STRUCTURE OF INTERLOCKING MEMBERS

Abstract: A structure comprises two interlocking members (11a, 11b), such as two panels, a first member (11a) having a first rectilinear location edge (34) for lying interlocked with a second rectilinear location edge (27) of a second of the two members, said first location edge (34) comprising a pair of elongate flange formations (33, 33') which define therebetween an elongate recess (36), said second location edge (27) having a tongue formation (28) adapted to be located in said elongate recess (36) by relative movement of the members in a direction substantially perpendicular to the length of said elongate recess (36), and retention means to resist separation of the interlocked location edges (27, 34) in at least a first direction of separation.

Description: STRUCTURE OF INTERLOCKING MEMBERS The present invention relates to a structure of interlocking members and in particular, though not exclusively, to a structure in which at least one of the members is in the form of a panel, the term "panel" being used herein to embrace an elongate type panel in the form of a plank. The structure of the present invention may comprise an assembly of two or more panels in which two panels are interlocked by an interposed connection member, or an assembly in which two panels are directly interconnected. In one of its aspects the present invention seeks to provide a structure in which a pair of members, such as a panel and another member, or two panels, may be readily interconnected, and may subsequently be selectively separated in a controlled manner. According to one aspect of the present invention a structure comprises two interlocking members, a first member having a first rectilinear location edge for lying interlocked with a second rectilinear location edge of a second of the two members, said first location edge comprising a pair of elongate flange formations which define therebetween an elongate recess, said second location edge having a tongue formation adapted to be located in said elongate recess by relative movement of the members in a direction substantially perpendicular to the length of said elongate recess, and retention means to resist separation of the interlocked location edges in at least a first direction of separation. Preferably the tongue formation and elongate recess are shaped to allow them to be brought together to an interlocked condition, and optionally also to be separated, without any substantial deformation of either of the members or substantial relative friction therebetween. Thus it is envisaged that the tongue formation shall be substantially freely received in the elongate recess and hence, even though the interlocking location edges may be of substantial length, they can nevertheless be brought together into an interlocked configuration without the need for application of substantial force. The invention requires that the two members are interlocked by relative movement in a direction substantially perpendicular to the length of the elongate recess, i.e. the length directions of the location edges, and thereby avoids the need for relative lengthwise sliding movement. A structure can therefore be assembled in a confined space. It is envisaged that said direction of relative movement may be an angular movement comprising rotation about an axis or axes parallel with the length directions of the location edges. Thus during that relative rotation at least a part of the location edge of one member (as viewed in transverse cross-section) will move relative to the other location edge in a direction which comprises a component that is substantially perpendicular to the length of the recess. When rotated to an interlocked position, the elongate recess and tongue formation may interengage to serve as said retention means and resist direct separation of the members, at least in a first rectilinear direction which is perpendicular to the length of the recess. Auxiliary means, which is additional to said members, may be provided as retention means to retain the members in a selected position of angular alignment at which they lie interlocked to resist a direct separation. The first location edge having a pair of elongate flange formations may be provided with a pivot formation over the surface of which a part of the second location edge may slide, and be supported, during relative angular movement of the members to an interlocked configuration. That pivot formation may be provided by one of the elongate flange formations. One of the elongate flange formations may comprise a longitudinally extending undercut zone and the tongue formation of the other member may comprise a protrusion which is received in the undercut zone in an assembled condition of the members. A flange formation with an undercut zone may be a flange formation which provides also a pivot surface as aforedescribed, or one flange formation of a pair may have an undercut zone and the other may have said pivot surface. One flange formation of a pair may serve primarily only to prevent relative transverse movement of the members in a direction perpendicular to that direction in which separation of the members is prevented by the interlock. To form an interlocked structure of three or more members at least one of the members may have two rectilinear location edges. Those two location edges may be a similar type, e.g. both having elongate flange formations