Note: Descriptions are shown in the official language in which they were submitted.
CA 02609807 2007-11-22
PANELLING SYSTEM
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
Various techniques have been proposed for the manufacture of wood
panel ftooring. 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.
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 aocepted as a high quality wood
product.
In published US Patent Application 2006/0076394 published April 13 th
2006 and in corresponding Canadian Application Serial No: 2,525,516 originally
published March 4th 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 mernbers defined by a rectangular panel formed of wood and along two
CA 02609807 2007-11-22
2
opposed side edges a der.orative dividing strip extending along the length of
the side
edge and having a top surFac:e of the strip iying in a common plane wi#h 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
It is one object of the invention to provide a panelling system.
According to one aspect of the invention there is provided a panelling
system comprising a plurality of panel members each formed from a plurality of
side
by side strips which are fastened together to form a common panel member for
transportation and installation, each panel member having a front surface for
defining an exposed surface of the panelling system and a rear surface for
engaging
a supporting surface;
wherein the strips are fastened together by corrugated joining plate
members;
each plate member bridging a butting line between the strips so as to
CA 02609807 2007-11-22
3
have a part of its length in one strip and a part of its length in a next
adjacent strip
and each plate member engaged into the strips through the rear surFac,.e
thereof
such that a height of the plate member extends into the thickness of the
strips, each
joining plate member being shaped with a series of corrugations spaced along
its
length with each corrugation extending through the height of the plate member.
Preferably the plate member is formed of a plastics material which can
be cut by a cutting blade when the strips are cut.
Preferably the strips are formed of a base layer and a hard wood
covering layer on the front surFaee and wherein the height of the plate
members is
such that the plate members extend from the rear surface into the base layer
and do
not reach the covering layer.
Preferably the base layer is plywood.
Preferably the strips are connected side by side by a tongue and
groove connection with the plate member bridging the tongue and groove and
extending into the strips on each side of the tongue and groove
interconnection.
According to a seoond aspect of the invention there is provided a
fastening member for fastening strips in side by side relation, the fastening
member
comprising:
a corrugated joining plate member arranged to bridge a butting line
between the strips so as to have a part of its length in one strip and a part
of its
length in a next adjacent strip;
the plate member being arranged to engage into the strips such that a
height of the plate member extends into the thickness of the strips;
CA 02609807 2007-11-22
4
the plate member being shaped with a series of transverse
corrugations spaced along its length with each corrugation extending through
the
height of the piate member;
the plate member being formed of a plastics material which can be cut
by a cutting blade when the strips are cut.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction
with the accompanying drawings in which:
Figure 1 is a plan view of a panel of a flooring system according to the
present invention.
Figure 2 is a plan view of four such panels assembled to form part of
the flooring system.
Figure 3 is a cross sectional view through a junction between two
boards of the panel of Figure 1 showing the pin connection therebetween.
Figures 4 and 5 show schematically a series of steps in a method for
assembly of the panel of Figure 1.
Figure 6 is a more detailed view of the carousel for forming and
attaching the dividing strips.
Figure 7 is a cross sectional view similar to that of Figure 3 through a
junction between two boards of the panel of Figure 1 showing an alternative
mode of
connection therebetween.
Figure 8 is a plan view of a plursility of assembled panels of a further
embodiment of flooring system according to the present invention where the
CA 02609807 2007-11-22
individual panels are hexagonal and there is provide an edge strip on each of
the six
sides.
Figure 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,
5 Figure 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.
Figure 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.
Figure 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.
Figure 13 is a plan view similar to that of Figure 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.
Figure 14 is a cross-sectional view along the lines 14-14 of Figure 13
showing the connection between two boards and the manufacture of the boards
from an engineered two component construction.
Figure 15 is a bottom plan view of the small portion of the board of
CA 02609807 2007-11-22
6
Figure 13 showing the fastening element.
