U.S. patent application number 12/016777 was filed with the patent office on 2009-07-23 for panelling system.
Invention is credited to Kelly Gibson, Len Hoard.
Application Number | 20090183458 12/016777 |
Document ID | / |
Family ID | 40875332 |
Filed Date | 2009-07-23 |
United States Patent
Application |
20090183458 |
Kind Code |
A1 |
Gibson; Kelly ; et
al. |
July 23, 2009 |
PANELLING SYSTEM
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 has a tongue or groove for mating with a
groove or tongue of a next adjacent panel. The strips are fastened
by pins or corrugated plates from the rear or by a bonded sheet
material on the rear. The strips may include tongue and groove
joints of the snap fastening type where the connection of each
strip to the next in the assembled panel can be simply by way of an
adhesive tape over the rear surface of the joint.
Inventors: |
Gibson; Kelly; (Keewatin,
CA) ; Hoard; Len; (Winnipeg, CA) |
Correspondence
Address: |
ADE & COMPANY INC.
2157 Henderson Highway
WINNIPEG
MB
R2G1P9
CA
|
Family ID: |
40875332 |
Appl. No.: |
12/016777 |
Filed: |
January 18, 2008 |
Current U.S.
Class: |
52/592.1 ;
52/717.03 |
Current CPC
Class: |
E04F 15/02038 20130101;
E04F 2201/0115 20130101; E04F 2201/07 20130101; E04F 2201/0511
20130101; E04F 2201/0153 20130101; E04F 2201/026 20130101; E04F
2201/043 20130101 |
Class at
Publication: |
52/592.1 ;
52/717.03 |
International
Class: |
E04F 13/08 20060101
E04F013/08; E04C 2/38 20060101 E04C002/38 |
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 at least partly 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 four side edges; each panel member comprising a
plurality of strips arranged side edge to side edge with each strip
having a tongue along one side edge and a corresponding groove
along an opposed side edge so that the strips are connected side by
side by interconnection of the tongues and the grooves; wherein the
tongue and the corresponding groove along the side edges of the
dividing strips and on the rectangular main portion are shaped in
transverse cross-section such that each tongue and cooperating
groove can be connected together to form a joint by sliding of the
tongue into the groove with the dividing strip pivoted about the
joint in the direction such that an angle between the dividing
strip and the rectangular main portion at the front surface of the
rectangular main portion is less than 180 degrees and such that the
cooperating shapes of the tongue and groove in transverse
cross-section act in a coplanar position of the dividing strip and
rectangular main portion to resist movement of the tongue and
groove in a direction away from the joint; wherein the joint when
fastened prevents pivoting movement of the strips to a position in
which the angle between the strips at the front surface of the
panel member is greater than 180 degrees; and a piece of a flexible
sheet material adhesively attached across the joint on the rear
surface of the panel member.
2. The panelling system according to claim 1 wherein the strips are
connected each to the next, to form the panel member, solely by the
tongue and groove joint and the piece of material.
3. The panelling system according to claim 1 wherein the piece of
material comprises a tape expending longitudinally of the
joint.
4. The panelling system according to claim 1 wherein the piece of
material includes fiber reinforcement.