or both having a tongue formation. Alternatively the member may have one location edge of the type having flange formations and a second location edge of the type comprising a tongue formation. The tongue formation may comprise a bulbous part connected to a location edge of a first member by a neck part, and an elongate recess formation may comprise a receiving part which opens from a side surface of a second, panel type member adjacent a location edge of the panel, to receive the bulbous formation, and an interlocking part which locates in a space at the neck between the bulbous part and the body of the first member when the members are brought into alignment. The structure may be a free standing structure such as a partition or may comprise a frame, e.g. of a building, to which the panels are connected. The structure may comprise a frame having frame members which interconnect with some of the tongue formations and elongate recesses of panel and other type members thereby to provide or add to the rigidity of the structure. The structure may include a batten which is engaged with each of the aligned panels of a structure to act as auxiliary retention means which prevents the panels moving out of alignment with one another. The members are thereby maintained interlocked to resist separation, in the case of a connection between two co-planar panels, whether a direct connection or one achieved with an interposed connection member, the interlock preferably resists separation in a direction parallel with the plane of the panels and perpendicular to the interlocked location edges. A batten for use as auxiliary retention means may comprise a channel member which receives the top or bottom edges of a plurality of aligned panels of one wall of a structure and, if desired, a pair of such battens may be provided, one at each of the opposite top and bottom edges of the wall structure. In the case of panels connected to a frame, alignment may be maintained by at least some of the panels being connected to the frame. At least some panels of a plurality of panels may include at least one additional opening in a side surface of the panel between the edges, by means of which a clip having a tongue formation can be interconnected to the panels, the clip enabling connection of the panel to a frame structure, or connection of an auxiliary component of the structure to be connected to the panels. The tongue formation of a clip may be received in the additional opening of the panel and interconnect to the panel by a movement including a rotational movement and may be removed from the additional opening by an opposite movement only, but such movement may be prevented once the clip is connected to the frame or an auxiliary component, as the case may be. The structure may include a window or door opening as desired which may be bounded by further channel shaped members which receive edges of panels and define the window or door opening. The structure may include at least one additional panel or other member which is interconnected with a panel so as to extend transversely thereto, preferably at or about right angles. An additional panel may include a tongue formation which is received in the or an additional opening in a side of another panel by a movement which includes a rotational movement. A reverse movement, which would release the additional panel from inter- engagement with said another panel, may be prevented by means of a bracket, but preferably simply by means of a filler element inserted into a space between an edge of the additional panel from which the tongue formation projects, and the side surface of the panel to which it is connected. According to a second aspect of the invention there is provided a building comprising at last one wall structure in accordance with the first aspect of the invention. The building may comprise a frame, or may be frameless. The building may be a free standing building having preferably, four walls, or may be a lean-to building having only two, or three walls. The building may comprise a roof being a structure in accordance with the first aspect of the invention. The roof may be generally flat or inclined to the horizontal, or may be pitched. One or more of the interlocking members may be hollow. A member may have an internal cavity which may be filled, for example with a thermal insulation material. One or more of the interlocking members may be transparent. A panel may comprise an outer skin which defines a cavity filled with insulation material. Part of the shape of a location edge may be defined by the insulation material and there may be a break in continuity of the skin so as to reduce any cold-bridging effect between opposite faces of the panel. The invention further provides an assembly comprising a plurality of panels with successive panels interconnected by connection members which in the assembly lie wholly or substantially wholly in confronting elongate recesses of the panels. A connection member may lie wholly concealed from external view or may, for example, have only a narrow rib portion, or a pair of rib portions, exposed; that rib portion optionally may be adapted to provide a decorative effect. Suitable material for the interlocking members include plastics materials and metals such as steel and aluminium. Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figures 1 and 2 are illustrative views only of examples of structures in accordance with the invention, which together form part of a building; Figure 3 is an illustrative plan view of part of a first embodiment of a structure in accordance with the invention, to an enlarged scale; Figure 4 is a transverse section of interlocking members; Figure 4a. shows one of the members of Figure 4 in more detail; Figures 5, 6 and 7 are transverse sections of interlocking members in accordance with other embodiments of the invention. Referring to Figure 1 , a first embodiment of a structure in accordance with the invention comprises a wall 10 and has a plurality of interlocking members in the form of panels, some of which are indicated at 1 1 a.-1 1β. The panels 1 1 a . -1 1β are interconnected edge to edge as hereinafter described when they are in alignment, alignment being maintained in the present example by a pair of battens 12a and 12b_. In the drawing, batten 12a is shown separated from the remainder of the structure, from which it can be seen that each batten 12a, 12β is of channel configuration, each receiving a respective top or bottom edge, 13, 14 of each of the panels 1 1a- 1 1 β . If desired, battens may be provided at intermediate edges 13, 14 and may be engaged with each of the panels 1 1a-11β by fasteners. However, the arrangement shown is preferred as this avoids the need for any such fasteners. In Figure 1 , a window opening 15 is shown provided in the wall, the window opening 15 being bounded by four channel-shaped members 16, 17, 18 and 19, each of which receives an edge of one or more of the panels 1 1 e_- 1 1] to define the window opening 15. In Figure 2, another structure comprising another wall is shown but instead of a window opening 15, a door opening 20 is provided in the wall, bounded by three channel-shaped members 21 , 22 and 23 which receive the edges of one or more of the panels to define the door opening 20. Referring now to Figure 3, panel 1 1 b. is shown connected edge to edge with panels 1 1a and 1 1β, only parts of which are shown. The panels 1 1a, 1 1c. 1 1fi. 1 1flr 1 11, 1 1k, 1 1m, 1 1e are each of substantially identical configuration to one another, being panels of a first type, whereas panels 1 1b, 1 1d_, 1 1 f, 1 1 h, 1 1 , 1 11, 1 1 h, 1 1β are also each of substantially identical configurations to one another, being panels of a second type. All of the panels 1 1a-11β comprise an outer skin 25 which may for example only, be made of sheet steel, or a polymer such as polycarbonate. The skin 25 defines an internal space 26 which may contain a filler such as am insulating foam. However, where the skin 25 is made of a transparent or translucent polycarbonate or other material, preferably no such filler is provided in space 26 so that light may pass right through the panel. In another arrangement, the skin 25 could be made of acrylic polymer, or the panels 1 1a-1 1β instead of having a skin 25 and inner space 26, may be solid, and may be made of a suitable plastics material, or of MDF compressed wood fillers for further examples only. It is envisaged that in a structure in accordance with the invention, some of the panels 1 1a-1 1β rnay be made of an opaque construction, such as having an outer steel skin and insulated and filled inner space 26, whereas others of the panels may be made of an at least translucent or transparent material, so as to provide the structure with a sufficient degree of insulation, and light. Each panel of the second type 1 1b, 1 1ώ, 1 1 f, 1 1 h, 1 1j, 1 1b, 1 1β, has along one side edge 27, a tongue formation 28 which comprises a bulbous protrusion part 29 connected to the edge 27 by a neck part 30. The bulbous part 29 includes a concave surface part 31 for a purpose hereinafter explained. Along an opposite edge 32 of the panels of the second type 1 1b, 1 lei, 1 1 f, 1 1 h, 1 1j, 1 1], 1 1 n, 1 1β, there is a further tongue formation 28a of substantially identical configuration to tongue formation 28, but being oppositely handed. Each of the panels of the first type 1 1a, 11 £, 1 £, 1 1 fl, 1 1 i, 11k, 1 1 m, 11fl, has along one edge 34 thereof a recess formation 36 which lies between flange type formations 33, 33' and which is adapted to receive the tongue formation 28 of an adjacent panel of the second type. The recess formation 36 comprises an undercut recess part 35 and also opens to a side surface 37 of the respective panel 11a of the first type, and includes a convex surface part 38 and an interlocking part 39. The arrangement of tongue and recess formations 28 and 36 is such that the tongue formation 28 of a panel of a second type can be received in the recess formation 36 of the adjacent panel of the first type only when the panels 1 1a and 1 1b are out of alignment with one another. A relative rotational movement between adjacent panels e.g. the panels 1 1a and 1 1b brings the panels into co-planar alignment when the interlocking parts 35, 39 of the recess formation 36 will move into co-operation with the neck part 30 of the tongue formation 28. The convex surface 38 of the recess formation 36 is received in the concave surface part 31 of the tongue formation 28 to trap the tongue formation in the recess 36. Co-operation between tongue formation 28a of e.g. panel 1 1b is achieved substantially identically, although a relative rotational movement in an opposite sense will be required to bring the tongue formation 28a into engagement with the recess formation 35a- In another