AU2017100048A4

AU2017100048A4 - A flooring board

Info

Publication number: AU2017100048A4
Application number: AU2017100048A
Authority: AU
Inventors: Kerry Brammer; Anthony Harris; Deborah Harris; David O'farrell
Original assignee: Decksheet Ip Pty Ltd
Current assignee: Decksheet Ip Pty Ltd
Priority date: 2016-10-26
Filing date: 2017-01-13
Publication date: 2017-02-23
Anticipated expiration: 2025-01-13
Also published as: AU2017349621A1; WO2018076043A1

Abstract

A flooring board having a first side and a second side, the first side opposed to the second side, a plurality of substantially parallel grooves formed in a first 5 surface of the flooring board and extending along the length of the flooring board, and a plurality of drainage ports, each of said drainage ports extend from one of the plurality of substantially parallel grooves to a second surface of the flooring board. C) 00 C%4 C%4 C) C%4 to vl- ic cj (N C\j CN C%4

Description

- 1 - 2017100048 13 Jan 2017

A FLOORING BOARD

FIELD OF INVENTION

The present invention relates to a flooring board. The present invention has 5 particular but not exclusive application for use as an external flooring board. This use is by way of example only and the invention is not limited to this use.

BACKGROUND OF THE INVENTION

High quality wooden flooring typically comes in long planks due to the way 0 that logs are cut to produce the wooden flooring. A problem with solid wood planks is that the planks can be prone to warping and splitting if they are exposed to water. Additionally, if the planks are cut from an exotic hardwood, the lumber can be scarce and very expensive.

When laying the wooden flooring planks, each plank has to be laid individually 5 before an adjacent plank can be laid. Typically, each plank also has to be fixed to joists or battens before an adjacent plank can be fixed to the joist or battens.

OBJECT OF THE INVENTION

It is an object of the present invention to overcome or at least alleviate one or 0 more of the above problems with flooring boards and/or provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

In one aspect the present invention broadly resides in a flooring board having 25 a plurality of wood veneer layers, each of the wood veneer layers is glued to an adjacent wood veneer layer of the wood veneer layers, wherein there are a plurality of substantially parallel grooves formed in a first surface of the plurality of wood veneer layers and extending along the length of the flooring board.

Preferably, the flooring board includes a plurality of drainage ports. Said 30 plurality of drainage ports are preferably located within one or more of the plurality of substantially parallel grooves. Preferably each of the drainage ports is located within a groove of the plurality of substantially parallel grooves and extends to a second surface of the flooring board. -2- 2017100048 13 Jan 2017

Preferably a plurality of drainage ports extend from each of the plurality of substantially parallel grooves to the second surface of the flooring board. Preferably each drainage port forms an aperture in the groove extending to the second surface.

Preferably each drainage port is elongate in shape. Preferably each drainage 5 port has an oval shaped aperture. In the embodiment with the oval shaped aperture, the shape of the drainage port is substantially constant from the opening in the groove to the opening in the second surface. Preferably each drainage port has a width between 2mm to 6mm. More preferably each drainage port has a width of 4mm. Preferably each drainage port has a length between 100mm and 600mm. 0 More preferably each drainage port has a length of about 200mm.

Preferably the plurality of substantially parallel grooves are cut into the surface of the flooring board. More preferably the plurality of substantially parallel grooves are routered into the surface of the flooring board. Preferably each of the plurality of substantially parallel grooves extends up to half the thickness of the 5 flooring board. Preferably each of the plurality of substantially parallel grooves has a width between 2mm to 6mm. More preferably each of the plurality of substantially parallel grooves has a width of 4mm. In a preferred embodiment, the depth of each of the plurality of substantially parallel grooves is about 6mm. In the preferred embodiment the thickness of the flooring board is about 19mm. 0 Preferably each of the plurality of substantially parallel grooves has a rounded corner between each side wall of the groove and the upper surface of the flooring board. Preferably the rounded corner is a radiused corner. Preferably the radius of the radiused corner is between 1 mm and 3mm. More preferably the radius of the radiused corner is about 2mm. 25 Preferably each of the plurality of substantially parallel grooves is spaced from an adjacent groove by between 40mm to 200mm. More preferably each of the plurality of substantially parallel grooves is spaced from an adjacent groove by between 90mm to about 140mm.