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. (canceled)
12. A floor panelling system comprising: a plurality of flooring
members for locating on a supporting surface generally edge to edge
in an array to at least partly cover the supporting surface; each
flooring member having a front surface for defining an exposed
surface of the floor panelling system and a rear surface for
engaging the supporting surface; the flooring members including: a
rectangular main portion having a first pair of opposed parallel
sides and a second pair of opposed parallel sides at right angles
to the first pair, wherein the rectangular main portion has a
tongue along a first of the first pair of opposed parallel sides
and a groove along a second of the first pair of parallel sides,
and wherein the rectangular main portion has a tongue along a first
of the second pair of opposed parallel sides and a groove along a
second of the second pair of parallel sides; a first dividing strip
arranged to extend along of the first of the first pair of opposed
parallel sides; and a second dividing strip arranged to extend
along of the second of the first pair of opposed parallel sides;
wherein each of the dividing strips has a tongue along one side
edge and a corresponding groove along an opposed side edge; wherein
the first dividing strip has the groove thereof engaged with the
tongue of the first of the first pair of parallel side edges;
wherein the second dividing strip has the tongue thereof engaged
with the groove of the second of the first pair of parallel side
edges; wherein the tongue and the corresponding groove along the
side edges of the dividing strips and on the rectangular main
portion are shaped in transverse cross-section such that each
tongue and cooperating groove can be connected together to form a
joint by sliding of the tongue into the groove with the dividing
strip pivoted about the joint in the direction such that an angle
between the dividing strip and the rectangular main portion at the
front surface of the rectangular main portion is less than 180
degrees and such that the cooperating shapes of the tongue and
groove in transverse cross-section act in a coplanar position of
the dividing strip and rectangular main portion to resist movement
of the tongue and groove in a direction away from the joint;
wherein the first and second dividing strips are arranged with a
portion at each end of each of the dividing strips projecting
beyond the rectangular main portion; wherein each end portion is
shaped to form two diagonal end edges each at an angle to a
respective side edge of the respective dividing strip with the
first and second diagonal end edges converging to an apex such
that, when the end portions of four such dividing strips are
located at a junction therebetween, the apexes and the diagonal end
edges meet; wherein the diagonal end edges of the end portions of
the four dividing strips at the junction are connected each to the
next adjacent by a tongue and groove connection along the diagonal
end edges; wherein the flooring members, when arranged in position
on the supporting surface, are arranged to float on the supporting
surface substantially without fastening thereto; wherein the
flooring members are formed from a lower layer defining the
transverse cross-sectional shape of the tongue and groove and an
upper layer different from the lower layer and fastened to the
lower layer which forms a flooring facing layer.
13. The panelling system according to claim 12 wherein the dividing
strips and the rectangular main portion are fastened together to
form a common panel member for transportation and installation.
14. The panelling system according to claim 12 wherein the end
portions of the dividing strips have the diagonal end edges thereof
in the front surface chamfered such that the dividing strips when
butting have a chamfered groove at the front surface.
15. The panelling system according to claim 12 wherein the tongue
and the corresponding groove are shaped in transverse cross-section
such that they can be connected, with the dividing strip and
rectangular main portion co-planar, by forcing of the tongue into
the groove in a snap fastening action, with the snap fastening
action acting to provide said resistance to movement in a direction
away from the joint.
16. The panelling system according to claim 12 wherein one of the
two diagonal end edges of each end portion has a tongue therealong
and the other of the two diagonal end edges of each end portion has
a groove therealong.
17. The panelling system according to claim 12 wherein the joint
when fastened prevents pivoting movement of the tongue and groove
to a position in which the angle between the dividing strip and the
rectangular main portion at the front surface of the panel is
greater than 180 degrees and there is provided a piece of a
flexible sheet material adhesively attached across the joint on the
rear surface of the panel.
18. A floor panelling system comprising: a plurality of flooring
members for locating on a supporting surface generally edge to edge
in an array to at least partly cover the supporting surface; each
flooring member having a front surface for defining an exposed
surface of the floor panelling system and a rear surface for
engaging the supporting surface; the flooring members including: 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 first ends of the main strips lie in a first
common line and second ends of the main strips lie in a second
common line; wherein the main strips have a tongue along the first
common line and a groove along the second common line; and wherein
a first main strip at one side of the main strips has an exposed
tongue along the first main strip and a second main strip at an
opposed second side of the main strips has an exposed groove along
the second main strip; the main strips thus defining a rectangular
main portion having a first pair of opposed parallel sides and a
second pair of opposed parallel sides at right angles to the first
pair, wherein the rectangular main portion has a tongue along a
first of the first pair of opposed parallel sides and a groove
along a second of the first pair of parallel sides, and wherein the
rectangular main portion has a tongue along a first of the second
pair of opposed parallel sides and a groove along a second of the
second pair of parallel sides; a first dividing strip arranged to
extend along of the first of the first pair of opposed parallel
sides; and a second dividing strip arranged to extend along of the
second of the first pair of opposed parallel sides; wherein each of
the dividing strips has a tongue along one side edge and a
corresponding groove along an opposed side edge; wherein the first
dividing strip has the groove thereof engaged with the tongue of
the first of the first pair of parallel side edges; wherein the
second dividing strip has the tongue thereof engaged with the
groove of the second of the first pair of parallel side edges;
wherein the tongue and the corresponding groove of the dividing
strips and of the main strips are shaped in transverse
cross-section such that each tongue and cooperating groove can be
connected together to form a joint of two joined strips by sliding
of the tongue into the groove with one strip pivoted about the
joint in the direction such that an angle between the joined strips
at the front surface is less than 180 degrees and such that the
cooperating shapes of the tongue and groove in transverse
cross-section act in a coplanar position of the joined strips to
resist movement of the tongue and groove in a direction away from
the joint; wherein the first and second dividing strips are
arranged with a portion at each end of each of the dividing strips
projecting beyond the rectangular main portion; wherein each end
portion is shaped to form two diagonal end edges each at an angle
to a respective side edge of the respective dividing strip with the
first and second diagonal end edges converging to an apex such
that, when the end portions of four such dividing strips are
located at a junction therebetween, the apexes and the diagonal end
edges meet; wherein the diagonal end edges of the end portions of
the four dividing strips at the junction are connected each to the
next adjacent by a tongue and groove connection along the diagonal
end edges; wherein the flooring members, when arranged in position
on the supporting surface, are arranged to float on the supporting
surface substantially without fastening thereto; wherein the
flooring members are formed from a lower layer defining the
transverse cross-sectional shape of the tongue and groove and an
upper layer different from the lower layer and fastened to the
lower layer which forms a flooring facing layer.
