Ultra-thin vertical core layer solid wood composite flooring and its manufacturing method

Abstract

This invention discloses an ultra-thin solid wood composite flooring. The ultra-thin solid wood composite flooring comprises multiple vertical core veneers, each of which has a grain direction. The multiple vertical core veneers are arranged such that the grain directions of adjacent vertical core veneers are perpendicular to each other. This invention also discloses a method for manufacturing the ultra-thin solid wood composite flooring. The method includes stacking multiple vertical core veneers, applying adhesive between the multiple vertical core veneers, and hot-pressing the multiple vertical core veneers.

Description

Technical Field

[0001] This disclosure generally relates to a solid wood composite floor and a method for manufacturing the same. More specifically and without limitation, this disclosure relates to an improved solid wood composite floor with an ultra-thin thickness and a method for manufacturing said solid wood composite floor. Background Technology

[0002] Currently, the global flooring market is dominated by engineered wood flooring and stone-plastic composite (SPC) flooring, which together account for the majority of the market share. As of 2024, engineered wood flooring held the largest market share, with high market penetration in Europe, North America, and China, and dominated high-end residential applications. Laminate flooring, once a major product category, has seen its market share decline continuously in recent years.

[0003] Market analysis indicates that the growth rate of stone-plastic composite flooring is four times that of engineered wood flooring, primarily due to its rapid installation. However, stone-plastic composite flooring is typically made by extruding a mixture of calcium carbonate (stone powder), polyvinyl chloride (PVC), and various additives, resulting in a high product density. This not only leads to high transportation costs but also causes environmental problems due to its disposal methods and long-term ecological impact.

[0004] Laminate flooring typically uses medium-density fiberboard (MDF) as its base material. While MDF offers certain processing advantages, its manufacturing process requires a large amount of adhesives, leading to increased formaldehyde emissions and poor moisture resistance. Therefore, this type of product is not suitable for installation in humid environments.

[0005] Traditional engineered wood flooring typically uses plywood as the core layer. However, plywood often cannot fully release internal stress, leading to warping and deformation of the finished product over long-term use. Therefore, the thickness of traditional engineered wood flooring is usually limited to 12 mm or more. This not only restricts design flexibility but also increases wood consumption and production costs.

[0006] Furthermore, traditional engineered wood flooring manufacturing processes are typically limited to a single rotary cutting process and a single hot-pressing cycle. Rotary-cut veneers are often affected by natural defects such as knots and cracks, rendering some materials unusable. This not only places higher demands on the quality of the raw wood but also reduces the yield. These issues further exacerbate resource consumption and limit product diversity in design and application.

[0007] Therefore, there is an urgent need to improve engineered wood flooring and its manufacturing process, and to develop an ultra-thin product to achieve the goals of increasing yield, reducing transportation costs, lowering the requirements for log quality, and improving eco-friendliness, while simultaneously addressing the shortcomings of traditional engineered wood flooring such as warping and deformation after long-term use and high wood consumption. The engineered wood flooring described in this disclosure provides an ideal alternative to stone-plastic composite flooring and laminate flooring.

[0008] The manufacturing process described in this disclosure can produce engineered wood flooring with a similar thickness to stone-plastic composite flooring, but with a much lower density. The engineered wood flooring described in this disclosure can have a thickness of 2-8 mm and a density of 0.6-0.7 g / cm³. 3 In contrast, stone-plastic composite flooring is typically 4-8 mm thick and has a density of approximately 1.9-2.1 g / cm³. 3 This process also boasts extremely high material utilization and low timber waste, with a timber yield of 76% or higher.

[0009] In addition, the manufacturing process described in this disclosure mainly adopts slicing and hot pressing processes, which have lower energy consumption than the manufacturing process of stone-plastic composite flooring (such as extrusion, UV curing, etc.).

