US20060185304A1 - Method of manufacturing a flooring panel - Google Patents

Method of manufacturing a flooring panel Download PDF

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Publication number
US20060185304A1
US20060185304A1 US11/342,813 US34281306A US2006185304A1 US 20060185304 A1 US20060185304 A1 US 20060185304A1 US 34281306 A US34281306 A US 34281306A US 2006185304 A1 US2006185304 A1 US 2006185304A1
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US
United States
Prior art keywords
slats
flooring panel
flooring
filler material
backing board
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/342,813
Inventor
Goran Wijkmark
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kasthall Mattor och Golv AB
Original Assignee
Kasthall Mattor och Golv AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kasthall Mattor och Golv AB filed Critical Kasthall Mattor och Golv AB
Publication of US20060185304A1 publication Critical patent/US20060185304A1/en
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/048—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top surface of assembled elongated wooden strip type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27M—WORKING OF WOOD NOT PROVIDED FOR IN SUBCLASSES B27B - B27L; MANUFACTURE OF SPECIFIC WOODEN ARTICLES
    • B27M3/00—Manufacture or reconditioning of specific semi-finished or finished articles
    • B27M3/04—Manufacture or reconditioning of specific semi-finished or finished articles of flooring elements, e.g. parqueting blocks
    • B27M3/06—Manufacture or reconditioning of specific semi-finished or finished articles of flooring elements, e.g. parqueting blocks of composite floor plates per se by assembling or jointing the parqueting blocks
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/022—Flooring consisting of parquetry tiles on a non-rollable sub-layer of other material, e.g. board, concrete, cork
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/041—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members with a top layer of wood in combination with a lower layer of other material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/045—Layered panels only of wood
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/04—Flooring or floor layers composed of a number of similar elements only of wood or with a top layer of wood, e.g. with wooden or metal connecting members
    • E04F15/045—Layered panels only of wood
    • E04F15/046—Plywood panels

Definitions

  • the present invention relates to a method of manufacturing a flooring panel.
  • Each slat has a length of about 160 mm, a width of about 8 mm and a thickness of about 20-22 mm.
  • Such slats are put side by side in parallel to a length of about 400 mm and are provided with adhesive tape to form a packet or panel with a length of 400 mm, a width of 160 mm and a thickness of 20-22 mm.
  • Such panels are consecutively glued to a sub-floor to form a covering flooring.
  • the flooring When the flooring is completed, it is ground at least two times. A filler material is manually applied over the surface by means of a putty knife or the like, and the flooring is again ground two times. Thereafter, it can be lacquered or oiled to receive its final appearance.
  • the entire laying and surface treatment process is very lengthy and expensive. It may take 5 days to lay a floor of 500 m2, 2-3 days to grind it, 2 days to apply the filler material, 1-2 days to grind again, and 1-2 days to apply lacquer or oil, whereupon a couple of days are needed for drying, i.e., altogether about two weeks.
  • a further disadvantage is of course that grinding dust and noise are spread in the room in question as well as in neighboring rooms.
  • the invention is directed to a manufacturing process for a flooring panel, comprising the steps of:
  • FIG. 1 is a perspective view of a flooring panel obtained by a method according to the invention.
  • FIG. 2 is a view from the right in FIG. 1 (and on a larger scale) of a portion of the flooring panel.
  • a rectangular flooring panel 1 includes a great number of wooden slats 2 with a generally square cross-section, glued to a backing board 3 transversely to the longitudinal direction of the panel 1 .
  • the backing board 3 preferably consists of a plywood board.
  • the panel 1 is on its side or edge surfaces provided with grooves and tongues for enabling connection to other similar panels on a sub-floor or floor substrate to form a wooden floor.
  • Each such flooring panel 1 is manufactured in the following way:
  • the wooden slats 2 (of a kind of wood suitable for flooring purposes) are produced in a dimension of, for example, 190 mm ⁇ 10 mm ⁇ 10 mm. These slats are mixed, so that the final flooring panel 1 provides an heterogenous and lively appearance, and are glued on the backing board 3 .
  • This backing board may have a thickness of 10 mm or more, a length of 1200 mm, and a width of 190 mm and is preferably a plywood board.
  • the slats 2 are glued transversely to the longitudinal direction of the plywood board 1 .
  • a transparent filler material which preferably is quickly hardening and may comprise 1,1-1,4-butandioldiacrylate, is applied over the wooden slats 2 , so that it covers the slats and fills all possible cracks or slots in or between the wooden slats and effectively locks the slats 2 together.
  • One important effect is that it will later be possible to perform a sawing or milling operation without any risk for the slats 2 to break up or break away.
  • the next operation is to saw and/or mill the flooring panel 1 into its final rectangular form with a width of 160 mm or 170 mm.
  • the flooring panel 1 is simultaneously herewith provided with grooves and tongues at all edge surfaces.
  • the filler material on and between the slats 2 will prevent the slats from splintering during this operation.
  • the further step is to grind away the filler material covering the slats 2 down to a clean wood surface, which means that the filler material remains between the slats and continues to provide the above advantages.
  • a final step in the manufacturing process may now be to apply a suitable lacquer in an industrial process, but it is alternatively possible to deliver the flooring panel without any surface treatment.
  • surface treatment for example application of a suitable oil, can be performed after laying the flooring panels to a floor, as is well known in the art.
  • the obtained flooring panels are comparatively heavy, which means that glue may be applied only in dots and does not necessarily need to be applied over the entire substrate. It may even be possible to lay the flooring panels without glue and to rely on the locking obtained by the grooves and tongues of the flooring panels, possibly strengthened by glue therein.
  • the applied filler material will still provide the advantage of keeping the slots 2 together and stabilize the structure.

