US2252431A - Method of producing and laying flooring products - Google Patents

Description

Aug. 12, 1941. A. KLAMMT 2,252,431

METHOD OF PRODUCING AND LAYING FLOORING PRODUCTS Original Filed July 23, 1938 3 Sheets-Sheet 1 [NVENTOR a? \tl BY ArfhurK/ammt ATTORNEYS 3 Sheets-Sheet 2 I I +I :E m n m n mK m n F N W mm m .1 m

A. KLAMMT METHOD OF PRODUCING AND LAYING FLOORING PRODUCTS Original Filed July 23, 1938 Aug. 12, 1941. A. KLAMMT 2,252,431

METHOD OF PRODUCING AND LAYING FLOORING PRODUCTS Original Filed July 23, 1938 3 Sheets-Sheet 3 g2? g INVENTOR 26 Arfhur K/ammf. 1- 6 BY Tg WM M ATTORNEYS Patentecl Aug. 12, 1941 METHOD OF PRODUCING AND LAYING FLOORING PRODUCTS Arthur Klammt, New York, N. Y., assignorto W. M. Bitter Lumber Company, a corporation of West Virginia Original application July 23, 1938, Serial No.

Divided and this application February 7, 1939, Serial No. 254,988

3 Claim.

This invention pertains to improvements in methods of producing and laying flooring products, the present application being a division of application Serial No. 220,845, filed July 23, 1938.

An object of the invention is to provide an improved method of producing composite blocks or sections of flooring comprised of a plurality of individual slats of parquetry or short cut-tolength flooring.

Another object of the invention is to provide a method of joining tongue and groove members by applying spots or strips of flexible adhesive to the groove and inserting the tongue, the adhesive spots being so spaced as to form a series of hinges sufliciently strong and elastic to prevent breakage of the tongue or separation of the members during transit or normal handling of the sections necessary in building them into a finished floor.

Another object is to provide a method of applying spots or strips of flexible adhesive to the channel of tongue and grooved members in a spaced relationship, such adhesive not being applied in sufiicient amount to cause the spots to meet when the tongue and groove are fitted, thereby preventing the adhesive from forcing up along the sides of the tongue and interfering with the normal fit of the joint.

A still further object is to provide an improved method of laying flooring comprising the .above product.

Other objects and advantages of the invention will appear during the course of the following description in connection with the accompanying drawings, in which:

Figure l is a side elevation of a preferred type ,of machine for applying spots of flexible ce- Figure 5 isan end elevation of a typical flooring slat;

Figure 6 is an end elevation of an improved type of slat; I

Figure 7 is an edgewise view of a slat illustrating the application of spots of cement to the groove;

Figure 8 is a bottom view of a slat illustrating application of the spots of cement to the tongue;

Figure 9 is a perspective view of a typical composite block or section;

Figure 10 is a similar view showing the block bent to illustrate the flexibility of the hinged structure;

Figure 11 is a cross sectional view of a section of flooring laid in accordance with the improved method; and

Figure 12 is a perspective view of a parquet floor constructed and laid in accordance with the invention.

It is obvious that where a floor is made up of small individual pieces, there is a distinct advantage in using grouped members if they can be so grouped as to not interfere with some preconceived design or cause a balance of the labor saving costs incident to break-age in transit or separation of the members during handling.

Many methods have been advanced for uniting individual members to form a composite section suitable for use in laying floors. In most of these methods a rigid structure is produced which is not good practice because these rigid sections when joined over a slightly uneven base will cause a strain at the joints unless an excess of plastic cement is used on the base to adjust for its irregularities.

Another undesirable feature of many of the proposed methods of forming composite sections is that when a cementing medium is applied to the tongue and groove either a snug fit is not obtained or the cement present in excess extrudes between the joints causing an unsightly appearance and endangering the perfection of the finish by the possibility of some component of the adhesive bleeding into the finishing material. If the adhesive used is a water soluble material, such as glue, under conditions of excess humidity, swelling may occur causing undue expansion of the sections and even breakage at the joints.