[0010] Because the engineered wood flooring described in this disclosure is made from natural wood, it is recyclable and can be used for other purposes, such as manufacturing other engineered wood products or biomass pellets. The product is compostable and biodegradable, making it eco-friendly and more likely to meet the certification requirements of the Forest Stewardship Council (FSC). Summary of the Invention

[0011] Embodiments of this disclosure may relate to an ultra-thin engineered wood flooring. In some embodiments, the ultra-thin engineered wood flooring may include a plurality of vertical core veneers. Each of the plurality of vertical core veneers has a grain direction. The plurality of vertical core veneers are arranged such that the grain directions of adjacent vertical core veneers are perpendicular to each other.

[0012] Other embodiments of this disclosure may relate to a method for manufacturing an ultra-thin engineered wood flooring. In some embodiments, the method may include stacking a plurality of vertical core veneers, applying adhesive between the plurality of vertical core veneers, and hot-pressing the plurality of vertical core veneers.

[0013] The accompanying drawings form part of this specification. The drawings illustrate several embodiments of this disclosure and, together with the specification, serve to explain the principles of certain disclosed embodiments as described in the appended claims. Attached Figure Description

[0014] The following detailed description and accompanying drawings illustrate embodiments and various aspects of this disclosure. It should be noted that, according to industry standard practice, the features are not drawn to scale. In fact, for clarity, the dimensions of the features may be arbitrarily enlarged or reduced.

[0015] Figure 1 This is a flowchart of the manufacturing process for ultra-thin vertical core layer solid wood composite flooring.

[0016] Figure 2This is a schematic diagram of wood veneer obtained by rotary cutting of logs.

[0017] Figure 3 This is a schematic diagram of stacking wood veneers to form laminated veneer lumber.

[0018] Figure 4 This is a schematic diagram of a vertical core veneer obtained by sawing or planing the laminated veneer material.

[0019] Figure 5A This is a schematic diagram of a three-layer vertical core plate.

[0020] Figure 5B This is a schematic diagram of a five-layer vertical core board.

[0021] Figure 5C This is a schematic diagram of a seven-layer vertical core board.

[0022] Figure 5D This is a schematic diagram of an ultra-thin vertical core layer solid wood composite flooring.

[0023] Unless otherwise explicitly stated, the same reference numerals may refer to the same parts in multiple figures.

[0024] All figures in this disclosure are not drawn to scale. Detailed Implementation

[0025] The following disclosure provides various exemplary embodiments or instances for implementing different features of the subject matter covered herein. Simplified examples of components and arrangements are described below to illustrate the disclosure. These are, of course, merely examples and are not intended to be limiting. Furthermore, reference numerals and / or letters may be repeated in various examples. Such repetition is for simplification and clarity and does not in itself represent a relationship between the various embodiments and / or configurations discussed.

[0026] Unless otherwise expressly defined, the terms used in this specification generally have their conventional meanings in the art and in the specific context in which they are used. The examples used in this specification (including examples of any term discussed herein) are for illustrative purposes only and are not intended to limit the scope or meaning of this disclosure or any of the example terms. Similarly, this disclosure is not limited to the various embodiments provided in this specification.

[0027] Figure 1 This is a flowchart of the manufacturing process 100 for ultra-thin vertical core layer engineered wood flooring. The structure of the ultra-thin vertical core layer engineered wood flooring will become clear during the description of detailed manufacturing process steps 110-190.

[0028] In step 110, the logs are prepared into rotary-cut timber. The logs used to make the flooring are typically made from poplar, pine, or other fast-growing tree species.

[0029] In step 120, the log is prepared into wood veneer 210 by rotary cutting (or veneer rotary cutting). Figure 2 This is a schematic diagram of wood veneer 210 obtained by rotary cutting of log 200. In some embodiments, log 200 is rotary cut into wood veneer 210 with a thickness ranging from 0.3 to 2.2 mm, depending on the specific application.

[0030] Each wood veneer 210 has a growth direction 220, which is usually the growth direction of the tree, usually parallel to the longitudinal axis of the log (i.e., the trunk) and parallel to the fibers.