In one form, the flooring board includes a plurality of transverse grooves 30 extending between adjacent pairs of the plurality of substantially parallel grooves. Preferably the transverse grooves extend at 90° to the plurality of substantially parallel grooves.

Preferably the flooring board has a longitudinal groove formed adjacent a lengthwise edge of the flooring board, with the longitudinal groove open to the -3- 2017100048 13 Jan 2017 lengthwise edge. Typically, when a flooring board is abutted to an adjacent flooring board, the longitudinal groove and a corresponding lengthwise edge of the adjacent flooring board define a groove similar to one of the plurality of substantially parallel grooves. 5 Preferably the flooring board has a connection means on each lateral side.

Preferably the flooring board has a connection means on each end. Preferably the connection means enables the flooring board to be attached to an adjacent flooring board. In one form the connection means is a tongue and groove type connector, with a tongue portion on one side and a groove portion on the opposed side of the 0 flooring board.

Preferably the plurality of wood veneer layers are between 3 and 9 layers of wood veneer. More preferably the plurality of wood veneer layers are between 5 and 7 layers of wood veneer. Preferably the thickness of each of the wood veneer layers is between 1mm and 4mm. Preferably each layer of wood veneer is placed at an 5 angle relative to the grain of an adjacent layer of wood veneer. Preferably, each layer of wood veneer is located at an angle of about 90° relative to the grain of an adjacent layer of wood veneer of the plurality of wood veneer layers. Alternatively, each layer of wood veneer is located at an angle of about 45° relative to the grain of an adjacent layer of wood veneer of the plurality of wood veneer layers. 0 Preferably each of the plurality of wood veneer layers is glued to an adjacent layer of wood veneer of the plurality of wood veneer layers using a resorcinol glue. Preferably the glue used to glue each of the plurality of wood veneer layers to an adjacent wood veneer layer includes an antifungal additive.

Preferably the plurality of wood veneer layers includes at least one of the 25 following wood species; Yellow Balau, Red Balau, Bangkirai, Keruing, Kempas, Pine, Merbau, Kwila, Vesi, Spruce, Teak, Mahogany, Iron Bark, Spotted Gum, Blackbutt, Tasmanian Oak and Jarrah. In one form the plurality of wood veneer layers includes an outer layer of an exotic and/or expensive wood species and subsequent layers of less exotic and/or expensive wood layers, the outer layer forming the surface of the 30 plurality of wood veneer layers.

Preferably each layer of the plurality of wood veneer layers is sealed. Alternatively, each layer of the plurality of wood veneer layers is left raw. In one form, at least one of the plurality of wood veneer layers is stained and/or varnished. -4- 2017100048 13 Jan 2017

Preferably the outer layer of the plurality of wood veneer layers is stained and/or varnished.

In one form, each of the plurality of substantially parallel grooves is filled with a sealant. Preferably the sealant is a mastic or a water resistant caulking. 5 Preferably the flooring board includes fastener apertures. Preferably the fastener apertures allow the flooring board to be attached to a flooring structure such as flooring joists, flooring battens or a concrete slab using fasteners such as screws, nails or the like. Preferably each of the fastener apertures is located between one of the plurality of substantially parallel grooves and a lower surface of the flooring 0 board. Typically, when the flooring board is attached to a flooring structure, the surface is an upper surface and the second surface is a lower surface.

In another form, the flooring board includes a plurality of clip grooves formed in the second surface. Preferably the plurality of clip grooves are adapted to accept corresponding clips to attach the flooring board to the clips. Preferably the clips are 5 attachable to a flooring structure such as flooring joists, flooring battens or a concrete slab.

Preferably the flooring board is between 500mm to 900mm wide. Preferably the flooring board is between 900mm to 5400mm long. Preferably the flooring board is about 900mm, 1800mm, 2700mm or 5400mm long. 0 Preferably the flooring board further includes an underlay layer attached to the second surface of the flooring board. Preferably the underlay layer reduces noise and/or vibration transfer between the flooring board and a flooring structure such as flooring joists, flooring battens or a concrete slab.

