U.S. patent application number 11/848452 was filed with the patent office on 2008-12-11 for panelling system formed from panels defined by tongue and groove strips.
Invention is credited to Kelly Gibson, Len Hoard.
Application Number | 20080302052 11/848452 |
Document ID | / |
Family ID | 40094580 |
Filed Date | 2008-12-11 |
United States Patent
Application |
20080302052 |
Kind Code |
A1 |
Gibson; Kelly ; et
al. |
December 11, 2008 |
PANELLING SYSTEM FORMED FROM PANELS DEFINED BY TONGUE AND GROOVE
STRIPS
Abstract
A panelling system preferably for floors is defined by a series
of panels each formed of a plurality of tongue and groove main
floor plank strips arranged side edge to side edge and cut to a
common length with a tongue along one cut edge and a groove along
the other. At the edges are attached edge strips formed also from
the flooring planks with tongue and groove and fastened together to
form a common panel member for transportation and installation. The
outwardly facing edge of each edge has a tongue or groove for
mating with a groove or tongue of a next adjacent panel. The strips
are fastened by pins from the rear or by a bonded sheet material on
the rear.
Inventors: |
Gibson; Kelly; (Keewatin,
CA) ; Hoard; Len; (Winnipeg, CA) |
Correspondence
Address: |
ADE & COMPANY INC.
2157 Henderson Highway
WINNIPEG
MB
R2G1P9
CA
|
Family ID: |
40094580 |
Appl. No.: |
11/848452 |
Filed: |
August 31, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11760093 |
Jun 8, 2007 |
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11848452 |
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Current U.S.
Class: |
52/588.1 ;
52/745.19 |
Current CPC
Class: |
E04F 2201/043 20130101;
E04F 2201/07 20130101; E04F 15/02038 20130101; E04F 2201/042
20130101 |
Class at
Publication: |
52/588.1 ;
52/745.19 |
International
Class: |
E04F 15/16 20060101
E04F015/16 |
Claims
1. A panelling system comprising: a plurality of panel members for
locating on a supporting surface generally edge to edge in an array
to cover the supporting surface; each panel member having a front
surface for defining an exposed surface of the panelling system, a
rear surface for engaging the supporting surface and a plurality of
side edges; each panel member comprising: a plurality of main
strips arranged side edge to side edge; each main strip having a
tongue along one side edge and a corresponding groove along an
opposed side edge; so that the main strips are connected side by
side by interconnection of the tongues and the grooves; wherein the
main strips have along a first end of the main strips a tongue and
have along a second end of the main strips a groove; a first edge
strip extending along the first ends of the main strips across at
least some of the main strips; a second edge strip extending along
the second ends of the main strips across at least some of the main
strips; wherein each of the edge strips has a front surface of the
dividing strip lying in a common plane with the front surfaces of
the main strips to define the front surface of the panel; wherein
each of the edge strips has a tongue along one side edge and a
corresponding groove along an opposed side edge; wherein the first
edge strip has the groove thereof engaged with the tongue along the
first ends of the main strips; wherein the second edge strip has
the tongue thereof engaged with the groove along the second ends of
the main strips; and wherein the edge strips and the main strips
are fastened together to form a common panel member for
transportation and installation.
2. The panelling system according to claim 1 wherein each of the
main strips has the same width between the side edges.
3. The panelling system according to claim 2 wherein each edge
strip has substantially the same width as the main strips.
4. The panelling system according to claim 2 wherein a longitudinal
line along the main strips lies at an angle less than 90 degrees to
a longitudinal line along an edge strip connected to ends of the
main strips.
5. A panelling system comprising: a plurality of panel members for
locating on a supporting surface; each panel member having a front
surface for defining an exposed surface of the panelling system, a
rear surface for engaging the supporting surface and a plurality of
side edges; the panel members being of polygonal shape in plan view
such that the panels can be arranged in an edge to edge array
covering the supporting surface; each panel member comprising: a
plurality of main strips arranged side edge to side edge; each main
strip having a tongue along one side edge and a corresponding
groove an opposed side edge; so that the main strips are connected
side by side to form a center panel portion by interconnection of
the tongues and the grooves; the center panel portion being
polygonal in plan view having a number of sides; each of the sides
having either a tongue or a groove therealong; a plurality of edge
strips equal in number to the number of sides; wherein each of the
edge strips has a front surface of the dividing strip lying in a
common plane with the front surfaces of the main strips to define
the front surface of the panel; wherein each of the edge strips has
a tongue along one side edge and a corresponding groove along an
opposed side edge; wherein the edge strips are each arranged in
engagement with a respective side of the center panel portion with
the tongue or groove thereof engaged with the groove or tongue of
the respective side; wherein the edge strips present outwardly of
the panel either a tongue or a groove for engaging a groove or a
tongue of an edge strip of a next adjacent panel; and wherein the
edge strips and the main strips are fastened together to form a
common panel member for transportation and installation.
6. The panelling system according to claim 5 wherein each of the
main strips has the same width between the side edges.
