INTERLOCKING PANEL

Abstract

An interlocking panel, and structures formed therefrom, are described herein. Embodiments of the present invention provide a panel including a protruding end including a receiving member for engaging a complementary engaging member of a first adjacent panel, and a receiving end including two flanges, at least one of the two flanges including an engaging member for engaging a complementary receiving member of a second adjacent panel, one or both of the two flanges configured to flex to allow the complementary receiving member of the second adjacent panel to engage the engaging member.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional Patent Application No. 60/895,939, filed Mar. 20, 2007, entitled “Interlocking Panel,” the entire disclosure of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

Embodiments of the invention pertain to interlocking panels and structures formed therefrom, and particularly to panels which may be assembled by engaging one another along their lengths for a removably coupled or interlocked engagement.

BACKGROUND

Structures having high flexural strength and rigidity as well as a degree of modifiability in terms of ultimate structure size are sometimes desirable. For example, tractor-trailer trucks may include cargo structures for transporting and/or storing material. Although the size of these structures may be known, it may be desirable to expand or decrease the size of the structure (for example, to accommodate the size of the trailer), or to completely disassemble the structure when not needed. In many cases, it is desirable for such an assembly process to be automated.

U.S. Publication No. 2006/059791 illustrates the use of panels having 1) a member-connecting side having a pivot-receiving slot for rotatably receiving the pivot, and 2) an arcuate wing-receiving slot for receiving the wing during relative rotation of at least one of the first and second members with respect to the other. This construction is inefficient and cumbersome, as it requires the rotating of the panels during assembly. Rotation of such panels makes the panels difficult to assembly quickly, particularly if the assembly process is to be automated.

DRAWINGS

Embodiments of the present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings. To facilitate this description, like reference numerals designate like structural elements. Embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.

FIG. 1 is a cross-sectional top view of a panel in accordance with various embodiments of the present invention.

FIG. 2A is a cross-sectional top view of two panels during an interlocking operation in accordance with various embodiments of the present invention. FIG. 2B is a cross-sectional view of the two panels of FIG. 2A after the interlocking operation.

FIG. 3A is a front view of a structure formed from a plurality of interlocked panels in accordance with various embodiments of the present invention. FIG. 3B is a cross-sectional view of the structure of FIG. 3A, taken along the 3B-4B line, and FIG. 3C is a cross-sectional view of the structure of FIG. 3A, taken along the 3C-3C line.

FIG. 4A is a front view of another structure formed from a plurality of interlocked panels in accordance with various embodiments of the present invention. FIG. 4B is a cross-sectional view of the structure of FIG. 4A, taken along the 4B-4B line, and FIG. 4C is a cross-sectional view of the structure of FIG. 4A, taken along the 4C-4C line.

FIG. 5A is a front view of another structure formed from a plurality of interlocked panels in accordance with various embodiments of the present invention. FIG. 5B is a front perspective view and FIG. 5C is a cross-sectional top view of the structure of FIG. 5A.

FIG. 6A and FIG. 6B are front views of another structure formed from a plurality of interlocked panels in accordance with various embodiments of the present invention.

FIG. 7 is a rear perspective view of another structure formed from a plurality of interlocked panels in accordance with various embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

In the following detailed description, reference is made to the accompanying drawings which form a part hereof wherein like numerals designate like parts throughout, and in which is shown by way of illustration embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments in accordance with the present invention is defined by the appended claims and their equivalents.

The description may use the phrases “in an embodiment,” “in embodiments,” “in some embodiments,” or “in various embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present invention, are synonymous.

The phrase “A/B” means A or B. For the purposes of the present invention, the phrase “A and/or B” means “(A), (B), or (A and B).” The phrase “at least one of A, B, and C” means “(A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C).” The phrase “(A)B” means “(B) or (AB),” that is, A is an optional element.

The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of embodiments of the present invention.

Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments of the present invention; however, the order of description should not be construed to imply that these operations are order dependent. Moreover, some embodiments may include more or fewer operations than may be described.

The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

The term “interlocking,” along with its derivatives, are used herein. These terms may broadly refer to structures being permanently or temporarily coupled, depending on the application.

Embodiments of the present invention may include panels configured to interlock to form various structures. In various embodiments, the interlocking panels may be suitable for applications including, for example, cargo enclosures for tractor-trailer trucks and similar vehicles. Other applications also may be within the scope of the present invention including storage structures, shipping containers and temporary shelters.

