GROOVED DECORATIVE ARTICLE

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/428,944, filed Nov. 30, 2022, the entirety of which is hereby incorporated by reference herein.

FIELD

This disclosure relates to decorative articles, such as decorative articles that can conform to desired 3-dimensional shapes for surface coverings.

BACKGROUND

Decorative articles are used for forming decorative surfaces. Typical decorative article solutions for use with structures having complex 3-dimensional (3D) shapes have included using pre-formed decorative articles that have been pre-formed to fit the complex 3D shape. Such pre-formed decorative articles are expensive to manufacture, heavy, and by the nature of their geometry, are expensive to store and to ship.

SUMMARY

Disclosed herein, in one aspect, is a decorative article comprising a sheet having a full thickness, a first surface, and a second surface opposite the first surface. Across at least a first region of the sheet, the second surface of the sheet defines a plurality of grooves, each groove of the plurality of grooves extending along a first axis. The plurality of grooves are configured to permit the first region of the sheet to conform to an application surface. Each groove of the plurality of grooves has, along a second axis that is transverse to the first axis, an operative width of at least 1 mm across which a depth of the groove is no less than ⅓ of the full thickness of the sheet. The sheet comprises, between adjacent grooves of the plurality of grooves, respective areas defined by the full thickness of the sheet, said full thickness being at least 0.5 mm along the second axis.

A system includes an installation surface and a decorative article as herein positioned on the installation surface. The first surface of the sheet forms a curve along at least a portion of the first region of the sheet.

A method of using the decorative article as disclosed herein includes applying the decorative article to an installation surface and bending at least a portion of the decorative article over the installation surface.

A method includes forming, into a sheet having a full thickness, a first surface, and a second surface opposite the first surface, plurality of grooves extending along a first axis so that, across at least a first region of the sheet, the second surface of the sheet defines the plurality of grooves, wherein the plurality of grooves are configured to permit at least the first region of the sheet to conform to an application surface. Each groove of the plurality of grooves has, along a second axis that is transverse to the first axis, an operative width of at least 1 mm across which a depth of the groove is no less than ⅓ of the full thickness of the sheet. The sheet comprises, between adjacent grooves of the plurality of grooves, respective areas defined by the full thickness of the sheet, said full thickness being at least 0.5 mm along the second axis.

Additional advantages of the disclosed apparatuses, systems, and methods will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the claimed invention. The advantages of the disclosed devices and systems will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the preferred embodiments of the invention will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

FIG. 1 is a schematic side view of an exemplary decorative article as disclosed herein.

FIG. 2 is a schematic side view of an installation comprising the decorative article of FIG. 1 on a complex structure.

FIG. 3 is a top view of an exemplary decorative article as disclosed herein.

FIG. 4 is a perspective view of the exemplary decorative article of FIG. 3 formed over a complex structure.

FIG. 5 is a perspective view of an exemplary partial installation of a plurality of exemplary decorative articles as disclosed herein over a complex structure.

FIG. 6 is a schematic partial side view of an exemplary decorative article illustrating exemplary groove geometry.

FIG. 7 is a schematic partial side view of an exemplary decorative article illustrating exemplary groove geometry.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

As used herein the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, use of the term “a groove” can refer to one or more of such grooves, and so forth.

All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedent “about,” it is contemplated that values within up to 20%, up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects. Similarly, in some optional aspects, when values are approximated by use of the terms “substantially” or “generally,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particular value can be included within the scope of those aspects. When used with respect to an identified property or circumstance, “substantially” or “generally” can refer to a degree of deviation that is sufficiently small so as to not measurably detract from the identified property or circumstance, and the exact degree of deviation allowable may in some cases depend on the specific context.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

As used herein, the term “at least one of” is intended to be synonymous with “one or more of.” For example, “at least one of A, B and C” explicitly includes only A, only B, only C, and combinations of each.

The word “or” as used herein means any one member of a particular list and, unless context dictates otherwise, can also include any combination of members of that list.

