Patent Application
20100247861
The present invention relates to a flooring product, and preferably to environmentally friendly flooring products, having a minimum top wear layer of traditional/exotic hardwood plank and a ecologically friendly substrate composed of a solid bamboo composite (strand woven) with an innovative interlocking T&G floating floor system called Wood-Boo-Too.
Bamboo is a rapidly replenishable asset. There are over a thousand species of perennial, woody, usually shrubby or treelike plants of the grass family. Bamboo usually grows in tropical and subtropical areas from sea level to snow capped mountain peaks. Some species reach to temperate areas. The species are most abundant in southeastern Asia. The various species can range from stiff reeds of about one meter tall to giants reaching as high as eighty feet in height.
One particular species called hairy bamboo has been found to grow up to eighty feet tall and up to ten inches in diameter at the base within a four to six year window.
The lower fifteen to twenty percent of the bamboo stock is the thickest outer wall portion and makes an excellent component for wood products. While planks from this section are very dense and heavy, these planks make an ideal component for flooring.
It has been noted that the hairy bamboo species is harder than northern red oak. Furthermore, it is more stable and resistant to movement caused by moisture than most other wood products. Furthermore, it has a tensile compression strength superior to some steel. Finally, it has been found to have a weight to strength ratio surpassing that of graphite, making bamboo the strongest growing woody plant on earth.
By recognizing the structural characteristics of bamboo, manufacturers have developed a number of bamboo flooring products, which have been sold in the United States and the world for a number of years.
The hardwood wear layer referred to in Paragraph [0001] is believed to be an improvement over the strand woven design because of its versatility in appearance. Strand Woven composite is a process in which the bamboo strands are separated from one another and then dipped in a pressure and heat sensitive solution and then drip-dried to the touch. They are then heated in a conveyer oven to reduce the moisture content. The bamboo strands are then placed into the pressing machine that compiles 36 inches of the bamboo strand materials that are compressed and intertwined into 6 inch high by 6 inch wide by 6 foot long blocks that are then subjected to heat to form a solid block of material. The solid blocks are then ripped into boards and then turned into lumber or finished planks.
While strand woven bamboo provides a beautiful and sturdy flooring product, they do not have the look of white oak, Brazilian cherry, Burma teak, black walnut, Chinese red maple, African mahogany, Kumaru, Merbau, Oaken, Asian Kulim, African Tiger Wood, Masserand Duba, African Kuku, and various combinations of stains, and other woods which have been utilized for flooring in the United States and around the world over the years.
While solid wood flooring is currently an option, solid wood flooring by its very nature requires the entire thickness of the flooring plank to be constructed of a single species such as white oak, Brazilian cherry, Burma teak, black walnut, Chinese red maple, African mahogany, Kumaru, Merbau, Oaken, Asian Kulim, African Tiger Wood, Masserand Duba, African Kuku, and various combinations of stains. This can result in the usage of a significant amount of raw material thereby depleting the forests at a relatively rapid rate.
Accordingly, there is believed to be the need to provide a traditional looking floor product while more efficiently utilizing these less replenishable natural resources.
What is consistent about traditional bamboo-flooring products is that they use only bamboo as the source of wood.
It is an object of the present invention to provide a traditional looking wood product, which is engineered to provide an environmentally friendlier product than traditional solid wood products.
It is another object of the present invention to provide an improved engineered flooring product.
Accordingly, in the present invention, the engineered wood product is comprised of the top layer, a solid wood product. This wear layer is a continuous piece taken from a single board, which spans the width and length of the plank. Below the top layer is a substrate of engineered material taken from the bamboo strand woven board. In the presently preferred embodiment, the substrate is bamboo with the top hardwood wear layer connected thereto. Additionally, the unique tongue and groove flooring product plank is preferably constructed different than other traditional flooring tongue and groove design.
See Paragraph [0001]
The first layer will have a maximum thickness of 5 mm and a minimum thickness of 2.5 mm. The length and the width of the hardwood wear layer will be a continuous plank. It is anticipated that the hardwood wear layer will be a continuous slab of wood cut from a tree and then connected to a substrate.
Bamboo for the body of the substrate has been found particularly attractive since bamboo is a rapidly replenishing resource with a majority of the bamboo utilized for such a product grown and harvested in a five year or less period.
The invention is comprised of a hardwood wear layer which has a minimum thickness of 2.5 mm and a maximum thickness of 5 mm. The substrate (strand woven—see Paragraph [0007]) is 7.5 mm to 12 mm. They are connected with a non-toxic formaldehyde free heat/pressure sensitive bonded adhesive. The overall thickness is 10 mm or 15 mm.
To date, no other company has produced an engineering flooring with a first layer of a wood with a substrate being a composite bamboo. This substrate is a bamboo composite product with the first layer being hardwood face connected thereto.
Also, it is worth observing the first layer is essentially rectangular and the length is perpendicular to the width, which is perpendicular to the thickness.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure related to the preferred embodiment of the invention, which is for purposes of illustration only, and not to be construed as a limitation of the invention. All such modifications, which do not depart from the spirit of the invention, are intended to be included within the scope of the appended claims.
| Number | Date | Country | |
|---|---|---|---|
| 61202378 | Feb 2009 | US |
