the second segment 104b of the decor layer, the third segment 104c decor layer, the fourth segment 104d decor layer, and the fifth segment104e of the decor layer may correspond to a core layer of a floor, such as the core layer of floor substrate 10a in Fig. 1, the core layer of floor substrate 10b in Fig. 1, the core layer of floor substrate 10c in Fig. 1, the core layer of floor substrate lOd in Fig. 1, and the core layer of floor substrate lOe in Fig. 1, respectively.

[0037] Fig. 6 shows an example flooring system described herein. The flooring system may comprise a first floor substrate lOf and a second floor substrate 10g. The first floor substrate lOf may comprise a first area indicative of a void 118f. The second floor substrate 10g may comprise a second area indicative of a void 118g. The first area indicative of a void 118f and the second area indicative of a void 118g may form a collective (combined, etc.) area indicative of a void 130. The collective area indicative of a void 130 may vary in width. The collective area indicative of a void 130 may comprise a width of the combined threshold or less in all locations between the first floor substrate lOf and a second floor substrate 10g. The first area indicative of a void 118f may vary in width. The first area indicative of a void 118f may comprise a width of the individual threshold or less in all locations along the first floor substrate lOf. The second area indicative of a void 118g may vaty in width. The second area indicative of a void 118g may comprise a width of the individual threshold or less in all locations along the second floor substrate 10g.

[0038] Fig. 7 shows an example flooring system described herein. The flooring system may comprise a first floor substrate lOh and a second floor substrate lOi. A decor layer 104h of the first floor substrate lOh may comprise an area indicative of a void 118h. The decor layer 104h may comprise an area indicative of a shadow 128h adjacent to the area indicative of a void 118h. The area indicative of the shadow 128h may be added to a design associated with the decor layer 104h. An area between a material (such as wood) on an image of the decor layer, such as the decor layer 104h, and the void, such as the void 118h. may comprise a shadow, such as the shadow 128h. In one aspect, the shadow 128h can be added to give the illusion of contour and shape. In some aspects, the combination of the shadow 128h, along with an actual indentation along an edge comprising the void 118h may create the “trompe 1’oeil” effect and may fool a viewer into thinking the apparent edge, curve and void are real. A width associated with the shadow 128h added to a width associated with the void 118h may be equal to or less than the combined threshold.

[0039] The first floor substrate lOh may comprise a first secure component 132h and a second secure component 134h. The second floor substrate lOi may comprise a first secure component 132i and a second secure component 134i. The second secure component 134h may be coupled to the first secure component 132i. The first floor substrate lOh and thesecond floor substrate lOi may be locked via the second secure component 134h and the first secure component 132i. A width associated with the first secure component 132i may be equal to or less than the combined threshold.

[0040] Fig. 8 shows example images of Versailles patterns 30a, 30b described herein. Images, such as the images of the Versailles patterns 30a, 30b may comprise blending edges. Images, such as the images of the Versailles patterns 30a, 30b may comprise depictions of parquet times. Systems and methods described herein to make images, such as the Versailles patterns 30a, 30b may comprise some tolerance / randomness between parquet tiles to enhance realism.

[0041] Although several aspects have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects will come to mind to which this disclosure pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the disclosure is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of any claims that can recite the disclosed subject matter.

[0042] It should be emphasized that the above-descnbed aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the abovedescribed aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.EXAMPLE CLAUSES

[0043] Example Clause 1 : A flooring substrate may include: a core layer may include: first and second long edges; and first and second short edges, where the first and second long edges and the first and second short edges form the perimeter of the core layer, where the core layer may include first and second long edge bevels formed along each of the first and second long edges, respectively; and a decor layer overlaid on the core layer may include an image, where the image may include a first area indicative of a void along at least one of the first and second long edges, and. where the first area indicative of a void is positioned on at least one of the first or second long edge bevels.

[0044] Example Clause 2: The flooring substrate of Example Clause 1, where the image may include the first area indicative of a void along the first long edge, where the first area indicative of a void is positioned on the first long edge bevel, where the image may include a second area indicative of a void along the second long edge, and where the second area indicative of a void is positioned on the second long edge second bevel.

[0045] Example Clause 3: The flooring substrate of Example Clause 1 or Example Clause 2, where the flooring substrate may include a first flooring substrate and a second flooring substrate, where the combination of the first area indicative of a void of the first flooring substrate and the second area indicative of a void are configured to align at least partially with one another to form a collective area indicative of a void.

[0046] Example Clause 4: The flooring substrate of any one of Example Clauses 1-3, where the collective area indicative of a void may include a width of 4 millimeters or less.

[0047] Example Clause 5: The flooring substrate of any one of Example Clauses 1-4, where the decor layer may include at least one of: paper or film.

[0048] Example Clause 6: The flooring substrate of any one of Example Clauses 1-5, where the decor layer is adhered to the core layer.

[0049] Example Clause 7: The flooring substrate of any one of Example Clauses 1-6, where the decor layer is directly printed on a surface of the core layer.