In a further aspect the present invention broadly resides in a flooring board 25 having a plurality of wood veneer layers, each of the wood veneer layers is glued to an adjacent wood veneer layer of the wood veneer layers, wherein there are a plurality of substantially parallel grooves formed in a first surface of the plurality of wood veneer layers and extending along the length of the flooring board; and 30 a plurality of drainage ports, each drainage port extending from one of the plurality of substantially parallel grooves to a second surface of the flooring board.

In a further aspect the present invention broadly resides in a method of forming a flooring board, including the steps of: -5 - 2017100048 13 Jan 2017 gluing a plurality of wood veneer layers together to form the flooring board, wherein each of the plurality of wood veneer layers is glued to an adjacent one of the plurality of wood veneer layers; cutting a plurality of substantially parallel grooves into a surface of the plurality 5 of wood veneer layers, such that the plurality of substantially parallel grooves extend along the length of the flooring board.

Preferably the method further includes the step of forming a plurality of drainage ports in the flooring board such that each drainage port extends from one of the plurality of substantially parallel grooves to a second surface of the flooring 0 board.

Preferably the step of cutting a plurality of substantially parallel grooves into an upper surface of the flooring board further includes using a router to cut the plurality of substantially parallel grooves into the upper surface of the flooring board.

Preferably the method further includes the step of cutting the plurality of wood 5 veneer layers to a predetermined size.

In a further aspect the present invention broadly resides in a plurality of flooring boards as described in this specification, wherein when installed, each of the plurality of flooring boards is staggered in a lengthwise or widthwise direction relative to an adjacent flooring board of the plurality of flooring boards. Preferably each of 0 the plurality of flooring boards is attached to an adjacent flooring board of the plurality of flooring boards.

In another aspect, the invention broadly resides in a structural board having a plurality of wood veneer layers, each of the wood veneer layers is glued to an adjacent wood veneer layer of the wood veneer layers, wherein there are a 25 plurality of substantially parallel grooves formed in a first surface of the plurality of wood veneer layers and extending along the length of the structural board.

In a further aspect, the present invention broadly resides in a flooring board having a first side and a second side, the first side opposed to the second side; 30 a plurality of substantially parallel grooves formed in a first surface of the flooring board and extending along the length of the flooring board; and a plurality of drainage ports, each of said drainage ports extend from one of the plurality of substantially parallel grooves to a second surface of the flooring board. -6- 2017100048 13 Jan 2017

Preferably the flooring board is made predominantly of wood. Preferably the flooring board has a plurality of wooden pieces. Preferably each of the plurality of wooden pieces are attached to an adjacent one of the plurality of wooden pieces. Preferably each of the plurality of wooden pieces is glued to an adjacent one of the 5 plurality of wooden pieces. Preferably each of the plurality of wooden pieces is glued to an adjacent one of the plurality of wooden pieces along a lengthwise side.

Preferably the plurality of wooden pieces includes at least one of the following wood species; Yellow Balau, Red Balau, Bangkirai, Keruing, Kempas, Pine, Merbau, Kwila, Vesi, Spruce, Teak, Mahogany, Iron Bark, Spotted Gum, Blackbutt, 0 Tasmanian Oak and Jarrah.

Preferably the plurality of wooden pieces define the first surface and the second surface.

In one form, each of the plurality of wooden pieces is a strip, slat or batten of wood. In another form, each of the plurality of wooden pieces is a wood plank. 5 Preferably each of the plurality of wood planks has a longitudinal groove formed adjacent a lengthwise edge. Preferably when the plurality of wood planks are attached to an adjacent one of the plurality of wood planks, the longitudinal grooves and corresponding lengthwise edges of adjacent wood planks form the plurality of substantially parallel grooves of the flooring board. 0 In one form, each of the plurality of wooden pieces is made of a number of wooden pieces. Preferably the number of wooden pieces are finger joined together in a lengthwise direction. Preferably each finger join is a tapered finger join.

Preferably each of the plurality of wooden pieces has a width of between 60mm to 150mm. More preferably each of the plurality of wooden pieces has a 25 width of substantially 90mm.

In one form, each of the plurality of wooden pieces is attached to an adjacent one of the plurality of wooden pieces with a tongue and groove join.

In another form, each of the plurality of wooden pieces has a rebated portion which engages with a lip portion of an adjacent one of the plurality of wooden pieces. 30 In another form, the flooring board is made predominantly of composite wood material. Preferably composite wood material includes oriented strand board (OSB), medium density fibreboard (MDF), high density fibreboard (HDF), and particle board.

