WOODEN PLATE AND ELASTIC JOINING MEMBER, AND WOODEN FLOOR USING THE SAME
Technical Field The present invention relates a wooden plate and elastic coupling member that can be easily assembled, disassembled and removed, and a wooden floor using the same. More specifically, the present invention relates to a wooden floor that can be partially replaced by assembling it using the elastic coupling member.
Background Art Wooden plates are widely used in the building such as houses or apartments.
This is because the atmosphere in the house can be gentle and mild when the wooden plates are used for a wooden floor. FIGS, la to lc show plates used in a conventional wooden floor. As seen from
FIGS, la and lb, the conventional plate 10 is formed with a protrusion 13 at one side thereof and with a groove 11 at the other side thereof. As shown in FIG. lc, the protrusions 13 are fitted into the corresponding recesses 11, respectively, so that these plates 10 can be assembled into the wooden floor 20. The wooden floor 20 is bonded onto the ground in a state where the plates are fitted into one another. As a result, it is essentially impossible to partially replace the plates and difficult to remove the plates since the respective plates are also bonded onto the ground. Further, since the plates of the conventional wooden floor are bonded directly onto the ground, there are problems in that a user feels uncomfortable walking on the wooden floor, that noise generated in the upstairs is transmitted directly to the downstairs, and that the plates are decayed if the ground gets damp.
Summary of Invention Accordingly, an object of the present invention is to provide a wooden floor that can be partially assembled and disassembled, does not use an adhesive, and can be easily
removed. Another object of the present invention is to provide a wooden floor that is superior in sound/heat insulation and feeling of walking. A further object of the present invention is to provide a wooden floor that can be conveniently constructed to have a variety of patterns. According to an aspect of the present invention, there is provided a wooden plate, comprising one or more thin wooden layers, wherein respective sides of the plate are tapered downward from above and are formed with coupling grooves in longitudinal directions thereof. Preferably, when a decorative layer is laminated on a surface layer of the plate, a pulp layer is interposed between the decorative layer and the surface layer of the plate. According to another aspect of the present invention, there is provided an elastic coupling assembly, comprising a plurality of elastic coupling members which are connected with one another and arranged in the form of a lattice, wherein each of the elastic coupling members includes at least one body standing upright from the ground, coupling jaws that protrude bilaterally from and are integrally formed with an upper end of the body, and a reinforcing/supporting portion that extends horizontally from a lower end of the body. According to a further aspect of the present invention, there is provided a wooden floor, comprising a plurality of plates each of which respective sides are tapered and formed with coupling grooves in longitudinal directions thereof, and at least one elastic coupling assembly including a plurality of elastic coupling members which are connected with one another and arranged in the form of a lattice. Further, each of the elastic coupling members includes at least one body standing upright from the ground, coupling jaws that protrude from and are integrally formed with an upper end of the body, and areinforcing/supporting portion that extends horizontally from a lower end of the body, and the plates are fixed to the elastic coupling assembly by causing the coupling jaws of the elastic coupling members to be fitted into the coupling grooves formed on the sides of the plates.
Brief Description of Drawings The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in connection with the accompanying drawings, in which: FIGS, la to lc show respective unit plates and their assembly for use in a related art wooden floor; FIGS. 2a to 2c show the exterior appearance and configuration of a wooden plate according to the present invention; FIGS. 3a to 3c show a wooden plate with a plurality of recesses formed on a bottom surface thereof; FIG. 4 shows a modified embodiment of a wooden plate according to the present invention; FIG. 5 shows a wooden plate with a plurality of fixing grooves formed on a bottom surface thereof; FIGS. 6a to 6c show elastic coupling members and their assembly for flooring according to the present invention; FIGS. 7a to 7c show a modified embodiment of elastic coupling members and their assembly for flooring according to the present invention; and FIGS. 8a to 8c schematically illustrate a process of constructing the wooden floor according to the present invention.
