Floorboard having locking mechanisms comprising polymer

Abstract

This present disclosure relates to a floorboard comprising a main panel and a polymer frame that is continuous and comprises along two opposing edges a first locking mechanism and along the other two opposing edges a second locking mechanism different from the first one.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present disclosure claims the benefit of priority from U.S. provisional application No. 62 / 516,243 filed on Jun. 7, 2017 and from Canadian application no. 2,979,897 filed on Sep. 19, 2017. These documents are hereby incorporated by reference in their entirety.FIELD OF THE DISCLOSURE[0002]The present disclosure relates to a floorboard. More particularly, the present disclosure relates to a floorboard with a continuous polymer frame. The present disclosure also relates to a floorboard with a polymer coating.BACKGROUND OF THE DISCLOSURE[0003]Traditional floorboards connect through locking mechanisms on the edges of each floorboard. The locking mechanism and main body of the floorboard are often made with the same material and usually from one piece of flat board, such that extensive machining is required to manufacture the locking mechanism. The process of manufacture not only requires special machineries and labourious handling, it gene...

AI Technical Summary

Benefits of technology

This patent describes a floorboard with connecting edges that are strong enough to withstand pressure. The manufacturing process eliminates waste and the floorboard maintains good esthetics. The polymer frame is more durable and resistant to deformation than traditional wood-based floorboards, and also helps prevent cracking and deformation. The floorboard also has recesses along its edges to further reduce deformation.

Problems solved by technology

The locking mechanism and main body of the floorboard are often made with the same material and usually from one piece of flat board, such that extensive machining is required to manufacture the locking mechanism.

The process of manufacture not only requires special machineries and labourious handling, it generates large amount of material waste since significant parts of the edges of the flat board need to be removed.

In addition, the material constituting the edges of the floorboard such as solid wood, compound wood, particle board, laminated wood and bamboo, is often soft and moisture sensitive, such that the connecting edges cannot withstand the constant forces exercised on the locking mechanism through daily wear, and the expansion and contraction associated with seasonal change in moisture and temperature.

This leads to cracks and warping of the floor.

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