7. The panelling system according to claim 6 wherein each edge
strip has substantially the same width as the main strips.
8. The panelling system according to claim 5 wherein a longitudinal
line along the main strips lies at an angle less than 90 degrees to
a longitudinal line along an edge strip connected to ends of the
main strips.
9. The panelling system according to claim 5 wherein the main
strips define an area which is square with four sides each
receiving a respective edge strip.
10. The panelling system according to claim 5 wherein the main
strips define an area which is triangular with three sides each
receiving a respective edge strip.
11. The panelling system according to claim 5 wherein the main
strips define an area which is hexagonal with six sides each
receiving a respective edge strip.
12. The panelling system according to claim 5 wherein the edge
strips have ends butting at a line extending outwardly from an apex
of the center panel portion.
13. The panelling system according to claim 5 wherein the line
extending outwardly from the apex intersects a center of the panel
so that the edge strips are symmetrical.
14. The panelling system according to claim 5 wherein the dividing
strips and the main strips are fastened together by a plurality of
pins each inserted at a butting edge between one strip and a next
adjacent strip through the rear surface at a groove on one side of
the butting edge and extending into a tongue in the groove with a
front end of the pin terminating at a position spaced from the
front surface.
15. The panelling system according to claim 14 wherein each pin is
inclined at an angle to a plane containing the butting edge so as
to pass through the plane.
16. The panelling system according to claim 14 wherein each main
strip is fastened to each next adjacent strip by a plurality of the
pins at spaced positions along the main strips and each dividing
strip is fastened to the main strips by a plurality of the pins at
spaced positions along the dividing strip.
17. The panelling system according to claim 14 wherein each pin is
inserted such that it is countersunk from the rear surface.
Description
[0001] This application is a continuation-in-part application from
application Ser. No. 11/760,093 filed Jun. 8, 2007.
[0002] This invention relates to a panelling system defined by a
plurality of inter-engaging panels. The system is primarily
designed for flooring but can be used for other surfaces requiring
to be paneled with an attractive layer of a covering material
formed in individual panels. The system is primarily designed for
use with panels formed of wood but other materials can be used
either to form the entire panel or a part of the panel.
BACKGROUND OF THE INVENTION
[0003] Various techniques have been proposed for the manufacture of
wood panel flooring. Conventionally wood panel flooring is formed
as tongue and groove planks which are arranged edge to edge so that
the tongue of one projects into a groove of the next. This
construction is time consuming and relatively inaccurate so that
gaps can be exposed leading to an unattractive appearance.
[0004] Floor panels in rectangular shape have been proposed which
generally again connect one to the next using a tongue and groove
arrangement so as to provide an improved laying system. Often such
panels are formed from laminated or other non-wood materials and
hence are not accepted as a high quality wood product.
[0005] In published US Patent Application 2006/0076394 published
Apr. 13, 2006 and in corresponding Canadian Application Serial No:
2,525,516 originally published Mar. 4, 2005 of Kelly Gibson, one of
the inventors herein, is disclosed a panelling system primarily for
flooring which is formed from a plurality of wood floor panel
members defined by a rectangular panel formed of wood and along two
opposed side edges a decorative dividing strip extending along the
length of the side edge and having a top surface of the strip lying
in a common plane with the upper surface of the panel with the
other opposed side edges of the panel being exposed for butting
directly against a next adjacent panel, The dividing strips project
beyond an end of the side edge and are cut at 45 degrees to form a
pointed portion having an apex at a position mid way through the
thickness of the dividing strip such that four dividing strips,
when the panels are laid on the floor, meet at the junction between
four of the panels with the apexes in contact at a center of the
rectangular area at the junction. This arrangement as disclosed was
proposed for use with rectangular panels of solid wood or for deck
strips and as such was not suitable for high quality interior
flooring The disclosure of this published application is
incorporated herein by reference.
SUMMARY OF THE INVENTION
[0006] It is one object of the invention to provide a panelling
system defined by a plurality of inter-engaging panels defined by
tongue and groove strips.
[0007] According to one aspect of the invention there is provided a
panelling system comprising:
[0008] a plurality of panel members for locating on a supporting
surface generally edge to edge in an array to cover the supporting
surface;
[0009] each panel member having a front surface for defining an
exposed surface of the panelling system, a rear surface for
engaging the supporting surface and a plurality of side edges;
[0010] each panel member comprising:
[0011] a plurality of main strips arranged side edge to side
edge;
[0012] each main strip having a tongue along one side edge and a
corresponding groove along an opposed side edge;
[0013] so that the main strips are connected side by side by
interconnection of the tongues and the grooves;
[0014] wherein the main strips have along a first end of the main
strips a tongue and have along a second end of the main strips a
groove;
[0015] a first edge strip extending along the first ends of the
main strips across at least some of the main strips;
[0016] a second edge strip extending along the second ends of the
main strips across at least some of the main strips;
[0017] wherein each of the edge strips has a front surface of the
dividing strip lying in a common plane with the front surfaces of
the main strips to define the front surface of the panel;
[0018] wherein each of the edge strips has a tongue along one side
edge and a corresponding groove along an opposed side edge;
[0019] wherein the first edge strip has the groove thereof engaged
with the tongue along the first ends of the main strips;
[0020] wherein the second edge strip has the tongue thereof engaged
with the groove along the second ends of the main strips;
[0021] and wherein the edge strips and the main strips are fastened
together to form a common panel member for transportation and
installation.
