Abstrict A wood flooring product for assembly into a wood floor is disclosed.
The flooring product includes a top, decorative layer, an intermediate
layer bonded to the top layer, and a base layer bonded to the intermediate
layer. The top, intermediate and base layers are bonded in registration
to define a laminated elongate wood flooring strip. A tongue and
a groove are formed on respective side edges of the flooring strip.
The tongue and groove extend along the length of the flooring strip,
and lock adjacent flooring strips together side-to-side to form
an assembled wood floor. The base layer has a multiplicity of closely
spaced-apart scores cut transverse to the length of the flooring
strip along substantially the entire length of the flooring strip.
The scores relieve stress and increase flexibility in the wood strip
for more closely adhering to irregularities of a sub-floor.
Claims I claim:
1. A wood flooring strip for assembly into a wood floor, said flooring
strip comprising:
(a) a top, decorative wood layer;
(b) an intermediate wood layer bonded to the top layer; and
(c) a base wood layer bonded to the intermediate layer;
(d) said top, intermediate and base layers bonded in registration
to define a three-layer laminated elongate wood flooring strip;
(e) locking means extending along the length of said flooring strip
on both side edges for locking adjacent flooring strips together
side-to-side to form an assembled wood floor, said locking means
comprises a tongue formed on one side edge of the flooring strip
and a mating groove on the other side edge of the flooring strip,
each of said tongue and said groove for mating connection with complementary
elements on adjacent flooring strips; and
(f) said base layer having a multiplicity of closely spaced-apart
scores cut therein transverse to the length of the flooring strip
along substantially the entire length of the flooring strip to relieve
stress and increase flexibility in the wood strip for more closely
adhering to irregularities of a sub-floor; and
(g) said flooring strips including opposing end portions, said
end portions each having a single flat area encompassing the entire
end portion surface area perpendicular to the plane of the flooring
strip for abutting engagement with like flat areas on adjacent flooring
strips.
2. A wood flooring strip according to claim 1 wherein said opposing
end portions include an upper flat area perpendicular to the plane
of the flooring strip for abutting engagement with like flat areas
on adjacent flooring strips, and a lower, chamfered area for spacing
the base layer of adjacent flooring strips apart from each other
on opposing ends of the flooring strips.
3. A wood flooring strip according to claim 1 wherein said scores
are approximately one-eighth inch wide and are spaced-apart approximately
one inch center-to-center.
4. A wood flooring strip according to claim 3 wherein said scores
extend into the base layer substantially the entire thickness of
the base layer.
Description TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a laminated wood flooring product, and
a wood floor assembled from strips of the laminated wood flooring
product. The flooring product which is the subject of this invention
relates generally to products which are intended to simulated far
more expensive solid wood flooring, such as oak, maple or ash. The
desire to create a flooring product simulating solid wood flooring
is apparent for reasons other than cost. For example, when a solid
wood flooring panel is subjected to moisture, the width of the panel
expands by as much as 11%. Because of this expansion, a stable solid
wood floor can be difficult to maintain.
Width expansion and instability of wood is a result of the wood's
hydroscopic nature. One way to stabilize an otherwise unstable wood
product is to make it out of plywood. A piece of plywood is made
by peeling a log to create thin wood strips. These strips are glued
together and turned ninety degrees from the adjacent strips. This
effectively stabilizes the unstable widthwise direction of the wood
panel, thereby resulting in a more stable wood product.
In order to achieve a solid wood appearance without moisture expansion
problems, a laminated wood flooring product was produced. This flooring
product has a top, relatively thin veneer layer of oak, maple, ash
or some other wood. The top layer is the exposed surface of the
laminated wood floor when the floor is laid. When properly installed,
the floor appears to be a solid wood floor, when in fact the floor
is far less expensive than a solid wood floor. This lower cost is
principally due to the use of less slow-growing hardwoods in favor
of cheaper, faster-growing softwoods such as lauan or the like.
Since laminated wood flooring products expand and contract in the
presence of moisture by less than 2%, they provide a more stable
floor.
