AU2017349621A1

AU2017349621A1 - A board

Info

Publication number: AU2017349621A1
Application number: AU2017349621A
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: 2017-09-08
Publication date: 2019-05-02
Also published as: WO2018076043A1; AU2017100048A4

Abstract

A board, and a method of forming a board, including a first side and a second side, the first side opposed to the second side. The first side of the board includes at least one groove extending substantially across the first side, and the board includes at least one drainage port extending from said at least one groove to the second side.

Description

A BOARD

FIELD OF INVENTION

The present invention relates to a board, especially to a flooring board, and to methods of making and using the board. The present invention has 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 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 and aligned individually 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.

SUMMARY OF THE INVENTION

The present invention is directed to a board, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

With the foregoing in view, the present invention in one form, resides broadly in a board, especially a flooring board.

In a first aspect, the present invention provides a board including:

a first side and a second side, the first side opposed to the second side;

wherein the first side includes at least one groove extending substantially across the first side; and wherein the board includes at least one drainage port extending from said at least one groove to the second side.

In one embodiment, there is provided 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

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PCT/AU2017/050986 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.

The board of the first aspect may be a sheet. The board may be of any suitable thickness or any suitable shape. In one embodiment, the board (or the first or second sides of the board) may be square, rectangular, a parallelogram, trapezoidal, or rhomboidal in shape; especially rectangular. The board may be of any suitable thickness. The board may be of substantially uniform thickness, or the board may include a thicker portion and a thinner portion. The board is especially of substantially uniform thickness.

The board may be made of any suitable material. The board may be made of (or include) a cellulosic material (especially wood), a polymer, a plastic (such as moulded plastic), a rubber, metal or glass. The board may be a wooden board. The board especially may be made of (or include) a cellulosic material, such as fibreboard or wood. The board may be made of or include oriented strand board (OSB), medium density fibreboard (MDF), high density fibreboard (HDF), particle board and solid wood. Preferably the board (especially flooring board) is made predominantly of wood.

The board of the first aspect may be a flooring board. However, the board of the first aspect may also be for use on walls or roofs. The board of the first aspect especially may be used for decking.

The board may be of any suitable dimensions. In one embodiment, the board is from 0.5 m to 6 m long, especially from 1.5 to 5 m long, or from 2 to 4 m long, more especially from 2.2 to 3.5 m long, or from 2.5 to 3.0 m long, most especially about 2.7 m long. In another embodiment, the board is from 0.5 to 3 m long, or from 0.5 to 2 m long, more especially from 0.5 to 1.5 m long, or from 0.6 to 1.2 m long, most especially about 0.9 m long. In a further embodiment, the board is from 1 to 3 m long, or from 1.2 to 2.5 m long, more especially from 1.5 to 2.2 m long, most especially about 1.8 m long.

The board may be from 0.1 m to 2 m wide, especially from 0.2 m to 1.5 m wide or from 0.3 m to 1.0 m wide, more especially from 0.4 m to 0.8 m wide, or from 0.4 m to 0.8 m wide, most especially from 0.5 to 0.65 m wide or from 0.55 to 0.6 m wide. The board may be from 8 mm to 50 mm thick, especially from 10 mm to 30 mm thick or from 14 mm to 25 mm thick, more especially from 16 mm to 22 mm thick, most especially about 19 mm thick.

In one embodiment the board is between 500mm to 900mm wide. In another embodiment the board is between 900mm to 5400mm long, or from 900 mm to 2700 mm long. In a further embodiment the board is about 900mm, 1800mm, 2700mm or 5400mm long.

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The first side of the board may be substantially parallel to the second side, especially parallel. The board may define at least one side wall (especially at least at least two, three or four side walls) extending between the first side and the second side. The board may include two pairs of opposed side walls extending between the first and second side. Each of said pair of side walls may be parallel. The said side walls may be a pair of lateral side walls and a pair of longitudinal side walls.

The first side (or surface) of the board includes at least one groove, especially at least two, three, four or five grooves. The first side may include a plurality of grooves. The plurality of grooves may be substantially parallel, especially parallel. The at least one groove may be formed in the first surface. The at least one groove may be parallel to the at least one (especially at least two) side wall of the board, especially at least one (especially at least two) longitudinal side wall of the board. With the exception of the at least one groove, the first side may be substantially planar.

The at least one groove may be formed in the first surface in any suitable way. In one embodiment, the at least one groove is formed by moulding, cutting, or being routered into the board. In 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.

The at least one groove may be of any suitable dimensions. In one embodiment, the at least one groove is of a width and/or depth to simulate the distance between two decking planks when laid. In one embodiment, the at least one groove is from 1 mm to 10 mm wide, especially from 1 mm to 8 mm wide, more especially from 2 mm to 6 mm wide, or from 3 mm to 5 mm wide, most especially about 4 mm wide.