[0022] Preferably each of the main strips has the same width
between the side edges so that the panel member can be formed from
a common supply of identical strip members. However this is not
essential and different widths may be used to obtain different
visual effects.
[0023] Also it is preferable that each edge strip has substantially
the same width as the main strips for the same reasons.
[0024] The panels are preferably arranged so that when arranged
edge to edge with the next adjacent panels the whole panel assembly
covers the supporting surface in the sense that there are no spaces
between the panels. However is will be appreciated as in any
panelling system that parts of the supporting surface may need to
be finished using cut sections of panels where the edges of the
panels do not coincide with the edges of the floor or other
supporting surface.
[0025] According to a second aspect of the invention there is
provided a panelling system comprising:
[0026] a plurality of panel members for locating on a supporting
surface;
[0027] each panel member having a front surface for defining an
exposed surface of the panelling system, a rear surface for
engaging the supporting surface and a plurality of side edges;
[0028] the panel members being of polygonal shape in plan view such
that the panels can be arranged in an edge to edge array covering
the supporting surface;
[0029] each panel member comprising:
[0030] a plurality of main strips arranged side edge to side
edge;
[0031] each main strip having a tongue along one side edge and a
corresponding groove an opposed side edge;
[0032] so that the main strips are connected side by side to form a
center panel portion by interconnection of the tongues and the
grooves;
[0033] the center panel portion being polygonal in plan view having
a number of sides;
[0034] each of the sides having either a tongue or a groove
therealong;
[0035] a plurality of edge strips equal in number to the number of
sides;
[0036] wherein each of the edge strips has a front surface of the
dividing strip lying in a common plane with the front surfaces of
the main strips to define the front surface of the panel;
[0037] wherein each of the edge strips has a tongue along one side
edge and a corresponding groove along an opposed side edge;
[0038] wherein the edge strips are each arranged in engagement with
a respective side of the center panel portion with the tongue or
groove thereof engaged with the groove or tongue of the respective
side;
[0039] wherein the edge strips present outwardly of the panel
either a tongue or a groove for engaging a groove or a tongue of an
edge strip of a next adjacent panel;
[0040] and wherein the edge strips and the main strips are fastened
together to form a common panel member for transportation and
installation.
[0041] Preferably each of the main strips has the same width
between the side edges.
[0042] Preferably each edge strip has substantially the same width
as the main strips.
[0043] Preferably a longitudinal line along the main strips lies at
an angle less than 90 degrees to a longitudinal line along an edge
strip connected to ends of the main strips.
[0044] Preferably the main strips define an area which is square
with four sides each receiving a respective edge strip.
[0045] Preferably the main strips define an area which is
triangular with three sides each receiving a respective edge
strip.
[0046] Preferably the main strips define an area which is hexagonal
with six sides each receiving a respective edge strip.
[0047] Preferably the edge strips have ends butting at a line
extending outwardly from an apex of the center panel portion.
[0048] Preferably the line extending outwardly from the apex
intersects a center of the panel so that the edge strips are
symmetrical.
[0049] In one particularly important arrangement, the dividing
strips and the main strips are fastened together by a plurality of
pins each inserted at a butting edge between one strip and a next
adjacent strip through the rear surface at a groove on one side of
the butting edge and extending into a tongue in the groove with a
front end of the pin terminating at a position spaced from the
front surface.
[0050] The term "pin" is intended to include nails or other
elongate mechanical fasteners with or without a discernible head
which can be driven from one end into the material. The front end
may or may not be sharpened. The pin may include a second
co-operating pin in the form of a staple where the two pins are
connected side by side
[0051] Preferably wherein each pin is inclined at an angle to a
plane containing the butting edge so as to pass through the
plane.
[0052] Preferably each main strip is fastened to each next adjacent
strip by a plurality of the pins at spaced positions along the main
strips and each dividing strip is fastened to the main strips by a
plurality of the pins at spaced positions along the dividing
strip.
[0053] Preferably each pin is inserted such that it is countersunk
from the rear surface.
[0054] Preferably at least one of the main strips is formed from
two strip portions butted end to end and wherein the ends are
connected by a tongue and groove connection. This allows material
to be used without any waste. However the main strips may also have
no joints between the ends by cutting and scrapping pieces which
are insufficient in length to span the distance between the
dividing strips.
[0055] The panels can be fastened to a sub-floor using screws (or
other fasteners) passing through a drilled hole in the panel
covered by a decorative plug, or may be attached using an adhesive
layer between the sub floor and the panels, or may be fastened
using traditional nails through the tongues as in traditional
tongue and groove flooring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
[0057] FIG. 1 is a plan view of a panel of a flooring system
according to the present invention.
