U.S. patent application number 12/116062 was filed with the patent office on 2009-11-12 for composite foorboard.
Invention is credited to Cheng-Yen Chen.
Application Number | 20090277128 12/116062 |
Document ID | / |
Family ID | 41265738 |
Filed Date | 2009-11-12 |
United States Patent
Application |
20090277128 |
Kind Code |
A1 |
Chen; Cheng-Yen |
November 12, 2009 |
COMPOSITE FOORBOARD
Abstract
A composite floorboard is formed by two outer wooden layers and
an intermediate flexible layer which has two longitudinal edges,
two transverse edges. The flexible layer may be foam, sponge or any
kinds of soundproof material. The composite floorboard has two
surfaces, a transverse tongue, a longitudinal tongue, a
longitudinal groove and a transverse groove each respectively
defined in or formed on corresponding edges of the composite
floorboard. Because the tongues are made by the flexible layer, the
composite floorboard is easy and convenient to assemble. Because
the flexible layer acts as a buffer, the composite floorboard
provides a soundproofing function. The composite floorboard also
requires less timber so may be lower cost to manufacture.
Inventors: |
Chen; Cheng-Yen; (Fongyuan
City, TW) |
Correspondence
Address: |
APEX JURIS, PLLC
12733 LAKE CITY WAY NORTHEAST
SEATTLE
WA
98125
US
|
Family ID: |
41265738 |
Appl. No.: |
12/116062 |
Filed: |
May 6, 2008 |
Current U.S.
Class: |
52/782.1 ;
52/588.1 |
Current CPC
Class: |
E04F 15/02 20130101;
E04F 2201/043 20130101; E04C 2/12 20130101 |
Class at
Publication: |
52/782.1 ;
52/588.1 |
International
Class: |
E04B 5/02 20060101
E04B005/02; E04C 2/00 20060101 E04C002/00; E04F 15/16 20060101
E04F015/16 |
Claims
1. A composite floorboard comprising two wooden layers and a
flexible layer, wherein the flexible layer is mounted between the
two wooden layers.
2. The composite floorboard as claimed in claim 1, wherein each of
the two wooden layers and the flexible layer has two longitudinal
edges and two transverse edges.
3. The composite floorboard as claimed in claim 1, wherein the
composite floorboard comprises two longitudinal edges; two
transverse edges; a transverse tongue protruding a distance from
one of the transverse edges of the composite floorboard; a
longitudinal tongue protruding a distance from one of the
longitudinal edges of the composite floorboard; a longitudinal
groove being defined in the composite floorboard at the other
longitudinal edge and having a depth equal to the distance of the
longitudinal tongue; and a transverse groove being defined in the
composite floorboard at the other transverse edge and having a
depth equal to the distance of the transverse tongue.
4. The composite floorboard as claimed in claim 1, wherein each
wooden layer further comprises a longitudinal strut and a
transverse strut respectively formed on and protruding from the
longitudinal and transverse edges of the wooden layer those
correspond to the tongues of the composite floorboard; and a
longitudinal step and a transverse step being respectively defined
in the longitudinal and transverse edges of the wooden layer those
correspond to and align with the grooves of the composite
floorboard.
5. The composite floorboard as claimed in claim 4, wherein the
struts are 0.5 mm to 1.0 millimeter (mm) in thickness; and the
steps are 0.5 mm to 1.0 mm in depth.
6. The composite floorboard as claimed in claim 1, wherein the
flexible layer is a foam layer.
7. The composite floorboard as claimed in claim 1, wherein the
flexible layer is a cork layer.
8. The composite floorboard as claimed in claim 1, wherein the
flexible layer is a rubber layer.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a composite floorboard,
more particular to a composite floorboard that has integrated
soundproofing and uses less wood.
[0003] 2. Description of the Related Art
[0004] Composite floorboards are frequently used in living areas,
such as living rooms and bedrooms and are preferred over stone or
linoleum since. Its wood surface is more pleasant to touch and adds
a natural feeling to rooms.
[0005] Conventional composite floorboards use tongue and groove
connections, wherein bilateral edges of each floorboard are
protrudent as a tongue, or recessed as a groove. The tongue of the
composite floorboard is inserted into a groove of an adjacent
composite floorboard. Since the tongue and the groove are formed
directly from the solid wood, therefore, it is less flexible and
requires more effort to install.
[0006] Further, conventional composite floorboard has poor sound
insulation. Therefore, a soundproof material, such as acoustic
matting is set under the composite floorboard which further
increases the complexity. Furthermore, in regions of high
temperature and humidity, the composite floorboards may move, curve
or twist after being laid. Importantly, the composite floorboards
are solidly formed from wood, meaning manufacturing costs of
composite floorboards is high.
[0007] To overcome the shortcomings, the present invention provides
a composite floorboard to mitigate the aforementioned problems.
SUMMARY OF THE INVENTION
[0008] The primary objective of the present invention is to provide
a composite floorboard having integrated soundproofing and uses
less wood.
[0009] The composite floorboard in accordance with the present
invention comprises two longitudinal edges, two transverse edges, a
flexible layer and two wooden layers. The flexible layer may be
foam, sponge or any soundproofing material and has two surfaces, a
transverse tongue, a longitudinal tongue, a longitudinal groove and
a transverse groove each respectively defined in or formed on
corresponding edges of the composite floorboard. The wooden layers
are respectively mounted on the surfaces of the flexible layer.