[0031] After the 210 wood veneer is rotary-cut and cut to the specified size, it is further dried to achieve a moisture content of 8-12% by weight, and then subjected to a balancing and conditioning treatment.

[0032] In step 130, multiple wood veneers 210 are stacked to form laminated veneer lumber (LVL) 300. Figure 3 Only the growth direction 220 of the top layer of wood veneer 210 is shown. Those skilled in the art will understand that the wood veneers 210 are arranged such that the growth direction 220 of the same layer of wood veneers 210 remains consistent, and the growth directions 220 of adjacent layers of wood veneers 210 are perpendicular to each other. The alternating growth directions 220 create a cross-laminated (interlaced) structure for the multiple layers of wood veneers 210.

[0033] In some embodiments, an adhesive (e.g., glue) is applied between the layers of wood veneer 210 before stacking them into laminated veneer lumber 300. The application of the adhesive can be performed by a glue applicator (not shown) or manually. In some embodiments, the glue applicator can be a roller applicator, a spray applicator, a scraper applicator, a multi-roller applicator, or any applicator capable of applying glue / adhesive to a surface. In some embodiments, the amount of glue applied per layer of wood veneer 210 ranges from 100 to 200 grams per square meter (g / m²). 2 ), or approximately 150-170 g / m 2 Or 155-165 g / m 2 .

[0034] In some embodiments, the stacked wood veneers 210 may be subjected to cold or hot pressing for approximately 4-6 hours, depending on ambient temperature and / or other conditions. In some embodiments, the pressing pressure is approximately 10-20 kg / cm². 2 ), or approximately 16 kg / cm2 In some embodiments, different adhesives are suitable for different pressing methods. For example, adhesives for cold pressing typically have a moisture content of 20% or higher; adhesives for hot pressing typically have a moisture content of 20% or lower. In some embodiments, the adhesive may be a mixture of the two types of adhesives described above. Different adhesive mixtures and their moisture contents will result in different hardnesses in the laminated veneer lumber 300. For example, a higher moisture content may result in a softer laminated veneer lumber 300, while a lower moisture content may result in a harder laminated veneer lumber 300.

[0035] In some embodiments, the laminated veneer lumber 300 may use different wood veneers 210 depending on the application. In this context, since the engineered wood flooring is a multi-layered structure, "different applications" here refers to which layer of vertical core veneer the laminated veneer lumber 300 will be used to produce. For example, the wood veneer lumber 210 used for the central core layer may have a thickness of 1.7-2.2 mm; the wood veneer lumber 210 used for the intermediate layer (sub-layer) may have a thickness of 1.0-1.7 mm; and the wood veneer lumber 210 used for the top layer (top layer) may have a thickness of 0.3-0.9 mm.

[0036] In some embodiments, after cold pressing or hot pressing, the laminated veneer material 300 is sealed with a stretch film for conditioning and balancing treatment. In some embodiments, the conditioning and balancing treatment can last for approximately 7-10 days.

[0037] In step 140, the laminated veneer 300 is sawed or planed to obtain a vertical core veneer 410. Figure 4 This is a schematic diagram of a vertical core veneer 410 obtained by sawing or planing a laminated veneer material 300. In some embodiments, the laminated veneer material 300 is first rotated 90 degrees around the growth direction 220. Since the growth directions 220 of adjacent layers are perpendicular to each other, the "growth direction of the vertical core veneer 410" here refers to the growth direction to be retained in the vertical core veneer 410. To avoid confusion, this disclosure defines the growth (texture) direction 220 retained after sawing or planing in step 140 as the "texture direction".