19. The panelling system according to claim 18 wherein each of the
main strips has the same width between side edges thereof and each
dividing strip has substantially the same width as the main
strips.
20. The panelling system according to claim 18 wherein the main
strips are parallel to the dividing strips.
21. The panelling system according to claim 18 wherein the main
strips are at right angles to the dividing strips.
22. The panelling system according to claim 18 wherein some of the
main strips are parallel to the dividing strips and some of the
main strips are at right angles to the dividing strips.
23. The panelling system according to claim 18 wherein the dividing
strips and the main strips are fastened together to form a common
panel member for transportation and installation.
24. The panelling system according to claim 18 wherein the end
portions of the dividing strips have the diagonal end edges thereof
in the front surface chamfered such that the dividing strips when
butting have a chamfered groove at the front surface.
25. The panelling system according to claim 18 wherein the tongue
and the corresponding groove are shaped in transverse cross-section
such that they can be connected, with the joined strips co-planar,
by forcing of the tongue into the groove in a snap fastening
action, with the snap fastening action acting to provide said
resistance to movement in a direction away from the joint.
26. The panelling system according to claim 18 wherein one of the
two diagonal end edges of each end portion has a tongue therealong
and the other of the two diagonal end edges of each end portion has
a groove therealong.
27. The panelling system according to claim 18 wherein the joint
when fastened prevents pivoting movement of the tongue and groove
to a position in which the angle between the dividing strip and the
rectangular main portion at the front surface of the panel is
greater than 180 degrees and there is provided a piece of a
flexible sheet material adhesively attached across the joint on the
rear surface of the panel.
Description
[0001] 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
[0002] 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.
[0003] 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.
[0004] 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 may be
referenced for more detail of this construction.
SUMMARY OF THE INVENTION
[0005] It is one object of the invention to provide a panelling
system.
[0006] According to the invention there is provided a panelling
system comprising:
[0007] a plurality of panel members for locating on a supporting
surface generally edge to edge in an array to at least partly cover
the supporting surface;
[0008] 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 four side edges;
[0009] each panel member comprising a plurality of main strips
arranged side edge to side edge with 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;
[0010] the tongues and grooves being shaped such that:
[0011] the strips can be connected each to the next by simple
sliding of the tongue into the groove with one strip pivoted about
the joint in the direction such that an angle between the strips at
the front surface of the panel is less than 180 degrees;
[0012] the strips can be connected each to the next with the strips
co-planar by forcing of the tongue into the groove in a snap
fastening action, with the snap fastening action resisting movement
of the strips in a direction away from the joint when fastened;
[0013] the joint when fastened prevents pivoting movement of the
strips to a position in which the angle between the strips at the
front surface of the panel is greater than 180 degrees;
[0014] and a piece of a flexible sheet material adhesively attached
across the joint on the rear surface of the panel.
[0015] Preferably the strips are connected each to the next, to
form the panel, solely by the tongue and groove joint and the piece
of material.
[0016] Preferably the piece of material comprises a tape expending
longitudinally of the joint.
[0017] Preferably the tape includes fiber reinforcement.
