Patent Publication Number: US-6668514-B2

Title: Apparatus and method for connecting adjacent panels

Description:
RELATED APPLICATION DATA 
     The present patent is a continuation-in-part of co-pending U.S. patent application Ser. No. 09/860,381, which was filed on May 18, 2001. 
    
    
     FIELD OF THE INVENTION 
     The invention is generally related to connecting plastic components, and more particularly to an apparatus and a method for interconnecting adjacent plastic panels. 
     BACKGROUND OF THE INVENTION 
     Plastic and other panels are used in many different applications for a wide variety of modular or multi-component products. In many of these applications, a plurality of panels and/or components are interconnected to one another to form a finished product assembly. A number of different structures and methods have been devised that are useful to interconnect or attach two adjacent components to one another. 
     In one example, two adjacent plastic or steel panels may be suitably welded together to form a permanent, water-tight joint at the intersection between the two panels. In another example, each adjacent panel may have a flange wherein the flanges abut or overlap one another when attached. Snap-in-place clips are sometimes used to sandwich or capture the flanges between parts of the clips to secure the flanges together. Alternatively, the abutting flanges may have holes that overlie one another. Standard threaded fasteners or snap-in fasteners can then be passed through the holes to secure the panels together in a known manner. Such fasteners can be fabricated from virtually any suitable material, but are very often formed from metals or plastics. 
     Problems associated with such connecting methods and structures are abundant. Conventional threaded fasteners result in use of a number of component parts (nuts, bolts, washers, and the like) that require significant labor to install. Small plastic clips and/or plastic snap-in fasteners can easily break or become damaged during installation and during use of the product. The joints formed between flanges of plastic panels tend to be relatively weak and susceptible to bending or breakage when external forces are applied. Such conventional joint structures do not provide for a sturdy combined panel because of the weakness in the joint. Welded joints, whether metal or plastic require significant labor and equipment expense to prepare, form, and cool the welded area. Further, other than the welded joints, such panel connections are not particularly water tight or leak resistant, unless additional elements, such as seals, are added to the joints. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Exemplary apparatuses and methods in accordance with the teachings of the present invention are described and explained in greater detail below with the aid of the drawing figures in which: 
     FIG. 1 is a perspective view of one example of a plurality of adjacent panels interconnected in accordance with the teachings of the present invention. 
     FIG. 2 is an exploded view of two of the interconnected panels as shown in FIG.  1 . 
     FIG. 3 is a transverse cross section across an interconnected joint between two of the adjacent panels and taken along line III—III of FIG.  1 . 
     FIG. 4 is a transverse cross section of the two adjacent panel edges shown just prior to attachment to one another and taken generally along line IV—IV in FIG.  2 . 
     FIG. 5 is a transverse cross section of the joint between the two panel edges shown just after attachment to one another, shown prior to installation of the connector, and taken along line V—V in FIG.  2 . 
     FIG. 6 is a transverse cross section of the joint between the two panel edges shown just after attachment to one another, shown prior to installation of the connector, and taken along line VI—VI in FIG.  2 . 
     FIG. 7 is a longitudinal cross section of a connector receiving slot of one panel and taken along line VII—VII in FIG.  2 . 
     FIG. 8 is a side elevation of one example of a connector constructed in accordance with the teachings of the present invention and illustrated in FIGS. 1-3. 
     FIG. 9 is a top plan view of the connector shown in FIG.  8 . 
     FIG. 10 is a forward end view of the connector shown in FIG.  8 . 
     FIG. 11 is a rear end view of the connector shown in FIG.  8 . 
     FIG. 12 is a side view in partial longitudinal cross section of the connector slot of FIG. 5 with the connector of FIG. 8 shown just prior to installation. 
     FIG. 13 is a side view of the connector slot shown in FIG. 12 after full installation of the connector. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The apparatuses and methods disclosed herein for interconnecting adjacent panels solve or improve upon the above-mentioned problems in the prior art. The apparatuses and methods disclosed are especially well suited for connecting plastic panels, although they can be easily adapted for use with other materials, if desired. A relatively wide connector of substantially rigid and sturdy construction is disclosed and described herein that spans and interconnects two adjacent panels. The connector interlocks with a portion of each of the adjacent panels to secure them together. In addition, each of the panels interlocks with one another to assist in forming the panel joint and to create a water or leak resistant joint. The disclosed interconnecting apparatuses are easy to install and assemble and the methods are easy to utilize. 