[0038] The veneer laminate 300 is rotated 90 degrees around the grain direction 420 and sawn or planed from the top to produce the vertical core veneer 410. In some embodiments, the thickness of the sawing or planing also depends on the application. For example, the thickness of the vertical core veneer 410 of the veneer laminate 300 used to prepare the central core layer can be 1.0-4.0 mm; the thickness of the vertical core veneer 410 of the veneer laminate 300 used to prepare the middle layer can be 0.8-1.0 mm; and the thickness of the vertical core veneer 410 of the veneer laminate 300 used to prepare the top layer can be 0.4-0.6 mm.

[0039] The choice between sawing and slicing depends on the hardness of the laminated veneer lumber 300, which is related to the adhesive used in step 130. Generally, sawing is more suitable for harder laminated veneer lumber 300, while slicing is more suitable for softer laminated veneer lumber 300.

[0040] In steps 150-180, three to seven vertical core veneer layers 410 are bonded to other layers by gluing and hot pressing to form solid wood composite flooring.

[0041] In step 150, a three-layer vertical core plate is formed by a first hot pressing. Figure 5A This is a schematic diagram of a three-layer vertical core panel 510. The three-layer vertical core panel 510 is composed of three vertical core veneers 410 stacked together. As mentioned earlier, the three vertical core veneers 410 can be from different veneer laminates 300 and have different thicknesses. For example, the thickness of the central vertical core veneer 410 can be 1.0-4.0 mm, while the thickness of the two outer vertical core veneers 410 can be 0.8-1.0 mm.

[0042] In some embodiments, the vertical core layer veneers 410 are arranged such that the texture directions 420 of adjacent vertical core layer veneers are perpendicular to each other. For example, the texture direction 420 (not shown) of the central vertical core layer veneer 410 is perpendicular to the texture directions 420 of the two outer vertical core layer veneers 410.

[0043] In some embodiments, adhesive is applied between the vertical core veneers 410 before stacking them into three layers. Adhesive application can be performed using an adhesive applicator (not shown) or manually. In some embodiments, the adhesive applicator can be a roller applicator, a spray applicator, a blade applicator, a multi-roller applicator, or any applicator capable of applying glue / adhesive to a surface. In some embodiments, the amount of adhesive applied to each vertical core veneer 410 ranges from 100-200 grams per square meter (g / m²). 2 ), or approximately 150-170 g / m 2 Or 155-165 g / m 2 .

[0044] In some embodiments, the three stacked vertical core veneers 410 may be pre-pressed (i.e., shaped) and then hot-pressed at a temperature of approximately 130-140°C or 133-137°C for approximately 1-2 minutes per millimeter of thickness, depending on the ambient temperature and / or other conditions. In some embodiments, the pressing pressure is approximately 5-20 kg / cm². 2 ), or approximately 10-12 kg / cm 2 .

[0045] In some embodiments, the hot-pressed three-layer vertical core plate 510 is subjected to constant temperature curing for at least 7 days to release internal stress.

[0046] In some embodiments, the cured three-layer vertical core plate 510 is sanded and its thickness is calibrated.

[0047] In step 160, by a second hot pressing, two additional vertical core layer boards 410 are added to both sides of the three-layer vertical core layer board 510 to form a five-layer vertical core layer board 520. Figure 5B This is a schematic diagram of a five-layer vertical core panel 520. The thickness of the two newly added vertical core panels 410 can be the same as or different from the outer layer thickness of the three-layer vertical core panel 510.

[0048] In some embodiments, the newly added vertical core layer veneer 410 is arranged such that its texture direction 420 is perpendicular to the texture direction 420 of the outer layer of the three-layer vertical core layer 510. For example, the texture direction 420 of the top vertical core layer veneer 410 is perpendicular to the texture direction 420 of the top outer layer vertical core layer veneer 410 of the three-layer vertical core layer 510 (e.g.) Figure 5A As shown, Figure 5B (Not shown in the image); the texture direction 420 of the bottom vertical core layer veneer 410 is perpendicular to the texture direction 420 of the bottom outer vertical core layer veneer 410 of the three-layer vertical core layer veneer 510 (e.g., ...). Figure 5A As shown, Figure 5B (Not shown in the image).