Abstract

A method of manufacturing a flooring panel is described which involves (a) gluing wooden slats in a covering fashion on a backing board, (b) applying a filler material over the wooden slats in such a manner that openings in or between the slats are filled, (c) forming the backing board with the wooden slats into a flooring panel with desired dimensions, and (d) grinding the upper surface of the flooring panel down to a clean wood surface.

Description

    FIELD OF INVENTION
  • The present invention relates to a method of manufacturing a flooring panel.
    • BACKGROUND OF THE INVENTION
  • There is presently on the market a flooring of parquet-type comprising thin or narrow wooden slats. Each slat has a length of about 160 mm, a width of about 8 mm and a thickness of about 20-22 mm. Such slats are put side by side in parallel to a length of about 400 mm and are provided with adhesive tape to form a packet or panel with a length of 400 mm, a width of 160 mm and a thickness of 20-22 mm.
  • Such panels are consecutively glued to a sub-floor to form a covering flooring.
  • When the flooring is completed, it is ground at least two times. A filler material is manually applied over the surface by means of a putty knife or the like, and the flooring is again ground two times. Thereafter, it can be lacquered or oiled to receive its final appearance.
  • The entire laying and surface treatment process is very lengthy and expensive. It may take 5 days to lay a floor of 500 m2, 2-3 days to grind it, 2 days to apply the filler material, 1-2 days to grind again, and 1-2 days to apply lacquer or oil, whereupon a couple of days are needed for drying, i.e., altogether about two weeks.
  • A further disadvantage is of course that grinding dust and noise are spread in the room in question as well as in neighboring rooms.
  • Although a homogenous wooden flooring accomplished in the described way is very high-class and beautiful, there is a need to provide a flooring material with the same appearance but without the drawbacks inherent in the described flooring.
    • SUMMARY OF THE INVENTION
  • The invention is directed to a manufacturing process for a flooring panel, comprising the steps of:
  • a) gluing wooden slats in a covering fashion on a backing board,
  • b) applying a filler material over the wooden slats in such a manner that cracks or slots in or between the slats are filled,
  • c) forming the backing board with its wooden slats into a flooring panel with desired dimensions, and
  • d) grinding the upper surface, namely the exposed slat surface, of the flooring panel down to a clean wood surface.
  • Further features of the invention are described below.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • The invention will be described in further detail below with reference to the accompanying drawing, in which
  • FIG. 1 is a perspective view of a flooring panel obtained by a method according to the invention, and
  • FIG. 2 is a view from the right in FIG. 1 (and on a larger scale) of a portion of the flooring panel.
    • BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
  • A rectangular flooring panel 1 includes a great number of wooden slats 2 with a generally square cross-section, glued to a backing board 3 transversely to the longitudinal direction of the panel 1. The backing board 3 preferably consists of a plywood board. In a preferred and shown embodiment, the panel 1 is on its side or edge surfaces provided with grooves and tongues for enabling connection to other similar panels on a sub-floor or floor substrate to form a wooden floor.
  • Each such flooring panel 1 is manufactured in the following way:
  • The wooden slats 2 (of a kind of wood suitable for flooring purposes) are produced in a dimension of, for example, 190 mm×10 mm×10 mm. These slats are mixed, so that the final flooring panel 1 provides an heterogenous and lively appearance, and are glued on the backing board 3. This backing board may have a thickness of 10 mm or more, a length of 1200 mm, and a width of 190 mm and is preferably a plywood board. As stated, the slats 2 are glued transversely to the longitudinal direction of the plywood board 1.