In another form, the flooring board is made from moulded plastic. -7- 2017100048 13 Jan 2017 ln one form the plurality of substantially parallel grooves are cut into the surface of the flooring board. More preferably the plurality of substantially parallel grooves are routered into the surface of the flooring board. Preferably the depth of each of the plurality of substantially parallel grooves is at least 6mm. 5 Preferably the second surface of the flooring board is kerfed. Preferably the kerfed second surface of the flooring board inhibits warping of the flooring board when the flooring board is exposed to moisture.

In a further aspect the present invention broadly resides in a method of forming a flooring board, including the steps of: 0 forming a plurality of substantially parallel grooves in a first surface of the flooring board, the plurality of substantially parallel grooves extending along the length of the flooring board; and forming a plurality of drainage ports, each drainage port extending from one of the plurality of substantially parallel grooves to a second surface of the flooring 5 board.

It will be appreciated that the features described in relation to the flooring board may also be applicable to the aspect of the present invention of the structural board, with the occurrences of “the flooring board” being replaced by “the structural board”. 0 It will be appreciated that the flooring board may also be referred to as a decking board.

The features described with respect to one aspect also apply where applicable to all other aspects of the invention. Furthermore, different combinations of described features are herein described and claimed even when not expressly 25 stated.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention can be more readily understood reference will now be made to the accompanying drawings which illustrate a preferred 30 embodiment of the invention and wherein:

Figure 1 is a schematic top view of a flooring board according to an embodiment of the present invention;

Figure 2 is a section view of the flooring board of Figure 1 along line AA;

Figure 3 is a view of detail B of Figure 1; -8- 2017100048 13 Jan 2017

Figure 4 is a perspective section view of Figure 1 along line CC;

Figure 5 is a schematic end view of a flooring board according to an embodiment of the present invention;

Figure 6 is a detailed view of the flooring board of Figure 5; 5 Figure 7 is a schematic end view of a flooring board according to an embodiment of the present invention;

Figure 8 is a detailed view of the flooring board of Figure 7; and

Figure 9 is a schematic top view of a flooring board according to an embodiment of the present invention. 0

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to Figures 1-4 there is shown schematic views of a flooring board 10 according to an embodiment of the present invention. The flooring board 10 is formed from a plurality of wood veneer layers glued to each other. The flooring 5 board 10 has a plurality of parallel grooves 12, which are formed into a surface in the form of a top surface 14 of the flooring board 10. The plurality of parallel grooves 12 extend along the length of the flooring board 10. The plurality of parallel grooves 12 give the appearance of the flooring board 10 being formed from a plurality of parallel individual planks. 0 A plurality of drainage ports 16 extend from each of the plurality of parallel grooves 12 to a second surface in the form of a lower surface 18 of the flooring board 10. The plurality of drainage ports 16 enable water or other liquid to drain from the grooves 12.

The plurality of parallel grooves 12 have radiused corners 20 between each 25 side wall 22 of the grooves 12 and the upper surface 14 of the flooring board 10. In the embodiment shown, the radiused corners have a radius of 2mm.

The flooring board 10 shown in the figures has a length of 2700mm, a width of 500mm, and a thickness of 19mm. The plurality of parallel grooves 12 extend into the flooring board by 6mm and have a width of 3.2mm. The plurality of drainage 30 ports 16 have a width of 3.2mm and a length of 200mm. The centres of adjacent drainage ports 16 extending from the same groove 12 are spaced by about 600mm.

In use the flooring board 10 is attached to a flooring structure (not shown) such as flooring joists, flooring battens or a concrete slab. Additional flooring boards -9- 2017100048 13 Jan 2017 (not shown) are then attached to the flooring structure adjacent to the flooring board 10.

With reference to Figures 5-6 there are shown schematic views of a flooring board 110 according to an embodiment of the present invention. The flooring board 5 110 is formed from a plurality of wooden planks 111, 113 glued to each other. The wooden planks 111 have a rebated portion 115 which engages with a nose portion 117 of an adjacent wooden plank 111,113.