It has hitherto been proposed, as set forth in U. S. Patent No. 2,018,711, to produce a preformed flooring in which wood tiles are united by an elastic rubber-like cement, the cement being of substantial thickness. It is apparent to those skilled in the art that this method of construction even if applied to comparatively small units would not only be expensive, but would make prefinishing of the wood sections almost imperative because the finishing materials ordinarily used for wood flooring are not satisfactory as finishes for elastic rubber on account of the great difference in elongation. Then too, modern vulcanized rubber compounds usually contain accelerators and antioxidants which have a tendency to discolor varnish films applied over them.

The present invention avoids the use of any method which will result in a composite structure having the individual members separated by a continuous sheet of cementing material throughout the joints. Such a result would be undesirable for the reasons before stated.

In the present invention a new and improved result is accomplished, which eliminates the difficulties and disadvantages of prior methods in the following manner:

Referring to Figure 5, the numeral 20 denotes a short slat of flooring having a rounded tongue 2| formed along one side and a square groove 22 formed along the other side and also along one or both of the ends. The bottom side of the slat may be formed with an extended portion 23 having angularly undercut edges 24 and one or more .grooves 25, this form of bottom being adapted to be firmly engaged by a plastic material in laying the floor as hereinafter described.

In forming a composite section or block of slats such as those shown in Figure 5, instead of applying adhesive throughout the entire tongue and groove joint, the joint is/made by means of small individual spots of flexible adhesive 26, preferably applied to the flat bottom side of the tongue 2| as shown in Figure. 8. When slats spotted in this manner are fitted together the flexible adhesive effect is limited to the lower side of the tongue and groove. Any extrusion of adhesive which may occur takes place at the bottom of the composite section where it cannot interfere with the fit or finish of the composite while each joint forms a flexible hinge.

Figure 6 shows an improved form of strip 21 in which the groove 28 is partially rounded to approximately the same contour as the tongue 29. In carrying out the method with this type of slat, the adhesive spots 26 are applied to the bottom of the groove 28 as shown in Figure '7. When the tongue 26 is entered firmly in the groove 28 the adhesive flows readily along thetongue and particularly toward the lower corner thereof, giving the greatest hinge effect with the smallest amount of adhesive.

In carrying out the fabricating method of the invention, it is preferred to apply the adhesive to the strips when they are in a position that will cause the surface tension of the adhesive to hold the spot in position until the tongue is entered. With the type shown in Figure the spots are applied with the strip in a horizontal position with the back up, as in Figure 8. With ,the type shown in Figure 2 the spots are applied with the strip in the vertical position, the groove being up and the tongue down. Any other positions of the respective types of strips would cause the spots to run by gravity unless the adhesive is used in a very viscous form which is undesirable.

In spotting the strips the frequency of the spots of adhesive must necessarily be regulated by the length of the strip, the viscosity of the adhesive, and the clearance between the tongue and the bottom of the channel. In all cases, regardless of the number of spots applied to any particular length of strip, it is preferred to keep the spots at the ends of pieces far enough away to avoid extrusion of the adhesive. The intermediate spots are spaced to allow sufficient flow of the tongue instead of up the sides. This result is best accomplished if the spots do not unite when the tongue is fully entered into the channel.

As an adhesive for use in producing the composite blocks by the new method described, it has been found that aqueous dispersions of tube or tire reclaim or rubber latex compounds give the best results. Rubber cements may be used as well as other solvent solutions of flexible adhesive materials such as nitrocellulose and various synthetic resins. Even thermo plastic materials such as non-hardening synthetics may be used, although in this case it is necessary to apply them at temperatures above that used for other materials. The preference for aqueous dispersions of rubber arises from the fact that the dried out films are inherently elastic and adhesive. The use of water emulsions of rubber permits carrying a very high solid content, even as high as 70% without attaining any substantial viscosity which would retard the flow. Another reason for preferring aqueous dispersions of rubber is that by their use fire hazards are eliminated, a very important consideration in factories producing wood flooring strips.