In the drawings like characters of referenoe indicate corresponding
parts in the different figures.
DETAILED DESCRIPTION
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
interconnectson between the four comers of the panels.
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 sifting on a sub floor of a
conventional nature.
Eaah of the panel members is formed from a plurality of side by side
main strips 10A to lOG 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,
The main strips are formed from tongue and groove boards which are
commonly available and are formed from many difl`erent 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
CA 02609807 2007-11-22
7
and groove ends so that the butting ands also inter-fit.
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.
In order to form these into a flooring system having an attractlve
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.
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 piane 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.
The panel 12 has the dividing strips indicated at 30A and 31A so that
the panel 13 is rotated through 180 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.
The panel 11 is also rotated through 1$0 relative to the panel 10 so
CA 02609807 2007-11-22
8
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 wiq be appreciated that the whole
floor can
be laid by rotating the panels back and forth through 180 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.
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 Figure 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
relative to the sides of the dividing strip so that they are 90 to each other
forming a
right angle triangie converging to the apex 54 which lies on a centre line 55
of the
dividing strips 30A.
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 comers 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
CA 02609807 2008-09-30
9
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.
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.
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 groove 19 on
one side
and a tongue 18 on the other side of a conventional nature.
As shown in Figure 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.
CA 02609807 2007-11-22
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 generaily
5 therefore have the same width of the strips 1 pA through lOG 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.
In the altemative 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
10 pattem. Yet further the strips may be stained or coloured to a different
oolour to
provide a visually distinct arrangement as preferred by the user of the
panels.
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.
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 materiais which are considered to be of less
quality.
The ends of the main strips 10 through 10g are cut to fonn 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
stfip
31.
A fastener arrangement for connecting each strip to the next adjacent
strip is shown in Figure 3. Thus a series of fastener pins 150 is provided and
these
CA 02609807 2007-11-22
11
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.
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.
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 suri"ace 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.
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.
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 whlch Is received within a groove 19
of the
strip 1 QB. The pin 150 has its rear end 151 in the strip 108 in the area
underneath
CA 02609807 2007-11-22
12
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 spiitting
of the
tongue during the pinning action.
Thus each strip is fastened to the next adjaoerrt 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.
Symmetrically further fasteners are inserted through the junction
between the tongue 41 and the groove 43 between the divider strip 30 and the
ends
of the main strips,
20 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
CA 02609807 2007-11-22
13
during the manufacturing process. However glue or other additional fastening
methods may be used if required.
Turning now to the method of manufacture shown in Figures 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.
Thus the manufaoturing process inctudes 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.
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
CA 02609807 2007-11-22
14
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.
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.
From the assembly station 60 the channels are arranged to feed the
strips fo+wardly 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 89 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 B9
indicated
that 696 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.
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
1 DG.
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 1 0A
through
CA 02609807 2007-11-22
1 DG, bearing in mind that such stri.ps when manufactured commonly have a
significant manufacturing tolerance.
The cutting wheel 72 is arranged to cut a fresh tongue 18 and
associated shoulders 18A and 188 above and below the tongue 18. Thus instead
of
5 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 raliers regardless of any
variations
or tolerance in the widths of the strips as supplied.
In this way the completed panel has a width between the sides 22 and
10 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.
15 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
690 and 73A arranged downstream of the guide rollers 73 and 69C. These rollers
are located at the fastening station 62 so that as the assernbied 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 oompression.
At the fastening station 62 is provided a series of pin inserting tools
CA 02609807 2007-11-22
16
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.
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 eiffer 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 adjaoent strip while ensuring that the pins are
inserted at a
position spaced from the junction lines.
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
CA 02609807 2007-11-22
17
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.
As shown in Figure 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 14A through 10G is moved into the tongue and groove
station 64.
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 whee! 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
CA 02609807 2007-11-22
i8
previously described.
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.
The carousel 65 is shown in more detail in Figure 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 out 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 85F 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.