     Also shown in the drawings is an exemplary accessory device for use with the panel construction. The disclosed accessory device is a utility hanger apparatus that mounts to the panels in a simple, efficient manner. The disclosed utility hanger and method to install the hanger generally follow the same principles as the methods and apparatuses described herein for interconnecting the panels. The illustrated accessory device results in a strong, secure, and easy to install utility hanger that can support a wide variety of objects. 
     In order to simplify the description herein, a general element is given a base reference number. If a number of essentially identical elements are shown or referred to herein, the discrete, identical elements are each given the same base reference number and a unique sub-reference character. As an example, and with reference to FIG. 1, a plurality of interconnected and laterally adjacent plastic panels  30  are illustrated. The panels are generally referred to herein as “panels  30 ,” and are each specifically identified as panels  30   a ,  30   b , and  30   c  where necessary. In addition, each specific panel has various components and elements associated with that particular panel that are also common to the other panels as well. Such components and elements are similarly identified herein utilizing only the base reference number when generally referring to the object, and utilizing the base reference number and sub-reference character, such as “a” or “b” when referring that object of a specific panel. 
     Also, terms of orientation, location, or part relationship are used herein, such as “top,” “bottom,” “front,” “back,” or other such descriptive terms. Such terms are utilized solely for ease of description and are not intended to specifically limit a component in any way. The panels and other components can be oriented and arranged in virtually any desired manner without being unnecessarily limited or restricted by the use of such terms herein. 
     As a further preliminary matter, the panels illustrated herein are for a modular shed or storage structure. However, the features of the disclosed examples have a much wider applicability. The panels and the accessory device and its illustrated mounting features can be used for other products including storage devices, units, enclosures, bins, boxes, containers, display panels, boards, totes, and other object storage and organization products. The connectors can be used for any of a variety of containers and the like as well. 
     The particular materials used to construct the exemplary panels are also illustrative. For example, blow molded, high density polyethylene is one preferred material and method for fabricating the disclosed panels. However, other materials can be used, such as other thermoplastic resins including polypropylene, acrylonitrile butadiene styrene (ABS), polyurethane nylon, homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, and the like. Also, molding or part forming operations other than blow molding can be used to form the various disclosed components, such as injection molding, rotational molding, and the like. 
     Further, injection molded, high density polyethylene is a preferred material and method for fabricating the connectors disclosed herein. However, other materials can certainly be used, such as other thermoplastic resins including polypropylene, acrylonitrile butadiene styrene (ABS), polyurethane nylon, homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, and the like. Still further, other molding operations or part forming operations can be used to form the connector components. 
     As will be evident to those having ordinary skill in the art, the various parts and components disclosed herein can be formed from other materials such as metal, wood, and the like, if desired and yet fall within the spirit and scope of the present invention. The components can also be fabricated utilizing a variety of manufacturing techniques such as stamping, casting, machining, and the like, as desired. 
     With the above in mind and with reference to FIG. 1, each of the panels  30  has a top edge  32 , a bottom edge  34 , a first side edge  36 , and a second side edge  38 . As described herein, a first side edge  36  of one panel  30  is interconnected or joined to a corresponding second side edge  38  of an adjoining panel. Each of the panels  30  also has a profile side  40  having a surface profile that yields particular characteristics in accordance with the teachings of the present invention. Each of the panels  30  also has what is termed herein as a decorative or cosmetic side  42  that is generally planar. The decorative side  42  need not be adapted to provide particular aesthetics, though in many instances it will be so configured. However, the decorative side  42  does not provide particular features necessary to the apparatus and method as disclosed. One or both of the profile side  40  and the decorative side  42  can be adapted to include features that add rigidity or enhance the structural characteristics of the panels, if desired, though not disclosed herein. 
     In the disclosed example, one or more accessory devices in the form of utility hangers  44  can be mounted to the profile side  40  of each panel. The accessory devices can be added to perform any number of desired functions, such as to provide shelving supports, tool hangers, and the like. As shown in FIG. 2, the utility hangers  44  or other accessory devices can be assembled to numerous different locations as desired on the profile side  40  of a given panel  30 . 