The term complex structure(s) as used herein may generally refer to stairs or stair treads without departing from a broader scope of the present disclosure. However, it is understood that complex structures are not limited to stairs or stair treads, and said complex structures can include other structures with at least a portion comprising a radius or sharp angles requiring the decorative article to be wrapped around or bent to fit said radius or sharp angles. Hereinafter, the term “complex structure” or “complex structures’ may be interchangeably referred to as “stair tread” or “stair treads” or “installation surface” or “application surface” without departing from a broader scope of the present disclosure.

The term “decorative article” as used herein may generally refer to a hard surface floor covering panel. In some aspects, the decorative article may be a flexible or semi-flexible panel. Examples of the decorative article can include, but are not limited to, LVT panels, LVP floor planks, composites boards (wood polymer composite, stone polymer composite), mineral boards, non-woven non-vinyl panels, or hybrid flat panels, etc. In some aspects, the decorative article may be rigid article. In one aspect, the decorative article may include a substrate that is polyvinyl chloride (PVC)-based, polypropylene (PP)-based, polyurethane (PU)-based, polyethylene terephthalate (PET)-based, polyethlyene (PE)-based, wood based, or mineral based. Further, the decorative article may include a decorative image layer disposed above the substrate, and a wear layer disposed above the image layer. The decorative article may include addition layers such as a primer layer, an acoustic layer, a balancing layer, a reinforcing layer, etc., disposed below the panel or in between the substrate and top layers (image and wear layers). The top layers may be PVC based or non-PVC based materials such as PP, PE, PET, PU, etc.

Pre-formed stair treads provide a hard surface solution for forming a decorative surface of a stair. Pre-formed stair treads are expensive to manufacture or source due to material and extrusion costs. The weight of the product drives up shipping costs as well, particularly when sourcing overseas and, in particular, when air freight is required. In addition, having a stair tread product separate from the rest of the hard surface flooring manufacturing process makes it extremely difficult to accurately match stair treads to the rest of the floor, in both pattern and color. Moreover, installing the stair covers can be arduous and can require professional installers.

Often, in multi-level (multi-story) buildings such as residential houses, because of the above-mentioned issues, the stairs are carpeted, which, in turn, creates a mismatch or discontinuity in the aesthetic appeal of the building. Using carpet on the stairs creates a situation at the top landing. When carpet is used on the stairs, the transition of carpet to hard surface is not aesthetically pleasing and can be problematic for an installer. One difficulty of using carpet is associated with working around the overlap of the landing and creating a transition area from carpet to hard surface.

Some attempts have been made to overcome the deficiencies of conventional systems. For example, U.S. Patent Application Publication No. 2021/0254345A1 to Douglas (hereinafter “the 345 publication”) describes V-shaped scores in LVP. However, the LVP of the '345 publication uses heat to form the LVP and can often become separated from the underlying surface. Further, U.S. Patent Application Publication No. 2020/0346482A1 to Mendez (hereinafter “the '482 publication”) describes a heating process used to form the tread. The decorative articles as described herein can be bent and installed securely without having a heating step.

Disclosed herein, in various aspects, are decorative articles that address deficiencies of pre-formed stair treads and carpet. For example, the disclosed decorative articles can allows for a level transition with the flooring (e.g., LVT) on the 2nd and subsequent floors.

Referring to FIGS. 1-4, a decorative article 10 can comprise a sheet 12 having a full thickness, t, a first surface 14 and a second surface 16 opposite the first surface. Across at least a first region 20 of the sheet 12, the second surface 16 of the sheet can define a plurality of grooves 30, each groove 30 extending along (e.g., parallel to) a first axis 32 (extending into the page in FIG. 1). The plurality of grooves 30 can be configured to permit at least the first region 20 of the sheet to conform to an application surface. For example, the plurality of grooves 30 can permit the first region to bend about an axis that is parallel to the first axis 32.

The sheet 12 can comprise polymer. For example, in some aspects, the decorative article 10 can be a luxury vinyl tile (LVT) panel. In other aspects, the decorative article 10 can be a luxury vinyl plank (LVP) panel. In still further aspects, the decorative article can be any other type of decorative article as disclosed herein, such as any hard surface floor covering panel, including, for example and without limitation, engineered flooring panels, composite flooring panels, laminate flooring panels, or rubber flooring panels.