[0018] In one arrangement the first ends of the main strips lie in
a first common line and second ends of the main strips lie in a
second common line; the main strips have a tongue along the first
common line and a groove along the second common line; a first main
strip at one side of the main strips has an exposed tongue along
the first main strip for co-operating with a groove of a next
adjacent panel and a second main strip at an opposed second side of
the main strips has an exposed groove along the second main strip
for co-operating with a tongue of a next adjacent panel; each panel
member having associated therewith a first dividing strip arranged
to extend along the first common line and a second dividing strip
arranged to extend along the second common line; each of the
dividing strips has a front surface of the dividing strip to define
with the front surfaces of the main strips the front surface of the
panel; each of the dividing strips has a tongue along one side edge
and a corresponding groove along an opposed side edge; the first
dividing strip has the groove thereof engaged with the tongue along
the first common line; the second dividing strip has the tongue
thereof engaged with the groove along the second common line; the
dividing strips being fastened to the ends of the main strips by
the tongue and groove joint and the piece of material.
[0019] Preferably the panel members include dividing strips
connected to the main strips where the dividing strips are arranged
with a portion of each of the dividing strips of each panel member
projecting beyond the main strips of the respective panel member
such that, when four of the panel members are assembled into the
system with one of the dividing strips between the main strips of
each panel member and the next so as to form a rectangular area at
a junction between corners of the main strips of the four of the
panels, the rectangular area defined at the junction between said
four of the panels is filled by said portions of the dividing
strips which are shaped to cooperate to fill the rectangular
area.
[0020] Preferably each end portion of the dividing strips is shaped
to form diagonal end edges at an angle to the respective side edge
such that the dividing strips meet at the junction between four of
the panel members with the apexes in contact at a center of the
rectangular area.
[0021] Preferably one end edge of each end portion has a tongue and
an opposed end edge of each end portion has a groove.
[0022] Preferably the dividing strips and the main strips are
fastened together to form a common panel member for transportation
and installation.
[0023] Preferably each of the main strips has the same width
between side edges thereof and each dividing strip has
substantially the same width as the main strips.
[0024] Preferably the end portions of the dividing strips have the
end edges thereof in the front surface chamfered such that the
dividing strips when butting have a chamfered groove at the front
surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] One embodiment of the invention will now be described in
conjunction with the accompanying drawings in which:
[0026] FIG. 1 is a plan view of a panel of a flooring system
according to the present invention.
[0027] FIG. 2 is a plan view of four such panels assembled to form
part of the flooring system.
[0028] FIG. 3 is a cross sectional view through a junction between
two boards of the panel of FIG. 1 showing the pin connection
therebetween.
[0029] FIGS. 4 and 5 show schematically a series of steps in a
method for assembly of the panel of FIG. 1.
[0030] FIG. 6 is a more detailed view of the carousel for forming
and attaching the dividing strips.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] FIG. 12 is a plan view of a plurality of assembled panels of
a further embodiment of flooring system according to the present
invention where the panels are rectangular and where some of the
panels have the divider strips parallel to the main strips and some
of the panels have the divider strips at right angles to the main
strips.
[0037] FIG. 13 is a plan view similar to that of FIG. 12 wherein
there is shown in addition that the pointed portions at the ends of
the divider strips have the sides thereof formed with co-operating
tongues and grooves.
[0038] FIG. 14 is a cross-sectional view along the lines 14-14 of
FIG. 13 showing the connection between two boards and the
manufacture of the boards from an engineered two component
construction.
[0039] FIG. 15 is a bottom plan view of the small portion of the
board of FIG. 13 showing the fastening element.
[0040] FIGS. 16, 17 and 18 are respectively cross-sectional views
through one joint in a panel, for example as shown in FIGS. 2 or
13.
[0041] In the drawings like characters of reference indicate
corresponding parts in the different figures.
DETAILED DESCRIPTION
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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 35 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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, 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.
[0066] 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.
[0067] 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.
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] The cutting wheel 72 is arranged to cut a fresh tongue 18
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.
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] 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.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.
[0091] 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.
[0092] 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.
[0093] 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.
[0094] 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.
[0095] 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.
[0096] 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.
[0097] 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;
[0098] In each case the edge strips and the main strips are
fastened together to form a common panel member for transportation
and installation.
[0099] 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.
[0100] The dividing strips and the main strips are fastened
together by the pin arrangement described above or by the adhesive
sheet method described above.