     Details of the various structures and methods in accordance with the teachings of the present invention are now described. In general, a pair of adjacent panels, such as the panels  30   a  and  30   b , can be interconnected by one or more connectors  46  that engage a portion of the profile side  40  of each adjoining panel. The adjacent panels  30   a  and  30   b  are first attached or interlocked with one another and then secured or connected to one another utilizing one or more of the connectors  46 . 
     As shown in FIGS. 1 and 2, each panel  30  includes at least one connector interface to accept and engage with one of the connectors  46 . In the disclosed example, the panels  30  each have a connector interface in the form of an elongate connector channel  50  disposed adjacent each of the side edges  36  and  38 . In an alternative example, each panel can have a connector interface, such as a connector channel  50 , disposed adjacent only one of the opposed side edges  36  or  38  so that only one of the panel edges is adapted to be joined to an adjacent panel. Depending upon the particular panel construction, a connector interface or channel  50  can be disposed adjacent any or all side, top, bottom, or other edges of a panel, as desired. 
     As illustrated in FIGS. 1 and 2, each connector channel  50  is a continuous channel having a plurality of discrete channel segments  52 . Alternatively, each connector channel  50  can be discontinuous or segmented and define intermittent, discrete channel segments  52  along an appropriate edge of the panel. In another alternative, a connector interface of channel  50  may include only a single segment, as such segments are described herein. Each segment  52  of each channel  50  in the disclosed example has a connector docking section  54  that is adapted for insertion and removal of a portion of a connector  46 . Each segment  52  also has a connector engaging section  56  that is adapted for connector installation when securely joining two adjacent panels. Each channel segment is adapted to accommodate, in this example, part of one of the connectors  46  as described below. Details of the channel segments  52  and sections  54  and  56  are also described in greater detail below. 
     As shown in FIG. 3, an apparatus as constructed and engaged in accordance with the teachings of the present invention generally utilizes at least one of the connectors  46  and at least a pair of the connector channel segments, one from each of the two adjacent panels. In this example, the panels  30   a  and  30   b  and thus, a segment  52   a  and  52   b , are utilized for the engaged apparatus. One of the segments is provided on each of two adjacent panels  30   a  and  30   b  to be connected. 
     Details of both the method and the apparatus in accordance with the teachings of the present invention are described, beginning with reference to FIG.  4 . Each of the panels has an interlocking element at all of the edges that are adapted to interconnect with an adjacent panel. The interlocking elements of the panels to be joined are first interlocked to one another. Then a connector is utilized to secure the adjacent panels together. 
     In this disclosed example, each adjacent panel edge to be joined, such as the side edges  38   a  of the panel  30   a  and  36   b  of the panel  30   b , has an interlocking lip  60   a  and  60   b , respectively, that extends from the corresponding panel edge. Each lip  60  extends from the panel edge at an angle, and in this example, is generally perpendicular to a plane of the corresponding panel. Each lip  60   a  and  60   b  defines a groove  62   a  and  60   b , respectively, between the lip and the panel edge. The lips  60  and grooves  62  of the respective panels are arranged in opposite directions so that the lip of one panel is received in and engages the groove of the adjacent panel in an interlocking relationship. For example, as shown in FIGS. 4 and 5, the lip  60   a  of the panel  30   a  is received in the groove  62   b  of the panel  30   b . Similarly, the lip  60   b  is received in the groove  62   a.    
     Once the two adjacent panels, such as the panels  30   a  and  30   b , are engaged or interlocked in this manner, the two panels, and thus the channels  50   a  and  50   b  are properly spaced apart laterally across the joint. However, the two panels  30   a  and  30   b  should also be aligned longitudinally so as to accommodate installation of a connector  46 . In the disclosed example, the connector  46  requires that the corresponding docking sections  54   a  and  54   b  and engaging sections  56   a  and  56   b  of the adjacent channels  50   a  and  50   b  be directly across from one another. In an alternative example, though not shown or described in detail herein, the connector  46  can be designed to require a different, non-mirror image alignment of the adjacent channels  50 , if desired. 