Due to the more or less temporary nature of the effect desired in producing composite sections or blocks by the method described, the method is not limited to any particular rubber compound. Rosin soap dispersions of inner tube reclaim work very well. Good results have also been achieved with commercial 60% latex as well as 70% latex known as Revertex. Vulcanizing ingredients are not necessary although they can of the adhesive material to follow along the tip be added. In cases where commercial latex products are used which do not penetrate well it has been found that the addition of about .2% of Tergitol as a wetting agent promotes better adhesion. The main qualifications desired in the adhesive are good adhesive qualities, sufficient elasticity to allow recovery when the composite block is flexed, and enough durability to withstand atmospheric changes during the interval between the manufacture of the block and its use as a flooring unit.

By the foregoing method of fabrication, composite blocks of various shapes and forms can be made, depending on the type of flooring pattern in which they are to be used, and while it is desirable for most purposes that the slats have the bottom extension 23 shaped as shown in Figures 5 and 6, it will be understood that the invention is not limited to this precise shape of slat. For example, Figure 9 illustrates a. composite block of square shape, composed of slats 28 having grooved flat bottoms 29. Such a block being fabricated by the spot adhesive method as illustrated in Figure 7 or as in Figure 8, may readily be flexed as shown in Figure 1Q, allowing for shipment without breakage and for ease of handling and proper laying under a variety of conditions encountered, the resilience of the adhesive spots permitting the unit to return to shape for acthat shown in Figures 1, 2, 3, 3A, and 4 may be 42. the eccentric 01 standing at upper dead provided. center. Referring to the above figures, the numeral II Mounted on the cross shaft 42 is a jaw clutch indicates an elongated machine frame having a ll having a driven member H slidably keyed to top plate 32 upon which are secured two longi- 5 the Shaft n 8 driving m e 3' n 'm l y tudinal guide angles 23 and I4. A channel ll tatable thereon. The driving member 12 is l in the plate 32 between the two angles 83 and 24 adapted to be continuously rotated by the concarries a conveyor h i a, Figure 3, provided veyor shaft '40 through a suitable driving means with sprocket or pulleys 31 and" carried on such as a V-belt II.

shafts l9 and 4 the shafts 39 and 40 being jourl a The riv n member II is provided with a shifter nailed in pillow blocks 4| and 42 secured reyoke 14 connected by a link 16 to a lever 16 on spectively to the end uprights 43 and 44. of the a vertical shaft I1 exten g upward through the frame ll. As conveyors of this type are well table II as shown in Figures 1 and 3. Secured known, the precise structure of the chain need on the top of the shaft TI is a toggle lever 18 not be described herein. and to simplify the drawequipped with a toggle pring 19. A bell crank ings, has been represented by a dotted and'dashed member ID, pivoted to an upright ti on the table line in Figures 1 and 2.