[0101] Turning now to the embodiments shown in FIGS. 12, 13, 14 and
15 these use the constructions and principles described before so
that only the important differences will be described herein
after.
[0102] Firstly, the construction shown in FIG. 14 uses a panelling
material formed of a base layer 110 and a covering or face layer
111. This can be of the type known as "engineered flooring" where
the base layer is commonly a plywood layer and the covering layer
is a facing layer of a hard wood. Such materials are well known and
widely used for high cost flooring where the facing layer forms the
actual floor layer and the support or base layer 110 acts as a
support to provide structural support both during laying and during
operation of the floor. Plywood is a convenient base material since
it is resistant to changes in dimension caused by moisture content,
since it is flexible, since it is formed of a soft wood material
and hence it can be attached to an underlying support surface 112
by a layer of adhesive 113. As the underlying base layer has the
above features it can be considerably thinner than conventional
flooring with the covering or face layer being merely sufficient to
provide the attractive upper layer with no requirement form
structural strength. The structural stability of the product allows
the bonding by adhesive of the flooring directly to a concrete base
using an adhesive without the change in dimension acting to crack
the adhesive.
[0103] Such materials are commercially available for example from
BOA-Franc of Quebec Canada and due to the above characteristics can
be manufactured very accurately with dimensional accuracy in the
range 0.001 inch.
[0104] Further details of such material are available to the person
skilled in this art from the actual products manufactured and sold
by this company under the trademarks "Mirage" flooring.
[0105] The flooring is generally wider than conventional hard wood
flooring having a width of the order of 3 to 5 inches and is
thinner than conventional hard wood flooring having a total
thickness of the order of 3/8 to 1/2 inches which is formed by
plywood base of the order of 1/4 to 3/8 inches and a covering layer
of the order of 1/16 to 5/32 inches.
[0106] The layer 111 is chamfered at the edges as indicated at 114
to form a groove 115 between side by side boards or strips of the
material.
[0107] Secondly the boards are fastened each to the next from the
rear using corrugated joining plate members 116 where each plate
member bridges a butting line 117 between the strip members 118 and
119 so as to have a part of its length in one strip member 118 and
a part of its length in a next adjacent strip member 119. Each
plate member is engaged or punched into the strip members through
the rear surface 120 thereof such that a height 121 of the plate
member extends into the thickness of the strip members. Each
joining plate member is shaped with a series of corrugations 122
spaced along its length with each corrugation extending through the
height of the plate member from the bottom edge 123 at the rear
surface 120 to the top edge 124.
[0108] This type of joining plate member is known and is
conventionally formed from steel or other metal so as to have
sufficient stiffness to undergo the insertion forces. However in
this case the plate is formed of a plastics material of a type
selected so that the material can be cut by a cutting blade when
the strip members are cut. In this way when cutting a panel to size
there is no risk that the plate will be broken or ripped out to
form flying debris of a dangerous nature. Also the person cutting
can cut the panel to size without worrying about hitting a
plate.
[0109] The height of the plate members is such that the plate
members extend from the rear surface 120 into the base layer and do
not reach the covering layer 111. Thus the plate is wholly within
the plywood section and can be punched into the plywood without
danger of splitting the wood due to the transverse strength
available in plywood.
[0110] Such corrugated fasteners are available from many different
manufacturers and are supplied in a row of fasteners connected
together for supply to a fastening gun which drives the fastener
into the material to be fastened by a bar which extends along a
center line of the corrugations and forces the fastener forwardly
into the material in a direction parallel to its height. The
fasteners are typically formed of steel and are used in fastening
wood furniture products at miter joints and the like. The fastener
is corrugated on each side of a mid line part way along the length
of the fastener. At the mid line the fastener is tapered slightly
so that the corrugations move closer together as the fastener
enters the material thus tending to draw the two parts together at
the butt line.
[0111] However these have not been used in flooring and have not
been manufactured from materials other than metal. Typically the
joining plates when formed from a suitable plastics composite
material, that is a polymer composite, will have a thickness of the
body of the material of order of 0.015 to 0.025 inches and a
corrugation height across the thickness of the fastener of the
order of 0.1 to 0.2 inches. Typical fasteners will have a height of
the order of 0.25 inches so that it extends only into the plywood
base and a length of the order of 1.0 inch. A strip of the
fasteners is manufactured by injection moulding with connecting
pieces between each fastener and the next which can be broken by
the driving tool as each fastener is driven forwards. The leading
edge can be chamfered for easier penetration but this is not
essential. The corrugations are tapered together at the center so
that there is a tendency to draw together the two strips as the
fastener enters. A company Utility Composites Inc in Round Rock
Tex. manufacture nails in a suitable composite plastics material
which can be used to manufacture the corrugated fasteners to be
used in the present arrangements.