embodiment, not illustrated, instead of the panels being of first and second types, the panels may be identical, each having a tongue formation along one edge thereof, and a recess type formation along an opposite edge. Referring again to Figure 3, panel 1 1b has an opening 40 provided in a side surface 41 thereof. The opening 40 is adapted to receive a tongue formation 42 of a clip 43. The opening 40 includes a convex surface part 44 and the tongue formation 42 includes a bulbous part 45 and a neck part 46. As will be appreciated from the drawings, the clip 43 can be received in the opening 40 by a rotational movement which introduces a nose of the bulbous part 45 into the opening 40, and that upon such rotational movement, the convex surface 44 will locate in a corresponding concave surface 47 of the clip 43, to maintain the clip 43 in engagement in the opening 40. The clip 43 may be used either to connect the panel 1 1b to a frame of a building, or to connect an auxiliary component such as a skirting, or cornice, to the panel 1 1b- When the clip 43 is thus connected to the frame or the further component, a rotational movement which would release the clip 43 from engagement with the opening 40, is thus prevented. The clip 43 may be made of metal, plastic, or any other suitable material. Whereas in Figure 3, the clip 43 comprises a simple shaped planar clip, in another example, a clip 43 having a more complex configuration may be provided. For example particularly where a clip 43 is utilised to secure a panel 1 1b to an upright frame member, the clip 43 may incorporate a twist to enable a fastener to pass through the clip in a direction generally parallel to the direction of the aligned panels. Clips 43 of different configurations may be utilised for securing guttering to a panel structure or otherwise. The opening 40 preferably extends for the full height of the panel 1 1b but may extend partway along the height of the panel only, if desired. The panel 1 1b further has in this example, another opening 50 which opens from an opposite side surface 51 of the skin 25 to side surface 41. The another opening 50 is adapted to receive a tongue formation 52 of another panel 53. The tongue formation 52 comprises a bulbous part 55, and a neck part 56, and the further recess formation 50 includes a convex surface nose 57. The tongue formation 52 can be introduced into the opening 50 by means of a rotational movement of panel 53 relative to panel 1 1b to move the bulbous part 55 past the convex surface of nose 57. When the panel 53 lies substantially perpendicularly relative to panel 1 1b, the tongue formation 52 is trapped in the opening 50 unless an opposite rotational movement is performed. A filler element 60 is provided in a space 62 between an edge 63 of panel 53 from which the tongue formation 52 projects, and side surface 51 of panel 1 lb- Each of the panels 1 1a-1 β or 11 , may be provided with the openings 40, 50 or only some of the panels, as necessary and as desired, or some only of the panels may have a single opening on one side only. It will be appreciated that by utilising panels 1 1a to 1 1β (or 1 ) and panels 53, together with suitable battens 12a, 12b, a structure may be built up to any desired shape and configuration which is particularly suited for use as a wall or roof of a lightweight building. It will be appreciated that any unoccupied opening such as opening 40 or 50 of panel 1 1b, may be utilised for trunking electrical cabling and/or water pipework, the cabling or pipework then being concealed by a suitable cover piece received in or simply covering recess 40 or 50. Preferably, where the structure is part of a building or the like, the building includes a frame to which the walls and/or roof and/or floor may be connected by means of brackets 43. Thus the resultant structure will have considerable rigidity. As mentioned above, the degree of insulation provided, and the amount of light permitted to pass through the structure, can be governed by choosing a combination of panels 1 1a-1 1β (or 1 1 ') of suitable materials and constructions. In the examples shown, the panels (1 1a-1 1β) or 1 1 ' are each of generally rectangular configuration, and are elongate, and are arranged with their longest edges, along which the tongue and necessary formations are provided, extending generally upright. Alternatively a structure can be provided in which the panels are arranged with their longest edges extending generally horizontally, or transverse to the horizontal and vertical, the panels being maintained in alignment by suitable battens or the like so as to maintain the respective tongue and recess formations in engagement. Instead of the panel structure making a building, panels may simply provide a free-standing structure such as a partition, for an example within an office environment. In such an application, the structure may be provided with feet. For example, a bottom batten like batten 12b shown in Figures 1 and 2, may be provided with sideways extending feet. In another example, panels of a structure may be connected to a frame member not by clips such as clip 43, but by interlocking with the frame member. In a second embodiment, shown in Figure 4, panels 70 of identical construction and each having two identical location edges 71 are held together in an interlocked assembly by interposed connection members 72. Each panel has an outer skin which provides