Because the tongues are made by the flexible layer, the composite
floorboard is easy and convenient to assemble. Because, the
flexible layer acts as a cushion, the composite floorboard provides
a soundproofing function. The composite floorboard also uses less
wood so may be lower cost to manufacture.
[0010] Other objectives, advantages and novel features of the
invention will become more apparent from the following detailed
description when taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded perspective view of composite
floorboards of a first embodiment of the present invention;
[0012] FIGS. 2A and 2B are operational cross sectional views of the
composite floorboard of FIG. 1 being combined;
[0013] FIG. 3 is a perspective view of the composite floorboards of
FIG. 1, shown mounted together; and
[0014] FIGS. 4A and 4B are cross sectional views of a second
embodiment of a composite floorboard of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] With reference to FIGS. 1, 2A and 2B, a preferred embodiment
of the present invention of a composite floorboard (10) is
substantially quadrangular, may be rectangular or square and has
two longitudinal edges, two transverse edges, a flexible layer (12)
and two wooden layers (11).
[0016] The composite floorboard (10) has two surfaces, a transverse
tongue (13), a longitudinal tongue (14), a longitudinal groove (15)
and a transverse groove (16). The transverse tongue (13) and
longitudinal tongue (14) respectively protrude from one of the
longitudinal and transverse edges of the composite floorboard (10).
The longitudinal groove (15) and the transverse groove (16) are
respectively defined at the other longitudinal and transverse edges
of the composite floorboard (10).
[0017] Each tongue (13, 14) protrudes a distance from the
respective edge and fits in a corresponding groove (15, 16) of
another composite floorboard (10). Each groove (15, 16) has a depth
equal to the distance of the tongues (13, 14).
[0018] The wooden layers (11) are respectively mounted on the
surfaces of the flexible layer (12). Each wooden layer (11) has two
longitudinal edges, two transverse edges, a longitudinal strut
(111), a transverse strut, a longitudinal step (113) and a
transverse step. The struts (111) are respectively formed on and
protrude from the longitudinal and transverse edges of the wooden
layers (11) corresponding to the tongues (13, 14) of the flexible
layer (12) and may be between 0.5 to 1 mm thick. The steps (113)
are respectively defined in the longitudinal and transverse edges
of the wooden layer (11) corresponding to and aligning with the
grooves (15, 16) and may be about 0.5 mm to 1 mm deep.
[0019] The flexible layer (12) is mounted between the wood layers
(11). The flexible layer (12) may be foam, sponge, cork, rubber or
any kinds of conventional soundproof materials. The dimension of
the flexible layer (12) is smaller than the wood layer (11) and has
a first longitudinal edge, a second longitudinal edge, a first
transverse edge and a second transverse edge. When the flexible
layer (12) is mounted between the wood layers (11), the first
longitudinal edge and the transverse edge of flexible layer (12)
are respectively aligned with the struts (111) of the wood layers
(11) and forms the tongues (13, 14) of the composite floorboard
(10). The second longitudinal edge and the second transverse edge
of the flexible layer (12) are respectively aligned with the steps
(113). Further with reference to FIG. 3, when assembling the
composite floorboard (10) of the present invention, the tongues
(13, 14) are inserted into the grooves (15, 16) of the adjacent
composite floorboard (10). Since the tongues (13, 14) are formed by
the flexible layer (12) and maybe by the struts (111), the struts
(111) and tongues (13, 14) are flexible and are easily inserted
into the grooves (15, 16) in the composite floorboard (10).
[0020] With reference to FIG. 4, a composite floorboard (20) of
another preferred embodiment of the present invention, the
composite floorboard (20) has two wood layers (21) and a flexible
layer (22). The wood layer (21) has a first longitudinal edge, a
second longitudinal edge, a first transverse edge and a second
transverse edge. The surface dimension of the flexible layer (22)
is approximately equal to that of the wood layers (21). The
flexible layer (22) is mounted between the wood layers (21) and has
a first longitudinal edge, a second longitudinal edge, a first
transverse edge, and a second transverse edge. The first
longitudinal edge and the first transverse edge of the flexible
layer (22) extend out of the first longitudinal edge and the first
transverse edge of the wood layer (21) and form the tongues (23) of
the composite floorboard (20). Because the flexible layer (22)
extends out the first longitudinal edge and the first transverse
edge of the wood layers (21), the grooves (24) will be formed at
the second longitudinal edge and the second transverse edge of the
composite floorboard (20).
[0021] The present invention provides a composite floorboard with
the flexible layer mounted between two wooden layers. This flexible
layer provides a cushion function of the composite floorboard when
in use and is also convenient for assembling the composite
floorboard. The flexible layer also provides an optional
moisture-proof function, so that the humid air will be stopped and
will not make the composite floorboard out of shape. With the
flexible layer made by foam, sponge or any kind of soundproof
materials, the composite floorboard provides a soundproof function
and does not require laying of an acoustic matting, therefore
simplifying and reducing end-user installation costs thereof. Also,
the composite floorboard is made using two wooden layers and a
flexible layer, so requires less wood. Therefore, production costs
of the composite floorboard may be reduced.
[0022] Even though numerous characteristics and advantages of the
present invention have been set forth in the foregoing description,
together with details of the structure and features of the
invention, the disclosure is illustrative only. Changes may be made
in the details, especially in matters of shape, size, and
arrangement of parts within the principles of the invention to the
full extent indicated by the broad general meaning of the terms in
which the appended claims are expressed.
* * * * *