[0112] As the plywood can be manufactured to high accuracy and
maintains that dimension despite changes in moisture, the panels
can be manufactured without the necessity for re-cutting the tongue
or groove along the edge after the required number of strips is
assembled side by side. The corrugations engage into the fibers of
the plywood to provide high strength in a direction tending to
resist separation of the strips.
[0113] The joining plates are used to connect the main strips of
the panels and the divider strips of the panels to the main strips.
Sufficient numbers of plates can be used to ensure a structurally
stable product.
[0114] The panels are formed from the material described to form a
construction of the same general type as described in shown in FIG.
1. One key difference being that the use of adhesive to fasten the
panel to the sub-floor avoids the necessity for through holes for
screws. These panels as shown in FIG. 1 have the divider strips 30
and 31 at right angles to the main strips 10A to 10G. Such panels
can be used in an array as previously described where the main
strips of each panel are at right angles to the main strips of the
next adjacent panel.
[0115] Turning now to FIG. 12, there is shown a flooring pattern
formed from two separate types of panels where one of the types is
as shown in FIG. 1 where the divider strips are at right angles to
the main strips and a second of the types is where the divider
strips are parallel to the main strips. As shown in FIG. 12 this
forms a pattern where all the main strips are oriented in a common
direction and the divider strips form a series of rows across the
main strips. It will be appreciated that the combination of such
panels can be used to create many different panelling effects.
[0116] As shown in FIG. 12, there is therefore provided a panelling
system defined by a plurality of first panel members 130 and a
plurality of second panel members 131. As previously described, the
first and second panel members are arranged for locating on a
supporting surface 112 generally edge to edge in an array to at
least partly cover the supporting surface. Each panel member has a
front surface 133 for defining an exposed surface of the panelling
system and a rear surface 123 for engaging the supporting surface.
Each panel member is formed from a plurality of main strips 135
arranged side edge to side edge to form a rectangular panel body
136 having four sides including a first pair of parallel sides 137,
138 parallel to the main strips and a second pair of parallel sides
139, 140 at right angles to the main strips.
[0117] In the first panels 130, the dividing strips 143 and 144 are
parallel to the main strips 135 and connected to the first sides
137, 138.
[0118] In the second panels 131, the dividing strips 141 and 142
are at right angles to the main strips 135 and connected to the
second sides 139, 140.
[0119] The dividing strips and the main strips are fastened
together using the joining plates 116 to form a common panel member
for transportation and installation.
[0120] In each of the first panel members 130, the main strips are
parallel to the dividing strips and each dividing strip 143, 144
extends along a respective one of the first pair of parallel sides
137, 138 so as to define a first inner side edge 145 engaging the
panel body 136 and a second exposed outer edge 146.
[0121] In each of the first panel members 130, the dividing strips
143, 144 include a first dividing strip 143 having a tongue along
the outer edge 146 thereof and a second dividing strip 144 having a
groove along the outer edge 146 thereof.
[0122] In each of the first panel members 130, a first one 140 of
the second parallel sides has a tongue therealong and a second one
139 of the second parallel sides has a corresponding groove
therealong.
[0123] In each of the second panel members 131, the main strips 135
are at right angles to the dividing strips 141, 142.
[0124] In each of the second panel members 131, each dividing strip
141, 142 extends along a respective one of the second pair of
parallel sides 139, 140 so as to define a first inner side edge 147
engaging the panel body 136 and a second exposed outer edge
148.
[0125] In each of the second panel members 131, the dividing strips
141, 142 include a first dividing strip 141 having a tongue along
the outer edge 148 thereof and a second dividing strip 142 having a
groove along the outer edge 148 thereof.
[0126] In each of the second panel members 131, a first one 138 of
the first parallel sides has a tongue therealong and a second one
137 of the first parallel sides has a corresponding groove
therealong.