[0050] Example Clause 8: The flooring substrate of any one of Example Clauses 1-7, where the core layer may include an ink adherence layer.

[0051] Example Clause 9: The flooring substrate of any one of Example Clauses 1 -8, where the image may include a depiction of a plank of wood.

[0052] Example Clause 10: The flooring substrate of any one of Example Clauses 1-9, where the image was created by a model trained to create a depiction of a plank of wood.

[0053] Example Clause 11: The flooring substrate of any one of Example Clauses 1-10, where the image may include an altered image of a plank of wood.

[0054] Example Clause 12: The flooring substrate of any one of Example Clauses 1-11, where the core layer further may include a micro bevel along each of the first and second short edges.

[0055] Example Clause 13: The flooring substrate of any one of Example Clauses 1-12, where the core layer further may include: a first secure component along the first long edge; and a second secure component along the second long edge, where the second secure component is configured to lock with the first secure component.

[0056] Example Clause 14: The flooring substrate of any one of Example Clauses 1-13, where the flooring substrate is a plank.

[0057] Example Clause 15: The flooring substrate of any one of Example Clauses 1-14, where the first area indicative of a void may include a width of 2 millimeters or less.

[0058] Example Clause 16: The flooring substrate of any one of Example Clauses 1-15, where the first area indicative of a void may include a void portion and a shadow portion.

[0059] Example Clause 17: The flooring substrate of any one of Example Clauses 1-16, where the first area indicative of a void may include a width, where the width is irregular along the length of the first long edge.

[0060] Example Clause 18: The flooring substrate of any one of Example Clauses 1-17, where the image may include a depiction of a Versailles pattern.

[0061] Example Clause 19: A flooring system may include: a first flooring substrate may include: a first long edge; a second long edge; two first short edges; a first decor layer may include a first image, where the first image may include a first area indicative of a void along the first long edge; a first core layer may include a first bevel along the first long edge and a second bevel along the second long edge, where the first area indicative of a void is positioned on the first bevel; a first secure component along the first long edge; and a second secure component along the second long edge, where the second secure component is configured to lock with the first secure component; and a second flooring substrate may include: a third long edge; a fourth long edge; two second short edges; a second decor layer may include a second image, where the second image may include a second area indicative of a void along the fourth long edge; a second core layer may include a third bevel along the third long edge and a fourth bevel along the fourth long edge, where the second area indicative of a void is positioned on the fourth bevel; a third secure component along the third long edge, where the third secure component is similar to the first secure component; and a fourth secure component along the fourth long edge, where the fourth secure component is similar to the second secure component.

[0062] Example Clause 20: The flooring system of Example Clause 19, where the first flooring substrate and the flooring substrate are locked together.

[0063] Example Clause 21: The flooring system of Example Clause 19 or Example Clause 20, where the first secure component is locked with the fourth secure component.

[0064] Example Clause 22: The flooring system of any one of Example Clauses 19-21, where the first area indicative of a void is adjacent to the second area indicative of a void.

[0065] Example Clause 23: The flooring system of any one of Example Clauses 19-22, where the first area indicative of a void may include a first width, where the second area indicative of a void may include a second width, and where a sum of the first width and the second width is 4 millimeters or less.

[0066] Example Clause 24: A method may include: receiving an image indicative of a decor layer, where the image may include at least one area indicative of a void; applying the image to a core layer; separating the core layer into two or more planks, where each plank may include two long edges and two short edges, and where each plank may include a portion of the at least one area indicative of a void along at least one long edge; pressing a bevel into the two long edges of the two or more planks; and pressing a micro bevel into the two short edges of the two or more planks.

[0067] Example Clause 25: The method of Example Clause 24, further may include: receiving training image data may include planks of wood; training a model to generate output image data, where the output image data may include depictions of one or more planks of wood based on the training image data; and using the model to create the image.

[0068] Example Clause 26: The method of Example Clause 24 or Example Clause 25. where the image may include depictions of two or more planks of w ood in image data, where each plank of wood in image data is separated by an area indicative of a void.

[0069] Example Clause 27: The method of any one of Example Clauses 24-26. where the area indicative of the void may include a shaded area and a gap area.

[0070] Example Clause 28: The method of any one of Example Clauses 24-27, where the area indicative of the void may include a width and a length, where the width is irregular along the length.

[0071] Example Clause 29: The method of any one of Example Clauses 24-28. where the separating the core layer occurs when pressing the bevel into the two long edges.

[0072] What has been described and illustrated herein is an example along w ith some of its variations. The terms, descriptions and figures used herein are set forth by way of illustration only and are not meant as limitations. Many variations are possible within the spirit and scope of the subject matter, which is intended to be defined by the following claims - and their equivalents - in which all terms are meant in their broadest reasonable sense unless otherwise indicated.