Laminated wood floors are known in the art, but they are subject
to a number of problems. For example, some laminated wood floors
are specified as only being suitable for installation over certain
types of subfloors. In other instances, subfloors must be removed
because of poor condition, or because of irregularities in the surface
which prevent proper installation. This is a particular problem
since many older flooring materials contain asbestos, and are therefore
expensive and potentially dangerous to remove. Prior art laminated
wood floors are often subject to warping twisting and cupping, thereby
requiring replacement or sanding to refurbish. In addition, a laminated
wood floor which does not adhere to the subfloor at all points will
create a hollow sound, and will flex slightly when walked on, clearly
indicating that the floor is not a solid floor. Prior art laminated
wood flooring strips are relatively stiff, thereby requiring a strong
adhesive, such as a chlorinated solvent adhesive, to bond the floor
to the subfloor. This is particularly true of subfloors which may
have irregularities in the surface.
The chlorinated solvent adhesive used to bond the laminated wood
flooring to the concrete had to be very rubbery, because despite
the lamination, the flooring moved slightly through the years. This
rubbery adhesive creates difficulties in installation. Furthermore,
methyl chloroform is typically a principle ingredient in chlorinated
solvent adhesives. Vapors emitted from this chemical are not only
an environmental threat, but are also potentially damaging to household
appliances, such as hot water heaters and furnaces. Regardless,
even with a very strong adhesive, bowing, sideways sliding and similar
problems are common.
In addition prior art laminated wood flooring strips have tongue
and groove locking edges on both ends and side edges. This prevents
pieces from being cut to length except on the periphery of the floor
being laid. The presence of tongue and groove locking edges on the
side edges and ends of the strips means that each flooring strip,
as installed, must be shifted both sideways and endways to lock
the tongue and groove locking members with the mating members of
the end and side adjacent strips. The presence of tongue and groove
locking edges o the side edges and ends of the strips also creates
a problem known as "overwood," meaning that the respective
surfaces of adjacent strips, when installed, are not exactly flush.
A prior attempt has been made to correct these problems. The Hartco
"Pattern-Plus" laminated wood floor is a two-piece laminated
floor, which has small wooden "slats" glued to the back
side of the wooden flooring strips to create a "slatted"
appearance, with small spaces between each flat to add additional
flexibility to the floor, and to permit conformation to slight irregularities
in the subfloor. This product has tongue and groove locking edges
on both ends and side edges. As is apparent, gluing numerous small
pieces of wood to the back of the flooring strips is a costly and
time-consuming process.
The invention according to this application solves these problems
in an inexpensive and efficient manner.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a laminated
wood floor which is inexpensive, easy to manufacture, easy to install,
and which provides wear equivalent to a solid wood floor.
It is another object of the invention to provide a laminated wood
floor which can be installed over virtually any time of existing
flooring, including those containing hazardous materials such as
asbestos.
It is another object of the invention to provide a laminated wood
floor which does not warp, cup or twist.
It is another object of the invention to provide a laminated wood
floor which can be refurbished without sanding.
It is another object of the invention to provide a laminated wood
floor which conforms exactly to the subfloor and therefore sounds
and feels solid when walked on.
It is another object of the invention to provide a laminated wood
floor which permits the use of a latex adhesive to secure the laminated
wood floor to the subfloor, instead of corrosive chlorinated solvent
adhesives.
It is another object of the invention to provide a laminated wood
flooring strip which does not bow either during or after installation.
It is another object of the invention to provide a laminated wood
flooring strip which does not slide sideways, and where the ends
of the laminated wood flooring strips ar held level by the sides.
It is another object of the invention to provide a laminated wood
flooring strips where cut pieces can be used anywhere on the floor,
and therefore can be installed with less waste.