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.
The carousel is of a conventional nature and uses conventional cutting,
CA 02609807 2007-11-22
19
routing and drilling tools to effect the above cutting aotions, 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.
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 desoribed into the junction between the dividing strip and
the ends
of selected ones of the main strips,
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.
In Figure 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 ahd
CA 02609807 2007-11-22
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
5 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.
Turning now to Figures 8 through 11, there is shown an alternative
arrangement where the finished panel is a polygon which therefore has a
plurality of
10 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.
Thus In Figure 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
15 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 buit line may
include
20 tongue and groove interconnection or may be merely a flat butt.
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
CA 02609807 2007-11-22
21
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 arrangernent, 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.
In Figure 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 Figure 8 and Figure 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.
In Figure 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 Figure 8. The butt line may indude tongue and groove interoxinneetion or
may be
merely a flat butt.
In Figure 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
CA 02609807 2007-11-22
22
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 Figure
B. The
butt line may include tongue and groove interconnection or may be merely a
flat butt.
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;
In each case the edge strips and the main strips are fastened together
to form a common panel member for transportation and Installation.
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.
The dividing strips and the main strips are fastened together by the pin
arrangement described above or by the adhesive sheet method described above.
Tuming now to the embodiments shown in Figures 12, 13, 14 and 15
these use the constructions and principles desCribed before so that only the
important differences will be described herein after.
Firstly, the construction shown In Figure 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 cov.ering 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
CA 02609807 2007-11-22
23
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 undedying 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.
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.
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.
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 r.onventional
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 oovering layer
of the
order of 1/16 to 5132 inches.
The layer 111 is chamfered at the edges as indicated at 114 to form a
groove 115 betwsen side by side boards or strips of the material.
CA 02609807 2007-11-22
24
Secondly the boards are fastened each to the next from the rear using
corrugated joining plate members 116 where each plate member br9dges 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.
This type of joining plate member is known and is conventionally
formed frnm 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.
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.
Such corrugated fasteners are available from many different
CA 02609807 2007-11-22
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
5 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.
10 However these have not been used in flooring and have not been
manufactured from materiels 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
15 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
20 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 Texas manufacture nails in a
suitable composite plastics materiai which can be used to manufacture the
CA 02609807 2007-11-22
26
corrugated fasteners to be used in the present arrangements.
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,
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.
The panels are formed from the material described to form a
construction of the same general type as described in shown in Figure 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 Figure 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 panei.
Turning now to Figure 12, there is shown a flooring pattern formed
from two separate types of panels where one of the types is as shown in Figure
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
Figure
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
CA 02609807 2007-11-22
27
appreciated that the combination of such panels can be used to create many
different panelling effects.
As shown in Figure 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 desoribed, 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 138 having fiour 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.
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.
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,
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.
In each of the first panel members 130, the main strips are paraiiel 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
CA 02609807 2007-11-22
28
engaging the panel body 136 and a second exposed outer edge 146.
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 atong the outer edge 146
thereof.
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.
In each of the second panel members 131, the main strips 135 are at
right angles to the dividing strips 141, 142.
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.
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.
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.
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
CA 02609807 2007-11-22
29
members 131 with the groove therealong.
The first and second panel members 130 and 131 are arranged such
that the outer edge 148 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.
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-operatirtg 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.
The first and second panel members 130 and 131 are arranged such
that the outer edge 148 of the second dividing strip142 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.
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.
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
CA 02609807 2007-11-22
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
5 between comers 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,
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
10 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.
In addition, as the appearance of the panels is generally formed by the
covering or facing layers and the chamfered grfloves 115 therebetween, the
main
15 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.
In Figure 13 is shown the same construction as in Figure 12 with the
20 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
pattem 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
CA 02609807 2007-11-22
31
approximately midway between tttie front and rear surfaces of the panels as
the
tongues and grooves along the side edges of the panels and dividing strips.
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.
