PLYWOOD FLOORING WITH AN ACOUSTIC BARRIER

Abstract

An improved plywood flooring and process of manufacturing. In one embodiment, the flooring is formed from two layers of Okoume wood sandwiching an acoustic sound barrier therebetween. A wear layer of veneer is adhered to a top face of the upper layer of Okoume wood and edge joinery shapes are cut through a CNC. The flooring is coated with a proprietary epoxy blend with a matt coating on the veneer surface. The process provides a flooring material that will not warp or otherwise degrade when subjected to standing water.

Description

FIELD OF THE INVENTION

This invention is directed to the field of water-resistant wood construction and, in particular, to an improved wood flooring.

BACKGROUND OF THE INVENTION

This invention applies to wood flooring that can be used in commercial buildings, residential homes, boats, recreational vehicles and the like. For ease of description, the examples used herein will be directed to boats due to the inherent exposure to water. The benefits of using wood on boats are numerous. Aesthetically, wood provides a classic and elegant look to a boat's interior. Functionally, wood is lightweight, easy to shape, and quality wood is resistant to moisture, rot, and insects. Wood flooring on a boat has both aesthetical design and functionality. Hardwoods such as teak and holly have been a mainstay in the boating industry. Depending on the type of wood selected, the texture of the wood can provide a non-slip surface, thereby enhancing safety onboard. However, a disadvantage of wood is that regular maintenance is needed to protect the wood from moisture and UV damage. It is not uncommon to find a boat with wood floors and walls to be stained from leaking windows, doors, and hatches. Further, an overflowing drain pan on an air conditioner compressor can quickly destroy a conventional wood floor. Water resistant wood does not equate to water proof. Standing water on conventional wood floors can ruin them within a day.

Wood floors on boats are susceptible to damage as they are utilized in a challenging marine environment. The constant exposure to moisture, whether from seawater, rain, or humidity, can irreparably degrade otherwise water resistant wood. Boat cabins are subject to leaking windows and doors due to the use of the boat in waves, which results in frame stresses. In many instances a boat cabin is heated or cooled only when occupied. Considering a boat is used for recreational purposes, a boat is not always occupied. Use of wood that is not specifically designed for marine environments can lead to rapid deterioration due to the lack of resistance to water, salt, and other marine-related factors.

Where a boat is used can also determine if wood will prematurely wear out. For instance, the high salt content in seawater can accelerate the corrosion of wood, particularly if the wood is not treated to withstand such conditions. Exposure to ultraviolet (UV) rays from the sun can break down the lignin in wood, causing it to fade, lose its strength, and become more susceptible to decay.

Hard woods commonly used in boats include teak and holly which have natural oils and resins that make them naturally water-resistant. This characteristic helps prevent water damage and rotting, which is especially crucial in the damp conditions found on a yacht. However, teak and holly are notorious for early degradation.

Wood is also used in sound attenuation on a boat. Boats have engine rooms containing inboard propulsion engines that generate noise during operation. Even when the propulsion engines are not operating, noise pollution can emanate from the engine room which will also house generators, air conditioning compressors, water pumps, bilge pumps, battery chargers, fuel polishers and the like. While the noise from engine rooms is expected when the propulsion engines are operating, the noise while moored at dock, or while anchored, can be most annoying. Typically, a boat manufacturer will outfit the cabins adjacent to an engine room with carpeting to lessen the noise. Carpeting tends to absorb and retain moisture, leading to mildew growth, unpleasant odors, and degradation of the carpet and underlying wood flooring. Cleaning carpeted surfaces on a boat can be time-consuming and challenging, especially in areas with limited ventilation.

What is lacking in the industry is a plywood composition that has superior water resistance and includes acoustic insulation.

SUMMARY OF THE INVENTION

Disclosed is a unique plywood and process of manufacturing. The plywood has high water resistance and an acoustic sound barrier integrally formed. In a preferred embodiment, the product and process employs a 4 mm thick plank of Okoume wood as a base, with a layer of a sound barrier adhesively attached thereto for use in reducing or blocking the transmission of sound waves. An upper layer is formed from a 4 mm thick plank of Okoume wood secured to the sound barrier with an adhesive, and a wear layer formed from a thick wood veneer is secured to the upper layer. The layers are permanently bonded together using at least 15 psi and a cure period of about 8 hours.

An objective of the invention is to provide a marine grade floor that includes an acoustic sound barrier.

Another objective of the invention is to provide a plywood flooring material that can literally be submerged in water for weeks without warping or other damage to the wood.

Still another objective of the invention is to provide flooring for boats that is aesthetically pleasing and is not affected due to leaking windows, doors, plumbing, AC units, ice makers, or defrosting refrigerators/freezers.

Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings, wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a flooring plank of the instant invention;

FIG. 2 is a cross-sectional view thereof; and

FIG. 3 is a flow diagram for the process of making the instant flooring plank.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

While the present invention is susceptible of embodiments in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. All materials, thicknesses and substrates are subject to change to meet the particular installation. The following is a preferred embodiment for use with marine vessels.

Referring to FIGS. 1 and 2, depicted is a flooring plank 10 constructed of a plywood. In this embodiment the ply is Okoume wood from the Okoume tree (Aucoumea klaineana) which is lightweight compared to other hard woods, making it suitable for marine and recreational vehicle applications where weight is a concern. Okoume wood is naturally resistant to warping and has a resistance to moisture. Other types of ply may be used and is selected based upon the particular application.

