Ladder-type solid-wood two-layer floor product and method

Abstract

A ladder-type solid-wood two-layer floor product and related methods are provided. The floor product includes a floor support main body layer and an upper decorative surface layer. The main body layer is formed by splicing two parallel frames and a group of strip-shaped solid-wood cores parallel to each other and perpendicular to the frames. The floor product has a simple structure and high economic value. It avoids bending, deformation and the like from internal stress due to temperature and humidity variations.

What is claimed is: 
     
         1 . A ladder-type solid-wood two-layer floor product, comprising:
 a floor support main body layer, wherein the main body layer comprises:
 two solid-wood frame components, each having a long axis disposed parallel to the long axis of the other; 
 a plurality of strip-shaped solid-wood cores disposed between said two solid-wood frame components, each core having a first end, a second end, and a long axis extending between the first and second ends, the long axis of each core being disposed parallel to the long axes of each other core and each core long axis disposed perpendicular to the long axes of the two solid-wood frame components, and each first end of each core being affixed to a first of said two solid-wood frame components, and each second end of each core being affixed to a second of said two solid-wood frame components; and 
   an upper decorative surface layer affixed to the main body layer.   
     
     
         2 . The floor product according to  claim 1 , wherein each of the two solid-wood frame components has a thickness and each of the plurality of strip-shaped solid-wood cores has a thickness and the thickness of each of the two solid-wood frame components is substantially the same as the thickness of each of the plurality of strip-shaped solid-wood cores. 
     
     
         3 . The floor product according to  claim 1 , wherein each of the two solid-wood frame components has an upper face and each of the plurality of strip-shaped solid-wood cores has an upper face, and the upper faces of the two solid-wood frame components lies on the same plane as the upper faces of the plurality of strip-shaped solid-wood cores. 
     
     
         4 . The floor product according to  claim 1 , wherein the plurality of strip-shaped solid-wood cores are arranged at substantially equal intervals with an empty space between each adjacent core. 
     
     
         5 . The floor product according to  claim 4 , wherein each of the substantially equal intervals is in the range of 1.5 centimeters to 2.5 centimeters. 
     
     
         6 . The floor product according to  claim 1 , wherein each of the two solid-wood frame components has a wood grain in a general direction and each of the plurality of strip-shaped solid-wood cores has a wood grain in a general direction. 
     
     
         7 . The floor product according to  claim 6 , wherein the general direction of the wood grain of each of the two solid-wood frame components is in alignment with one another. 
     
     
         8 . The floor product according to  claim 6 , wherein the general direction of the wood grain of each of the strip-shaped solid-wood cores is in alignment with one another. 
     
     
         9 . The floor product according to  claim 6 , wherein the general direction of the wood grain of each of the two solid-wood frame components is in alignment with the general direction of the wood grain of each of the strip-shaped solid-wood cores. 
     
     
         10 . The floor product according to  claim 9 , wherein the general direction of the wood grain is vertical, extending from a bottom side of the main body layer upward toward the upper decorative surface layer. 
     
     
         11 . The floor product according to  claim 1 , wherein each of the two solid-wood frame components has a thickness and the thickness of each of the frames is in the range of 0.8 centimeters to 1.5 centimeters. 
     
     
         12 . A method of manufacturing a ladder-type solid-wood two-layer floor product, the method comprising:
 assembling a floor support main body layer, wherein the main body layer comprises:
 two solid-wood frame components, each having a long axis disposed parallel to the long axis of the other; 
 a plurality of strip-shaped solid-wood cores disposed between said two solid-wood frame components, each core having a first end, a second end, and a long axis extending between the first and second ends, the long axis of each core being disposed parallel to the long axes of each other core and each core long axis disposed perpendicular to the long axes of the two solid-wood frame components; 
   affixing each first end of each core to a first of said two solid-wood frame components;   affixing each second end of each core to a second of said two solid-wood frame components; and   affixing an upper decorative surface layer to a top side of the main body layer.   
     
     
         13 . A method of using the ladder-type solid-wood two-layer floor product of  claim 1 , the method comprising:
 positioning the floor product of  claim 1  on top of a floor substrate; and   affixing the floor product of  claim 1  in position on top of a floor substrate.   
     
     
         14 . The method of  claim 13 , further comprising:
 cutting the floor product of  claim 1  to match the size and shape of the floor substrate at least in part.   
     
     
         15 . The method of  claim 13 , further comprising:
 positioning a second floor product of  claim 1  on top of the floor substrate and adjacent to the other floor product of  claim 1 ; and   affixing the second floor product of  claim 1  in position on top of the floor substrate.