[0058] FIG. 2 is a plan view of four such panels assembled to form
part of the flooring system.
[0059] FIG. 3 is a cross sectional view through a junction between
two boards of the panel of FIG. 1 showing the pin connection
therebetween.
[0060] FIGS. 4 and 5 show schematically a series of steps in a
method for assembly of the panel of FIG. 1.
[0061] FIG. 6 is a more detailed view of the carousel for forming
and attaching the dividing strips.
[0062] FIG. 7 is a cross sectional view similar to that of FIG. 3
through a junction between two boards of the panel of FIG. 1
showing an alternative mode of connection therebetween.
[0063] FIG. 8 is a plan view of a plurality of assembled panels of
a further embodiment of flooring system according to the present
invention where the individual panels are hexagonal and there is
provide an edge strip on each of the six sides.
[0064] FIG. 9 is a plan view of a panel of one square panel of a
further embodiment of a flooring system according to the present
invention.
[0065] FIG. 10 is a plan view of a panel of one square panel of a
yet further embodiment of a flooring system according to the
present invention and there is provide an edge strip on each of the
four sides.
[0066] FIG. 11 is a plan view of a plurality of assembled panels of
a further embodiment of flooring system according to the present
invention where the individual panels are triangular and there is
provide an edge strip on each of the three sides.
[0067] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION
[0068] Reference is made to the above published application of
Gibson which shows and describes the details of the panels with the
dividing strips and the interconnection between the four corners of
the panels.
[0069] The arrangement described herein comprises a floor system
defined by a series of panel members, four of which are shown at 10
through 13. Each of the panel members has a top surface 16 defining
a floor surface on which the user walks and providing an attractive
appearance as described hereinafter. Each of the panel members
includes a bottom surface 17 for sitting on a sub floor of a
conventional nature.
[0070] Each of the panel members is formed from a plurality of side
by side main strips 10A to 10G which are connected together side by
side to form an initial panel portion which has four side edges so
that for example the panel 10 has side edges 20 and 21 which form a
first pair of opposed side edges and side edges 22 and 23 which
form a second pair of opposed side edges.
[0071] The main strips are formed from tongue and groove boards
which are commonly available and are formed from many different
wood varieties. Thus each board has a tongue 18 on one side and a
groove 19 on the opposite side arranged to inter-fit to hold the
boards side by side. Such boards are supplied in various lengths
which can include random lengths and generally are supplied with
tongue and groove ends so that the butting ands also inter-fit.
[0072] Each board conventionally has a chamfered edge 19A in the
top surface 16 where the boards meet to form a micro-groove between
the two butting chamfered edges.
[0073] In order to form these into a flooring system having an
attractive appearance, each base panel formed by the side by side
boards has attached two dividing strips which are attached to
opposite side edges of the panel. Thus for example the panel 10 has
two dividing strips 30 and 31 attached along the side edges 20 and
21. The dividing strips are formed from a board similar in
appearance to the boards forming the panel but is arranged at right
angles to the boards so as to provide an attractive appearance in
the floor when completed and laid.
[0074] Each dividing strip has a depth equal to the thickness of
the boards so that a bottom surface of the dividing strip is
coincident with the plane of the bottom surface 17 and similarly a
top surface of the dividing strip is coincident with the plane of
the top surface 16. The dividing strips are preferably formed from
the same boards as the main strips 10A to 10G so as to have the
same dimensions and the same appearance.
[0075] The panel 12 has the dividing strips indicated at 30A and
31A so that the panel 13 is rotated through 180.degree. relative to
the panel 10. In this way the dividing strip 30A carried by the
panel 13 engages the side edge 23 of the panel 10 which is free
from any dividing strips and is simply bare for butting the
dividing strips 30A. Similarly the dividing strips 31A butts the
next adjacent panel not numbered.
[0076] The panel 11 is also rotated through 180.degree. relative to
the panel 10 so that its bare edge 23A butts the dividing strip 31
and its dividing strip 30A butts the edge 23B of the panel 13, In
this way it will be appreciated that the whole floor can be laid by
rotating the panels back and forth through 180.degree. and laying
them each to the next with the side edges butting. In this way
between each panel and the next adjacent panel is one dividing
strip thus separating the panels by the thickness of the dividing
strip while allowing the bare edge of the strip to butt against the
outside surface of the dividing strip.
[0077] Each of the dividing strips extends along the full length of
the respective side edge of the panel and also extends beyond the
end of the side edge into a pointed portion 50. Thus as shown in
FIG. 2 the dividing strip 30A is fastened to the panel 12 and the
dividing strip 31 is fastened to the panel 10. The dividing strip
30A extends to the end corner 51 of the side edge 22A of the panel
13. The dividing strips 30A then include the pointed portion 50
which is cut to form two side edges 52 and 53 converging to an apex
54. The ends 52 and 53 are cut at 45.degree. relative to the sides
of the dividing strip so that they are 90.degree. to each other
forming a right angle triangle converging to the apex 54 which lies
on a centre line 55 of the dividing strips 30A.