[0127] The first and second panel members 130 and 131 are arranged
such that the outer edge 146 of the first dividing strip 143 of the
first panel members 130 with the tongue therealong is arranged for
co-operating engagement with the second one 137 of the first
parallel sides 137, 138 of a respective one of the second panel
members 131 with the groove therealong.
[0128] The first and second panel members 130 and 131 are arranged
such that the outer edge 146 of the second dividing strip 144 of
the first panel members 130 with the groove therealong is arranged
for co-operating engagement with the first one 138 of the first
parallel sides 137, 138 of a respective one of the second panel
members 131 with the tongue therealong.
[0129] The first and second panel members 130 and 131 are arranged
such that the outer edge 148 of the first dividing strip 141 of the
second panel members 131 with the tongue therealong is arranged for
co-operating engagement with the second one 139 of the second
parallel sides 139, 140 of a respective one of the first panel
members 130 with the groove therealong.
[0130] The first and second panel members 130 and 131 are arranged
such that the outer edge 148 of the second dividing strip 142 of
the second panel members 131 with the groove therealong is arranged
for co-operating engagement with the first one 140 of the second
parallel sides 139, 140 of a respective one of the first panel
members 130 with the tongue therealong.
[0131] In all the panels each of the main strips preferably has the
same width between side edges thereof and each dividing strip has
substantially the same width as the main strips.
[0132] In all of the panels, the dividing strips include the
pointed portions 50 as previously described projecting beyond an
edge of the panel body. Thus the dividing strips of the panel
members are arranged with the portions 50 of the dividing strips of
each panel member projecting beyond the main strips of the
respective panel member such that, when four of the panel members
are assembled into the system with the main strips of one panel
member at right angles to the main strips of each next adjacent
panel and with one of the dividing strips between the main strips
of each panel member and the next so as to form a rectangular area
at a junction between corners of the main strips of the four of the
panels; the rectangular area defined at the junction between said
four of the panels is filled by said portion of said at least one
dividing strip.
[0133] While it is preferred that the main strips are fastened to
one another by tongue and groove connection and also the dividing
strips are fastened to the edge of the main panel body also by
tongue and groove connection, any one or all of these connections
may be formed by simple butt joints due to the strength and
effectiveness of the plate type fasteners.
[0134] In addition, as the appearance of the panels is generally
formed by the covering or facing layers and the chamfered grooves
115 therebetween, the main body portion can be formed using a back
plate of the plywood which is square with the strips applied
directly to the upper surface thereof. The dividing strips can then
be fastened to the sides of the square main panel to simulate the
flooring boards without actually forming such boards.
[0135] In FIG. 13 is shown the same construction as in FIG. 12 with
the difference that the points 50 are modified to include on one
side edge a groove 151 and on the other side edge a tongue 152.
Inspection of the drawing will show the pattern of the tongues and
grooves which allow the sides of the points 50 to meet at the
apexes 54 with the grooves and tongues intermeshing in the same
plane approximately midway between the front and rear surfaces of
the panels as the tongues and grooves along the side edges of the
panels and dividing strips.
[0136] Turning now to FIGS. 16, 17 and 18, there is shown a further
embodiment using panels formed in the manner known as laminated
flooring. Such flooring is commonly formed from a base or core
layer of MDF which is a fabricated wood product using wood or fiber
particles bound in a resin material. The details of such materials
are well known in the industry and hence will not be recounted
here. On top and on the bottom of such a core layer is provided a
covering material layer. In the laminated product this is commonly
a plastics layer of vinyl or the like which provides a base for
resting on a support surface and provides a top appearance layer
which has the appearance required such as a wood grain appearance.
The appearance layer is commonly a paper product on which the
appearance is printed and is covered by the hard plastics layer to
protect it from damage. Thus the MDF provides the structure and the
plastics and appearance layers provide the wear coats.
[0137] Similar products are manufactures using cork veneers on top
and bottom of an MDF core. These products simulate cork flooring
and again use the MDF core layer as the structure of the
product.
[0138] Such MDF material is strong and dimensionally stable so that
it can provide suitable joints and can be held together as a floor
structure without structural or dimensional changes due to moisture
and humidity differences. Both of these types of flooring therefore
can be formed as "floating" floors where the complete floor
covering acts as a single layer floating on the support surface or
substrate without the necessity to attach the floating floor to the
substrate by adhesive or other means. Thus installation is
simplified and replacement is possible of pieces or the whole
floor.