Detailed Description of the Preferred Embodiment A wooden floor of the present invention is constructed in such a manner that a plurality of plates are inserted into an elastic coupling assembly by causing coupling jaws of elastic coupling members to be fitted into coupling grooves of the plates. In such a case, the coupling grooves are formed on lateral sides of the plates and the elastic coupling assembly is formed by connecting a plurality of the elastic coupling members with one another in the form of a lattice. Further, each of the elastic coupling members includes, as one unit, at least one body standing upright from the ground, coupling jaws that protrude bilaterally from and are integrally formed with an upper end of the body, and a
reinforcing/supporting portion that extends horizontally from a lower end of the body. According to the wooden floor so constructed, neighboring plates are not directly connected with each other but they are fixed to the ground through an elastic coupling member. According to the construction of the wooden floor, the coupling jaw of the elastic coupling member fixed to the ground is fitted into the coupling groove formed on the sides of the plate so that the plate can be supported by the elastic coupling member. That is, the wooden floor is constructed in such a manner that the elastic coupling member is first fixed to the ground and the plate is then press-fitted into and attached to the elastic coupling member. At this time, since at least two opposite sides, preferably four sides of the attached plate are supported by the elastic coupling member fixed to the ground, the plate can be firmly supported without using an additional adhesive. Therefore, the wooden floor can be partially disassembled and exchanged if desired, because it is completely unnecessary to use the adhesive when installing the individual plates to construct the wooden floor. Furthermore, costs, amounts of wastes, noise and the like can be greatly reduced since only the plates can be removed with the elastic coupling members kept intact even in a case where the plates are partially removed. Meanwhile, in the present invention, a space is formed between the ground and a bottom surface of the plate. Therefore, a load applied to the plate is transmitted to the body of the elastic coupling member, the reinforcing/supporting portion and an extending/supporting portion through lower lateral sides of the plate, and the bottom surface of the plate does not come into direct contact with the ground. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. A wooden plate according to the present invention will be first explained. FIG. 2a is a perspective view of a plate corresponding to a component of the wooden floor according to the present invention. Referring to this figure, a plate 100 is formed with coupling grooves 120 at lateral sides thereof and is divided into upper lateral sides 110 and lower lateral sides 130 by the coupling grooves. The coupling grooves are formed along at least two opposite lateral sides of the plate 100 in its longitudinal direction
and preferably along all the four sides thereof, whereby the plate can be firmly coupled with the neighboring plate. It is preferred that the lateral sides of the plate be inclined so that the upper sides of the neighboring plates cannot be in close contact with one another. This is because a partially damaged plate of the wooden floor can be easily removed since interference due to friction between the upper sides of the neighboring plates is minimized or eliminated. Thus, the sides of the plate 100 should be inclined inward from above, and their inclined angles may be properly changed depending on the shape of elastic coupling members for coupling the neighboring plates with each other. Such a type of construction in which longitudinal grooves are formed on the lateral sides of the plate 100 can be applied to various wooden plate. The structure of the plywood flooring will be described in a preferred embodiment of the present invention in consideration of its productivity and unit cost of production. The plywood flooring by nature has a structure in which a plurality of thin wooden layers are laminated. Thus, it is necessary to understand the structural characteristics of the plywood flooring if it can be employed in the present invention. FIG. 2b shows a sectional view of the plate 100 with a plurality of grooves formed thereon. Referring to this figure, the coupling grooves 120 are formed on all the lateral sides of the plate 100. The coupling grooves 120 are preferably formed along longitudinal centerlines of the sides, but may be changed depending on the shape of the elastic coupling members. An enlarged section A of a portion of the plate 100 shown in FIG. 2b illustrates the structure of respective layers of the plate 100, i.e. five layers 140, 142, 144, 146 and 148 that are integrally laminated with grain directions of the abutting layers different from each other. A decorative layer 150 is laminated on a top surface layer 140 with a pulp layer 152 inteφosed therebetween. The pulp layer 152 also performs a shock-absorbing function at a position between the decorative layer 150 and the surface layer 140. In a case where the plywood flooring is used as the plate 100, the grain directions of the respective layers thereof should be carefully considered. The wooden floor of the present invention is preferably constructed by causing the plates 100 to be bent and then coupled with the elastic coupling members. As shown in FIG. 2c, the grain direction of