These and other objects of the present invention are achieved in
the preferred embodiments disclosed below by providing a wood flooring
product for assembly into a wood floor. The flooring product includes
a top, decorative layer, an intermediate layer bonded to the top
layer, and a base layer bonded to the intermediate layer. The top,
intermediate and base layers are bonded in registration to define
a laminated elongate wood flooring strip. Locking means extend along
the length of the flooring strip on both side edges for locking
adjacent flooring strips together side-to-side to form an assembled
wood floor. The base layer has a multiplicity of closely spaced-apart
scores cut transverse to the length of the flooring strip along
substantially the entire length of the flooring strip to relieve
stress and increase flexibility in the wood strip for more closely
adhering to irregularities of a sub-floor.
According to one preferred embodiment of the invention, the locking
means comprises a tongue formed on one side edge of the flooring
strip and a mating groove on the other side edge of the flooring
strip. Each of the tongue and the groove mate with complementary
elements on adjacent flooring strips.
According to another preferred embodiment of the invention, the
flooring strips include opposing end portions, the end portions
each having a flat are perpendicular to the plane of the flooring
strip for abutting engagement with like flat areas on adjacent flooring
strips.
According to yet another preferred embodiment of the invention,
the opposing end portions include an upper flat area perpendicular
to the plane of the flooring strip for abutting engagement with
like flat areas on adjacent flooring strips. The opposing end portions
also include a lower, chamfered area for spacing the base layer
of adjacent flooring strips apart from each other on opposing ends
of the flooring strips.
Preferably, the scores are approximately one-eighth inch wide and
are spaced-apart approximately one inch center-to-center.
According to one preferred embodiment of the invention, the scores
extend into the base layer substantially the entire thickness of
the base layer.
A wood floor assembled from wood flooring strips according to the
invention is also described and claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects of the invention have been set forth above.
Other objects and advantages of the invention will appear as the
invention proceeds when taken in conjunction with the following
drawings, in which:
FIG. 1 is a perspective view of the bottom side of a prior art
laminated wood flooring strip;
FIG. 2 is an enlarged end elevation of the prior art laminated
wood flooring strip shown in FIG. 1;
FIG. 3 is a perspective view of the bottom side of a laminated
wood flooring strip according to an embodiment of the invention;
FIG. 4 is a an enlarged end elevation of the laminated wood flooring
strip shown in FIG. 3;
FIG. 5 is a fragmentary side elevation of two laminated wood flooring
strips as shown in FIGS. 3 and 4 end to end; and
FIG. 6 is a fragmentary perspective view of a wood floor assembled
from the laminated wood flooring strips shown in FIGS. 3 4 and
5.
DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE
Referring now specifically to the drawings, a laminated wood flooring
strip according to the prior art is illustrated in FIG. 1 and shown
generally at reference numeral 10. The laminated wood flooring strip
10 according to the prior art is a conventional laminated wood flooring
strip having three laminates, a top laminate 11 which is typically
a veneer of a quality hardwood such as oak, ash or maple. An intermediate
layer 12 is bonded to the underside of the top layer 11 leaving
exposed the finished surface. The intermediate layer 12 has a grain
perpendicular to the top layer 11 to provide dimensional stability
to the product. A bottom layer 13 with a grain running in the same
direction as the top layer 11 and perpendicular to the intermediate
layer 12 is bonded to the intermediate layer 12. The intermediate
layer 12 and bottom layer 13 are fabricated of relatively inexpensive
wood, since only the top surface 11 is visible when the floor is
installed.
Conventional laminated wood flooring strips, such as the laminated
wood flooring strip 10 in FIG. 1 are typically manufactured in
widths of from 1.5 to 7 inches, and in lengths of from 6 to 8 feet
long. Depending on the width, the flooring material may be referred
to as a strip or plank.
As is also shown in FIG. 1 a tongue 15 is machined into one end
and one side of the laminated wood flooring strip 10 and a groove
16 is machined into the opposite end and side of laminated wood
flooring strip 10.
Referring now to FIG. 2 when multiple laminated wood flooring
strips 10 are installed side-by-side and end-to-end, the groove
16 of one laminated wood flooring strip 10 will mate with the tongue
15 of the adjacent laminated wood flooring strips 10. Generally,
adjacent laminated wood flooring strips 10 are installed in a staggered
configuration so that the ends do not coincide. Thus, a floor which
is interlocked both on the ends and the sides is formed.