[0139] The floating floor system has become important in recent
years based ion the development of joints which snap or lock into
place. One example which is widely used is known as the "Uniclic"
system and is shown in U.S. Pat. No. 6,006,486 (Moriau) issued Dec.
28, 1999 and many other related patents. The disclosure of this
document can be referred to for further details of this type of
joint and is incorporated herein by reference.
[0140] FIGS. 16 and 17 are taken from this patent and FIG. 18
includes also the assembled joint part of which is taken from the
same patent.
[0141] The joint used in these figures can be used in any of the
above described panelling systems. While the joint is best used in
a laminated type product using MDF as the core layer, the same
joint can also be used in other materials and in wholly wood
products such as hard wood flooring.
[0142] It will be appreciated that where the term "tongue and
groove" is used in this document to refer to such joints, the term
can include conventional tongues and simple grooves where there is
no interlocking effect and more complex tongue and groove joints
where a snap lock effect is obtained tending to hold the boards
connected edge to edge.
[0143] Thus in the above figures two of the boards indicated at 160
and 161 are connected together at a joint 162 using the tongue and
groove arrangement from the above patent or using a similar
interlocking system.
[0144] In the above patent and as used herein, there is a tongue
164 on the board 161 and a groove 163 on the board 160 which are
shaped in general such that:
[0145] a) the strips can be connected as shown in FIG. 16 each to
the next by simple sliding of the tongue 164 into the groove 163
with one strip or board 161 pivoted about the joint 162 in the
direction as shown at 165 such that an angle A is formed between
the strips with the strip 161 pivoted upwardly away from the
support surface 166. This provides an angle between the strips at
the front surface 168 of the panel which is less than 180 degrees.
The strip 161 can then be bent downwardly to the coplanar position
to snap the strips into the locked position by the rib 170 on the
strip 161 slipping over the rib 173 into the groove 172 on the
strip 160.
[0146] b) The strips can be connected each to the next with the
strips co-planar as shown in FIG. 17 by forcing of the tongue 164
into the groove in a snap fastening action along the line 169. The
snap fastening action is caused by the necessary distortion of the
edge of the strip 160 at the rib 173 at the groove to allow the rib
170 to snap over into its groove 171. The movement along the
coplanar line 169 is guided by the support surface on which both
strips are placed and by the nose 175 of the tongue 164 sliding
over the surface 176 of the groove.
[0147] c) As shown in FIG. 18, the snap fastening action resists
movement of the strips in a direction 177 away from the joint when
fastened. Also the joint when fastened prevents pivoting movement
of the strips in a direction 178 to a position in which the angle
between the strips at the front surface of the panel is greater
than 180 degrees. This is resisted by the top surface of the tongue
164 pressing against the surface 176 of the groove.
[0148] However pivoting movement back to the position shown in FIG.
16 is possible with only little force. Hence a piece or strip of a
flexible sheet material 180 is attached by an adhesive layer across
the joint on the rear surface 182 of the strips.
[0149] Thus the panels previously shown and described are
manufactured to form the completed panel formed by the main strips
and the dividing strips by assembling the strips edge to edge using
the snap lock connections primarily by the pivoting technique shown
in FIG. 16. When the strips are assembled, the panel is held in
place as a stable accurate structure using the adhesive tapes on
the joints at the rear surface. The use of the adhesive tape merely
on the rear surface is sufficient to hold the strips in place
because the snap lock prevents movement in the direction 177 and
prevents pivotal movement in the direction 178 so that the tape as
only to hold the strips against movement in the direction 184.
[0150] When the panels including the dividing strips and the main
strips are assembled and taped, the panels are stable and can be
shipped in assembled condition to the place of installation. When
being installed, the panels are located side by side and where
possible the pivoting connection technique is used. However it will
be appreciated that some joints are not linear so that the pivoting
technique cannot be used. In these cases the coplanar snap
technique of FIG. 17 is used. When completed the floor is a
floating floor arrangement with the connections holding the panels
together without the need for adhesive or for connection to the
sub-floor.
[0151] The piece of material 180 can comprise a tape expending
longitudinally of the joint or can be pieces of tape across the
joint or can be formed by a whole layer covering the whole of the
rear surface of the panel.
[0152] In order that the tape does not stretch and holds the panel
stable, the tape includes fiber reinforcement 185 preferably of a
bidirectional nature.
[0153] 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.
* * * * *