According to various embodiments, the panels may be interlocked by engaging the panels with each another along their lengths by a snap-fit/interlocked engagement. This novel structure allows for simple assembly by pushing one end of a panel into a complementarily configured other end of another panel without the need to rotate one or both of the panels, and generally without the need for special tools or complicated assembly techniques.

FIG. 1 illustrates a cross-sectional view of a panel 100 in accordance with various embodiments of the present invention. Panel 100 includes a protruding end 102 and a receiving end 104. Protruding end 102 includes at least one receiving member 106, and receiving end 104 includes generally parallel flanges 108 including at least one engaging member 110 disposed on facing surfaces of flanges 108.

Panel 100 may be configured to couple to another panel. For coupling, receiving member 106 may be configured to engage a complementary engaging member (similar to engaging member 110) of another panel. Similarly, engaging member 110 may be configured to engage a complementary receiving member (similar to receiving member 106) of yet another panel. In various embodiments, one or both flanges 108 may be configured to flex to allow a complementary receiving member of another panel to engage engaging member 110.

FIGS. 2A and 2B illustrate an exemplary operation for coupling two panels 200a, 200b. Similarly to panel 100 illustrated in FIG. 1, panels 200a, 200b each include a protruding end 202a, 202b and a receiving end 204a, 204b. Protruding ends 202a, 202b each include at least one receiving member 206a, 206b, and receiving ends 204a, 204b each include at least one engaging member 210a, 210b carried by flanges 208a, 208b. In various embodiments, non-coupling ends such as 202b and 204a may be of a different configuration for coupling to a different structure (e.g., a door, a frame, etc.).

Panel 200a may be coupled with panel 200b by inserting protruding end 202a of panel 200a into receiving end 204b of panel 200b. As illustrated in FIG. 2A, panel 200a is inserted into panel 200b along a direction substantially parallel to flanges 208b.

As protruding end 202a is inserted into receiving end 204b, flanges 208b may flex to a degree sufficient to allow engaging members 210b to engage receiving members 206b. Once the engaging members 210b engage receiving members 206a, flanges 208b may snap back to their non-flexed position to hold panels 200a, 200b together, as illustrated in FIG. 2B.

According to various embodiments, the panels may be configured to provide a desired degree of flexural resistance. As illustrated in FIG. 2A and FIG. 2B, for example, panels 200a, 200b, rather than being hollow, may include at least one intermediate structure 212a, 212b disposed between outer surfaces 214a, 214b. Intermediate structure 212a, 212b may prevent or resist flexing in a desired direction, and/or collapsing of panels 212a, 212b under pressure. In various embodiments, intermediate structure 212a, 212b may be oriented perpendicularly to outer surfaces 214a, 214b, respectively, for providing the flex-resistance. In some embodiments, a panel may include no such structures, depending on the application. For example, in low-stress applications, strengthening features may not be necessary. Further, in various embodiments, the panels may be filled with a material such as foam to provide additional strength, rigidity, noise reduction, etc.

Any material suitable for the particular application in which panels 200a, 200b are enlisted may be used to form panels 200a, 200b. For example, any one or more of various metals and their alloys may be appropriate or desirable for an application. Aluminum, for example, may be an appropriate material for a number of applications. In some embodiments, plastic or similar materials may be appropriate.

Panels in accordance with various embodiments of the present invention may be used for forming a variety of structures. For example, interlocked panels may be used for forming enclosures, doors, walls, or the like. In some embodiments, interlocked panels may be suitable for cargo enclosures configured to mount onto a vehicle such as, for example, tractor-trailer trucks, trains, or similar vehicles. Other applications also may be within the scope of the present invention including storage structures and temporary shelters.

FIG. 3A is a front view of an exemplary structure 314. FIG. 3B is a cross-sectional view of the structure of FIG. 3A, taken along the 3B-4B line, and FIG. 3C is a cross-sectional view of the structure of FIG. 3A, taken along the 3C-3C line.

As illustrated, structure 314 is formed from a plurality of interlocked panels 300, coupled as described herein. In various embodiments, panels 300 may be disposed, with respect to the resultant structure, in a generally horizontal, vertical, diagonal, or other orientation, depending on the application.

In some embodiments, one or more trim or edge structures 316 may be coupled to interlocked panels 300 for adapting structure 314 for the particular application. For example, trim structures 316 may include, for example, rail and/or stile elements (for a door, for example), hinges, or the like.

