Abstract:
A ladder-type solid-wood two-layer floor product and related methods are provided. The floor product includes a floor support main body layer and an upper decorative surface layer. The main body layer is formed by splicing two parallel frames and a group of strip-shaped solid-wood cores parallel to each other and perpendicular to the frames. The floor product has a simple structure and high economic value. It avoids bending, deformation and the like from internal stress due to temperature and humidity variations.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to Chinese utility model patent no. CN203569853U, filed Nov. 19, 2013, the entire disclosure of which is incorporated herein by reference. 
       FIELD 
       [0002]    The inventive concept relates to the field of wooden flooring products, and particularly to specific solid-wood floor structure systems and related methods of use and manufacture. 
       BACKGROUND 
       [0003]    Solid-wood flooring products are becoming increasingly popular. Production of solid-wood products, including flooring, is limited by environmentally friendly timber harvesting practices. To ease the burden placed on forests of the world, the prior art teaches that many wooden products, including flooring, can be made from compressed sawdust or other imitation wood materials. Some disadvantages of the prior art compressed sawdust, especially when used in flooring products, include shrinkage and/or expansion due to changes in temperature and/or humidity. Flooring plates are particularly susceptible to deformation and separation of layers under use and over time. 
       SUMMARY 
       [0004]    The inventive concept overcomes various disadvantages of the prior art. Additionally, the inventive concept is a simple structure and provides high economic value. It reduces or eliminates bending, shrinkage, expansion, deformation and the like from internal stress, and may improve the buckling deformation or anti-twist deformation performances when in use, particularly in dry, humid or highly temperature-variant environments. Moreover, due to its use of environmentally-friendly, economically sound, reliable and various material resources, the inventive concept is more aligned with the ecological protection requirements of society. 
         [0005]    One object of the general inventive concept is to provide a ladder-type solid-wood two-layer floor product. The floor product includes a floor support main body layer and an upper decorative surface layer affixed to the top of the main body layer. The main body layer includes two solid-wood frame components arranged in parallel to one another. The main body layer also includes two or more strip-shaped solid-wood cores disposed between the two frame components. The cores are all arranged parallel to one another and perpendicular to the frame components. The cores are attached to the frame at each end. When arranged flat, the surface layer is affixed to the top of the main body layer. 
         [0006]    In some embodiments, the thickness (top to bottom) of the frame is the same as the thickness of the core. In some embodiments, the upper face of the frame lies in a singular common plane with the upper face of the cores. In some embodiments, the cores are arranged at substantially equal intervals with an empty space between each adjacent core. In some embodiments, the interval between cores is 1.5 cm to 2.5 cm. In some embodiments, the wood grain of the cores is aligned with the wood grain of the frame and arranged in a vertical direction. In some embodiments, the thickness of the frame is 0.8 cm to 1.5 cm. 
         [0007]    Another object of the general inventive concept is to provide a method of manufacturing the floor product described herein. The method includes assembling the floor support main body layer and affixing an upper decorative surface layer to the top side of the main body layer. Assembling the main body layer includes positioning two solid-wood frame components in parallel to one another with a space between them, inserting two or more strip-shaped solid-wood cores in the space between the two solid-wood frame components (with the cores being arranged perpendicular to the frames), and attaching each end of the cores to the frames pieces. 
         [0008]    Another object of the general inventive concept is to provide a method of using the floor product described herein. The method includes positioning the floor product (as described herein) on top of a floor substrate and affixing the floor product in position on top of a floor substrate. In some embodiments, the method further includes cutting the floor product to match the size and shape of the floor substrate, at least in part. In some embodiments, the method further includes positioning a second piece of floor product on top of the floor substrate and adjacent to the previously used floor product and affixing the second floor product in position on top of the floor substrate. 
         [0009]    The foregoing and other objects are intended to be illustrative of the general inventive concept and are not meant in a limiting sense. Many possible embodiments of the general inventive concept may be made and will be readily evident upon a study of the following detailed description and accompanying drawings. Furthermore, various features and subcombinations of general inventive concept may be employed without reference to other features and subcombinations. Other objects and advantages of the general inventive concept will become apparent from the following description taken in connection with the accompanying drawings. 
     
    
     
       DRAWINGS 
         [0010]    Embodiments of the general inventive concept are set forth herein and are shown in the following drawings: 
           [0011]      FIG. 1  is a top view of a floor without the upper decorative surface layer. 
           [0012]      FIG. 2  is a sectional diagram of the floor. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    The following detailed description references the accompanying drawings that illustrate specific embodiments in which the general inventive concept can be practiced. The embodiments are intended to describe aspects of the general inventive concept in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. 
         [0014]    In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein. 
         [0015]    With respect to the Figures, a ladder-type solid-wood two-layer floor product is provided. The floor product is made of a floor support main body layer and an upper decorative surface layer (shown as  1  in  FIG. 2 ) affixed to the top of the main body layer. A top view of the main body layer (without the upper decorative surface layer) is shown in  FIG. 1 . A cross-sectional diagram of the floor product is shown in  FIG. 2 . 
         [0016]    As shown in  FIG. 1 , the main body layer includes two solid-wood frame components  2 . Each frame  2  has a long axis and they are disposed parallel to one another with a space between them. The main body layer also includes a plurality of strip-shaped solid-wood cores  3  disposed between the two solid-wood frame components  2 . Each core  3  has two ends and a long axis extending between the two ends. The long axis of each core  3  is arranged in parallel to the long axes of each other core  3  and each core long axis is disposed perpendicular to the long axes of the two solid-wood frame components  2 . The ends of each core  3  are affixed to the frames  2 . 