  • A transparent filler material, which preferably is quickly hardening and may comprise 1,1-1,4-butandioldiacrylate, is applied over the wooden slats 2, so that it covers the slats and fills all possible cracks or slots in or between the wooden slats and effectively locks the slats 2 together. One important effect is that it will later be possible to perform a sawing or milling operation without any risk for the slats 2 to break up or break away.
  • The next operation is to saw and/or mill the flooring panel 1 into its final rectangular form with a width of 160 mm or 170 mm. In a preferred case, the flooring panel 1 is simultaneously herewith provided with grooves and tongues at all edge surfaces. As said, the filler material on and between the slats 2 will prevent the slats from splintering during this operation.
  • The further step is to grind away the filler material covering the slats 2 down to a clean wood surface, which means that the filler material remains between the slats and continues to provide the above advantages.
  • A final step in the manufacturing process may now be to apply a suitable lacquer in an industrial process, but it is alternatively possible to deliver the flooring panel without any surface treatment. In the latter case, surface treatment, for example application of a suitable oil, can be performed after laying the flooring panels to a floor, as is well known in the art.
  • The obtained flooring panels are comparatively heavy, which means that glue may be applied only in dots and does not necessarily need to be applied over the entire substrate. It may even be possible to lay the flooring panels without glue and to rely on the locking obtained by the grooves and tongues of the flooring panels, possibly strengthened by glue therein.
  • As an alternative to the use of locking together different flooring panels by means of grooves and tongues, other known joining techniques, such as by clips, may be used. It is even possible to lay the flooring panels without joining them together. By its construction, the flooring panel is very stable against effects of moisture.
  • If certain flooring panels need to be cut at the laying in order to obtain adaptation to the surface to be covered, the applied filler material will still provide the advantage of keeping the slots 2 together and stabilize the structure.

Claims (8)

1. A method of manufacturing a flooring panel comprising:
(a) gluing wooden slats in a covering fashion on a backing board,
(b) applying a filler material over the wooden slats in such a manner that openings in or between the slats are filled with said filler material,
(c) forming the backing board with said wooden slats into a flooring panel with an exposed slat surface, and
(d) grinding the exposed slat surface down to a clean wood surface.
2. A method according to claim 1, wherein the backing board is provided with grooves and tongues at side edges thereof in step (c).
3. A method according to claim 1, wherein the backing board is a plywood board.
4. A method according to claim 1, wherein the filler material comprises a transparent, quick-hardening material.
5. A method according to claim 4, wherein the filler material comprises 1,1-1,4-butandioldiacrylate.
6. A method according to claim 1, wherein each of said wooden slats has a cross-sectional dimension of 10 mm×10 mm.
7. A method according to claim 3, wherein the plywood board has a thickness of 10 mm or more.
8. A method according to claim 1, wherein the flooring panel has a length of about 1200 mm and a width of about 160-170 mm and wherein the wooden slats are glued to the backing board in a direction transverse to a longitudinal direction of the flooring panel.
US11/342,813 2005-02-07 2006-01-31 Method of manufacturing a flooring panel Abandoned US20060185304A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE0500280-3 2005-02-07
SE0500280A SE529641C2 (en) 2005-02-07 2005-02-07 Ways to make a floor panel