In another embodiment, the at least one groove provides a channel for liquid (such as water) on the board. The at least one groove may be from 1 mm to 12 mm deep, especially from 2 mm to 10 mm deep, more especially from 4 mm to 8 mm deep, most especially from 5 mm to 7 mm deep, or about 6 mm deep. The at least one groove may be of non-uniform depth, for example the at least one groove may be inclined away from the at least one drainage port. In this way, a liquid entering the at least one groove may be directed to the at least one drainage port. The at least one (or each) of the grooves (especially the plurality of substantially parallel grooves) may extend by up to half (or up to a third) of the thickness of the board.

The at least one groove extends substantially across (especially across) the first side. The at least one groove may extend substantially across the first side longitudinally, laterally,

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PCT/AU2017/050986 or obliquely. The at least one groove may extend along the length of the board. The at least one groove may extend between two opposed side walls of the board.

Preferably the at least one (or each) groove (or each of the plurality of substantially parallel grooves) has a rounded comer between each side wall of the groove and the first side of the board. Preferably the rounded comer is a radiused corner. Preferably the radius of the radiused corner is between 1mm and 3mm. More preferably the radius of the radiused corner is about 2mm.

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 80 or 90mm to about 160 or 140mm.

In one embodiment the board (or the flooring board) has at least one terminal groove (or a longitudinal groove) formed in the first side adjacent a longitudinal (or lengthwise) or lateral edge of the flooring board. The at least one terminal groove may be open to the lengthwise or lateral edge. Typically, when a board (or flooring board) is abutted to an adjacent board (or flooring board), the at least one terminal groove (or longitudinal groove) and a corresponding longitudinal (or lengthwise) or lateral edge of the adjacent flooring board define a groove similar to the at least one groove defined above.

The board of the first aspect includes at least one drainage port extending from the at least one groove to the second side. In one embodiment, each of said at least one grooves includes at least one drainage port extending from the said groove to the second side. Each of said at least one grooves may include one, two, three, four or five of said drainage ports. The at least one drainage port may be a plurality of drainage ports.

The at least one (or each) drainage port may be elongate in shape. The at least one (or each) drainage port may define an oval shaped aperture. The at least one (or each) drainage port may be of substantially constant cross-sectional shape from the first side to the second side. The at least one (or each) drainage port may be from 1 mm to 10 mm wide, especially from 1 mm to 8 mm wide, more especially from 2 mm to 6 mm wide, or from 3 mm to 5 mm wide, most especially about 4 mm wide. The at least one (or each) drainage port may have a width between 2mm to 6mm, or 2 mm to 4 mm. The at least one (or each) drainage port may have a width of 4mm or 3.2 mm. The at least one (or each) drainage port may have a length of from 50 mm to 600 mm, or from 100 mm to 600mm, or from 100 mm to 400 mm, especially from 150 mm to 300 mm, most especially about 200 mm. The at least one (or

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PCT/AU2017/050986 each) drainage port may have a length between 100mm and 600mm. More preferably each drainage port may have a length of about 200mm.

The at least one drainage port (or each drainage port) may be formed in any suitable way. In one embodiment, the at least one drainage port (or each drainage port) may be formed by moulding, cutting, or being routered into the board.

Where the at least one drainage port is a plurality of drainage ports located in a plurality of grooves, the location of drainage ports may be staggered so that no two drainage ports are in the same location on neighbouring grooves. This arrangement advantageously may permit adequate drainage whilst minimising the impact of the drainage ports on the strength of the board as a whole. The plurality of drainage ports may be arranged in a staggered manner. In one embodiment, the plurality of drainage ports are positioned so as not to be placed over structural members, such as floor joists.

In one embodiment, the board includes a plurality of segments. The plurality of segments may be fastened together. The plurality of segments may be adhered (especially glued) together. In one embodiment, the plurality of segments are adhered together along their longitudinal side walls. Any suitable adhesive (or glue) may be used. In one embodiment the adhesive is a water proof adhesive, especially a marine grade adhesive. The adhesive may be resorcinol. Each of said plurality of segments may abut and/or be fastened to an adjoining segment. In one embodiment, the adhesive may include an antifungal additive.

Each of said plurality of segments may include a first side and a second side opposed to the first side. Each of said plurality of segments may include at least one side wall, especially a plurality of side walls (such as at least two, three or four side walls) extending between the first and second sides. The said at least one side wall may be a longitudinal side wall or a lateral side wall. Each of said plurality of segments may include two pairs of opposed side walls extending between the first and second side. Each of said pair of side walls may be parallel. Each of said plurality of segments may be fastened to at least one adjoining segment along a side wall, especially along a longitudinal side wall or a lateral side wall. At least one of said plurality of segments may be fastened to at least one adjoining segment along a side wall, especially along a lateral or longitudinal side wall. The first side of the plurality of segments may define the first side of the board, and the second side of the plurality of segments may define the second side of the board. The board may be formed by application of the adhesive to abutting side walls of adjoining segments.

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Each of said plurality of segments may be of any suitable shape. In one embodiment, each of said plurality of segments (or the first or second sides of the plurality of segments) may be square, rectangular, a parallelogram, trapezoidal, or rhomboidal in shape; especially rectangular. Each of said plurality of segments may be of any suitable thickness. Each of said plurality of segments may be of substantially uniform thickness, or may include a thicker portion and a thinner portion. Each of said plurality of segments is especially of substantially uniform thickness.