However, the provision of tongue and groove interlocking on the
ends, as shown in FIGS. 1 and 2 can cause the ends of adjacent
laminated wood flooring strips 10 to be uneven, particularly if
the tongue and grooves 15 and 16 on the ends of the laminated wood
flooring strip 10 are not in exact registration with the tongue
and grooves 15 and 16 cut into the sides. This is relatively common,
since it is relatively easy to obtain exact registration of the
tongue and grooves extending along the length of the strips, but
very difficult to obtain exact registration of the tongue and groove
on the very short ends of the strips.
The laminated wood flooring strip 10 also includes three cross-cut
scores 18a, 18b, and 18c in the bottom layer 13. Some other prior
art products may have four or five such scores. These scores 18a-18c
are intended to allow some flexibility to the laminated wood flooring
strip 10 and to reduce bowing. Note that the scores 18a-18c are
centered, and the portion of the laminated wood flooring strip 10
near the ends have no such scores. It has been observed that while
a certain minimum amount of increased flexibility is provided by
the scores 18a-18c, the amount is insufficient to provide an actual
improvement in performance of the laminated wood flooring strip
10 when installed, and provides essentially no increase in the ability
of the laminated wood flooring strip 10 to conform to irregularities
in the subfloor.
Furthermore, the relatively stiff laminated wood flooring strip
10 requires a very strong adhesive, such as a chlorinated solvent
adhesive, to securely bond it to the subfloor. The requirement for
tongue and groove locking on the ends of the laminated wood flooring
strip 10 as well as on the side edges necessitates that cut strips
cannot be used except along the edges of the installed floor, where
the edges will be covered by shoe molding or the like.
In distinct contrast to the laminated wood flooring strip 10 shown
in FIGS. 1 and 2 a laminated wood flooring strip 20 which solves
numerous problems in prior art flooring products is shown in FIGS.
3-6. Referring specifically to FIG. 3 the laminated wood flooring
strip 20 as shown, is constructed of three layers. A top layer
21 which is typically a veneer of a quality hardwood such as oak,
ash or maple forms the visible surface of the floor when installation
is complete. An intermediate layer 22 is bonded to the underside
of the top layer 21. The intermediate layer 22 has a grain perpendicular
to the top layer 21 to provide dimensional stability to the product.
A bottom layer 23 with a grain running in the same direction as
the top layer 21 and perpendicular to the intermediate layer 22
is bonded to the intermediate layer 22. The intermediate layer 22
and bottom layer 23 are fabricated of relatively inexpensive wood,
since, when the floor is installed, only the top surface 21 is visible.
According to another embodiment of the invention (not shown), additional
intermediate layers 22 may be included to form a four or five-layer
laminated wood flooring strip.
As with the conventional laminated wood flooring strip of FIGS.
1 and 2 laminated wood flooring strip 20 is manufactured in widths
of from 1.5 to 7 inches, and in lengths of from 6 inches to 8 feet
long.
As is also shown in FIG. 4 a tongue 25 is machined into one side
of laminated wood flooring strip 20 and a groove 26 is machined
into the opposite side of laminated wood flooring strip 20. When
multiple laminated wood flooring strips 20 are installed side-by-side
and end-to-end, the groove 26 of one laminated wood flooring strip
20 will mate with the tongue 2 of the adjacent laminated wood flooring
strips 20. Generally, adjacent laminated wood flooring strips 20
are installed in a staggered configuration so that the ends do not
coincide. Thus, a floor such as shown in FIG. 6 which is interlocked
on the sides is formed.
The bottom layer 23 of laminated wood flooring strip 20 includes
a multiplicity of closely spaced-apart, cross-cut scores 28 which
extend completely across the width of the laminated wood flooring
strip 20 from side edge to side edge. The scores 28 are preferably
positioned at uniform intervals, running substantially from one
end of the laminated wood flooring strip 20 to the opposite end.
