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.

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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a perspective view of a flooring plank of the instant invention;

[0015] FIG. 2 is a cross-sectional view thereof; and

[0016] FIG. 3 is a flow diagram for the process of making the instant flooring plank.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0017] 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.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] 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.