Each of said plurality of segments may be made of any suitable material. Each of said plurality of segments may be made of (or include) a cellulosic material (especially wood), a polymer, a plastic (such as moulded plastic), a rubber, metal or glass. Each of said plurality of segments especially may be made of (or include) a cellulosic material, such as fibreboard or wood (including solid wood). Each of said plurality of segments may be made of or include oriented strand board (OSB), medium density fibreboard (MDF), high density fibreboard (HDF), and particle board. Preferably each of said plurality of segments is made predominantly of wood.

In one embodiment, the board and/or plurality of segments may be made from (or include) a wood selected from the group consisting of: Yellow Balau, Red Balau, Bangkirai, Keruing, Kempas, Pine, Merbau, Kwila, Vesi, Spruce, Teak, Mahogany, Iron Bark, Spotted Gum, Blackbutt, Tasmanian Oak and Jarrah.

Each of said plurality of segments may be a piece, strip, slat, plank or batten, especially a wooden piece, wooden strip, wooden slat, wooden plank or wooden batten.

The plurality of segments may be of any suitable dimensions. In one embodiment, the plurality of segments is from 0.5 m to 6 m long; especially from 0.5 m to 1.5 m long or from 1.3 m to 2.5 m long, or from 2.2 m to 3.5 m long; most especially about 0.9 m long, or about

1.8 m long or about 2.7 m long. The plurality of segments may be from 50 mm to 250 mm wide, especially from 70 mm to 200 mm wide, more especially from 70 mm to 120 mm wide or from 120 mm to 170 mm wide; most especially from 90 to 100 mm wide or from 140 to 150 mm wide. Each of said plurality of segments may be the same or different width. For example, the terminal segments on either side may be of different width to the other segments. The plurality of segments may be from 8 mm to 50 mm thick, especially from 10 mm to 30 mm thick or from 14 mm to 25 mm thick, more especially from 16 mm to 22 mm thick, most especially about 19 mm thick.

At least one of said at least one groove (especially at least two, three, four or five grooves) may extend from a first side of the at least one segment (especially at least two

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PCT/AU2017/050986 segments). At least one of said at least one groove (especially at least two, three, four or five grooves) may extend substantially along (especially along) a side wall of the at least one segment (especially at least two segments). In one embodiment, the plurality of segments are adhered together along their longitudinal side walls, and the at least one groove extends along longitudinal side walls of the plurality of segments. In one embodiment, at least one (or each) groove is centred over the join between two abutting segments. In one embodiment, the plurality of segments are adhered together along their longitudinal side walls, and at least one of said groove extends along two adjoining side walls of the plurality of segments

In one embodiment, the plurality of segments may be fastened together along their respective side walls. At least one side wall (especially at least one longitudinal and/or lateral side wall) of a segment (especially a plurality of segments) may include a rebated portion, a lip portion, a tongue, a groove or a plurality of fingers which is fastened to a rebated portion, a lip portion, a tongue, a groove or a plurality of fingers of a side wall of an adjoining segment. In one embodiment, the rebated portion of the side wall of one segment may be fastened to and/or engage with a lip portion of an adjoining segment. In another embodiment, the tongue of the side wall of one segment may be fastened to and/or engage with a groove of an adjoining segment. In another embodiment, the plurality of fingers of the side wall of one segment may be fastened to and/or engage with a plurality of fingers of an adjoining segment. In one embodiment, the at least one side wall (especially at least one longitudinal and/or lateral side wall) of a segment (especially a plurality of segments) may include planar side wall which is fastened to a planar side wall of an adjoining segment. Consequently, the plurality of segments may be fastened together along one or more of: tongue-in-groove joins, finger-joins, lip-in-recess joins or butt joins. Said plurality of segments may be fastened together laterally or longitudinally. If the plurality of segments are fastened together by way of butt joins (or joints), this advantageously may not result in a weaker product as a glue such as resorcinol may be stronger than a timber segment.

The board may include any number of segments. In one embodiment, the board includes 2, 3, 4, 5, 6, 7, 8, 9 or 10 segments, especially 4, 5, 6, 7, 8, 9 or 10 segments. The board may include a plurality of parallel segments. The board may include one, two, three, four, five, six, seven or eight segments in a longitudinal or lateral cross-section of the board. In one embodiment the board includes one, two or three (especially one or two) segments in a longitudinal cross-section of the board. In another embodiment the board includes two, three, four, five, six, seven or eight (especially three to seven, or four to six) segments in a lateral

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PCT/AU2017/050986 cross-section of the board. In one embodiment, from 50 to 100% of the segments extend from one lateral side wall of the board to the other lateral side wall, especially 60 to 100%, or 70 to 100%, or 80 to 100% of the segments extend from one lateral side wall of the board to the other lateral side wall. In another embodiment, none of the segments extend from one longitudinal side wall of the board to the other longitudinal side wall.

The plurality of segments may be pieces. The segments may be made of wood. Accordingly, 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 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, 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.

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.

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 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.

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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.