[0078] Symmetrically the dividing strip 30A includes an end portion
56 also converging to an apex which touches the apex 54 at the
center of the rectangular area between the corners of the panels
10, 12 and the further two panels not numbered. In this way, in
each of the square intersections between the edges of the panels,
each panel at the intersection carries one of the dividing strips
with each of the dividing strips having the pointed extension
portion symmetrical to the extension portion 50 and extension
portion 56 projecting into the center of the square area with the
apexes of these pointed portions touching at the center of the
square area.
[0079] The panels are fastened to the sub floor 18 by screws 60
which are located in screw holes 61 located at the end of the
respective dividing strip spaced from the apex 54. Each panel has
four such screw holes 61 arranged adjacent the corners of the panel
and spaced inwardly from the apexes of the dividing strips of the
panel. Thus at each junction between floor panels, four screw holes
61 surround the junction and provide an attractive appearance, when
those screw holes are plugged by visually distinct plugs in known
manner. Thus the dividing strips coming to a junction where the
junction is visually distinct together with the surrounding four
holes of the screw pattern which are also visually distinct
provides a visually distinct and attractive pattern across the
whole extent of the floor when laid.
[0080] Each of the strips 10A through 10G is of an equal common
width and is formed from conventional floor planking so each strip
has a grove 19 on one side and a tongue 18 on the other side of a
conventional nature.
[0081] As shown in FIG. 1, some of the strips are continuous as
indicated at 10A and 10C so as to extend from the side edge 20 to
the side edge 21. Others of the strips are discontinuous and
include a join 36 between two portions 36 and 37 of the strip. The
joint 35 similarly includes a tongue and groove arrangement 38
where a tongue at the end of the strip portion 36 is joined into a
groove at the end of the strip portion 37. This provides an
integrated structure throughout the strip but allows lengths of
strip material to be used which are not necessarily continuous
along the full length of the panel.
[0082] The divider strips are formed from a material of the same
width and same construction as the strips forming the panel. Thus
each divider strip itself has a groove 40 along one side and a
tongue 41 along the opposite side. The divider strips are formed
from a common source of the same material and generally therefore
have the same width of the strips 10A through 10G and can be taken
from the same supply. The divider strips are therefore not visually
distinct from the main strips but are visibly distinguished by the
right angle orientation.
[0083] In the alternative divider strips of a different width may
be used and the divider strips may be of a different wood variety
thus providing a visually distinct pattern. Yet further the strips
may be stained or coloured to a different colour to provide a
visually distinct arrangement as preferred by the user of the
panels.
[0084] Most examples will have a divider strip that will be of the
same width and the same variety so that the whole panel can be
formed from a common supply of the wood strip materials.
[0085] Use of wood is not essential in this construction but is
obviously preferred to provide a high quality finished wooden floor
product as opposed to laminate materials or other materials which
are considered to be of less quality.
[0086] The ends of the main strips 10 through 10g are cut to form a
groove 43 at the edge 20 to receive the tongue 41 and symmetrically
these strips are cut to form a tongue 44 at the edge 21 to
corporate with the grove 40 of the divider strip 31.
[0087] A fastener arrangement for connecting each strip to the next
adjacent strip is shown in FIG. 3. Thus a series of fastener pins
150 is provided and these fastener pins are engaged into the tongue
and groove joint between each main strip and the next adjacent main
strip and between at least some of the ends of the main strip and
the respective divider strip.
[0088] Each pin 150 is of a type which has no head at a rear end
151 for the forward end 152 maybe pointed or may simply be straight
to form a straight pin that can be simply driven into the wood at
the joint using conventional driving tools. Such pins are
previously known and the tools for driving them are commercially
available.
[0089] With this arrangement, however, the pin 150 is driven
through the bottom surface 17 and the pin is selected to have a
length so that the rear end 151 is recessed from the surface 17
after the application is complete. Thus the rear end 151 is
recessed below an adjacent portion of the surface 17 so if it is
not proud of that surface then you've the possibility of snagging
or catching or damaging any materials.
[0090] The leading end 152 is arranged by selecting a length of the
pin so that the leading end 152 engages into the adjacent board to
a position beyond the tongue 18.
[0091] The pin is driven at an angle to the surface 17 and
therefore at an angle to the surface 16 so the pin passes through a
plane P which joins the ends of the two strips indicated at 10A and
10B. Thus at the junction fastened by the pin 150, which is one
example of a series of such fastened joints throughout the
structure of the panel. The strip 10A has a tongue 18 which is
received within a groove 19 of the strip 10B. The pin 150 has its
rear end 151 in the strip 10B in the area underneath the groove 19
and passes from that area into the tongue 18, extending through the
tongue and into the upper part of the strip 10A above the upper
surface of the tongue 18. In this way the pin provides an effective
fastening arrangement but the pin is wholly contained within the
structure of the strips with neither the front end nor the trailing
end exposed beyond the surfaces 16 and 17. The angle of the pin
relative to the surface 17 is preferably of the order of 45 to 60
degrees and more preferably 54 degrees. The fact that the pin
extends through the tongue 18 while the tongue is housed or
contained in the groove inhibits or prevents any splitting of the
tongue during the pinning action.