In some embodiments, panels may be further fastened in addition to interlocking. For example, in the embodiment illustrated in FIG. 4A-4C, the panels 400 are fastened at each interconnection point by fasteners 424. This embodiment may be useful for applications in which the panels will not be disassembled for some period of time. This embodiment may also be useful if additional structural fortification is desired.

Fasteners 424 may be used for fastening panels 400 together and/or for fastening one or more panels 400 to various trim structures 416. As described herein, trim structures 416 may be coupled to interlocked panels 400 for adapting structure 414 for the particular application, and may include, for example, rail and/or stile elements (for a door, for example), hinges, or the like.

Various fasteners 424 may be suitable for fastening panels 400 together. In various embodiments, suitable fasteners may include rivets. Other fasteners may be similarly suitable. For example, in some embodiments, any one or more of screws, bolts, clips, and/or pins may be used for fastening panels 400 together. In still further embodiments, panels 400 may be, welded, glued, or soldered together in addition to or instead of using mechanical fasteners.

An exemplary structure 514 formed using a plurality of panels is illustrated in FIG. 5A. FIG. 5B illustrates a front perspective view of structure 514, and FIG. 5C illustrates a cross-sectional top view of structure 514. The illustrated structure 514 is a pair of doors 518a, 518b, each door including a plurality of interlocked panels 500 and various trim structures including rails/stiles 522, and carrying hinges 520.

As illustrated in FIG. 5C, hinges 520 are recess-mounted to align with the outer surface of doors 518a, 518b. This embodiment may be particularly useful for applications wherein a substantially smooth outer surface is desired. In some embodiments, for example, ease in cleaning the outer surfaces of doors 518a, 518b may be necessary.

FIG. 5C also illustrates a sealing strip 521 disposed on door 518b. Sealing strip 521 may abut door 518b when doors 518a, 518b are closed. Although sealing strip 521 is illustrated in its unflexed configuration, sealing strip 521 would normally be flexed to abut the edge of door 518b to provide the desired contact between doors 518a, 518b.

FIG. 6A and FIG. 6B are front views of another structure 614 formed from a plurality of interlocked panels 600 in accordance with various embodiments of the present invention. The illustrated structure 614 is a pair of doors 618a, 618b, each door including a plurality of interlocked panels 600 and various trim structures including rails/stiles 622, and carrying hinges 620.

FIG. 6A and FIG. 6B also illustrate a locking system 623 for locking doors 618a, 618b to a carrying structure 629. Carrying structure 629 may comprise any structure onto which doors 618a, 618b may be mounted. For example, carrying structure 629 may comprise a cargo enclosure, a storage structure, a shipping container, a shelter structure, a vehicle, etc.

Locking system 623 includes a locking bar 625 (illustrated in phantom), which may be disposed on a rear/inner surface or within the door, depending on the application. Accordingly, locking bar 625 may effectively be “invisible” from an exterior side of doors 618a, 618b. The placement of locking bar 625 on a surface other than an exterior surface of doors 618a, 618b may be desirable for providing a substantially smooth outer surface of doors 618a, 618b, security reasons (e.g., to prevent tampering with locking bar 625), and/or aesthetic reasons.

Locking system 623 may allow for locking and unlocking of doors 618a, 618b by way of a latch 626. In various embodiments, unlatching of latch 626 may cause locking bar 625 to rotate and either raise or lower (depending on whether latching or unlatching, respectively) for engaging or disengaging a receiver 627.

Structure 614 may include any number of locking systems 623, depending on the application. For example, in the illustrated embodiment, each of doors 618a and 618b include two locking systems 623. In various other embodiments, however, a door may include just one locking system 623 or may instead have none.

Other locking systems may be similarly suitable for locking doors or panels within the scope of the present disclosure. As illustrated in FIG. 7, for example, a structure 714 includes doors 718a, 718b, and locking bars 725a, 725b on a rear surface door 718b. An actuator 728 may be configured to cause locking bar 725a to raise or lower, and resultantly, engage or disengage a receiver (not illustrated), respectively. Similarly, actuator 728 may be configured to cause locking bar 725b to raise or lower, and resultantly, disengage or engage a receiver (not illustrated), respectively.

Although certain embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope of the present invention. Those with skill in the art will readily appreciate that embodiments in accordance with the present invention may be implemented in a very wide variety of ways. This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments in accordance with the present invention be limited only by the claims and the equivalents thereof.