Preferably the second surface of the board (especially the flooring board) is kerfed. Preferably the kerfed second surface of the board inhibits warping of the board when the board is exposed to moisture.

In one embodiment the second surface of the board includes at least one groove. The at least one groove may be at least one stress groove (or tension groove) for alleviating stress in the board and/or at least one segment. The second side and/or at least one, a plurality or each segment may include at least one groove (or stress groove), especially at least two grooves. In one embodiment, each segment may include one or two grooves (or stress grooves).

The second side may include a plurality of grooves (or stress grooves). The plurality of grooves (or stress grooves) may be substantially parallel, especially parallel. The at least one groove (or stress groove) may be formed in the second side. The at least one groove (or stress groove) may be parallel to the at least one (especially at least two) side wall of the board, especially at least one (especially at least two) longitudinal side wall of the board. With the exception of the at least one groove (or stress groove), the second side may be substantially planar.

The at least one groove (or stress groove) may be formed in the second surface in any suitable way. In one embodiment, the at least one groove (or stress groove) is formed by moulding, cutting, or being routered into the board.

The at least one groove (or stress groove) may be of any suitable dimensions. In one embodiment, the at least one groove (or stress groove) is from 1 mm to 5 mm wide, especially from 1 mm to 4.5 mm wide or from 1 mm to 4 mm wide, more especially from 1.5 mm to 3.5 mm wide, or from 2.0 to 3.0 mm wide, most especially about 2.5 mm wide. The at least one groove (or stress groove) may be from 1 mm to 12 mm deep, especially from 2 mm to 10 mm deep, more especially from 4 mm to 8 mm deep, most especially from 5 mm to 7 mm deep, or about 6 mm deep.

The at least one groove (or stress groove) may extend substantially across (especially across) the second side. The at least one groove (or stress groove) may extend substantially across the second side longitudinally, laterally, or obliquely. The at least one groove (or stress groove) may extend along the length of the board. The at least one groove (or stress

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PCT/AU2017/050986 groove) may extend substantially parallel to (and apart from) at least one longitudinal side wall of the board. The at least one groove (or stress groove) may be spaced away from the at least one drainage port. The at least one groove (or stress groove) may extend from one lateral side wall of the board to the other lateral side wall.

In use, the second side of the board may be laid against structural members, such as joists, studs, concrete or battens. In use the first side of the board may be exposed, for example for walking on.

The board may further include a stain, veneer or varnish. In one embodiment, the board may include a sealant. In one embodiment the board is or includes raw wood. In one embodiment, the board does not include a stain, veneer or varnish. The veneer may be as defined below.

In one embodiment, the join between at least two segments, or the at least one groove is substantially filled with a sealant. The sealant may be a mastic or a water resistant caulking.

The board may include fastener apertures. The fastener apertures may allow the board to be fastened 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 the at least one groove and the second side of the board. Typically, when the board is attached to a flooring structure, the first side is an upper surface and the second side is a lower surface.

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

In one embodiment, the board further includes an underlay layer attached to the second side of the board. In another embodiment the underlay layer reduces noise and/or vibration transfer between the board and a flooring structure such as flooring joists, flooring battens or a concrete slab.

When the board is made of a cellulosic material such as wood, the board (and/or each segment) may have a moisture content of from about 5% to 20%, especially from about 6 % to 15%, more especially from about 8 % to 12% or from about 8 % to 10%. The optimum moisture content for the board (and/or each segment) may vary depending on the location of intended use. For example, a lower moisture content would be beneficial for a drier climate, whereas a higher moisture content would be beneficial for a wetter climate.

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In a second aspect, the present invention provides a board including: a first side and a second side, the first side opposed to the second side;

wherein the first side includes at least one groove extending substantially across the first side.

In an embodiment of the second aspect, the board may further include at least one drainage port extending from said at least one groove to the second side.

In an embodiment of the second aspect, the board includes a plurality of wood planks adhered together along their longitudinal side walls, and wherein the at least one groove extends along at least one the longitudinal side walls (especially adhered longitudinal side walls) of the plurality of segments. In one embodiment, said at least one groove extends along the side wall of adjoining segments. In one embodiment, the board includes a plurality of wood planks adhered together along their longitudinal side walls, and wherein at least one of said groove extends along two adjoining side walls of the plurality of segments.

Features of the second aspect of the present invention may be as described for the first aspect.

In a third aspect, the present invention provides a method of forming a board, the method including the steps of:

forming at least one groove in a first side of the board, wherein the at least one groove extends substantially across the first side; and forming at least one drainage port extending from said at least one groove to a second side of the board, wherein the second side is opposite the first side.

Features of the third aspect of the present invention may be as described for the first or second aspects of the present invention. The board formed by the third aspect may be the board of the first or second aspects of the present invention.

The at least one groove may be formed in the first surface of the board in any suitable way. In one embodiment, the at least one groove is formed by injecting polymer (or plastic) into a mould. In another embodiment, the at least one groove is formed by cutting the at least one groove into the first side of the board.