the decorative layer 150 laminated on the surface layer 140 should be the same as that of the surface layer 140 so that If the plates 100 can be easily bent. However, if the grain directions of the decorative layer 150 and the surface layer 140 are the same as each other, there is a problem in that the two layers are apart from each other due to the same grain directions thereof To avoid this problem, the pulp layer 152 is preferably inteφosed between the decorative layer 150 and the surface layer 140 when the plywood flooring is used as a plate in the present invention. To facilitate coupling the plates with the elastic coupling members in the wooden floor according to the present invention, it is preferable to form other grooves on a bottom surface of the plate at a regular interval. These bottom grooves do not only prevent a bending phenomenon occurring at both ends of the plate in their longitudinal direction and allow the plates to be applied even to the curved ground, but also allow the plates to be easily bent so that the constructability of the plates can be greatly enhanced. FIGS. 3a and 3b show the plate 100 with the bottom grooves 160 formed on the bottom surface thereof at a regular interval. The bottom grooves 160 are preferably formed to extend from the bottom surface of the plate 100 toward a top surface thereof by a predetermined depth. In case of the plywood flooring in which a plurality of thin wooden layers are laminated, for example, it is preferable to form the bottom grooves 160 up to a layer 142 (FIG. 2c) just below the surface layer 140. At this time, it is preferred that the bottom grooves 160 be formed in accordance with the grain direction of the plate so that the plate can be easily bent. FIG. 3c shows a state where the plate 100 has been bent by a predetermined force applied to both ends thereof. With the help of the plurality of bottom grooves 160 formed on the bottom surface of the plate 100, the plate is elastically deformed so that the plate subjected to the force can be flexibly bent. The plate can be easily fitted into the elastic coupling member in such a bent state. FIG. 4 shows a case where a plurality of bottom grooves are employed in a panel plate 100'. As viewed from this figure, a plurality of horizontal bottom grooves 160a and vertical bottom grooves 160b are formed on a bottom surface 130' of the plate 100'. The plate 100' can be easily bent in the horizontal and vertical directions with the help of the
first and second bottom grooves 160a and 160b. Further, it is preferred that the bottom grooves be formed to extend almost up to a top surface 110' of the plate 100'. Furthermore, the wooden floor of the present invention may be provided with additional fixing grooves so that the plate 100 and the elastic coupling members can be firmly coupled with each other. FIG. 5 shows the plurality of fixing grooves formed on the bottom surface 130' of the plate 100. The fixing grooves 170a, 170b, 170c and 170d formed in a longitudinal direction of the plate 100 function to prevent a neighboring plate adjacent to the plate 100 from being apart from the plate 100. Further, the fixing grooves 180a, 180b and 180c formed in a transverse direction of the plate 100 function to increase the coupling force between the elastic coupling members and the plate with its end partially cut away (e.g., a plate installed at an edge area where the floor meets a wall). These fixing grooves formed on the bottom surface of the plate prevent the plate from being easily apart from the ground and a height difference between the installed plates from occurring in a case where the ground is not uniformly even but partially curved. FIG. 5 exemplifies the fixing grooves, but the number and positions of the fixing grooves may be variously changed in accordance with the use and construction state of the plate. Next, an elastic coupling member for supporting plates in the wooden floor according to the present invention will be explained in detail. FIG. 6a is a perspective view of an elastic coupling member according to an embodiment of the present invention. Referring to this figure, the elastic coupling member 200 is made of an elastic material, and comprises a body 230 that stands vertically from the ground, coupling jaws 220 that protrude from both sides of an upper end of the body to support vertical and lateral loads from the plate 100, and a reinforcing/supporting portion 240 that protrudes from lateral sides of a lower end of the body to additionally support a vertical load from the plate 100. Further, a bottom groove 250 is formed on a bottom surface of the body 230 along a longitudinal direction of the elastic coupling member 200. The bottom groove 250 flexibly copes with the deformation due to contraction/expansion of the plate 100 and increases the bonding area of the elastic coupling member 200, thereby allowing the elastic coupling member to be efficiently bonded onto the ground. Furthermore, a top groove