[0049] In some embodiments, adhesive is applied between the two newly added vertical core veneers 410 and the three vertical core veneers 510 before stacking them into five layers of vertical core veneers 520. Adhesive application can be performed using an adhesive applicator (not shown) or manually. In some embodiments, the adhesive applicator can be a roller applicator, a spray applicator, a blade applicator, a multi-roller applicator, or any applicator capable of applying glue / adhesive to a surface. In some embodiments, the amount of adhesive applied to each layer of vertical core veneer 410 ranges from 100 to 200 grams per square meter (g / m²). 2 ), or approximately 130-150 g / m 2or 135-145 g / m 2 .

[0050] In some embodiments, the stacked structure (i.e., two additional vertical core layer panels 410 and three vertical core layer panels 510) may be pre-pressed (i.e., shaped), and then hot-pressed at a temperature of approximately 130-140°C or 133-137°C for approximately 2-4 minutes per millimeter of thickness of the additional vertical core layer panels 410, depending on the ambient temperature and / or other conditions. In some embodiments, the pressing pressure is approximately 5-20 kg / cm². 2 ), or approximately 10-12 kg / cm 2 .

[0051] In some embodiments, the hot-pressed five-layer vertical core plate 520 is subjected to constant temperature curing for at least 7 days to release internal stress.

[0052] In some embodiments, the five-layer vertical core plate 520 after curing is sanded and its thickness is calibrated.

[0053] In step 170, by a third hot pressing, two additional vertical core layer sheets 410 are added to both sides of the five-layer vertical core layer sheet 520 to form a seven-layer vertical core layer sheet 530. Figure 5C This is a schematic diagram of a seven-layer vertical core panel 530. The thickness of the two vertical core panels 410 can be the same as or different from the outer layer thickness of the five-layer vertical core panel 520.

[0054] In some embodiments, the newly added vertical core layer veneer 410 is arranged such that its texture direction 420 is perpendicular to the texture direction 420 of the outer layer of the five-layer vertical core layer 520. For example, the texture direction 420 of the top vertical core layer veneer 410 is perpendicular to the texture direction 420 of the top outer layer vertical core layer veneer 410 of the five-layer vertical core layer 520 (e.g.) Figure 5B As shown, Figure 5C (Not shown in the image) The grain direction 420 of the bottom vertical core layer veneer 410 is perpendicular to the grain direction 420 of the bottom outer vertical core layer veneer 410 of the five-layer vertical core layer veneer 520 (e.g., ...). Figure 5B As shown, Figure 5C (Not shown in the image).

[0055] In some embodiments, adhesive is applied between the two newly added vertical core veneers 410 and the five vertical core veneers 520 before stacking them into seven layers of vertical core veneers 530. Adhesive application can be performed using an adhesive applicator (not shown) or manually. In some embodiments, the adhesive applicator can be a roller applicator, a spray applicator, a blade applicator, a multi-roller applicator, or any applicator capable of applying glue / adhesive to a surface. In some embodiments, the amount of adhesive applied to each layer of vertical core veneer 410 ranges from 100 to 200 grams per square meter (g / m²). 2 ), or approximately 110-130 g / m 2 or 115-125 g / m 2 .

[0056] In some embodiments, the stacked structure (i.e., two additional vertical core layer panels 410 and five vertical core layer panels 520) may be pre-pressed (i.e., shaped) and then hot-pressed at a temperature of approximately 130-140°C or 133-137°C for approximately 1-2 minutes per millimeter of thickness, depending on the ambient temperature and / or other conditions. In some embodiments, the pressing pressure is approximately 5-20 kg / cm². 2 ), or approximately 10-12 kg / cm 2 .

[0057] In some embodiments, the hot-pressed seven-layer vertical core plate 530 is subjected to constant temperature curing for at least 7 days to release internal stress.

[0058] In some embodiments, the seven-layer vertical core plate 530 after curing is sanded and its thickness is calibrated.