Claims

CLAIMSWhat is claimed is:1 . A flooring substrate comprising: a core layer comprising: first and second long edges; and first and second short edges, wherein the first and second long edges and the first and second short edges form the perimeter of the core layer, wherein the core layer comprises first and second long edge bevels formed along each of the first and second long edges, respectively; and a decor layer overlaid on the core layer comprising an image, wherein the image comprises a first area indicative of a void along at least one of the first and second long edges, and, wherein the first area indicative of a void is positioned on at least one of the first or second long edge bevels.

2. The flooring substrate of claim 1, wherein the image comprises the first area indicative of a void along the first long edge, wherein the first area indicative of a void is positioned on the first long edge bevel, wherein the image comprises a second area indicative of a void along the second long edge, and wherein the second area indicative of a void is positioned on the second long edge second bevel.

3. The flooring substrate of claim 1, wherein the decor layer comprises at least one of: paper or film.

4. The flooring substrate of claim 3, wherein the decor layer is adhered to the core layer.

5. The flooring substrate of claim 1, wherein the decor layer is directly printed on a surface of the core layer.

6. The flooring substrate of claim 5, wherein the core layer comprises an ink adherence layer.

7. The flooring substrate of claim 1, wherein the image comprises a depiction of a plank of wood.

8. The flooring substrate of claim 1, wherein the image was created by a model trained to create a depiction of a plank of wood.

9. The flooring substrate of claim 1, wherein the image comprises an altered image of a plank of wood.

10. The flooring substrate of claim 1, wherein the core layer further comprises a micro bevel along each of the first and second short edges.

11. The flooring substrate of claim 1, wherein the core layer further comprises: a first secure component along the first long edge; and a second secure component along the second long edge, wherein the second secure component is configured to lock with the first secure component.

12. The flooring substrate of claim 1, wherein the flooring substrate is a plank.

13. The flooring substrate of claim 1, wherein the first area indicative of a void comprises a width of 2 millimeters or less.

14. The flooring substrate of claim 2, wherein the flooring substrate comprises a first flooring substrate and a second flooring substrate, wherein the combination of the first area indicative of a void of the first flooring substrate and the second area indicative of a void are configured to align at least partially with one another to form a collective area indicative of a void.

15. The flooring substrate of claim 14, wherein the collective area indicative of a void comprises a width of 4 millimeters or less.

16. The flooring substrate of claim 1, wherein the first area indicative of a void comprises a void portion and a shadow portion.

17. The flooring substrate of claim 1, wherein the first area indicative of a void comprises a width, wherein the width is irregular along the length of the first long edge.

18. The flooring substrate of claim 1, wherein the image comprises a depiction of a Versailles pattern.

19. A flooring system comprising: a first flooring substrate comprising: a first long edge; a second long edge; two first short edges; a first decor layer comprising a first image, wherein the first image comprises a first area indicative of a void along the first long edge; a first core layer comprising a first bevel along the first long edge and a second bevel along the second long edge, wherein the first area indicative of a void is positioned on the first bevel; a first secure component along the first long edge; anda second secure component along the second long edge, wherein the second secure component is configured to lock with the first secure component; and a second flooring substrate comprising: a third long edge; a fourth long edge; two second short edges; a second decor layer comprising a second image, wherein the second image comprises a second area indicative of a void along the fourth long edge; a second core layer comprising a third bevel along the third long edge and a fourth bevel along the fourth long edge, wherein the second area indicative of a void is positioned on the fourth bevel; a third secure component along the third long edge, wherein the third secure component is similar to the first secure component; and a fourth secure component along the fourth long edge, wherein the fourth secure component is similar to the second secure component.

20. The flooring system of claim 19, wherein the first flooring substrate and the flooring substrate are locked together.

21. The flooring system of claim 20, wherein the first secure component is locked with the fourth secure component.

22. The flooring system of claim 21. wherein the first area indicative of a void is adjacent to the second area indicative of a void.

23. The flooring system of claim 22, wherein the first area indicative of a void comprises a first width, wherein the second area indicative of a void comprises a second width, and wherein a sum of the first width and the second width is 4 millimeters or less.

24. A method comprising: receiving an image indicative of a decor layer, wherein the image comprises at least one area indicative of a void; applying the image to a core layer;separating the core layer into two or more planks, wherein each plank comprises two long edges and two short edges, and wherein each plank comprises a portion of the at least one area indicative of a void along at least one long edge; pressing a bevel into the two long edges of the two or more planks; and pressing a micro bevel into the two short edges of the two or more planks.

25. The method of claim 24, further comprising: receiving training image data comprising planks of wood; training a model to generate output image data, wherein the output image data comprises depictions of one or more planks of wood based on the training image data; and using the model to create the image.

26. The method of claim 25, wherein the image comprises depictions of two or more planks of wood in image data, wherein each plank of wood in image data is separated by an area indicative of a void.

27. The method of claim 26. wherein the area indicative of the void comprises a shaded area and a gap area.

28. The method of claim 26, wherein the area indicative of the void comprises a width and a length, wherein the width is irregular along the length.

29. The method of claim 24, wherein the separating the core layer occurs when pressing the bevel into the two long edges.

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