210 is formed along a centerline of the coupling jaws 220 in its longitudinal direction to classify the coupling jaws into left and right ones. The top groove 210 allows the coupling jaw 220 to be withdrawn when the plate 100 is fitted into the elastic coupling member 200. Thus, the top groove 210 functions to prevent the lower lateral side 130 of the plate 100 from being damaged and to allow the plate to be easily fitted into coupling member. The elastic coupling member 200 may be made of either polyolefin such as polypropylene, polyethylene and polybutene, or other materials such as polystyrene, acrylonitrile-butadiene-styrene, copolymer, polyamide, polyvinyl chloride or polycarbonate. In a special case, the elastic coupling member may be manufactured through a die casting process using non-ferrous metals such as aluminum and copper. FIG. 6b is a perspective view of an elastic coupling member according to another embodiment of the present invention. Referring to this figure, the elastic coupling member 202a comprises a body 232 that stands upright from the ground, and coupling jaws 222 that protrude bilaterally from and are integrally formed with an upper end of the body. Further, the elastic coupling member 202a is discontinuously connected with a neighboring elastic coupling member 202b through a reinforcing/supporting portion 242. Unlike in the previous embodiment shown in FIG. 6a, the reinforcing/supporting member 242 is formed to extend from a longitudinal end of the body rather than the lateral sides of the lower end of the body 232. A hole 252 is formed within the reinforcing/supporting portion 242, and functions to share vertical and horizontal loads applied to the body 232 with the coupling jaws and to support the plate 100. Furthermore, an extending/supporting portion 260 protrudes from a lateral side of the reinforcing/supporting portion 242 to be integrally formed with the portion 242. The extending/supporting portion 260 functions not only to distribute the vertical load applied to the elastic coupling member in a horizontal direction but also to connect with the reinforcing/supporting portion of the neighboring elastic coupling member so that a plurality of elastic coupling members are assembled into a single assembly. The elastic coupling member, the reinforcing/supporting portion and the extending/reinforcing portion described in connection with FIG. 6a becomes a single unit,
and a plurality of units may be integrally coupled with one another to construct an elastic coupling assembly. FIG. 6c shows an example of this elastic coupling assembly 200'. Referring to FIG. 6c, the elastic coupling assembly 200' includes a plurality of elastic coupling members 204 ("longitudinal elastic coupling members") that are arranged in the form of a lattice and integrally connected to one another through the reinforcing/supporting and extending/supporting portions 242 and 260, and a plurality of elastic coupling members 206 ("transverse elastic coupling members") that are formed peφendicular to the longitudinal elastic coupling members 204. The transverse elastic coupling members 206 function to restrict the longitudinal positions of the plate (not shown in this figure) coupled with the elastic coupling assembly 200'. In the meantime, the extending/supporting portion 260 is integrally formed with the reinforcing/supporting portion 242 connected to the elastic coupling member 204 and coupled with the portion 242 in a direction peφendicular to the longitudinal direction of the elastic coupling member 204. The extending/supporting portion 260 prevents the whole structure of the elastic coupling assembly 200' from being twisted due to the load applied thereto. Further, the portion 260 prevents itself from being bent when load is applied to the plate, since it supports from below the plate coupled with the elastic coupling member 204. The structure of the elastic coupling assembly 200' shown in FIG. 6c corresponds only to an example, and it is apparent that the other modified configuration can be made. Therefore, the flooring can be constructed in various patterns and artistic modes of expression according to the present invention. The elastic coupling assembly 200' may be manufactured as a single unit using the injection molding process and the like. A plurality of elastic coupling assembly units can be installed on the ground of a desired space in the building, if necessary. FIG. 7a is a perspective view of a modified elastic coupling member 300 according to a further embodiment of the present invention. In this embodiment, a body and coupling jaw are formed in a state where they are divided into right and left ones, respectively. That is, the body 330 are divided into first and second bodies 330a and 330b in right and left direction, and it is formed with the coupling jaws 320a and 320b protruding outward from both lateral sides of an upper ends thereof, respectively. This