[0059] Those skilled in the art will understand that the exemplary process described above can be repeated to produce vertical core panels with more layers. For example, nine-layer, eleven-layer, or thirteen-layer vertical core panels. Those skilled in the art will also understand that steps 160 and / or 170 can be omitted to produce vertical core panels with fewer layers. For example, omitting step 170 can produce a five-layer vertical core panel; omitting both steps 160 and 170 can produce a three-layer vertical core panel. Multi-layer vertical core panel 540 refers to a cured vertical core panel suitable for use in step 180, and its number of layers can be three, five, seven, nine, eleven, or more. In some embodiments, the number of layers in multi-layer vertical core panel 540 depends on product specifications (e.g., floor size), customer budget, installation specifications (e.g., ground flatness), and environmental conditions of the installation site (e.g., humidity).

[0060] In step 180, a decorative layer and a balancing layer are added to both sides of the multilayer vertical core board 540 by a final hot pressing (the fourth time in this exemplary embodiment) to produce a vertical core solid wood composite floor. Figure 5D This is a schematic diagram of an ultra-thin vertical core layer solid wood composite floor made of multiple layers of vertical core board 540.

[0061] In some embodiments, the decorative layer 560 may include a top layer and a base layer. Similarly, the balancing layer 570 may also include a top layer and a base layer. In some embodiments, the base layers of both the decorative layer 560 and the balancing layer 570 are high-density fiberboard (HDF) with a thickness of 0.6-2.0 mm. In some embodiments, the top layer of the decorative layer 560 may be a solid wood veneer, printed decorative paper, or a paper-based finish, or it may be a decorative film or decorative membrane, depending on the product type and aesthetic requirements. In some embodiments, the top layer of the decorative layer 560 may be solid wood so that the flooring product can be painted after grooving or tongue-and-groove, or even after installation. In some embodiments, the top layer of the balancing layer 570 may be a wear-resistant layer (e.g., polyvinyl chloride (PVC) material) or balancing paper (i.e., decorative paper 560 without decorative patterns). In some embodiments, the top layer of the balancing layer 570 may be transparent or opaque. In some embodiments, the choice of the top layer of the balancing layer 570 depends on the choice of the top layer of the decorative layer 560. For example, if the top layer of the decorative layer 560 is a solid wood veneer, then the top layer of the balancing layer 570 must also be solid wood. This arrangement is designed to balance the internal stresses from the decorative layer 560.

[0062] In some embodiments, melamine-impregnated paper may be laid between the top layer of decorative layer 560 and the base layer, and then the structure after stacking decorative layer 560 or balancing layer 570 may be hot-pressed. In some embodiments, the hot-pressing pressure is 5-25 MPa, or about 6-20 MPa, the temperature is about 100-300°C, or about 150-240°C, and the time is 10-40 seconds, or about 16-32 seconds, depending on the thickness of the base layer (e.g., high-density fiberboard) and environmental factors. In some embodiments, after hot pressing, decorative layer 560 and balancing layer 570 are humidified (e.g., sprayed with water mist) and cured for 5-7 days. The cured decorative layer 560 and balancing layer 570 can then be applied to multilayer vertical core board 540. The process of pre-preparing the decorative layer 560 and the balancing layer 570 before stacking with the multilayer vertical core plate 540 reduces the quality requirements of the multilayer vertical core plate 540, while improving efficiency, reducing energy consumption, and providing excellent wear resistance.

[0063] In some embodiments, the balancing layer 570 can balance the internal stress generated by the decorative layer 560 and the multilayer vertical core plate 540, thereby preventing warping and other deformations.

[0064] In some embodiments, the stacked structure (i.e., decorative layer 560, balancing layer 570, and multilayer vertical core plate 540) may be hot-pressed at a temperature of approximately 190-220°C or 200-210°C for approximately 18-40 seconds. In some embodiments, the pressing pressure is approximately 10-30 kg / cm². 2 or approximately 16-18 kg / cm 2 .