[0092] Thus each strip is fastened to the next adjacent strip by a
series of such pins, the number of which can be selected depending
upon structural strength required. In addition there is a
connection between the ends of some of the strips 10A through 10G
and the divider strip 31 which extends similarly through the tongue
44 at the grove 40. The number of such fastening pins can be
selected again according to structural strength required so that
only some of the ends of the strips are fastened or all of the ends
or the strips are fastened as required.
[0093] Symmetrically further fasteners are inserted through the
junction between the tongue 41 and the groove 43 between the
divider strip 30 and the ends 20 of the main strips.
[0094] In this way the panel when completed is fixed in place and
integrated by the fasteners so that the structure is prevented from
twisting by side to side movement of the divider strips. It is
preferred that the connection of the panel is effected without the
use of glue so as to avoid the necessity for application of glue
during the manufacturing process, However glue or other additional
fastening methods may be used if required.
[0095] Turning now to the method of manufacture shown in FIGS. 4, 5
and 6, there are shown a serious of manufacturing stations through
which the materials pass to complete assembly of the structure as
describe above.
[0096] Thus the manufacturing process includes a first assembly
station 60, a second convergence station 61, a fastening station
62, a cutting station 63, a tongue and groove station 64, a
carousel 65, and a final assembly station 66.
[0097] In the assembly station 60, a number of channels 67 are
formed each containing a respective one of the strips 10A through
10G. Thus each channel 67A through 67G contains a respective one of
the strips which are fed forwardly in a continuous manner to the
convergence station 61. The strips are introduced into the channel
67 so that they are in continuous manner including the connection
lines or joints 35. Either automatically or manually at the
assembly station, the strips are assembled so that the joint lines
35 are offset in a longitudinal direction from each channel
relative to the next adjacent channel so that in this way no
junction lines are arranged so that they are aligned or closely
adjacent between side by side channels. This can be done in
practice by providing the channels of sufficient length that a
skilled operator can select the strips of different lengths and
locate them so that the joint lines 35 are longitudinally offset.
If the strips are of all identical length, this can be simply done
by selecting the position of the ends of the strips in a staggered
manner at the outset and the strips will remain in the staggered
manner throughout the assembly provided the strips are carefully
butted end to end and are all of a common length. In the
alternative strips of different lengths can be selected and the
operator arranged to select required lengths to ensure the required
staggering of the butt joints.
[0098] Of course each strip in each channel has the groove and
tongue arranged so that the strips can be brought together and
interconnected in the proper tongue and grove arrangement side by
side.
[0099] From the assembly station 60 the channels are arranged to
feed the strips forwardly while at the same time converging those
strips to bring them together using a series of converging rollers
68. The strips are thus brought to a position immediately side by
side and brought to a position where the strips are compressed
between a converging roller 69 on one side and a compressing roller
70 on the other side. In the arrangement shown, the converging
roller 69 carries a tongue 69A which runs in the groove 19 on the
right hand side of the assembled strips. In the convergence station
there are series of such guide rollers 69 indicated that 69B and
69C and these are arranged at a specific fixed location to provided
a datum line which accurately locates the position of the edge of
the outside strip 10G and its grove 19.
[0100] On the opposite side of the datum line defined by the guide
rollers 69, there is provided a cutting wheel 72 downstream of the
compression roller 70. The cutting wheel 72 is located at a fixed
determined distance from the guide rollers 69 to provide a cutting
action on the edge of the strip 10A remote from the strip 10G.
[0101] The distance of the cutting wheel 72 from the datum line is
accurately fixed and is slightly less than the minimum width of the
converged strips 10A through 10G, bearing in mind that such strips
when manufactured commonly have a significant manufacturing
tolerance.
[0102] The cutting wheel 72 is arranged to cut a fresh tongue 15
and associated shoulders 18A and 18B above and below the tongue 18.
Thus instead of relying on the position of the tongue of the strip
10A, a fresh tongue and associated shoulders is cut so that the
width of the converged strips is accurately equal to the distance
between the cutting wheel and the guide rollers regardless of any
variations or tolerance in the widths of the strips as
supplied.
[0103] In this way the completed panel has a width between the
sides 22 and 23 which is accurately cut and is exactly equal for
each subsequent panel that is manufactured. In addition the amount
of compression between the strips is accurately maintained so that
the strips are held at this fixed spacing while substantially
ensuring that any warping or bending of the strips is removed by
sufficient transverse compression across the panel.
[0104] Downstream of the cutting wheel 72 is provided a guide
roller 73 which is arranged opposite to a respective guide roller
69C. The guide roller 73 preferably contains a groove for receiving
the tongue 18 recently cut by the cutting wheel 72. Thus the strips
are maintained by these guide rollers and by further guide rollers
69D and 73A arranged downstream of the guide rollers 73 and 69C.
