Method for manufacturing and installing a prefabricated hardwood floor

Abstract

Described is a prefabricated hardwood floor apparatus that is installed with substantially more ease and efficiency than conventional hardwood floors. The floor apparatus includes a rigid board to which planks of hardwood are secured in an aesthetic manner. A non-slip pad is also secured to the rigid board, but at the face opposite that of the hardwood planks. The non-slip pad includes a frictional characteristic that prevents the floor apparatus from sliding on a surface, such as a sub-flooring, in response to force components parallel to the sub-flooring. The floor apparatus is installed by simply placing the floor apparatus on a sub-flooring such that the non-slip pad mechanically engages the sub-flooring.

1 . A floor apparatus for providing an existing structure with a prefabricated hardwood floor, said floor apparatus comprising: 
 a rigid board;    a hardwood layer secured to a first side of said rigid board; and    a non-slip pad secured to a second side of said rigid board, whereby the second side of said rigid board is geometrically opposing the first side of said rigid board, said non-slip pad compositionally characterized by a substantially high coefficient of friction.    
   
   
       2 . The floor apparatus of  claim 1  wherein said rigid board is a fibrous board.  
   
   
       3 . The floor apparatus of  claim 2  wherein said rigid board is a cut of hardboard.  
   
   
       4 . The floor apparatus of  claim 1  wherein said hardwood layer includes a plurality of hardwood planks.  
   
   
       5 . The floor apparatus of  claim 1  wherein said hardwood layer is secured to said rigid board by way of a wood glue.  
   
   
       6 . The floor apparatus of  claim 1  wherein said non-slip pad is a laminate pad.  
   
   
       7 . The floor apparatus of  claim 1  wherein said non-slip pad is secured to said rigid board by way of an adhesive.  
   
   
       8 . A floor apparatus for providing an existing structure with a prefabricated hardwood floor, said floor apparatus comprising: 
 a cut of hardboard;    a plurality of hardwood planks secured to the top face of said cut of hardboard by way of a wood glue; and    a laminate pad secured to the bottom face of said cut of hardboard, said laminate pad including the compositional characteristic of a substantially high frictional coefficient.    
   
   
       9 . A method for constructing the floor apparatus, said method comprising the steps of: 
 securing at least one plank of hardwood to a first side of a rigid board; and    securing a non-slip pad to a second side of the rigid board, whereby the second side of the rigid board is geometrically opposite of the first side of the rigid board.    
   
   
       10 . The method of  claim 9  further comprising the step of cutting the rigid board to a tailored shape and/or size prior to said step of securing at least one plank of hardwood and prior to said step of securing a non-slip pad.  
   
   
       11 . The method of  claim 10  further comprising the step of cutting the non-slip pad to substantially the same size and shape as the rigid board.  
   
   
       12 . A method for constructing the floor apparatus, said method comprising the steps of: 
 applying a wood glue to a first side of a rigid board;    disposing at least one piece of hardwood on the first side of the rigid board such that the hardwood is secured to the rigid board by way of the wood glue;    mounting a non-slip pad to a second side of the rigid board by way of an adhesive, the second side of the rigid board being opposite the first side of the rigid board; and    restraining the non-slip pad, the rigid board, and the hardwood to their designed positions until the adhesive and the wood glue dry, such that the non-slip pad and the hardwood are positionally secured to the rigid board by the adhesive and the wood glue respectively.    
   
   
       13 . The method of  claim 12  further comprising the step of cutting the floor apparatus to a tailored shape and/or size.  
   
   
       14 . The method of  claim 12  wherein said step of disposing at least one piece of hardwood onto the first side of the rigid board includes substantially covering the first side of the rigid board with the hardwood.  
   
   
       15 . The method of  claim 12  wherein said step of restraining the non-slip pad, the rigid board, and the hardwood to their designed positions includes clamping the non-slip pad, the rigid board, and the hardwood into their designed positions.  
   
   
       16 . A method for installing the floor apparatus, said method comprising the steps of: 
 exposing the sub-flooring at the desired location of the floor apparatus;    ridding the exposed sub-flooring of debris;    leveling the exposed sub-flooring substantially, said leveling the exposed sub-flooring including hammering down protruding nails, screws, and high spots; and    placing the floor apparatus at the exposed sub-flooring such that the non-slip pad mechanically engages the exposed sub-flooring;    
   
   
       17 . The method of  claim 16  wherein said step of exposing the sub-flooring includes cutting and removing a section of existing carpet at the desired location of the floor apparatus.  
   
   
       18 . The method of  claim 17  further comprising the step of securing a tack strip to the sub-flooring proximate to the floor apparatus at edges of the floor apparatus bordered by the existing carpet.  
   
   
       19 . The method of  claim 18  further comprising the step of securing the remaining portions of the existing carpet that border the floor apparatus to the tack strip.  
   
   
       20 . The method of  claim 19  further comprising the step of trimming the existing carpet that boarders the floor apparatus such that a substantially small portion of carpet extents past the tack strip in the direction of the floor apparatus.  
   
   
       21 . The method of  claim 20  further comprising the step of tucking the portion of carpet extending past the tack strip between the tack strip and the floor apparatus to the extent that a fluid transition exists between the existing carpet and the floor apparatus.