Publications (1)

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US20060185304A1 true US20060185304A1 (en) 2006-08-24

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EP (1) EP1688560A3 (en)
SE (1) SE529641C2 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5097604B2 (en) * 2008-04-16 2012-12-12 オリンパス株式会社 Wood molding method
CN106013717B (en) * 2016-07-18 2018-04-06 嘉兴隆宜家具有限公司 A kind of three-layer wood composite flooring and its processing method

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1925070A (en) * 1930-10-04 1933-08-29 Bruce E L Co Laying wood block flooring
US2252430A (en) * 1938-07-23 1941-08-12 W M Ritter Lumber Company Composite flooring product
US3365850A (en) * 1965-03-03 1968-01-30 Mari & Sons Flooring Co Inc Dimensionally stable wood flooring
US4233793A (en) * 1975-07-07 1980-11-18 Omholt Ray Resiliently cushioned adhesive-applied wood flooring system and method of making the same
US4360992A (en) * 1978-11-22 1982-11-30 Marino Vincent J Dimensionally stable wood flooring
US5894700A (en) * 1997-08-04 1999-04-20 Triangle Pacific Corporation Glue-down prefinished wood flooring product
US6247285B1 (en) * 1997-10-04 2001-06-19 Maik Moebus Flooring panel
US6546691B2 (en) * 2000-12-13 2003-04-15 Kronospan Technical Company Ltd. Method of laying panels
US20030233809A1 (en) * 2002-04-15 2003-12-25 Darko Pervan Floorboards for floating floors
US20040074190A1 (en) * 2000-10-08 2004-04-22 Hai Lin Two-ply flooring having a cross-grain bottom ply

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH255650A (en) * 1947-04-05 1948-07-15 Eggstein Julius End-grain parquet floor.
FR1117506A (en) * 1954-12-10 1956-05-23 Floor consisting of the assembly of wooden blocks cut perpendicular to the grain direction
FR2039506A5 (en) * 1969-04-01 1971-01-15 Michalopoulos Spiridion Mosaic floors with joints of thermoplastic - material
JPS5923324B2 (en) * 1976-11-29 1984-06-01 三菱油化株式会社 Oil-modified alkyd resin composition
FR2811355B1 (en) * 2000-07-05 2003-06-20 Geroclair Sa PARQUET ELEMENT WITH COMPENSATING JOINTS

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1925070A (en) * 1930-10-04 1933-08-29 Bruce E L Co Laying wood block flooring
US2252430A (en) * 1938-07-23 1941-08-12 W M Ritter Lumber Company Composite flooring product
US3365850A (en) * 1965-03-03 1968-01-30 Mari & Sons Flooring Co Inc Dimensionally stable wood flooring
US4233793A (en) * 1975-07-07 1980-11-18 Omholt Ray Resiliently cushioned adhesive-applied wood flooring system and method of making the same
US4360992A (en) * 1978-11-22 1982-11-30 Marino Vincent J Dimensionally stable wood flooring
US5894700A (en) * 1997-08-04 1999-04-20 Triangle Pacific Corporation Glue-down prefinished wood flooring product
US6247285B1 (en) * 1997-10-04 2001-06-19 Maik Moebus Flooring panel
US20040074190A1 (en) * 2000-10-08 2004-04-22 Hai Lin Two-ply flooring having a cross-grain bottom ply
US6546691B2 (en) * 2000-12-13 2003-04-15 Kronospan Technical Company Ltd. Method of laying panels
US20030233809A1 (en) * 2002-04-15 2003-12-25 Darko Pervan Floorboards for floating floors

Also Published As

Publication number Publication date
SE0500280L (en) 2006-08-08
SE529641C2 (en) 2007-10-09
EP1688560A3 (en) 2008-04-30
EP1688560A2 (en) 2006-08-09

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