[0065] In some embodiments, the vertical core layer engineered wood flooring is cured again under constant temperature conditions for at least 7 days.

[0066] In step 190, the vertical core layer engineered wood flooring undergoes further processing, including cutting, grooving, and tenoning, to produce the final flooring product. For example, the engineered wood flooring obtained in step 180 can be cut from large boards into individual floor strips. Depending on the product specifications, the floor strips may be grooved or tenoned, for example, by machining to form tongue and groove joints or other locking structures for installation.

[0067] The foregoing description is presented for illustrative purposes only and is not exhaustive, nor is it limited to the precise forms or embodiments disclosed. Modifications and adjustments to the embodiments will be apparent from practice based on the specification and the disclosed embodiments. For example, the described implementations include hardware, but systems and methods conforming to this disclosure can be implemented through a combination of hardware and software. Furthermore, although some components are described as coupled to each other, these components may also be integrated with each other or distributed in any suitable manner.

[0068] Furthermore, although exemplary embodiments are described herein, the scope of this disclosure includes any and all embodiments based on this disclosure, having equivalent elements, modifications, omissions, combinations (e.g., across various aspects of different embodiments), adjustments, or variations. Elements in the claims should be interpreted broadly according to the language used in the claims and are not limited to the examples described in this specification or during the examination of this application, which should be interpreted as non-exclusive. Further, the steps of the disclosed method can be modified in any way, including reordering steps, insertion steps, or deletion steps.

[0069] It should be noted that relational terms such as "first" and "second" used herein are used only to distinguish one entity or operation from another, and do not require or imply any actual relationship or order between these entities or operations. These terms are used to distinguish one element from another. For example, without departing from the scope of the embodiments, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element.

[0070] Furthermore, this document may use spatial relative terms (e.g., "below," "below," "lower part," "above," "upper part," etc.) to describe the relationship between one element or feature in the accompanying drawings and another element(s) or feature(s). These spatial relative terms are intended to cover different orientations of the device other than those shown in the accompanying drawings when in use or operation. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptive terms used herein shall be interpreted accordingly.

[0071] Furthermore, the terms “including,” “having,” “containing,” “comprise,” and other similar expressions should be considered equivalent in meaning, and are all open-ended expressions, meaning that one or more items listed after these words are not intended to be an exhaustive list of such items, nor are they intended to be limited to only the listed items.

[0072] The features and advantages of this disclosure will become apparent from the detailed description; therefore, the appended claims are intended to cover all systems and methods falling within the true spirit and scope of this disclosure. In this document, the indefinite articles “a” and “an” mean “one or more.” Similarly, the use of plural terms does not necessarily indicate a plural number unless the meaning is clear in a particular context. Furthermore, since many modifications and variations are readily apparent from studying this disclosure, it is not intended to limit this disclosure to the precise structures and operations illustrated and described; therefore, all suitable modifications and equivalents falling within the scope of this disclosure are permitted.

[0073] In this document, unless otherwise expressly stated, the terms "and / or" and "or" cover all possible combinations except where it is impractical. For example, if a system is mentioned as potentially including A or B, then unless otherwise expressly stated or impractical, the system may include A, or B, or A and B. As another example, if a system is mentioned as potentially including A, B, or C, then unless otherwise expressly stated or impractical, the database may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C.

[0074] In the foregoing specification, numerous implementation details have been described with reference to which may vary depending on the implementation. Certain adjustments and modifications may be made to the described embodiments. Other embodiments will be apparent to those skilled in the art based on this specification and the practices disclosed herein. This specification and examples are for illustrative purposes only, and the true scope and spirit of this disclosure are as described in the claims. It should also be noted that the sequence of steps shown in the accompanying drawings is for illustrative purposes only and is not intended to limit one to any particular order of steps. Therefore, those skilled in the art will understand that these steps may be performed in a different order when implementing the same method.