Similar to the flooring board 10 shown in Figures 1-4, the flooring board 110 in figures 5-6 has a plurality of parallel grooves 112, which are formed into a top 0 surface 114 of the flooring board 110. The plurality of parallel grooves 112 extend along the length of the flooring board 110. A plurality of drainage ports (not shown) extend from each of the plurality of parallel grooves 112 to a lower surface 118 of the flooring board 110. The plurality of drainage ports (not shown) enable water or other liquid to drain from the grooves 5 112.

The plurality of parallel grooves 112 have radiused corners 120 between each side wall 122 of the grooves 112 and the upper surface 114 of the flooring board 110. In the embodiment shown, the radiused corners have a radius of 2mm.

With reference to Figures 7-8 there are shown schematic views of a flooring 0 board 210 according to an embodiment of the present invention. The flooring board 210 is similar to the flooring board 110 shown in Figures 5-7, except that the flooring board 210 is formed from a plurality of wooden planks 211,213 glued to each other, and the wooden planks 211 have a groove 215 which engages with a tongue 217 of an adjacent wooden plank 211,213. 25 The flooring board 210 has a plurality of parallel grooves 112, which are formed into a top surface 114 of the flooring board 210. The plurality of parallel grooves 112 extend along the length of the flooring board 210. A plurality of drainage ports (not shown) extend from each of the plurality of parallel grooves 112 to a lower surface 118 of the flooring board 210. The plurality 30 of drainage ports (not shown) enable water or other liquid to drain from the grooves 112.

The plurality of parallel grooves 112 have radiused corners 120 between each side wall 122 of the grooves 112 and the upper surface 114 of the flooring board 210. - 10- 2017100048 13 Jan 2017

Figure 9 shows a top view of a flooring board 310. The flooring board 310 has a plurality of parallel grooves 312 formed in a top surface 314. Drainage ports 316 extend from the parallel grooves 312 to a bottom surface (not shown). In the embodiment shown, the drainage ports 316 are arranged in a staggered manner. 5 The drainage ports 316 are about 250mm in length and about 3.2mm in width.

The drainage ports 316 are spaced from adjacent drainage ports 316 in the same parallel groove 312 by about 650mm.

In one embodiment (not shown) each of the flooring boards is staggered in a lengthwise direction relative to an adjacent flooring board. 0 In another embodiment (not shown), each flooring board is attached to an adjacent flooring board. Each flooring board is attached to an adjacent flooring board using a tongue and groove connection.

In a further embodiment (not shown) the flooring structure is a concrete slab or other type of solid base and the flooring boards are laid on the concrete slab or 5 solid base in a “free floating” manner, with each flooring board being attached to an adjacent flooring board.

ADVANTAGES

An advantage of the preferred embodiment of the flooring board includes that 0 the flooring board is less labour intensive and easier to lay in position compared to individual wooden flooring planks. Another advantage of the preferred embodiment of the flooring board includes that the flooring board is easier and safer to transport compared to individual wooden planks. An advantage of including drainage ports is that liquids can drain from the flooring board. An advantage of placing each layer of 25 wood veneer at an angle relative to the grain of an adjacent layer of wood veneer is that this can reduce the instances of warping and splitting compared to individual wooden planks.

VARIATIONS 30 It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth. 2017100048 13 Jan 2017 - 11 -

Throughout the description and claims of this specification the word “comprise” and variations of that word such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps.

Claims

1. A flooring board having a first side and a second side, the first side opposed to the second side; a plurality of substantially parallel grooves formed in a first surface of the flooring board and extending along the length of the flooring board; and a plurality of drainage ports, each of said drainage ports extend from one of the plurality of substantially parallel grooves to a second surface of the flooring board.

2. A flooring board as claimed in claim 1 including a plurality of wooden pieces, wherein each of the plurality of wooden pieces are attached to an adjacent wooden piece.

3. A flooring board as claimed in claim 2, wherein each of the plurality of wooden pieces is a wooden plank, and each wooden plank is glued to an adjacent wooden plank.

4. A flooring board as claimed in any one of the preceding claims, wherein each drainage port has a length between 100mm and 600mm, and a width between 2mm and 6mm.

5. A method of forming a flooring board, including the steps of: forming a plurality of substantially parallel grooves in a first surface of the flooring board, the plurality of substantially parallel grooves extending along the length of the flooring board; and forming a plurality of drainage ports, each drainage port extending from one of the plurality of substantially parallel grooves to a second surface of the flooring board.