In some aspects, the sheet 12 can be flat (e.g., so that the first surface is planar or generally planar). For example, the sheet 12 can be flat prior to installation, thereby permitting the decorative article to be efficiently stacked, packed, stored, and shipped.

In some aspects. the grooves 30 can have a depth. In some aspects, the depth can be determined by the full thickness of the sheet 12 (e.g., a ratio of the full thickness of the sheet to the depth of the groove 30). For example, a sheet 12 (e.g., an LVT panel) having a full thickness of 2.5 mm with a groove depth of 1.25 mm can provide a ratio of 2. In various aspects, the ratio of the full thickness of the sheet to the groove depth can be from about 1.5 to about 4, or at least 1.5, or at least 1.75. The remaining material between the groove 30 and the first side 14 of the sheet can be sufficient to be malleable while still resisting telegraphing. In some examples, the depth of the groove can be greater than the depth of the remaining material. In other examples, the depth of the groove can be less than the depth of the remaining material. In yet another example, the depth of the groove and the remaining material may be equal or substantially equal (e.g., within 15%, within 10%, within 5%, or within 1%).

In various aspects, the grooves 30 can be equally spaced along a second axis 34 that is transverse to (e.g., perpendicular to) the first axis 32. In other aspects, the grooves 30 can be unevenly spaced along the second axis 34.

In some aspects, the plurality of grooves 30 can be rectangular (optionally, square) in cross-sectional planes perpendicular to the first axis 32. In other aspects, and with further reference to FIGS. 6-7, the plurality of grooves 30 can be trapezoidal (FIG. 7), rounded (FIG. 6), or any suitable cross-sectional shape. In some optional aspects, the sheet 12 can have a full thickness, t, between the first and second surfaces between the grooves. In some aspects, the each groove 30 can be formed to have. along the second axis 34, an operative width, w, of at least 1 mm (e.g., from about 1 mm to about 8 mm or from about 2 mm to about 6 mm) across which a depth of the groove is no less than a predetermined portion, p, of the full thickness of the sheet (e.g., ⅓ of, or ½ of the full thickness of the sheet). In further aspects, the operative width can be a ratio of 1:1 to 5:1 depth to operative width. For example, in one embodiment, the grooves can have a depth of 1 mm and an operative width of 4 mm. In some aspects, in which the grooves are not rectangular (e.g., the groove profiles in FIGS. 6-7), the ratio of depth to width can be a function a measurement from a lowest part of the groove to the top end. More generally, the grooves can be formed so that opposed side surfaces 36 of the grooves do not touch when the decorative article 10 is bent to a predetermined radius (e.g., a ½ inch radius). For example, a stair bull nose can have a radius of ½ inch, and the grooves can be shaped and sized to permit the first region 20 to bend with a radius of ½ inch without opposed side surfaces 36 of any of the grooves 30 touching. In other aspects, the grooves can be formed so that opposed side surfaces 36 of the grooves do not touch when the decorative article 10 is bent at a 90 degree bend, such as a square edge stair. In practice. the bend around a 90 degree bend can have a radius and need not be an absolute 90 degree bend. Flexible LVT can advantageously flex to form a bend around such small radii as 90 degree bends over corners.

In some aspects, the grooves are not V-shaped. For example, at every depth, the groove can have a width that is greater than zero (e.g., at least 0.2 mm, or at least 0.5 mm). In some aspects, the grooves can have a base and sides spaced from each other by a width of the base (such that the sides do not intersect). The operative width can permit flexibility of the sheet that V-shaped scoring is incapable of providing. Further, the operative width can permit adhesive to be received within the groove when the sheet article is folded/wrapped around an application surface in order to improve adhesion.

In some aspects, and with reference to FIG. 2, the grooves 30 can be rectangular (e.g., optionally, square) in cross-sectional planes perpendicular to the first axis 32 when the sheet is flat. When the sheet is bent over a surface, one or more of the grooves can have increasing width (e.g., a dovetail shape) in a direction from the second surface 16 toward the first surface 14 of the sheet 12, with opposed side surfaces 36 of the grooves diverging in the direction from the second surface 16 toward the first surface 14.