     Details of the channel segments  52  are described with particular reference to FIGS. 5-7. FIG. 5 illustrates a transverse cross section across two engaged panels  30   a  and  30   b  prior to installation of a connector  46 , and taken through the properly longitudinally aligned (side-by-side) connector docking sections  54   a  and  54   b . As shown, each docking section  54  of each channel has a pair of side walls  58  and a bottom wall  59  that define a depth and a width intended to easily accommodate insertion of a connector therein. A connector  46  is placed into the profile side  40  of the engaged panels  30  at the docking sections  54  and readied for installation. In the present example, each docking section  54  also has a length, as illustrated in FIG. 7, that extends between longitudinally adjacent engaging sections  56  of two channel segments  52  in the channel  50 . As discussed above, each docking section need not extend continuously to another channel segment, but instead may terminate at a discrete segment end (not shown) if desired. In any case, the docking section  54  must have a length, width, and depth combination that permits adequate insertion of a connector  46  into the docking section to facilitate proper installation and engagement of the connector. 
     FIG. 6 illustrates a transverse cross section across two engaged panels  30   a  and  30   b , prior to installation of a connector  46 , and taken through the side-by-side connector engaging sections  56   a  and  56   b . Each connector engaging section  56  of a channel  50  has side walls  64  and a generally planar bearing surface  66 . A connector slot  68  is provided in the bearing surface  66  and extends longitudinally along the length of the connector engaging section  56 . The connector slot  68  provides access deeper into the engaging section, and particularly, into a connector latching tunnel  70 . The width of the connector slot  68  is narrower than the width of the latching tunnel  70  for reasons described in greater detail below. One end of the latching tunnel narrows to define a connector stop surface  72 , limiting the travel of a connector when installed. The opposite end of the latching tunnel  70  and connector slot  68  can be tapered slightly radially outward, as shown, to define an entry opening  74  into the connector slot and latching tunnel. 
     The connector interface of one or both of the adjacent panels can include a detente mechanism to provide a positive fully installed feel or indication. The detente mechanism can also assist in holding a connector in an installed position. In this example, a detent ramp  80  is provided on at least one of the bearing surfaces  66  adjacent the connector slot  68 . In the present example, a ramp  80  is provided on the side of the bearing surface  66  furthest from the panel edge so that when the connector  46  is installed, its outer most forward edges each engage a detent ramp to assist in holding the connector in the installed or engaged position. In the present example, the detent ramps  80  each have an inclined ramp surface  82  that can be inclined at a desired angle to make installation of the connector relatively easy. The ramps  80  in this example are located near the forward, narrowed end or stop surfaces  72  of the latching tunnel  70 . However, the ramps can alternatively be provided anywhere along the bearing surfaces and yet provide the attendant function. Each ramp surface terminates at its inclined end at a front end  84 . 
     Referring now to FIGS. 8-11, one example of the connector  46  is shown and described. However, as will be evident to those having ordinary skill in the art, many modifications and changes to the disclosed connector  46  can be made without departing from the spirit and scope of the present invention. The connector  46  generally has a base and a pair of engaging parts projecting from the base. The base is sized to span between or traverse the two adjacent panels and to reach the connector interface of each panel. The engaging parts are positioned and constructed such that one of the parts engages with each of the connector interfaces of the panels. 
     The disclosed connector  46  has a body or base  100 , which in this example is generally rectangular, and nearly square. The disclosed base  100  is a molded thermoplastic component having a wall thickness and a structural design sufficient to render the base substantially rigid. In the present example, the base has a top wall or surface  102 , an annular depending skirt  104 , which in this example is in the form of a plurality of depending skirt walls  104   a ,  104   b , and  104   c , and  104   d  necessitated by the polygonal shape of the base. The wall  104   a  is positioned at a leading end of the connector  46  and the wall  104   b  is positioned at a trailing end. The walls  104   c  and  104   d  define sides of the connector. The height of the annular skirt or side walls  104  creates a bottom well or depression  106  in the connector  46 . A plurality of structural ribs  108  extend both longitudinally and transversely across the well  106  to provide additional structural rigidity to the connector  46  while minimizing the weight of the part and the amount of material necessary to form the part. The bottom well  106  and the ribs  108  of the base  100  are shown in simplified form in FIGS. 1 and 2, as well as in greater detail in FIG.  3 . 
     The engaging parts of the connector  46  in this example each include a plurality of discrete engaging or locking pins  110  that extend generally perpendicular from the top wall  102 . Each of the locking pins  110  has a narrow stalk section  112  connecting the pin to the base and an engagement head  114  spaced from the top wall by a respective stalk. The transverse width of the stalk essentially corresponds to the width of the connector slot  68  described previously for the channels  50 . Similarly, the size and contour of the heads  114  correspond in size and shape to the cross sectional shape of the connector tunnel  70 . In the present example, the pins  110  are open at the top and thus have a partly open interior  116  to reduce the weight of the part and to reduce the amount of material needed to fabricate the part. 