32, has an arm l2 adapted to engage the toggle The nveyor 36 has. attached thereto a.suclever 12 as shown in Figure 2. A finger 82 is cession of cleats 45. The shaft 29 carries a drive slidablym un d on the other arm 84 of the bell pulley 46 adapted to be connected to any suit- 20 crank 40, and is normally held in extended posiable source of power. Obviously. if desired the li 88 h wn n Figure 2 y means of a i ht pulley may be mounted on the shaft 40. When leaf spring GI secured to the rear of the member the shafts are revolved, the conveyor It draws the 80. A torsion spring 8 urges the bell crank memcleats 45 successively along the channel I! from be! It counterclockwise against a stop 87. Figure right to left, (Figure l), throughoutthe length In his no mal position, as shown in Figures of the top plate or table 32. 2 and 3, the finger "lies in the path of slats 21 A feed hopper 41 secured tothe plate 32 and ing carried along by the conveyor cleats 45. The 1 spanning the path of the conveyor 26, is adapted end ll of finger 22 is curved rearwardly for a purto receive a stack of slats 21 disposed vertically pose hereinafter set forth. with their grooved edges upward. Thus as the The slidable driven member ll of the clutch 1t cleats move under the hopper 41, each withcarries a face cam 89 which has a lobe 90. A draws the lowermost slat from the stack. and the roller l r y secured to a frame crossslats are successively conveyed along the plate 32 member 22. is adapted to be engaged by the lobe between the angles a: and 34 which act as guides 90 as the clutch revolves i en a ed position as to maintain the slatsin accurate lateral position. 35 illus ra ed in gure 3A. It will be seen that en- A stationary upright guide 48 has vertically agement between the cam lobe 90 and roller 9| sli bl therein a cross head 49 (Figures 2 and 3), will force the driven member to the right arid to which is secured a spotting head 50. The head thereby r lease the clutch. 50 overhangs the angles 33 and 34 and the con- The operation of the machine is as follows: veyor 36, and comprises principally afluid-tight a s 21 are stacked in the hopp with their tank 5i shown in cross sectional detail in Figure r ves upward. as previously noted. The cleats 4. A plurality of valve stems 52 are vertically 45 convey e slats e y one under he spotslidable in plugs 53 in the top of the tank a: and s head As each l 2 p roaches cenin a yoke 54 ins e the bottom thereof. The valve ter Position der the head. it enga s e fin stems 52 have reduced lower portions 55 extend- 45 Swinging the lr n m m r" l w ing from shoulders 56 downward through small referring o Figure 2. The arm 82 throws the discharge pipes 51, the tips 58 protruding below ss lever 18 over n r ck n he shaft 11 the lower ends of the pipes. Compression springs. which lli'lillllliiies the lower level link "and a 59, disposed between caps 60 on the valve stems shifter yoke to age the clutch as shown in Glands 53a and packing 53b are provided to precross-head 49 at their top position in the guide 7 5g and plugs 6| in an upper i t channel 50 Fi ure 3A. The shaft 68 and eccentric 61 are member 52, urge the stems 52 downward, northereby revolved through one revolution, the cam mally holding the shoulders 56 against the upper 99 8 8 8 the ler II o release the clutch ends of pipes 51 to form valves, A thr a inlet as the end of the revolution approaches while the opening 63 is provided in the side of the tank 5|, tension spring operates o insure exact rethrough which opening a suitable adhesive such 55 turn the eccentric o upper dead center. As as an aqueous diffusion of rubber may be fed into the eccentric evmvesi e spotting head 59 is the tank under any desired pressure through a given stmke dOWhWflrd n pward. At the flexible hose connection 64 as shown in Figure 3. 1Wer end of ihe stroke e v v em ips 58 obviously if desired the tank may be partially encounter the bottom of the groove 28 as previfilled with adhesive and compressed air admitted described, causing a h sive to be forced through the hose 64 to maintain the pressure on through the Pipes 57 and deposited in spots 3 t adhes1ve gure 7. The timing of the spotting head is so It is evident that if the tank 5| be moved downsynchmnized with the m ion of the slat 21, ward above a slat 21 until the tips 5a of the stems that the spots are deposited venly with regard 52 encounter the bottom of the groove 28, the 65 to the length tlhe Slat. and he amount of mashoulders 56 are raised from the pipes 51, allowterm] F is determined by cohtmllihg the mg adhesive to be for ed through the pipes 51 viscosity and pressure of the adhesive in the tank and into the groove, as hereinafter set forth. obvmusly the head may be designed to posit any desired number and spacing of spots vent leakage upward along the stems 52. P operly carry out th etho t various A wrist pin in the cross head is linked Standardized Sizes 01' slats. is also Obvious by a connecting rod to an e entri on a the head may be provided a large lower cross shaft 68. A tension spring 69 (Figures number of p n va v s and various spotting 1 and 3), normally holds the spotter head 50 and Patterns arranged y moving such valves as are not required for a particular pattern and plugging their openings. The parts may readily be proportioned, if desired, to carry slats through flat instead of vertically. and to deposit the spots 25 on the underside of the tongue 2| in the manner shown in'l igure 8.

