Method of forming rectangular panels for use in a 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 first and second dividing strips formed also from the flooring planks fastened together to form a common panel member for transportation and installation. Each divider strip includes a ninety degree point extending beyond the sides of the main strips to meet with the points of other strips to fill the spaces between the panels. The strips are fastened by pins from the rear or by a bonded sheet material on the rear. A method for assembly includes re-cutting the tongue or groove along one edge after compression of the main strips together to ensure accuracy.

1 . A method of manufacturing a panel member for use in a paneling system including a plurality of the panel members for locating on a supporting surface generally edge to edge in an array to at least partly cover the supporting surface, the method comprising:
 providing a plurality of main strips arranged in a row generally side by side;   each main strip having a tongue along one side edge and a corresponding groove an opposed side edge;   converging the main strips together so that the main strips are connected side by side by interconnection of the tongues and the grooves and so that 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;   applying pressure to the converged main strips in a direction to compress the main strips together to hold the exposed tongue and the exposed groove at positions spaced by the combined width of the main strips;   fastening the main strips each to the next to form a common panel member for transportation and installation;   and using a re-cutting tool to effect re-cutting one of the exposed tongue and the exposed groove so as to remove a portion of material therefrom while holding the other of the exposed tongue and the exposed groove at a predetermined spacing from the re-cutting tool so as to provide an accurate spacing between the exposed tongue and the exposed groove.   
     
     
         2 . The method according to  claim 1  further including cutting the interconnected main strips across the main strips to form a first common cut line, cutting the interconnected main strips across the main strips to form a second common out line spaced from the first cut line, operating a cutting tool to form a tongue along the first common cut line and operating a cutting tool to form a groove along the second common cut line. 
     
     
         3 . The method according to  claim 2  further including supplying dividing strips from a supply thereof where each of the dividing strips has a tongue along one side edge and a corresponding groove along an opposed side edge, attaching a first dividing strip along the first common cut line and attaching a second dividing strip extending along the second common line, such that each of the dividing strips has a front surface of the dividing strip lying in a common plane with the front surfaces of the main strips to define the front surface of the panel, and such that the first dividing strip has the groove thereof engaged with the tongue along the first common line and wherein the second dividing strip has the tongue thereof engaged with the groove along the second common line. 
     
     
         4 . The method according to  claim 3  further including clamping the interconnected main strips together when compressed and maintaining the interconnected main strips clamped when cutting the main strips, operating the cutting tool and attaching the dividing strips. 
     
     
         5 . The method according to  claim 3  wherein the main strips and the dividing strips are supplied from a common supply of strips of identical width and material. 
     
     
         6 . The method according to  claim 1  further including fastening together the main strips by a plurality of pins each inserted at a butting edge between one strip and a next adjacent strip through the rear surface at a groove on one side of the butting edge and extending into a tongue in the groove with a front end of the pin terminating at a position spaced from the front surface. 
     
     
         7 . The method according to  claim 6  wherein each pin is inclined at an angle to a plane containing the butting edge so as to pass through the plane. 
     
     
         8 . The method according to  claim 6  wherein each main strip is fastened to each next adjacent main strip by a plurality of the pins at spaced positions along the main strips. 
     
     
         9 . The method according to  claim 6  wherein each pin is inserted such that it is countersunk from the rear surface. 
     
     
         10 . The method according to  claim 1  further including forming each main strip from a series of strip portions arranged butting end to end to form a butt joint therebetween; fastening together the main strips by operating an insertion tool to insert a plurality of pins at spaced positions along the length of the main strips, detecting the location of a butt joint and operating the insertion tool at a location spaced from the butt joint. 
     
     
         11 . The method according to  claim 10  further including forwarding each main strip from a supply such that each main strip is continuous as it is converged with the other main strips together, passing the continuous converged main strips past a plurality of insertion tools at spaced positions across the converged main strips and operating each of the insertion tools at timed intervals so as to apply the pins at the spaced locations while avoiding the butt joints. 
     
     
         12 . The method according to  claim 10  wherein the ends at the but joint are connected by a tongue and groove connection. 
     
     
         13 . A method of manufacturing a panel member for use in a paneling system including a plurality of the panel members for locating on a supporting surface generally edge to edge in an array to at least partly cover the supporting surface, the method comprising:
 providing a plurality of main strips arranged in a row generally side by side;   each main strip having a tongue along one side edge and a corresponding groove an opposed side edge;   converging the main strips together so that the main strips are connected side by side by interconnection of the tongues and the grooves and so that 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;   fastening the main strips each to the next to form a common panel member for transportation and installation;   cutting the interconnected main strips across the main strips to form a first common cut line;   cutting the interconnected main strips across the main strips to form a second common cut line spaced from the first cut line;   operating a cutting tool to form a tongue along the first common cut line and operating a cutting tool to form a groove along the second common cut line;   supplying dividing strips from a supply thereof where each of the dividing strips has a tongue along one side edge and a corresponding groove along an opposed side edge;   attaching a first dividing strip along the first common cut line;   and attaching a second dividing strip extending along the second common line;   such that each of the dividing strips has a front surface of the dividing strip lying in a common plane with the front surfaces of the main strips to define the front surface of the panel;   and such that the first dividing strip has the groove thereof engaged with the tongue along the first common line and wherein the second dividing strip has the tongue thereof engaged with the groove along the second common line.   
     
     
         14 . The method according to  claim 13  further including clamping the interconnected main strips together when compressed and maintaining the interconnected main strips clamped when cutting the main strips, operating the cutting tool and attaching the dividing strips. 
     
     
         15 . The method according to  claim 13  wherein the main strips and the dividing strips are supplied from a common supply of strips of identical width and having as supplied a tongue on one side and a groove on the other side. 
     
     
         16 . The method according to  claim 13  further including cutting the dividing strips so as to define end portions which extend beyond the sides of the main strips and operating a tool at the end edges thereof in the front surface to form a chamfer such that the dividing strips when butting have a chamfered groove at the front surface. 
     
     
         17 . A method of manufacturing a panel member for use in a paneling system including a plurality of the panel members for locating on a supporting surface generally edge to edge in an array to at least partly cover the supporting surface, the method comprising:
 providing a plurality of main strips arranged in a row generally side by side;   each main strip having a tongue along one side edge and a corresponding groove an opposed side edge;   converging the main strips together so that the main strips are connected side by side by interconnection of the tongues and the grooves and so that 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;   fastening the main strips each to the next to form a common panel member for transportation and installation;   forming each main strip from a series of strip portions arranged butting end to end to form a butt joint therebetween;   the main strips being fastened together by operating an insertion tool to insert a plurality of pins at spaced positions along the length of the main strips,   passing the continuous converged main strips past a plurality of the insertion tools at spaced positions across the converged main strips;   detecting the location of a butt joint;   and operating each of the insertion tools at timed intervals so as to apply the pins at the spaced locations while avoiding the butt joints.   
     
     
         18 . The method according to  claim 17  wherein the insertion tools are operated such that each pin is inserted at a butting edge between one strip and a next adjacent strip through the rear surface of the panel member at a groove on one side of the butting edge and extending into a tongue in the groove with a front end of the pin terminating at a position spaced from the front surface of the panel member. 
     
     
         19 . The method according to  claim 18  wherein each pin is inclined at an angle to a plane containing the butting edge so as to pass through the plane. 
     
     
         20 . The method according to  claim 18  wherein each pin is inserted such that it is countersunk from the rear surface.