In further aspects, the sheet can further comprise areas, a, between adjacent grooves 30 defined by the full thickness of the sheet (e.g., portions of the sheet where grooves are not formed), said areas having a dimension along the second axis 34 of at least 0.5 mm, or at least 1 mm. These areas can improve attachment and adhesion to underlying installation surfaces as compared to sawtooth V-shaped scores.

The decorative article 10 can have, when viewing the first surface 14, a wood grain pattern, a stone pattern, an abstract pattern, a photographic image, a printed film, a tile pattern, a bast pattern, a non-woven pattern, a woven pattern, a metallic pattern, a brick pattern, a concrete pattern, or combinations thereof. For example, the decorative article 10 can have a décor layer that provides such a pattern.

In some embodiments, an entirety of, or substantially an entirety of the sheet 12 can have grooves 30 extending along the second side 16. That is, the sheet 12 can be defined entirely by the first region 20. In other aspects, with reference to FIG. 1, the sheet can comprise a second region 22 across which the second surface of the sheet is free of any groove. In further aspects, the sheet 12 can comprise a third region 24 that is free of any groove. In some aspects, the first region 20 can be positioned between the second and third regions 22, 24 along the second axis 34. For example, the second region 22 can be configured (e.g., sized) to cover an upper surface of a stair tread (or cover a desired portion thereof). The first region 20 can be configured to wrap around the nose of the stair tread. Accordingly, the first region 20 can have appropriate dimension along the second axis 34 to allow for bending around either a square or bullnose stair. For example, for use with a 1-inch thick stair tread, the first region 20 can have a dimension along the second axis 34 of at least 1.5 inches, or at least 2.5 inches or from about 2.5 inches to 4 inches, or about 3.5 inches. The third region 24 can be configured to be positioned under the nose of the stair tread. The third region 24 can be glued, nailed, and/or stapled to the stair tread. In some aspects, the third region 24 can have a dimension from about 0.25 inches to about 1 inch along the second axis 34 (e.g., about ½ inch). In other aspects, the third region 24 can be omitted. For example, in these aspects, the first region 20 can extend to an end (e.g., a first end 40) of the sheet 12. In some optional aspects, the second region 22 can define a majority of an area of the sheet 12. That is, the second region 22 can be longer than the third region 24 along the second axis 34. For example, the second region 22 of the sheet 12 can have a dimension along the second axis 34 of about 10 inches or from about 8 inches to about 10 inches.

Referring to FIG. 3, the sheet 12 can have a first end 40 and a second end 42 spaced along the second axis 34. The first and second regions 20, 22 can be positioned between the first and second ends 40. 42. Optionally, the sheet 12 can comprise a third region 24 (FIG. 1), with the second region 22 positioned between the first and third regions 20, 24. The sheet 12 can further have third and fourth ends 44, 46 spaced along the first axis 34. The decorative article 10 can be configured for use with an open staircase with additional grooving transverse to (e.g., perpendicular to) the stair tread length. In these aspects, the first region 20 of the sheet 12 can cover (e.g., wrap around) a front stair nose and the sheet 12 can further comprise one or more side regions 26 that are configured to cover (e.g., wrap around) respective side edges of the stair. Said side regions 26 can have respective grooves that extend along respective axes 38 transverse to the first axis 32 so that the side regions 26 can bend around axes parallel to the axis 38 along which the grooves of the side regions 26 extend. Optionally, each axis 38 can be parallel to the second axis 34. In other aspects, the axis 38 along which the grooves of each of the side regions 26 extend can intersect the second axis 32 at an acute angle. In some aspects, the sheet 12 can further comprise regions free of grooves between the side regions 26 and the respective adjacent third and fourth ends 44, 46.