structure allows the coupling jaws 320a and 320b to be elastically deformed more easily due to deformation of the plate coupled with the elastic coupling member 300, and thus, the constructability of the plate can be greatly enhanced. The bodies are separated from each other, but they are fixed to a longitudinal shock-absorbing portion 340 that is integrally formed with the bodies at lower rear ends thereof. Thus, the bodies generally function as a single structure. The longitudinal shock-absorbing portion 340 performs a function similar to the reinforcing/supporting portion 240 or 242 illustrated in the previous embodiment, and it can more effectively distribute the load applied to the elastic coupling member 300 since its own size and the size of a fixing groove 342 formed therein are relatively larger than those of the reinforcing/supporting portion. A transverse shock-absorbing portion 350 for performing another shock-absorbing function is also integrally formed with the longitudinal shock-absorbing portion 340. The transverse shock-absorbing portion 350 also performs a function similar to the extending/supporting portion 260 illustrated in the previous embodiment and it can distribute the load applied to the elastic coupling member 300 more effectively in a horizontal direction since its own size and the size of a fixing groove 342 formed therein are relatively larger than those of the extending/supporting portion. Moreover, the transverse shock-absorbing portion 350 is integrally coupled with the neighboring longitudinal shock-absorbing portion and functions to connect a plurality of elastic coupling members with one another. The elastic coupling member 300 in which the body 330 is divided into the right and left ones and the longitudinal and transverse shock-absorbing portions are included has an advantage in that it can be flexibly coupled with the plate while maintaining its own elasticity even in a case where it expands or contracts due to the change in temperature or heat (the plastic expands by 0.03% when its temperature increases by 1 °C). An example of a single elastic coupling assembly 300' into which the plurality of elastic coupling members 300 are assembled is shown in FIG. 7b. It can be seen from this figure that the plurality of shock-absorbing portions for performing the longitudinal and transverse shock-absorbing function cause a plurality of elastic coupling members
300a in the form of a lattice. In addition, a plurality of elastic coupling members 330b are arranged at a longitudinal end of the elastic coupling assembly 300' peφendicular to a direction in which the elastic coupling members 300a are arranged. It can also understood that the elastic coupling assembly 300' are provided with additional components adjacent to the respective elastic coupling members 300a and 300b. The additional components correspond to protrusions 360a and 360b fitted into a variety of fixing grooves that are formed on the bottom surface 130' of the plate 100 and also described in connection with FIG. 5. The protrusions 360a formed adjacent to the elastic coupling members 300a are fitted into the longitudinal fixing grooves 170a, 170b, 170c and 170d formed on the bottom surface of the plate, whereas the protrusions 360b formed adjacent to the other elastic coupling members 300b are fitted into the transverse fixing grooves 180a, 180b and 180c. The protrusions 360a and 360b are fitted into and coupled with the relevant fixing grooves so that the plate can be more tightly coupled with the elastic coupling assembly in both longitudinal and transverse directions. FIG. 7c is an enlarged view of a portion of the elastic coupling assembly 300' and shows a state where the protrusion 360a are fitted into the longitudinal fixing groove 170a in the plate 100. The plate 100 is fixed to the elastic coupling assembly in such a manner that it is engaged with the elastic coupling member 300a and its fixing groove 170a is also fitted into the protrusion 360a. It can be seen from this figure that the protrusion 360a takes the shape of trapezoid tapered from bottom to top. The trapezoidal shape of the protrusion allows the plate 100 to be smoothly and stably fitted into the fixing grove 170a. As described above, the protrusions 360a and 360b function as an auxiliary support for improving the coupling force of the plate. In particular, the protrusions improve a lateral supporting force for the plate, thereby greatly reducing a height change or gap occurring between the neighboring plates even in a case where the ground is uneven. In the meantime, it can be seen from FIG. 7b that connection portions are formed at an outer periphery of the elastic coupling assembly 300' so as to connect two or more elastic coupling assemblies with one another. The connection portions comprise protruding portions 370a similar to the bolts and recessed portions 370b similar to the female screws. Larger elastic coupling assembly can be obtained by fitting the protruding