In the exemplary embodiment shown and described, the scores 28 are
each one-eighth inch wide and are spaced-apart one inch on center.
The scores 28 extend to within approximately 1/32 inch of the boundary
of the bottom layer 23 thickness.
By supplying the laminated wood flooring strip 20 with a multiplicity
of scores 28 it becomes more flexible, and thus more easily conforms
to any irregularities in the surface of the subfloor. The multiplicity
of scores 28 substantially increases the flexibility of the laminated
wood flooring strip 20. In addition, the scores 28 provide substantially
increased surface area for bonding between the bottom layer 23 and
the adhesive. The increased adhesion between the adhesive and the
laminated wood flooring strip 20 permits a water-based latex adhesive
to be used to bond the laminated wood flooring strips 20 to the
subfloor. The scores 28 also act as "pockets" which receive
and hold adhesive, thus substantially increasing resistance against
shifting of the flooring strips 20 especially during installation
and adhesive curing. The ability to use latex adhesive means that
the floor and the installation tools ar easily cleaned.
The laminated wood flooring strip 20 retains its shape after being
laid, including any adjustment to irregularities in the subfloor.
The laminated wood flooring strip 20 does not warp, cup or twist.
For this reason, the laminated wood flooring strip 20 remains securely
fastened to the subfloor and therefore sounds and feels solid when
walked on.
The opposing ends 29 and 30 of the laminated wood flooring strip
20 are formed without tongue and groove locking means, but are cut
to provide a abutting connection between the end 29 and the end
30 of adjacent laminated wood flooring strips 20. The abutting ends
29 and 30 of the laminated wood flooring strip 20 permit an absolutely
flush joint which will not pull open. A chamfer 31 is formed at
both ends 29 and 30 in the bottom layer 23 of the laminated wood
flooring strip 20. The chamfer 31 forms an undercut area adjacent
the lower edge of the ends 29 and 30. The chamfer 31 allows the
laminated wood flooring strip 20 to flex freely in conformity with
the surface of the subfloor, without effecting or otherwise interfering
with the placement of adjacent laminated wood flooring strips 20.
For this reason, adjacent, end-to-end laminated wood flooring strips
20 can be made to lie perfectly flush edge-to-edge, without using
tongue and groove or other locking means. The ability to eliminate
the tongue and groove locking means on the ends 29 and 30 of the
flooring strips 20 simplifies installation, since each strip 20
can be placed onto the subfloor in exact endwise alignment with
the end 29 of one flooring strip 20 flush against the end 30 of
an adjacent flooring strip 20. Thus, the flooring strip 20 need
only be shifted sideways to lock the tongue 25 of one flooring strip
20 into the groove 26 of the adjacent flooring strip 20.
The provision of abutting end engagement between end-to-end adjacent
laminated wood flooring strips 20 provides a much smoother and more
consistent floor surface, because the side edge tongue and groove
connections 25 and 26 hold the ends 29 and 30 as well as the sides,
level. Furthermore, the laminated wood flooring strip 20 as described
in the above embodiment can be cut to length and pieced anywhere
on the floor, since a tongue and groove or other positive locking
means is no longer necessary to lock the ends 29 and 30 together
with adjacent laminated wood flooring strips 20.
The number and spacing of the scores 28 can be varied depending
on the width and length of the laminated wood flooring strip 20
as can the depth of the scores 28.
Referring now to FIG. 6 an assembly of laminated wood flooring
strips 20 adjacently placed to form a wood floor surface 40 is illustrated.
As shown, the side-edges' tongue and groove 25 and 26 and the ends
29 and 30 closely form to adjacent laminated wood flooring strips
20 to create a smooth and continuous floor surface 40.
A laminated wood flooring strip is described above. Various details
of the invention may be changed without departing from its scope.
Furthermore, the foregoing description of the preferred embodiment
of the invention and the best mode for practicing the invention
are provided for the purpose of illustration only and not for the
purpose of limitation--the invention being defined by the claims.
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