         [0017]    As shown in  FIG. 2 , the upper decorative surface layer  1  is affixed to the top of the main body layer. The frame components  2  and cores  3  have a thickness as measured from the bottom to the top. As shown in  FIG. 2 , the thickness of the frames  2  and cores  3  are substantially the same as one another. In some embodiments, the thickness of the frames  2  is in the range of 0.8 centimeters to 1.5 centimeters. As shown in  FIG. 2 , the frames  2  and cores  3  have an upper face in contact with the upper decorative surface layer  1 . The upper face of the frames  2  and cores  3  are aligned on a single, common plane. 
         [0018]    As shown in  FIG. 1 , the cores  3  are arranged at substantially equal intervals with an empty space between each adjacent core  3 . In some preferred embodiments, the intervals are in the range of 1.5 centimeters to 2.5 centimeters. 
         [0019]    According to some embodiments, the frame components  2  and cores  3  each have a general wood grain direction. Preferably, the direction of the respective wood grains of the frames  2  and cores  3  are all aligned with one another. More preferably, the wood grains are aligned in a vertical direction (vertical with respect to  FIG. 2 ). 
         [0020]    In general, a ladder-type solid-wood two-layer floor is provided. The floor product includes a floor support main body layer and an upper decorative surface layer. The floor support main body layer is formed by splicing two parallel frames and a group of strip-shaped solid-wood cores perpendicular to the frames and fixed between the two frames. 
         [0021]    The thickness of each of the strip-shaped solid-wood cores is the same as that of each of the frames, and the upper end faces of the strip-shaped solid-wood cores and the frames are in a same plane during splicing. 
         [0022]    The strip-shaped solid-wood cores are arranged at equal intervals, and each of the intervals is set as 1.5-2.5 cm. 
         [0023]    The direction of wood grains of the frames is perpendicular to the direction of wood grains of the strip-shaped solid-wood cores. The thickness of each of the frames is 0.8-1.5 cm. 
         [0024]    During the specific implementation of the inventive concept shown in the Figures, the wood plate mainly includes a plurality of strip-shaped solid-wood cores  3  and frames  2  fixed on two sides of the plurality of strip-shaped solid-wood cores  3 , and the cores and the frames are combined by arranging their wood grains vertical and compressing and gluing. The arrangement combination of the frames and the strip-shaped solid-wood cores  3  of inner cores employs crisscrossing technology. Specifically, the inner cores consists of a plurality of strip-shaped solid-wood cores  3  arranged transversely, the frames  2  on two sides are longitudinally fixed on side faces of the plurality of strip-shaped solid-wood cores  3 , and then the upper decorative surface layer  1  is assembled to form the floor. 
         [0025]    As the plate provided by the present invention is designed as a ladder type structure, the inner cores consisting of the strip-shaped solid-wood cores  3  are arranged in a cavity formed by the frames  2 , and the strip-shaped solid-wood cores  3  forming the inner cores are of a transversely arranged structure while the frames  2  are of a longitudinal structure, so that the arrangement combination of the frames  2  and the strip-shaped solid-wood cores  3  of the inner cores employs crisscrossing technology. Thus, the stresses in the arranged frames and on the surface or the external layer of the whole plates may be balanced, and it is advantageous to avoid bending deformation and the like resulted from internal stress. 
         [0026]    In addition, as the inner cores consists of a plurality of strip-shaped solid-wood cores  3  arranged transversely, when the wood plates are assembled into a floor, the transverse structure may improve buckling deformation or anti-twist deformation performances when in use, particularly in dry, humid or terrestrial heat supply environments. 
         [0027]    In addition, during material selection, the plurality of strip-shaped solid-wood cores  3  and the frames  2  are both made of fast-growing timbers, so the inventive concept has environmental, economical, stable and multiple-choice material resources and is more aligned with the ecological protection requirements of the society. 
         [0028]    In addition, a two-layer structure is employed in this embodiment. Compared with other three-layer structures, the raw materials are saved, and the bending deformation of the surface layer and bottom layer of a three-layer structure due to different materials and thicknesses is avoided. 
         [0029]    In addition, a two-layer structure is employed in this embodiment, so the plurality of strip-shaped solid-wood cores  3  and the frames  2  are completely exposed outside, thereby avoiding adulteration and falsification and making users more assured. 
         [0030]    In other embodiments, a method of manufacturing the floor product described above is provided. The method includes assembling the floor support main body layer and affixing an upper decorative surface layer to the top side of the main body layer. Assembling the main body layer includes positioning two solid-wood frame components in parallel to one another with a space between them, inserting two or more strip-shaped solid-wood cores in the space between the two solid-wood frame components (with the cores being arranged perpendicular to the frames), and attaching each end of the cores to the frames pieces. 
         [0031]    In other embodiments, a method of using the floor product described above is provided. The method includes positioning the floor product (as described herein) on top of a floor substrate and affixing the floor product in position on top of a floor substrate. In some embodiments, the method further includes cutting the floor product to match the size and shape of the floor substrate, at least in part. In some embodiments, the method further includes positioning a second piece of floor product on top of the floor substrate and adjacent to the previously used floor product and affixing the second floor product in position on top of the floor substrate. 
         [0032]    While the present general inventive concept has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use. 
         [0033]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. Hence, the proper scope of the present general inventive concept should be determined only by the broadest interpretation of the appended claims so as to encompass all such modifications as well as all relationships equivalent to those illustrated in the drawings and described in the specification. 
         [0034]    Finally, it will be appreciated that the purpose of the annexed Abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. Accordingly, the Abstract is neither intended to define the invention or the application, which only is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.