Claims

1. An apparatus comprising:

a first panel including a protruding end including a receiving member; and

a second panel coupled to the first panel, the second panel including a receiving end including two flanges, at least one of the two flanges including an engaging member;

wherein the engaging member engages the receiving member for coupling the first and second panels; and

wherein one or both of the two flanges flex to allow the protruding end to be inserted into the receiving end for engaging the receiving member with the engaging member.

2. The apparatus of claim 1, wherein at least one of the first panel and the second panel further includes a first outer surface and a second outer surface, and further including at least one intermediate structure disposed between the first and the second outer surfaces to increase structural integrity.

3. The apparatus of claim 2, wherein the first and the second outer surfaces are generally parallel to each other, and wherein the at least one intermediate structure is oriented perpendicularly to the first and the second outer surfaces.

4. The apparatus of claim 1, wherein the two flanges are generally parallel to each other, and wherein the engaging member is disposed on a surface of one of the two flanges, the surface facing the other one of the two flanges.

5. The apparatus of claim 1, wherein the receiving end is configured to receive the protruding end along a direction substantially parallel to the two flanges.

6. The apparatus of claim 1, wherein the first panel is fastened to the second panel by a fastener.

7. The apparatus of claim 6, wherein the fastener is selected from a group consisting of a rivet, a screw, a bolt, a clip, a pin, glue, and solder.

8. The apparatus of claim 1, further comprising at least one trim structure coupled to the first and second panels.

9. The apparatus of claim 8, wherein the trim structure is selected from a group consisting of a rail, a stile, and a carrying hinge.

10. The apparatus of claim 1, further comprising a locking bar coupled to at least one of the first and second panels, the locking bar configured to lock the apparatus to a carrying structure.

11. The apparatus of claim 10, wherein the locking bar is coupled to an interior surface of the at least one of the first and second panels.

12. An interlocking panel comprising:

a protruding end including a receiving member for engaging a complementary engaging member of a first adjacent panel; and

a receiving end including two flanges, at least one of the two flanges including an engaging member for engaging a complementary receiving member of a second adjacent panel, one or both of the two flanges configured to flex to allow the complementary receiving member of the second adjacent panel to engage the engaging member.

13. The panel of claim 12, further comprising a first outer surface and a second outer surface, and further including at least one intermediate structure disposed between the first and the second outer surfaces for resisting flexing of the first and the second outer surfaces toward each other.

14. The panel of claim 13, wherein the first and the second outer surfaces are generally parallel to each other, and wherein the at least one intermediate structure is oriented perpendicularly to the first and the second outer surfaces.

15. The panel of claim 12, wherein the two flanges are parallel to each other, and wherein the engaging member is disposed on a surface of one of the two flanges, the surface facing the other one of the two flanges.

16. The panel of claim 12, wherein the receiving end is configured to receive the second adjacent panel along a direction substantially parallel to the two flanges.

17. A method of interlocking panels comprising:

providing a first panel including a protruding end including a receiving member;

providing a second panel including a receiving end including two flanges, at least one of the two flanges including an engaging member, and one or both of the two flanges being adapted to flex to allow the protruding end to be inserted into the receiving end allow the receiving member to engage the engaging member; and

engaging the engaging member with the receiving member to interlock the first panel with the second panel.

18. The method of claim 17, wherein the engaging of the engaging member with the receiving member comprises flexing at least one of the two flanges, and inserting the protruding end into the receiving end.

19. The method of claim 17, wherein the providing of the second panel comprising providing a second panel including two parallel flanges, and wherein the engaging of the engaging member with the receiving member comprises inserting the protruding end into the receiving end along a direction substantially parallel to the two parallel flanges.

20. The method of claim 17, further comprising fastening the first panel with the second panel.

21. The method of claim 20, wherein the fastening of the first panel comprises fastening the first panel with the second panel using a fastener selected from the group consisting of a rivet, a screw, a bolt, a clip, and a pin.

22. The method of claim 20, wherein the fastening of the first panel comprises gluing the first panel with the second panel or soldering the first panel with the second panel.

23. The method of claim 17, further comprising coupling at least one trim structure to the first and second panels.

24. The apparatus of claim 23, wherein the coupling of the at least one trim structure comprises coupling at least one trim structure selected from a group consisting of a rail, a stile, and a carrying hinge to the first and second panels.