The at least one drainage port may be formed in the board in any suitable way. In one embodiment, the at least one drainage port is formed by injecting polymer (or plastic) into a mould. In another embodiment, the at least one drainage port is formed by cutting the at least one groove into the first side of the board.

In one embodiment of the third aspect, the board is a wooden board.

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In one embodiment, the method further includes the step of cutting raw timber (or wood) in a mill.

In a further embodiment, the method further includes the step of drying the raw timber (or wood) in a kiln. The kiln may operate at a high temperature, a medium temperature or a low temperature, as would be known to a person skilled in the art. Typically a kiln operating at a higher temperature will dry the wood more quickly than a lower temperature. The optimum temperature for drying the wood will depend upon the type of wood being dried. For example, a hardwood typically cannot be dried at too high a temperature as it may crack.

In another embodiment, the method further includes the step of machining or processing the dried timber. The step of machining may produce a plurality of segments as described in the first aspect. At this time, at least one groove (or stress groove) may be cut into the second side of at least one (or each) of said segments. The at least one groove (or stress groove) may be as described above for the first aspect and may ameliorate twisting of each segment.

In a further embodiment, the method includes the step of contacting an adhesive to at least one side wall of at least one (or each) of said plurality of segments. The adhesive may be as described for the first aspect. The plurality of segments may then be pressed together, for example in a laminating press, to form a board. The plurality of segments may be pressed together at room temperature or at a temperature above room temperature (which accelerates drying of the adhesive).

In another embodiment, the method includes the step of forming at least one groove and at least one drainage port in the board including a plurality of segments. The at least one groove and the at least one drainage port may be as described for the first aspect of the present invention.

In an embodiment of the third aspect, there is provided 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.

In a fourth aspect, the present invention provides a method of forming a board, the method including the step of:

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PCT/AU2017/050986 forming at least one groove in a first side of the board, wherein the at least one groove extends substantially across the first side.

In one embodiment of the fourth aspect, the method further includes the step of forming at least one drainage port extending from said at least one groove to a second side of the board, wherein the second side is opposite the first side.

In another embodiment, the method includes the steps of contacting an adhesive to at least one longitudinal side wall of at least one of a plurality of wood planks, and pressing the longitudinal side walls of the plurality of wood planks together to form a board; and forming at least one groove in a first side of the board, wherein at least one of said groove extends along two adjoining side walls of the plurality of segments. In one embodiment, at least one of said groove extends along a longitudinal side wall of at least one of said segments. In another embodiment, each of said at least one grooves extend along at least two side walls of the plurality of segments. In one embodiment, said at least one groove extends along the side wall of adjoining segments.

Features of the fourth aspect of the present invention may be as described for the first, second or third aspects of the present invention. The board formed by the fourth aspect may be the board of the first or second aspects of the present invention.

In a fifth aspect the present invention provides a flooring 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 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 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.

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 port has an oval shaped aperture. In the embodiment with the oval shaped aperture, the shape of the drainage port is substantially constant in cross sectional area from the opening in the groove to the opening in the second surface. Preferably each drainage port has a width between

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2mm to 6mm, or 2 mm to 4 mm. More preferably each drainage port has a width of 4mm or 3.2 mm. Preferably each drainage port has a length between 100mm and 600mm. 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 flooring board. Preferably each of the plurality of substantially parallel grooves has a width between 2mm to 6mm, or 2 mm to 4 mm. More preferably each of the plurality of substantially parallel grooves has a width of 4mm or 3.2 mm. 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.

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 comer is a radiused corner. Preferably the radius of the radiused corner is between 1mm and 3mm. More preferably the radius of the radiused comer is about 2mm.

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 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 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.

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 flooring board.

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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 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.

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 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 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. 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.

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 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

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PCT/AU2017/050986 clips to attach the flooring board to the clips. Preferably the clips are 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, or from 900 mm to 2700 mm long. Preferably the flooring board is about 900mm, 1800mm, 2700mm or 5400mm long.

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.

Features of the fifth aspect of the present invention may be as described (where appropriate) as for the first or second aspects of the present invention.

In a sixth aspect the present invention provides a flooring 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 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 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.

Features of the sixth aspect of the present invention may be as described for the fifth aspect.

In a seventh aspect the present invention provides a method of forming a flooring board, including the steps of:

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 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 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.

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

In an eighth aspect the present invention provides a plurality of boards (or flooring boards) as described in this specification, wherein when installed, each of the plurality of boards is staggered in a lengthwise or widthwise direction relative to an adjacent board of the plurality of boards. Preferably each of the plurality of boards is attached to or abutted against an adjacent board of the plurality of boards.

In a ninth aspect, the invention provides 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 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 tenth aspect, the invention provides a method of fastening the board of a previously defined aspect to a structural member. The structural member may be a stud, a floor joist, a concrete slab or a batten, for example. The board may be fastened using an adhesive or a mechanical fastener, such as rivets, nails, nuts and bolts or screws.

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”.

