Plywood flooring with an acoustic barrier

Abstract

An improved plywood flooring and process of manufacturing. In one embodiment, the flooring is formed from two layers of Okoume wood sandwiching an acoustic sound barrier therebetween. A wear layer of veneer is adhered to a top face of the upper layer of Okoume wood and edge joinery shapes are cut through a CNC. The flooring is coated with a proprietary epoxy blend with a matt coating on the veneer surface. The process provides a flooring material that will not warp or otherwise degrade when subjected to standing water.

What is claimed is: 
     
         1 . A method for manufacturing a flooring plank, comprising the steps of providing a) a base formed of Okoume; b) placing a first adhesive layer to a top of said base; c) positioning an acoustic sound barrier over said first adhesive layer; d) placing a second adhesive layer over said sound barrier; e) positioning an upper layer of plywood onto a top face of said second adhesive layer; f) placing a third adhesive layer to a top of said upper layer; g) attaching a veneer wear layer onto said third adhesive layer; h) applying a pressure of at least 15 psi to squeeze said veneer wear layer to said base for a period of about 8 hours to form a plywood plank; i) forming interlocking joinery on at least one edge of said plywood plank; and j) sealing the work piece with an epoxy to provide water resistance. 
     
     
         2 . The method of  claim 1 , wherein said plywood is Okoume. 
     
     
         3 . The method of  claim 1 , wherein said first and second adhesive layers are a proprietary adhesive constructed and arranged to bond said acoustic sound barrier to said base and upper layer of wood. 
     
     
         4 . The method of  claim 1 , wherein the step of attaching the veneer wear layer comprises using a bonding agent to adhere the veneer securely to the upper layer of wood. 
     
     
         5 . The method of  claim 1 , wherein said epoxy is applied in a controlled thickness to ensure uniform water resistance across the plank outer surface. 
     
     
         6 . The method of  claim 1 , including the step of spraying a matte coat on the face of the veneer in a controlled manner to achieve a desired level of surface texture and appearance. 
     
     
         7 . The method of  claim 2 , wherein said Okoume wood is 4 mm in thickness. 
     
     
         8 . The method of  claim 1 , wherein said veneer is 2.4 mm thick. 
     
     
         9 . The method of  claim 1 , wherein said bond acoustic sound barrier extends through said interlocking joinery. 
     
     
         10 . A flooring plank comprising: a base formed of plywood; a first adhesive layer to a top of said base; an acoustic sound barrier over said first adhesive layer; a second adhesive layer over said sound barrier; an upper layer of plywood onto a top face of said second adhesive layer; a third adhesive layer to a top of said upper layer; and a veneer wear layer onto said third adhesive layer. 
     
     
         11 . The flooring plank according to  claim 10  wherein said plywood is Okoume. 
     
     
         12 . The flooring plank according to  claim 10  wherein said flooring plank includes interlocking joinery with said acoustical sound barrier extending through said joinery. 
     
     
         13 . The flooring plank according to  claim 10  wherein said flooring plank is sealed to provide water resistance. 
     
     
         14 . The flooring plank according to  claim 10  wherein said Okoume wood is 4 mm in thickness. 
     
     
         15 . The flooring plank according to  claim 10  wherein said veneer is 2.4 mm thick.