a pair of faces 73, 74 and the location edges 71 are each of the type having an elongate recess 75 defined by the space between a pair of flange formations 76, 76' of identical shape. Each flange formation 76, 76' comprises a convex pivot shape formation 77 and an undercut zone 78. Each connection member 72 (see Figure 4a) has a pair of tongue formations 79 which depend from a central zone 80, each tongue formation being adapted to be received in and to interlock with a panel location edge 71 . For that purpose each tongue formation comprises a concave pivot bearing surface 81 for pivotal sliding movement over the convex pivot surface formation 77 of a panel edge 71 , and an elongate protrusion 82 which is received in the undercut zone 78 of a panel edge 71 . In the assembled condition shown in Figure 4 one of the pair of undercut zones 78, in flange formation 76, at a panel edge 71 is occupied by an elongate protrusion 82 whereas the other undercut zone 78, in flange formation 76', is unoccupied, leaving a small space identified by reference 83. The connection member 72 is hollow and can be used to locate a captive fixing device 85 (see Figure 5) by means of which the member 72 may be secured to a support structure 84. That fixing arrangement may serve also as auxiliary retention means to maintain successive panels aligned in a co-planar configuration. The member 72 has a tubular side cavity 86 which is circular and can be closed as shown in Figure 4a or may be slit as indicated in Figure 5 to receive the support web 87 of a decorative cover strip 88. In the alternative construction of Figure 6 a connection member 90 is of a narrower construction such that in the assembled condition confronting panel flange formations 91 come into abutting contact and the member 90 is concealed. Figure 7 shows a panel 100 of a construction which differs from that of Figure 4 but can be interconnected in a similar manner by connection members 72. The panel 100 differs in that it has a filling of poiyurethane insulation foam 101 that is bonded to the outer skin material of the panel. The outer skin material is in two sections 102, 103 and these are spaced apart at the recess base regions 104. In consequence even if the skin sections are of a material that is a good conductor, the transfer of heat between opposite panel faces is advantageously impeded by the gaps 105 between the skin sections 102, 103.

Claims: CLAIMS: 1 . A structure comprising two interlocking members, a first member having a first rectilinear location edge for lying interlocked with a second rectilinear location edge of a second of the two members, said first location edge comprising a pair of elongate flange formations which define therebetween an elongate recess, said second location edge having a tongue formation adapted to be located in said elongate recess by relative movement of the members in a direction substantially perpendicular to the length of said elongate recess, and retention means to resist separation of the interlocked location edges in at least a first direction of separation. 2. A structure according to Claim 1 wherein the two interlocking members are interlocked by relative angular movement in a direction substantially perpendicular to the length of the elongate recess. 3. A structure according to Claim 2 wherein interlocking of the members by relative movement in a direction substantially perpendicular to the length of the elongate recess is achieved only by said relative angular movement. 4. A structure according to Claim, 2 or Claim 3 wherein when rotated to an interlocked position the elongate recess and tongue formation may interengage to serve as said retention means. 5. A structure according to Claim 4 wherein said retention means resists direct separation of the members in a first rectilinear direction which is perpendicular to the length of the recess. 6. A structure according to any one of the preceding claims and comprising auxiliary retention means additional to said members and which serves to retain the members in a selected position of angular alignment. 7. A structure according to any one of the preceding claims wherein the first location edge having a pair of elongate flange formations is provided with a pivot formation over which a part of the second location edge may slide. 8. A structure according to Claim 7 wherein said pivot formation is provided by one of the elongate flange formations. 9. A structure according to any one of the preceding claims wherein one of the elongate flange formations comprises a longitudinally extending undercut zone. 10. A structure according to Claim 9 wherein the tongue formation of the other member comprises a protrusion which is received in said undercut zone in an assembled condition of the members. 1 1 . A structure according to Claim 9 or Claim 10 wherein the flange formation with the undercut zone provides also a pivot surface over which a part of the second location edge may slide. 12. A structure according to Claim 9 or Claim 10 wherein one flange formation has an undercut zone and the other provides a pivot surface over which a part of the second location edge may slide. 13. A structure according to any one of the preceding claims wherein one of the flange formations prevents relative transverse movement of the members substantially only in a direction perpendicular to that direction in which separation of the members is prevented by the interlock. 