It will be appreciated that the flooring board may also be a decking board or a 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 stated. Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

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 preferred embodiments 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;

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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;

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;

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

Figure 10 is a further schematic end view of the flooring board of Figure 5;

Figure 11 is a detailed view of the flooring board of Figure 10;

Figure 12 is a detailed view of a portion of the flooring board of Figure 11;

Figure 13 is a schematic end view of an intermediate board used to form the board of figure 15, showing segments adhered together, in which each segment is 92-96 mm wide;

Figure 14 is a schematic end view of an intermediate board used to form the board of figure 16, showing segments adhered together, in which each segment is 142-146 mm wide;

Figure 15 is a schematic end view of a board according to an embodiment of the present invention, showing segments adhered together and at least one groove cut into the first side and at least one stress groove cut into the second side, in which each segment is 9296 mm wide;

Figure 16 is a schematic end view of a board of an embodiment of the present invention, showing segments adhered together and at least one groove cut into the first side and at least one stress groove cut into the second side, in which each segment is 142-146 mm wide;

Figure 17 is a schematic top view of an embodiment of the present invention, showing finger jointing between segments; and

Figure 18 is a flow chart illustrating a method according to an embodiment of the present invention.

DETAIEED DESCRIPTION OF PREFERRED EMBODIMENTS

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 board 10 has a plurality of parallel grooves 12, which are formed into a surface in the form of a top surface (or first

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PCT/AU2017/050986 side) 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.

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 (or second side) 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 side wall 22 of the grooves 12 and the upper surface (or first side) 14 of the flooring board 10. In the embodiment shown, the radiused corners have a radius of 2mm.

The flooring board 10 shown in figures 1-4 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 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 (not shown) are then attached to the flooring structure adjacent to the flooring board 10.

With reference to Figures 5-6 and 10-12 there are shown schematic views of a flooring board 110 according to an embodiment of the present invention. The flooring board 110 is formed from a plurality of segments in the form 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 and 10-12 has a plurality of parallel grooves 112, which are formed into a top surface (or first side) 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 (or second side) 118 of the flooring board 110. The plurality of drainage ports (not shown) enable water or other liquid to drain from the grooves 112.

The plurality of parallel grooves 112 have radiused comers 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.

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In figures 10-12, the segments 111, 113 are each about 90 mm wide, and the at least one groove 112 is 4 mm wide and 6 mm deep. The board is 564 mm wide and 19 mm thick. The nose portion 117 is 10 mm long, and the rebated portion is 6 mm long.

With reference to Figures 7-8 there are shown schematic views of a flooring board 210 according to an embodiment of the present invention. The flooring board 210 is similar to the flooring board 110 shown in Figures 5-6, except that the flooring board 210 is formed from a plurality of segments in the form 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.

The flooring board 210 has a plurality of parallel grooves 212, which are formed into a top surface (or first side) 214 of the flooring board 210. The plurality of parallel grooves 212 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 212 to a lower surface (or second side) 218 of the flooring board 210. The plurality of drainage ports (not shown) enable water or other liquid to drain from the grooves 212.

The plurality of parallel grooves 212 have radiused comers 220 between each side wall 222 of the grooves 212 and the upper surface 214 of the flooring board 210.

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 (or first side) 314. Drainage ports 316 extend from the parallel grooves 312 to a bottom surface (or second side) (not shown). In the embodiment shown, the drainage ports 316 are arranged in a staggered manner.

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.

With reference to figures 13-16, figures 15 and 16 show further boards 410, 510 according to an embodiment of the present invention.

In the board 410, each segment 411, 413, 416 is from 92-96 mm wide. The two terminal segments 413, 416 on either side are of different width to the other segments 411. Each segment 411 is 94 mm wide, segment 413 is 92 mm wide and segment 416 is 96 mm wide. The board 410 is 2.7 m long and 19 mm thick.

The board 410 includes a plurality of longitudinally extending grooves 412 on the first side 414. Each longitudinally extending groove 412 is 4 mm wide and 6 mm deep, and extends from one end of the board to the other, parallel to the side wall of the board and to each other. Each longitudinally extending groove 412 is centred over the join between two

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PCT/AU2017/050986 abutting segments 411, 413, 416. However, the terminal groove 455 is open to the lengthwise edge, and is also 4 mm wide and 6 mm deep. This way, exactly 90 mm separates each groove 412, 455, and if two boards 410 are adjoined together, when the terminal groove 455 abuts the next board 410 at segment 413 terminal groove 455 appears substantially identical to the other grooves 412.

The board 410 also includes stress grooves 430 for alleviating stress in the board and each segment 411, 413, 416. The stress grooves 430 extend from the second side 418 and extend from one end (or lateral side wall) of the board 410 to the other, parallel to the side wall of the board and to each other. Each segment 411, 413, 416 includes two longitudinally extending stress grooves 430. The stress grooves 430 are 6 mm deep and 2.5 mm wide.

The board 410 also includes a plurality of drainage ports (not shown) which extend from the grooves 412, 455 to the second side 418. The drainage ports are staggered, similarly to that illustrated in figure 9.

The board 410 is 564 mm wide. The join between each segment 411, 413, 416 is a butt joint. Resorcinol adhesive fastens the segments 411, 413, 416 together.