These rollers are located at the fastening station 62 so that as
the assembled panel formed by the individual strips is moved into
the fastening station 62 it is maintained at the required fixed
spacing and under the required compression.
[0105] At the fastening station 62 is provided a series of pin
inserting tools indicated at 62A through to 62F. These fastening
tools are arranged at positions bridging the junctions between the
strips so as to be operable to insert the pins 150 at the required
position and at the required angle.
[0106] The pin inserters 62A through 62F are controlled by a
control unit 62G. The control unit receives inputs from a series of
detectors 75A through 75G which are arranged each in a respective
one of the channels for detecting the forwarding action of the
respective strips. Each detector 75 is arranged to detect the
presence of a junction line 35. Thus the pin inserting devices 62A
through 62F are controlled so that they are operated at a time to
ensure that a pin is inserted at a position spaced from a junction
line 35 on either side of the pin. The controlled unit is arranged
to determine a predetermined distance on either side of a junction
line 35 within which a fastener pin is not permitted to be
inserted. The control unit is arranged to determine the positions
of insertion of pins based upon the presence of the junction line
35 to ensure that sufficient pins are inserted in the junction
between each strip and the next adjacent strip while ensuring that
the pins are inserted at a position spaced from the junction
lines.
[0107] Downstream from the fastening station is provided a clamping
assembly generally indicated at 76. This includes a pair of
clamping members 77 and 78 each on a respected side of the
assembled fastened panel and which includes clamping engagements 79
which engage onto the sides 22 and 23 of the assembled panel formed
by the strips 10A through 10G. Thus after the panel is released
from the clamping rollers, is engaged by clamping members which are
intended to hold that structure while it is moved at right angles
to the forming line into the further stations 64 and 66. After the
fastened panel formed by the panel is moved to up to a required
location and engaged by the clamping members 77 and 78, this
position is detected by a sensor 80 which therefore locates the
edge 20 of the panel. At this position a cutting device 81 is
operated which moves across the panel to provide a cutting action
to define the side edge 21. The cutting device includes a
conventional blade 82 carried on a track 83 with the distance
between the cutting blade and the sensor 80 being accurately
determined to ensure an accurate spacing between the sides 20 and
21 of the panel when cut.
[0108] As shown in FIG. 5, the panel so formed and fastened with
the accurate spacing between the sides 20 and 21 and the accurate
spacing between the tongue at the side 23 and the groove 19 at the
side 22 is carried in the gripping members 77 and 78 on a suitable
transport track (not shown), the formed panel defined by the main
strips 10A through 10G is moved into the tongue and groove station
64.
[0109] At the tongue and groove station 64, the panel supported in
the clamping members 78 and 79 is moved along the track past a set
of guide rollers 85 and 86 which control the position of the edges
20 and 21 accurately in a predetermined spaced position. The guide
rollers 85 and 86 include a second set 85A and 86A downstream
thereof so that the panel is maintained accurately positioned and
accurately square. A tongue cutter wheel 87 is provided on the side
edge 21 and a groove cutter wheel 88 is provided on the side edge
20. These cutter wheels rotate relative to the panel as it is moved
past the cutter wheels to effect a cutter action to form at the
side edges 20 and 21 the respected tongue and groove previously
described.
[0110] After the formation of the tongue and groove, the completed
panel formed by the main strips is moved into the final assembly
station 66 at the carousel 65.
[0111] The carousel 65 is shown in more detail in FIG. 6 and
comprises a series of stations arranged around the carousel which
rotates around a central support 88. Thus the carousel defines a
first station 65A at which tongue and groove strip from a supply
65B is cut to a required length by a cutting device 65C. At a
second station 65D; the cut length of the strip is cut to define
the pointed portion 50 at the front end. At a third station 65E,
the cut strip is passed through a cutting station to effect cutting
of the pointed section 50A at the rear end of the strip. The
cutting stations are of course arranged so that the length of the
dividing strip now formed from the supply of the board is
accurately to the required length between the points of the pointed
portions and the pointed portions have the accurate 90 degree
angle. At the next station 65F the formed dividing strip is passed
through a set of cutting members which form the chamfered edge 19A
on the pointed portions 50 and 50A. At a further station 65G, the
dividing strip is drilled to form the holes 61 at the base of the
pointed portions 50 and 50A.
[0112] At a final station 65H, the completed dividing strip is
moved into position onto the edge of the panel so that the groove
in the dividing strip engages onto the tongue of the side edge on
one side of the panel and on the other side the tongue of the
dividing strip is engaged onto the groove at the side of the
panel.
[0113] The carousel is of a conventional nature and uses
conventional cutting, routing and drilling tools to effect the
above cutting actions. The selection of the necessary tools is
within the skill of a person skilled in this art so that
description of the necessary tools is not required here. Carousels
of this type are commonly available providing a series of stations.
Of course the first carousel is arranged on one side and the second
carousel is arranged on the second side of the panel moved along
the track as carried by the clamping members 78 and 79.