portions 370a of one elastic coupling assembly 300' into the recessed portions 370b of another elastic coupling assembly 300'. Hereinafter, a wooden floor 400 in which the plates are engaged with the elastic coupling assembly will be explained. FIG. 8a is a schematic sectional view of the wooden floor 400 manufactured by a stepped construction method corresponding to the general floor installation. According to the stepped construction, the transverse elastic coupling members 206 are arranged horizontally at a predetermined step as illustrated in FIG. 6c. On the contrary, the floor installation can also be made by arranging the transverse elastic coupling members 206 either in a line or in a modified form with various arrangement patterns. It can be seen from this figure that a plate 100a is coupled with the longitudinal elastic coupling member 204 and another plate 100b is coupled with both the longitudinal and transverse elastic coupling members 204 and 206. FIG. 8a also shows a state where another plate 103c is being press-fitted into the longitudinal elastic coupling member 204. FIG. 8b is a partial enlarged view illustrating the press-fit state. The plate 100c is press-fitted into the elastic coupling member by applying vertical load using a tool such as a hand or rubber hammer. When the vertical load is applied to the plate 100c, the lower lateral side 130 of the plate 100c is subjected to friction against and guided by the coupling jaw 220, and the coupling jaw is then fitted the coupling groove 120. The level and lateral position of the fitted plate 100c are determined by the coupling jaw 220. The vertical load is carried by the reinforcing/supporting portion 240 and the extending/supporting portion 260 (FIG. 6b). To perform the smooth connection between the elastic coupling member 204 and the plate 100c, it is preferred that the lower lateral side 130 of the plate 100c be inclined and the coupling jaw 220 of the elastic coupling member 204 be rounded. It can be also seen from FIG. 8a that a predetermined space 420 is formed between the ground 430 and the plates 100a, 100b and 100c. Air in the space 420 functions as an insulation layer, and the air insulation layer enhances a heating efficiency of the room space and improves the feeling of walking by absorbing the shock exerted on the humans when they walk on the plate. Further, the air layer functions to prevent noise from being
transmitted from one story to another story through the ground 430. Furthermore, the air layer in the space 420 can prevent the plate 100a, 100b and 100c from being decayed or deformed due to moisture since the air can circulate through a gap between the ground 430 and the elastic coupling members 204 and 206. FIG. 8c is a perspective view of the wooden floor 400 under construction.
Referring to this figure, four sheets of the unit elastic coupling assemblies 200' are connected with one another and the plates 100 are coupled onto the elastic coupling assemblies. In accordance with the area and structure of the ground of the building, some elastic coupling assemblies 200' may be used in a state where they are connected with one another or cut using tools such scissors. According to the present invention, the wooden floor is constructed by inserting the plates downward from above using the elastic coupling members instead of fixing the interconnected plates onto the floor with an adhesive. Therefore, general consumers other than experts can directly remove and exchange the plates since the plates are easily detached from the wooden floor by using the tools such as gimlets or awls. Further, the noise, vibration and dusts generated in the process of installation and removal of the wooden floor can be remarkably reduced. In addition, the deformation of plates can be absorbed by using the elastic coupling members. Since the air layer formed in the space between the floor and the plates of the wooden floor functions as an insulation layer, it can prevent the floor from being rapidly cooled and contribute to enhancement of the heating efficiency in the room. Furthermore, there are advantages in that the transmission of noise generated in the upstairs above the wooden floor to the downstairs through the floor can be prevented and the feeling of walking on the floor can also be greatly improved. Although the present invention has been described and illustrated in connection with the preferred embodiments, it will be understood that various modifications, changes and additions can be made thereto without departing from the scope and spirit of the present invention.