In the board 510, each segment 511, 513, 516 is from 142-146 mm wide. The two terminal segments 513, 516 on either side are of different width to the other segments 511. Each segment 511 is 144 mm wide, segment 513 is 142 mm wide and segment 516 is 146 mm wide. The board is 2.7 m long and 19 mm thick.

The board 510 includes a plurality of longitudinally extending grooves 512 on the first side 514. Each longitudinally extending groove 512 is 4 mm wide and 6 mm deep, and extends from one end of the board to the other, parallel to the side wall of the board and to each other. Each longitudinally extending groove 512 is centred over the join between two abutting segments 511, 513, 516. However, the terminal groove 555 is open to the lengthwise edge, and is also 4 mm wide and 6 mm deep. This way, exactly 140 mm separates each groove 512, 555, and if two boards 510 are adjoined together, when the terminal groove 555 abuts the next board 510 at segment 513 terminal groove 555 appears substantially identical to the other grooves 512.

The board 510 also includes stress grooves 530 for alleviating stress in the board and each segment 511, 513, 516. The stress grooves 530 extend from the second side 518 and extend from one end (or lateral side wall) of the board 510 to the other, parallel to the side wall of the board and to each other. Each segment 511, 513, 516 includes two longitudinally extending stress grooves 530. The stress grooves 530 are 6 mm deep and 2.5 mm wide.

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The board 510 also includes a plurality of drainage ports (not shown) which extend from the grooves 512, 555 to the second side 518. The drainage ports are staggered, similarly to that illustrated in figure 9.

The board 510 is 576 mm wide. The join between each segment 511, 513, 516 is a butt joint. Resorcinol adhesive fastens the segments 511, 513, 516 together.

Figure 17 illustrates how segments of different length may be used in the board 610. The board 610 is similar to the board 410 of figure 15. The board 610 is 2.7 m long, 564 mm wide, and 19 mm thick. However, in the board 610 of figure 17 four segments 620 are 2.7 m long, two segments 630 are 1.8 m long, and two segments 640 are 0.9 mm long. Finger joints are used to connect segments 630 with segments 640, however butt joints may also be used (i.e. a straight edge between the two adjoining segments). Resorcinol adhesive is used to fasten the segments 620, 630, 640 together.

The boards of figures 13-17 are made from Merbau timber.

A method of making the board 410, 510 is now described with reference to figures 13-16 and 18, and especially figure 18. Raw Merbau wood or timber is first cut or sawn in a mill 910. The cut wood is then dried in a kiln 920. The cut wood was dried at a low temperature to minimise the possibility of cracking during the drying process. The cut wood was dried for 2-3 weeks in the kiln at a temperature of 45 °C to 70 °C (which is raised and lowered as required, as would be known by a skilled person). The drying step reduced the moisture content of the dried wood to from 8 to 12 %. This moisture content is believed to be the optimum moisture content for the climate in Brisbane.

The dried wood was then machined or processed into segments 930. The machining was performed with high precision to provide 2.7 m long segments (in the form of planks), which were 19 mm thick. To form the board 710 of figure 13, one 92 mm wide plank 713, four 94 mm wide planks 711, and one 96 mm wide plank 716 were needed. To form the board 810 of figure 14, one 142 mm wide plank 813, two 144 mm wide planks 811, and one 146 mm wide planks 816 were needed. Stress grooves (not shown in figures 13 and 14 but illustrated in figures 15 and 16 at 430 and 530) were also cut into the planks 711, 713, 716, 811, 813, 816 at this time. The stress grooves extend parallel to the side wall of each plank 711, 713, 716, 811, 813, 816 and extend from one lateral side wall of each plank to the other. Two stress grooves are cut into each plank 711, 713, 716, 811, 813, 816. The stress grooves are intended to ameliorate twisting of the finished board. The stress grooves are each about 6 mm deep and about 2.5 mm wide.

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In the next step, the segments were contacted with an adhesive (resorcinol) and pressed together 940, in a laminating press. The resorcinol was added to the longitudinal side walls of abutting segments 711, 713, 716, 811, 813, 816. The segments 711, 713, 716, 811, 813, 816 each have flat side walls to form butt joints. The resorcinol was set more quickly through application of heat. The segments 711,713,716, 811, 813, 8f were pressed together for about 3 hours at a temperature of from about 40 to 100 °C (the segments can also be adhered together at room temperature by pressing for 3-4 hours). However, in a hot climate such as Malaysia the segments 711, 713, 716, 811, 813, 816 may be pressed together for about 5 hours at room temperature to fasten the segments 711, 713, 7f6, 811, 813, 816 together. This step forms board 710 and 810.

In the next step, at least one groove 950 is formed in the board 710 and 810. The at least one groove is centred over the join between each pair of abutting segments 711, 713, 716, 811, 813, 816. To form the board of figure 15, five parallel grooves 412 were cut into the first side 414 of the board 410, along with one terminal groove 455. The grooves 412, 455 are also parallel to the side walls of the board. The grooves 412, 455 were each about 4 mm wide and about 6 mm deep. After the grooves 412, 455 were cut, the board 410 simulated a 2.7 m long section of a deck, formed from six 90 mm planks spaced 4 mm apart. If two boards 410 are abutted along their longitudinal side wall, the segment 416 of one board 410 abuts the segment 413 of the adjoining board 410. Due to the terminal groove 455 the raised portion in the first side 414 of each board seems to be evenly spaced. When cutting the grooves 412, 455 a rounded comer is provided between the side wall of the groove 412, 455 and the first side 414 of the board 410. The rounded comer has a radius of about 2 mm.