The panel can be formed as shown in FIG. 3, and wrapped, adhered, and/or clamped on three sides to the tread to provide the shape illustrated in FIG. 4. For example, the decorative article 10 can comprise an outer periphery having pairs of opposed portions 50 that, when folded around a stair tread, join together at the corners of the stair tread. Accordingly, the opposed portions 50 can have arcuate shapes. The decorative article 10 can further comprise a straight edge 52 extending between the pairs of opposed portions 50.

Exemplary System Installation

Referring to FIG. 2, a system 100 includes an installation surface 110 and a decorative article 10 positioned on the installation surface 110. The first surface 14 of the sheet 12 can be curved along at least a portion of the first region 20 of the sheet 12.

In some aspects, the installation surface 110 is a stair tread having a stair nose 112. The first region can at least partly cover a stair nose 112 of the stair tread. The system 10 can further comprise an adhesive 120 between the installation surface 110 and the second surface 16 of the sheet 12 of the decorative article 10. The adhesive 120 can fill at least a portion of at least one groove of the plurality of grooves.

In some aspects, and with reference to FIGS. 2 and 5, the system 10 can further comprise a riser 130. For example, the riser 130 can have an upper end that is positioned below a portion of the decorative article 10. For example, the riser 130 can have a thickness of about ½ inch to about 1 inch or of about ¾ inch. In this way, the riser 130 can cover a portion 18 (shown in broken lines in FIG. 2) of the decorative article 10 (e.g., an edge below the stair tread) to provide a finished look. Further, the riser can impinge on the decorative article 10, pressing the decorative article between the stair tread and the riser to retain the decorative article against the stair tread.

In some aspects, the system can further comprise at least one additional decorative article positioned adjacent the decorative article 10. The at least one additional decorative article can be free of any groove. For example, the at least one additional decorative article can be formed from the same type material as the decorative article 10, but has not been modified to include grooves. Optionally, in these aspects, the decorative article 10 and at least one additional decorative article can have the same (or a matching pattern).

Exemplary Installation Method

A method of using the decorative article 10 can include applying the decorative article to an installation surface 110. At least a portion of the decorative article can be bent over the installation surface. In some aspects, bending the at least a portion of the decorative article over the installation surface can be performed without heating the decorative article. One or more clamps can secure the decorative article 10 to the installation surface. For example, the clamps can be used to hold the decorative article 10 while adhesive cures as illustrated in FIG. 5.

Exemplary Advantages

The disclosed grooves (e.g., rectangular grooves), as opposed to V-shaped scores, were discovered to be surprisingly superior by providing a larger angle of deflection when bending, as well as a higher area of contact to the stair nose along the bend (e.g., contact between the second side 16 of the sheet 12 and the stair nose). The disclosed grooves (e.g., rectangular grooves) provide better flexibility when wrapping and conforming around a radius or square stair tread than a material with V-shaped scores by providing more bendable points closer the upper surface. The disclosed grooves (e.g., rectangular grooves) allow for the groove width to remain independent of the full thickness of the product, whereas the depth of V-shaped scores is limited on the depth when used on thicker product, particularly if a 90-degree scoring tool, as disclosed in the '345 publication, is used. Otherwise, the overall thickness of the product in grooved area would be reduced from the full thickness.

Further, as illustrated in FIG. 2, the disclosed grooves (e.g., rectangular grooves) can trap more adhesive than V grooves, as shown in FIG. 2. This improves adhesion by providing a mechanical advantage in addition to the chemical bond.

Additionally, the grooves can be limited to 1 mm or greater from the first surface 14 (leaving at least 1 mm of the full thickness of the sheet remaining between the groove and the first surface 14). Further, each bend of 90 degrees can have at least two grooves 30 in a bend of from 60 degrees to 90 degrees. In the case of a bull nose stair tread there will be multiple grooves can extend over the radius. The decorative article can be used with stair noses having a large radius (e.g., as shown in FIG. 2) as well as square cuts (shown in FIG. 5). The addition of more grooves 30 can allow for 360 degrees wrapping of poles or other radiused surfaces. Grooves for multiple 90-degree bends are distinguishable over an embodiment that has a single groove for 90-degree bends. The decorative article can have grooves appropriate for the end use. In exemplary implementations, one set of grooves can be configured to cover all surfaces and angles. In other implementations, it is contemplated that grooves can be provided across an entirety of the back (e.g., for full wrapping of a mandrel or pole).