In the embodiment having a preferred application to a boat, a plywood plank is constructed from 4 mm Okoume wood 12 used for a base. An acoustic sound barrier 16 is attached to the base layer of Okoume wood 12 using an adhesive 14. The acoustic sound barrier 16 is constructed and arranged to reduce or block the transmission of sound waves. The barrier 16 is especially useful in marine and RV applications wherein flooring can be placed over an engine or drive train to help isolate the noise emitted from the engine room or from road noise. In one embodiment, the acoustic sound barrier 16 is known as tuff mass. An upper layer 20 of Okoume wood, having a 4 mm thickness is adhesively secured to the top face of the acoustic sound barrier 16 by a layer of adhesive 18. A wear layer composed of an engineered veneer 24, approximately 2.4 mm ( 3/32″) thick, is adhered to the top face of the Okoume wood upper layer 20 by an adhesive layer 22. In a preferred embodiment, the veneer 24 is made of Okoume. However, other hardwood species, such as Douglas fir, mahogany, or the like, could be used as they are known for their strength and resistance to water damage. The layers are placed under a press or clamped at a minimum pressure of 15 psi for at least 8 hours to fully bond the layers together.

The flooring plank 10 includes interlocking joinery, such as tongue 28 and groove 30, to facilitate installation. Preferably, the flooring planks are cut by use of a Computer Numeric Control, or CNC. The whole plank will be sealed with epoxy 34 for water resistance, and the face 26 will be sprayed with a clear matte coat 32. The plywood flooring planks 10 can be outfitted to the cabin floor of a boat, which further operates to insulate a boat's engine room. The use of insulation in the flooring helps contain and manage the heat generated by internal combustion engines. The insulation helps to contain the heat by reducing the ability of engine heat to spread through the flooring and to other areas of the boat. Further, boat engines can be quite loud as they are placed in an enclosed engine room. The plywood of the instant invention can significantly reduce engine noise, making the boat more enjoyable for passengers and crew. Similarly, reducing road noise in a recreational vehicle (RV) can significantly enhance the overall comfort of the passengers. Using the plywood of the instant invention can help reduce noise from both the road and the engine, creating a quieter living space.

Referring to FIG. 3, disclosed is a method for manufacturing a flooring plank, comprising the steps of providing a) a base formed of Okoume wood; b) placing a first adhesive layer to a top of said base; c) positioning an acoustic sound barrier over said first adhesive layer; d) placing a second adhesive layer over said sound barrier; e) positioning an upper layer of Okoume wood onto a top face of said second adhesive layer; f) placing a third adhesive layer to a top of said upper layer; g) attaching a veneer wear layer onto said third adhesive layer; h) applying a pressure of at least 15 psi, squeezing said base and said veneer wear layer together for a period of about 8 hours to form an Okoume plywood plank; i) forming interlocking joinery on at least one edge of said plywood plank; j) sealing the plywood plank with an epoxy to provide water resistance; and k) spraying a clear matte coating on the upper surface of said veneer layer to obtain a desired texture. In a preferred embodiment, once the layers are stacked, the entire assembly is placed into a press. The press applies pressure to bond the layers together. Preferably, the press includes heat to liquefy the adhesive layers and assure grain integration.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Claims

1. A method for manufacturing a flooring plank, comprising the steps of providing a) a base formed of Okoume; b) placing a first adhesive layer to a top of said base; c) positioning an acoustic sound barrier over said first adhesive layer; d) placing a second adhesive layer over said sound barrier; e) positioning an upper layer of plywood onto a top face of said second adhesive layer; f) placing a third adhesive layer to a top of said upper layer; g) attaching a veneer wear layer onto said third adhesive layer; h) applying a pressure of at least 15 psi to squeeze said veneer wear layer to said base for a period of about 8 hours to form a plywood plank; i) forming interlocking joinery on at least one edge of said plywood plank; and j) sealing the work piece with an epoxy to provide water resistance.

2. The method of claim 1, wherein said plywood is Okoume.

3. The method of claim 1, wherein said first and second adhesive layers are a proprietary adhesive constructed and arranged to bond said acoustic sound barrier to said base and upper layer of wood.

4. The method of claim 1, wherein the step of attaching the veneer wear layer comprises using a bonding agent to adhere the veneer securely to the upper layer of wood.

5. The method of claim 1, wherein said epoxy is applied in a controlled thickness to ensure uniform water resistance across the plank outer surface.

6. The method of claim 1, including the step of spraying a matte coat on the face of the veneer in a controlled manner to achieve a desired level of surface texture and appearance.

7. The method of claim 2, wherein said Okoume wood is 4 mm in thickness.

8. The method of claim 1, wherein said veneer is 2.4 mm thick.

9. The method of claim 1, wherein said bond acoustic sound barrier extends through said interlocking joinery.

10. A flooring plank comprising: a base formed of plywood; a first adhesive layer to a top of said base; an acoustic sound barrier over said first adhesive layer; a second adhesive layer over said sound barrier; an upper layer of plywood onto a top face of said second adhesive layer; a third adhesive layer to a top of said upper layer; and a veneer wear layer onto said third adhesive layer.

11. The flooring plank according to claim 10 wherein said plywood is Okoume.

12. The flooring plank according to claim 10 wherein said flooring plank includes interlocking joinery with said acoustical sound barrier extending through said joinery.

13. The flooring plank according to claim 10 wherein said flooring plank is sealed to provide water resistance.

14. The flooring plank according to claim 10 wherein said Okoume wood is 4 mm in thickness.

15. The flooring plank according to claim 10 wherein said veneer is 2.4 mm thick.