The purpose of the spring-pressed arrangement of the finger 83 is to permit the latter to snap back to normal position as the clutch is released by the cam 89 as described, since the latter action operates through the yoke 14 and connected mechanism to force the toggle lever back to normal position as shown in Figure 2. After the initial swing of the finger 83 and bell crank member 88 have caused engagement of the clutch, the finger continues its clockwise movement until the curved end 88 over-rides the corner of the moving slat 21. Thereupon, due to the backward curvature of the end 88, a counter-clockwise pressure on the finger, generated both by the torsion spring 88 and finally by the releasing of the clutch, causes the finger to telescope back along the bell-crank member and snap to its initial angle without possibility of jamming against the slat. The finger thus rides resiliently against the moving slat until the latter has passed it, whereupon the leaf spring 85 projects the finger forward to engage the next slat.

It is obvious that in carrying out the method of constructing composite units, the operation of the machine described automatically insures rapid, uniform spotting of exactly proper amounts of adhesive to produce the best hinging, resulting in maximum production of uniform sections with minimum expenditure of time, labor and adhesive.

Composite blocks or strips made by the foregoing method may be laid in a number of ways, but a preferred method is to lay them in a layer of permanently resilient mastic comprising an aqueous dispersion of rubber. This material may have various compositions, a typical formula for good results calling for a dispersion of reclaimed rubber containing 50% of rubber solids. To 100 parts of this dispersion may advantageously be added 25 parts of a resilient fibrous material such as shredded cork.

In forming afioor by this method, a thin layer 93 of uncured mastic is spread cold on the supporting surface such as the concrete under-floor 84, Figures 11 and 12. The blocks of slats are then fitted together and pressed down in place in the layer of mastic, which adheres to their lower sides and rises into the lower portions of the joints, but is prevented by tongues 29 from rising to the upper surface. Such a layer of mastic, when allowed to cure, forms a permaaently resilient support which itself is unafi'ected by heat, cold, moisture or finishing materials. It holds the flooring strips down firmly not only by adhesion but by the formation of a plurality of dove-tail Joints with the bottom extensions 23. Due to its permanent resilience, the mastic layer allows expansion and contraction without rupture of the upper or lower joinings or disintegration of its own internal structure, and together with the resilient hlnging of the composite sections, provides a completely cushioned floor not subject to squeaks.

While the invention has been set forth in preferred form throughout, its practice is not limited to the precise structures, compositions and procedures set forth, as various modifications may be made without departing from the scope of the appended claims.

What is claimed is:

1. That method of laying a floor of tongued and grooved wood strips which comprises applying a layer of cold aqueous dispersion of rubber to a supporting surface, securing said strips together by applying spots of flexible adhesive to the tongues thereof and inserting same in the grooves to form a series of flexible hinged strips, pressing said hinged strips into adhesion with said layer while the latter is fresh, and allowing said dispersion to set.

2. That method of forming a permanently resilient bond between a supporting sub-surface and a floor composed of tongue and groove slats having lower dove-tail projections which comprises applying a layer of aqueous dispersion of rubber to said sub-surface, securing said slats together by applying spots of flexible adhesive to the tongues thereof and inserting same in the grooves to form a series of flexible hinged slats, pressing the bottom of said hinged slats downward against said fresh layer whereby said dispersion may adhere to said slats and may be forced into interlocking relationship about said dove-tailed extensions, and allowing said dispersion to set.

3. That method of forming a. parquet floor which comprises spreading a layer of an aqueous dispersion of rubber on a supporting sub-surface, joining together a plurality of tonguedand grooved pre-fabricated composite parquet blocks in a predetermined pattern by applying spots of flexible adhesive to the tongues thereof and inserting same in the grooves to form a series of flexible hinged blocks, pressing said hinged blocks into adhesive relationship with said layer while said layer is fresh, and allowing said dispersion to cure.

- ARTHUR KLAMMT.

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