Claims

1. An ultra-thin engineered wood flooring, comprising: Multiple vertical core layer panels, each of which has a texture direction; The arrangement of the multiple vertical core layer panels is such that the texture directions of adjacent vertical core layer panels are perpendicular to each other.

2. The ultra-thin solid wood composite flooring according to claim 1, wherein, Multiple vertical core veneers are hot-pressed and glued together.

3. The ultra-thin engineered wood flooring according to any one of claims 1-2, further comprising a decorative layer.

4. The ultra-thin solid wood composite flooring according to claim 3, wherein, The decorative layer is bonded to the adjacent vertical core veneer via melamine-impregnated film paper.

5. The ultra-thin engineered wood flooring according to any one of claims 3-4, further comprising a balancing layer disposed on the opposite side of the decorative layer.

6. The ultra-thin engineered wood flooring according to any one of claims 3-5, wherein, The decorative layer is made of solid wood veneer.

7. The ultra-thin engineered wood flooring according to any one of claims 3-6, wherein, The decorative layer is made of paper-based material.

8. The ultra-thin engineered wood flooring according to any one of claims 3-7, wherein, The decorative layer is made of a thin film.

9. The ultra-thin engineered wood flooring according to any one of claims 1-8, wherein, Each of the plurality of vertical core veneers is sliced ​​from laminated veneer lumber, wherein the laminated veneer lumber includes a plurality of wood veneers, each of the plurality of wood veneers being rotary-cut from logs.

10. The ultra-thin solid wood composite flooring according to claim 9, wherein, The arrangement of the multiple wood veneers is such that the grain directions of adjacent wood veneers are perpendicular to each other.

11. A method for manufacturing ultra-thin engineered wood flooring, the method comprising: Stacking multiple vertical core layer PCBs; Each of the plurality of vertical core layer single boards has a texture direction; The arrangement of the multiple vertical core layer boards is such that the texture directions of adjacent vertical core layer boards are perpendicular to each other; Apply adhesive between the plurality of the vertical core veneers; Multiple vertical core layer panels are hot-pressed.

12. The method for manufacturing ultra-thin solid wood composite flooring according to claim 11 further includes constant temperature curing.

13. The method for manufacturing ultra-thin engineered wood flooring according to any one of claims 11-12, further comprising: Apply adhesive to the outside of the stacked vertical core veneer; Two additional vertical core layers are stacked on opposite sides of the stacked vertical core layer veneer, wherein the texture direction of each of the two additional vertical core layers is perpendicular to the texture direction of the vertical core layer veneer adjacent to it in the stacked vertical core layer veneer. Multiple vertical core layer panels are hot-pressed.

14. The method for manufacturing ultra-thin solid wood composite flooring according to claim 13 further includes repeating the steps described in claim 13.

15. The method for manufacturing ultra-thin engineered wood flooring according to any one of claims 11-13, further comprising: Decorative layers and balancing layers are stacked on opposite sides of the stacked vertical core veneer, respectively; Perform hot pressing and constant temperature curing.

16. The method for manufacturing ultra-thin solid wood composite flooring according to claim 15, wherein, The decorative layer is made of solid wood veneer.

17. The method for manufacturing ultra-thin engineered wood flooring according to any one of claims 15-16, wherein, The decorative layer is made of paper-based material.

18. The method for manufacturing ultra-thin engineered wood flooring according to any one of claims 15-17, wherein, The decorative layer is made of a thin film.

19. The method for manufacturing ultra-thin engineered wood flooring according to any one of claims 11-18, wherein, Each of the plurality of vertical core veneers is sliced ​​from laminated veneer lumber, wherein the laminated veneer lumber includes a plurality of wood veneers, each of the plurality of wood veneers being rotary-cut from logs.

20. The method for manufacturing ultra-thin solid wood composite flooring according to claims 11-19, wherein, The arrangement of the multiple wood veneers is such that the grain directions of adjacent wood veneers are perpendicular to each other.

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