The size of the decorative article 10 (e.g., an LVT panel) can be over 12 inches, at least 14 inches, at least 17 inches, or greater than 17 inches (e.g., from 12 inches to 24 inches) deep along the second axis 34, allowing for full coverage of a stair tread without piecing multiple panels together on the tread. This single panel can provide more longevity to the installation. As should be understood, these dimensions are larger than typical LVT cut planks. In one example, the LVT size may be 42 inches (along the first axis 32)×14 inches (along the second axis 34) and may be a unitary (one-piece) construction, which can be easier to install and provide a better seamless finish to the stair landings than piecing together multiple planks or tiles to form the stairs.

In some aspects, decorative articles 10 covering stair treads can be made of the same material as flooring adjacent the stair treads. In another aspect, the decorative articles 10 covering the treads can be made of LVT, and the flooring adjacent the stair treads can comprise stone plastic composite (SPC) or wood plastic composite (WPC). The image can be the same for flooring and treads by using the same printed image or a coordinating image or finish. The stair tread can pass slip resistance testing using a James Machine as is known in the art. The surface of the tread can have additional embossing to improve slip resistance.

In some aspects, the decorative article disclosed herein can be formed from an LVT product that is currently manufactured rather than being a standalone product requiring sourcing or separate manufacturing processes. In other words, existing LVT panels can be modified or retrofitted to be used as stair covers, thereby allowing the same flooring style, color, and type that is used throughout the different floors of the installation (e.g., house) to also be easily used as stair coverings or other surface coverings. This permits continuity of the same flooring material through throughout an installation (e.g., an entire house). This modification of existing material can reduce logistics complexity and can simplify the manufacturing process. Further, the decorative article with the grooves as described herein is configured for DIY installation and does not need a professional installer.

In addition, the decorative article for a stair tread can be easily made from a variety of LVT patterns and colors, allowing for easy matching with the rest of the flooring in an installation as described above.

In one example, the grooves can be formed using a modified planar or molder that is stationary with rotating tool head and allowing the sheet (e.g., LVT or LVP panel) to pass under the tool head to create the grooves. For example, the planar or molder can be modified to have a plurality of cutting elements spaced at known distances on one or more rotating cutting heads. The sheet 12 can be fed under the rotating heads. In other aspects, groove cutting can be performed using a gang saw. More generally, a cutting device can comprise tooling configured to form a plurality of grooves. In some aspects, the grooves may be made on-site by a user with said modified planar or molder. Alternatively, a dedicated stationary tool with rotating tool head can be used in a factory setting with the sheet (e.g., LVT or LVP panel) being conveyed on a moving conveyor to pass under the tool head to create the grooves. In another example, the sheet (e.g., LVT or LVP panel) can be kept stationary, and the tool can be moved across the plank to create the grooves.

An exemplary stair comprising a decorative article as disclosed herein was tested using human walker to simulate an installed tread. The steps of the walker were counted, and the stair tread visually evaluated. After 100.000 steps there was no visual indication of wearing or telegraphing of the groove in the landing or radius areas. In the tested decorative article, the grooves were cut to 3.75 mm width and 1 mm depth. This width and depth are sufficient to allow for easy bending and installation, but not so wide and deep as to promote telegraphing with wear. These dimensions can be modified as necessary for different applications.

Although LVT panels and LVP floor planks are described as exemplary embodiments, the present disclosure can apply to other types of floor coverings such as, but not limited to, composites boards (wood polymer composite. stone polymer composite), mineral boards, non-woven non-vinyl or hybrid flat panels, etc. In one example, the side on which the grooves are formed may be the bottom side of the panels or the side that faces a substructure (e.g., subfloor) when installed (i.e., the side not seen by the user when installed).