14. A structure according to any one of the preceding claims wherein said tongue formation is substantially freely received in said recess. 15. A structure according to any one of the preceding claims wherein the members can be interlocked without either being subjected to any substantial deformation. 16. A structure according to any one of the preceding claims wherein at least one member has an outer skin and an internal cavity which contains an insulation material. 17. A structure according to Claim 16 wherein part of the shape of a location edge is defined by said insulation material. 18. A structure according to Claim 16 or Claim 17 wherein there is a break in continuity of the outer skin at a location edge to impede thermal conductivity between opposite faces of the member. 19. A structure according to any one of the preceding claims and comprising a plurality of panel type members and a channel member which receives edges of the panels to maintain the panels aligned. 20. A structure according to Claim 1 and substantially as hereinbefore described. 21. An assembly comprising a plurality of panels with successive panels interconnected by connection means which in the assembly lie wholly or substantially wholly in recesses in confronting elongate recesses of the panels. 22. A structure assembly comprising a structure or assembly according to any one of the preceding claims and a frame having frame members which interconnect with some of the tongue formations and elongate recesses to provide or add to the rigidity of the structure. 23. A structure assembly according to Claim 22 and substantially as hereinbefore described. AMENDED CLAIMS [received by the International Bureau on 29 January 1996 (29.01.96); original claims 14,15,21 and 23 amended; new claims 20,21 and 23 added; original claims 20,21,22 and 23 renumbered claims 22,24,25 and 26 remaining claims unchanged (2 pages)] undercut zone. 10 A structure according to Claim 9 wherein the tongue formation of the other member comprises a protrusion which is received in said undercut zone in an assembled condition of the members 1 1 A structure according to Claim 9 or Claim 10 wherein the flange formation with the undercut zone provides also a pivot surface over which a part of the second location edge may slide 1 2 A structure according to Claim 9 c Claim 10 wherein one flange formation has an undercut zone and the otner provides a pivot surface ove r which a par: of the second location edge may slide 1 3 A structure according to any one of the preceding claims wnerem one of the flange formations prevents relative transverse movement o* the members substantially only in a direction perpendicular to that direction in which separation of the members is prevented by the interlock 14 A structure according to any one of the preceding claims wherein said tongue formation is substantially freely received in said recess 15 A structure according to any one of the Dreceding claims wherein the members can be interlocked without either being subjected to any substantial deformation 1 6 A structure according to any one of the preceding claims wnerem at least one member has an outer skin and an internal cavity which contains an insulation material. 17 A structure according to Claim 16 wherein part of the shape of a location edge is defined by said insulation material 18 A structure according to Claim 16 or Claim 1 7 wnerem there is a brea* in continuity of the outer skin a: a location edge to impede tnerma 1 conductivity between opDOSite faces of the memper 19 A structure according to any one o' the preceding claims and comprising a plurality of panel type members ana a channel membe which receives edges of the panels to maintain the panels aligned 20 A structure according to any one of tne preceding claims wherein at least one of the members comprises two rectilinear location edges of a sιmιia r type. 21 . A structure according to Claim 20 wherein one of said two interlocking members comprises two rectilinear location edges of a similar type, and each having a flange formation, and the other of said two interlocking members comprises two rectilinear location edges of a similar type and each comprising a tongue formation. 22. A structure according to Claim 1 and substantially as hereinbefore described. 23. A structure assembly comprising a structure according to any one of the preceding claims and comprising at least a third interlocked member which corresponds with one of said first and second members, the other of said first and second members being a connection member which interconnects the other two members. 24. An assembly according to Claim 23 and comprising a plurality of panels with successive panels interconnected by connection means which in the assembly lie wholly or substantially wholly in recesses in confronting elongate recesses of the panels. 25. A structure assembly comprising a structure or assembly according to any one of the preceding claims and a frame having frame members which interconnect with some of the tongue formations and elongate recesses to provide or add to the rigidity of the structure. 26. A structure assembly according to Claim 23 or Claim 24 and substantially as hereinbefore described.

Inventors: GILL NORMAN DOUGLAS, GILL, NORMAN, DOUGLAS
Applicants: GILL NORMAN DOUGLAS, GILL, NORMAN, DOUGLAS
Application year: 1995
Main classification: E04B1
IPC codes: E04B1, E04C2, F16B5