[0114] At the final assembly station 66 including the two carousels
65 and 65X, there are provided additional pin driving members 62X,
62Y and 62Z for driving pins as previously described into the
junction between the dividing strip and the ends of selected ones
of the main strips.
[0115] After the final assembly station 66, the completed panel
assembled by the pins is moved to a stacking station (not shown)
where it is released from the clamping members 78 and 79 for
stacking onto a pile of finished such panels for transportation to
a remote location for installation.
[0116] In FIG. 7 is shown an alternative arrangement for fastening
the strips of the panel member together and this comprises a sheet
90 of a fabric or similar flexible material which can be applied
onto the whole of the rear surface of the panel member so as to
cover all of the joints with the sheet being bonded to the rear
surface 17 by a layer of an adhesive 91. While it is preferred that
a common sheet covers all of the joints so that its dimension is
substantially equal to the rear of the panel, it will be
appreciated that separate strips can be applied along each joint or
separate strips may cover some of the joints. Thus a single piece
many be applied over the main strips when assembled and converged
at the fastening station and separate pieces applied over the
joints of the divider strips in the final assembly station. The
fabric pieces can be unrolled from a supply of the required width
and cut to length. The strips preferably carry the adhesive from
the supply or the adhesive may be applied separately. The adhesive
may be a hot melt which is activated by a heated plate or roller
brought up onto the rear surface of the assembled panel which
presses the fabric into engagement with the rear surface and
activates the adhesive.
[0117] Turning now to FIGS. 8 through 11, there is shown an
alternative arrangement where the finished panel is a polygon which
therefore has a plurality of sides converging to an apex where each
side is arranged to co-operate with a side of next adjacent panel
without any intervening divider strips of the type described
above.
[0118] Thus in FIG. 8 the panels 80 are hexagonal with a central
panel section 81 which is hexagonal and with an edge strip 82 at
each side edge of the center section. Thus when a panel butts with
another panel there are two butting edge strips side by side as
indicated at 82A and 82B, as opposed to the single divider strip of
the above described arrangements. Each edge strip butts at its end
with its next adjacent strip at a butt line 83 which is diagonal
along a line 84 extending from a center of the panel 81 as
indicated at 85. The butt line may include tongue and groove
interconnection or may be merely a flat butt.
[0119] The center panel is formed from side by side tongue and
groove main strips as previously described. In view of the hexagon
shape, when arranged in a symmetrical manner, four of the edge
strips extend in a direction at an angle of 120 degrees to the
longitudinal direction of the main strips and two of the edge
strips are parallel to the main strips. As an alternative it will
be appreciated that, in another symmetrical arrangement, the main
strips may be arranged at right angles to those shown or may be at
another angle intermediate the angle of the two symmetrical
arrangements.
[0120] In FIG. 9, the panel 90 is square with two edge strips 91
parallel to the main strips 93 and two edge strips 92 at right
angles to the main strips 93. Again when a panel butts with another
panel there are two butting edge strips side by side. Each edge
strip may butt at its end with its next adjacent strip at a butt
line which is diagonal, similar to the arrangement of FIG. 8 and
FIG. 10, but in the example shown the edge strips 92 extend across
the full width of the panel. The butt line may include tongue and
groove interconnection or may be merely a flat butt. In the
arrangement shown, the ends of the edge strips 92 include tongue
and groove connections.
[0121] In FIG. 10, the panel 95 is also square with four edge
strips 96 at an angle of 45 degrees to the main strips 97. Again
when a panel butts with another panel there are two butting edge
strips side by side. Each edge strip butts at its end with its next
adjacent strip at a butt line which is diagonal, similar to the
arrangement of FIG. 8. The butt line may include tongue and groove
interconnection or may be merely a flat butt.
[0122] In FIG. 11, the panels 99 form an equilateral triangular
shape with three edge strips 100 two of which 101 and 102 lie at an
angle of 60 degrees to the main strips 100 and one of which 103 is
at right angles to the strips. Again, when a panel butts with
another panel there are two butting edge strips side by side. Each
edge strip butts at its end with its next adjacent strip at a butt
line which is diagonal passing through a center of the triangle,
similar to the arrangement of FIG. 8. The butt line may include
tongue and groove interconnection or may be merely a flat butt.
[0123] In each case the edge strips present outwardly of the panel
either a tongue or a groove for engaging a groove or a tongue of an
edge strip of a next adjacent panel;
[0124] In each case the edge strips and the main strips are
fastened together to form a common panel member for transportation
and installation.
[0125] As shown, each of the main strips has the same width between
the side edges with each edge strip having substantially the same
width as the main strips.
[0126] The dividing strips and the main strips are fastened
together by the pin arrangement described above or by the adhesive
sheet method described above.
[0127] Since various modifications can be made in my invention as
herein above described, and many apparently widely different
embodiments of same made within the spirit and scope of the claims
without department from such spirit and scope, it is intended that
all matter contained in the accompanying specification shall be
interpreted as illustrative only and not in a limiting sense.
* * * * *