Exemplary Embodiments

In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

Aspect 1: A decorative article comprising:

• • a sheet having a full thickness, a first surface, and a second surface opposite the first surface, wherein:
    • across at least a first region of the sheet, the second surface of the sheet defines a plurality of grooves, each groove of the plurality of grooves extending along a first axis;
    • the plurality of grooves are configured to permit the first region of the sheet to conform to an application surface;
    • each groove of the plurality of grooves has, along a second axis that is transverse to the first axis, an operative width of at least 1 mm across which a depth of the groove is no less than ⅓ of the full thickness of the sheet; and
    • the sheet comprises, between adjacent grooves of the plurality of grooves, respective areas defined by the full thickness of the sheet, said full thickness being at least 0.5 mm along the second axis.

Aspect 2: The decorative article of aspect 1, wherein the plurality of grooves are rectangular.

Aspect 3: The decorative article of aspect 1 or aspect 2, wherein the sheet is flat.

Aspect 4: The decorative article of any one of the preceding aspects, wherein the first surface has a wood grain pattern, a stone pattern, an abstract pattern, a photographic image, a printed film, a tile pattern, a bast pattern, a non-woven pattern, a woven pattern, a metallic pattern, a brick pattern, or a concrete pattern.

Aspect 5: The decorative article of any one of the preceding aspects, wherein the sheet comprises polymer.

Aspect 6: The decorative article of any one of the preceding aspects, wherein the decorative article is a LVT panel.

Aspect 7: The decorative article of any one of aspects 1-5, wherein the decorative article is a LVP panel.

Aspect 8: The decorative article of any one of the preceding aspects, wherein the sheet further comprises a second region across which the second surface of the sheet is free of any groove.

Aspect 9: The decorative article of aspect 8, wherein the sheet further comprises a third region across which the second surface of the sheet is free of any groove, wherein the first region is positioned between the second and third regions along the second axis.

Aspect 10: The decorative article of any one of the preceding aspects, wherein the sheet further comprises at least one side region across which the second surface of the sheet defines a second plurality of grooves, each groove of the second plurality of grooves extending along an axis transverse to the first axis.

Aspect 11: A system comprising:

• • an installation surface; and
  • a decorative article as in any one of the preceding aspects positioned on the installation surface, wherein the first surface of the sheet forms a curve along at least a portion of the first region of the sheet.

Aspect 12: The system of aspect 11, wherein the installation surface is a stair tread having a stair nose, wherein the first region at least partly covers the stair nose.

Aspect 13: The system of aspect 11 or aspect 12, further comprising an adhesive between the installation surface and the second surface of the sheet of the decorative article.

Aspect 14: The system of any one of aspects 11-13, wherein the adhesive fills at least a portion of at least one groove of the plurality of grooves.

Aspect 15: The system of any one of aspects 11-14, wherein at least one groove of the plurality of grooves has an increasing width in a direction from the second surface toward the first surface.

Aspect 16: The system of any one of aspects 11-15, further comprising a riser, wherein a portion of the decorative article is positioned between the riser and the stair tread.

Aspect 17: The system of any one of aspects 11-16. wherein the decorative article is a first decorative article, the system further comprising at least one additional decorative article positioned adjacent the first decorative article, wherein the at least one additional decorative article is free of any groove.

Aspect 18: A method of using the decorative article as in any one aspects 1-10 includes:

• • applying the decorative article to an installation surface; and
  • bending at least a portion of the decorative article over the installation surface.

Aspect 19: The method of aspect 18, wherein bending the at least a portion of the decorative article over the installation surface is performed without heating the decorative article.

Aspect 20: A method comprising:

• • forming, into a sheet having a full thickness, a first surface, and a second surface opposite the first surface, plurality of grooves extending along a first axis so that, across at least a first region of the sheet. the second surface of the sheet defines the plurality of grooves, wherein the plurality of grooves are configured to permit at least the first region of the sheet to conform to an application surface,
  • wherein each groove of the plurality of grooves has, along a second axis that is transverse to the first axis, an operative width of at least 1 mm across which a depth of the groove is no less than ⅓ of the full thickness of the sheet, and
  • wherein the sheet comprises, between adjacent grooves of the plurality of grooves, respective areas defined by the full thickness of the sheet. said full thickness being at least 0.5 mm along the second axis.

Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.