To form the board of figure 16, three parallel grooves 512 were cut into the first side 514 of the board 5f0, along with one terminal groove 555. The grooves 512, 555 are also parallel to the side walls of the board. The grooves 5f2, 555 were each about 4 mm wide and about 6 mm deep. After the grooves 5f2, 555 were cut, the board 5f0 simulated a 2.7 m long section of a deck, formed from four 140 mm planks spaced 4 mm apart. If two boards 5f0 are abutted along their longitudinal side wall, the segment 516 of one board 5f0 abuts the segment 513 of the adjoining board 510. Due to the terminal groove 555 the raised portion in the first side 514 of each board seems to be evenly spaced. When cutting the grooves 512, 555 a rounded corner is provided between the side wall of the groove 5f2, 555 and the first side 514 of the board 5 f 0. The rounded comer has a radius of about 2 mm.

At least one drainage port was next formed 960 in the board. Each of the at least one drainage ports is generally ovoid in shape and is about 4 mm wide and about 200 mm long.

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As illustrated in figure 9, board 410 has three drainage ports in each groove 412, 455. The drainage ports are cut into and located in the centre of each groove. The location of the drainage ports are staggered so that no two drainage ports are in the same location on neighbouring grooves, and also so that no drainage ports would be positioned over structural members such as floor joists.

The boards 410, 510 may be laid by placing the boards 410, 510 upon floor joists, and then nailing the boards 410, 510 to the joists. One nail may be used per segment within the board to fasten the board to each floor joist.

In one embodiment (not shown) each of the flooring boards is staggered in a lengthwise direction relative to an adjacent flooring board.

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 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 board (especially a flooring board) includes that the board is less labour intensive and easier to lay and align in position compared to individual wooden planks. Another advantage of the preferred embodiment of the board includes that the board is easier and safer to transport compared to individual wooden planks. Advantageously, the board is large enough to minimise time when laying the board, whilst being small enough to be manually lifted into place. An advantage of including drainage ports is that liquids can drain from the board. An advantage of placing each layer of 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

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.

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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.

Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any 10 suitable manner in one or more combinations.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, 15 claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims

1. A board including:

a first side and a second side, the first side opposed to the second side;

2. The board according to claim 1, wherein the board is a flooring board.

3. The board according to claim 1 or claim 2, wherein the at least one groove extends substantially longitudinally across the first side.

4. The board according to any one of claims 1 to 3, wherein the at least one groove is a plurality of grooves extending substantially across the first side.

5 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.

19. A method of forming a board, the method including the steps of:

contacting an adhesive to at least one longitudinal side wall of at least one of a

5. The board according to claim 4, wherein the plurality of grooves are substantially parallel.

6. The board according to any one of claims 1 to 5, wherein the at least one drainage port is a plurality of drainage ports extending from said at least one groove to the second side.

7. The board according to any one of claims 1 to 6, wherein the at least one drainage port is from 100 mm to 600 mm long.

8. The board according to claim 1, wherein the board is a flooring board wherein the at least one groove is a plurality of substantially parallel grooves formed in the first side and extending along the length of the board; and wherein the at least one drainage port is a plurality of drainage ports, each of said drainage ports extending from one of the plurality of substantially parallel grooves to the second side of the board.

9. The board according to any one of claims 1 to 8, wherein the board is a wooden board.

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10 plurality of wood planks, and pressing the longitudinal side walls of the plurality of wood planks together to form a board; and forming at least one groove in a first side of the board, wherein at least one of said groove extends along two adjoining side walls of the plurality of segments.

10. The board according to any one of claims 1 to 9, wherein the board includes a plurality of segments adhered together.

11. The board according to claim 10, wherein the plurality of segments are adhered together along their longitudinal side walls, and wherein at least one of said groove extends along two adjoining side walls of the plurality of segments.

12. The board according to claim 10 or 11, wherein each of the plurality of segments is a wood plank.

13. The board according to any one of claims 1 to 12, wherein the board includes at least one stress groove in the second side for alleviating stress in the board.

14. The board according to claim 13, wherein each stress groove extends from one lateral side wall of the board to the other.

15. The board according to claim 13 or 14, wherein each stress groove extends substantially longitudinally across the second side.

16. A board including:

a first side and a second side, the first side opposed to the second side;

wherein the first side includes at least one groove extending substantially across the first side;

wherein the board includes a plurality of wood planks adhered together along their longitudinal side walls, and wherein at least one of said groove extends along two adjoining side walls of the plurality of segments.

17. A method of forming a board, the method including the steps of:

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18. 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

15 20. The method of any one of claims 17 to 19, wherein the board is the board according to any one of claims 1 to 14.