     The pair of engaging parts of the disclosed connector  46  are arranged as a pair of pin rows  120   a  and  120   b  disposed adjacent and arranged along the opposite edges or sides of the connector  46 . Each pin row  120  can alternatively be replaced by a unitary elongate structure or engaging part with no discrete segments or pins, if desired. Elongate strengthening ribs  121  are arranged parallel to and spaced apart from one another and extend longitudinally between the discrete pins  110  in each of the rows  120   a  and  120   b.    
     Suitable recesses, openings, and the like can be provided such as the openings  122  in the connector  146 . Such features may be necessary or advantageous when molding or otherwise forming the connector. As will be evident to those having ordinary skill in the art, the shape, construction, and various features of the pins and base can vary considerably and yet fall within the scope of the present invention. 
     As shown in FIGS. 8 and 10, a forward or leading end  124  of the connector  46  has additional features that are not found on the trailing or rear end  126  of the connector. For example, the forward facing ends  128  of the forward most pins  110  include notches or cutouts  130 . The notches are disposed in a lower portion of the head  114  near the stalk  112 . The notches  130  effectively narrow the leading end of each row  120  of pins  110  for ease of installation as described in greater detail below. 
     Similarly, a recess  132  is provided near each forward corner  134  of the base  100 . Each recess  132  has an inclined surface  136  and a front detent barrier wall  138 . The recesses  132  are open both to the top wall  102  and the skirt or side walls  104   c  and  104   d . However, each recess is closed off toward the front wall or skirt  104   a  by a part of the front wall that defines the detente barrier wall  138  for reasons described below. 
     FIG. 11 simply illustrates a rear elevation of the disclosed exemplary connector  46 . The general contour of the pins  110  including the stalks  112  and heads  114  of the trailing pins  110  in each row  120   a  and  120   b  can be seen. One or more upstanding ribs  150  can optionally be placed at the leading end  124 , extending from the base  102 . One rib  150  is shown in front of each of the engaging pin rows  120 . The ribs  150  or other such barrier mechanism can be used to prevent reverse installation of the connector  46 , if desired. 
     The procedure for installing a connector  46  in order to interconnect two adjacent panels  30 , and the corresponding component features, are now described with particular reference to FIGS. 12 and 13. First, two adjacent panels, such as the panels  30   a  and  30   b , are oriented and placed with the edges  38   a  and  36   b  (or the edges intended for connection) adjacent one another. The panels are then longitudinally aligned as needed to accommodate and receive the selected connector  46 . The lips  60   a  and  60   b  and grooves  62   a  and  62   b  are then interlocked as described above and shown in FIGS. 4 and 5. 
     A connector  46  is then selected and oriented with the pins  110  facing the profile sides or surfaces  40   a  and  40   b  of the interlocked panels  30   a  and  30   b . The connector is also oriented such that the connector leading end  124  generally faces toward the connector slot  68  and tunnel  70  into which the connector is to be installed. The pins  110  are then moved directly over the connector channels  50  and  50  of the panels. One row  120   a  of pins  110   a  is inserted into the docking section  54   a  of the channel  50   a  and the other row  120   b  of pins  110   b  is inserted into the docking section  54   b  of the channel  50   b  as shown in FIG.  12 . In this pre-installation position, the pins  110  and base  100  essentially float freely within the docking sections  54  of the channels  50 . The center part of the connector base wall  102  can be designed rest or bear against portions of the panels  30   a  and  30   b  between the channels  50   a  and  50   b , if desired. These regions of the panels can be sized to precisely vertically position the connector relative to the depth of the channels. 
     To complete installation of the connector  46 , the connector is moved in the direction of the arrow “A” toward the engaging sections  56   a  and  56   b , as shown in FIG.  12 . The notches  130  on the pin leading ends and the tapered entry  74  into the connector slot  70  each assist in guiding the heads  114  and stalks  112  of the pins  110  into and between edges of the tunnel  70  and slot  68 , respectively. The heads  114  are then guided along the tunnel  70  by the close fitting and complimentary relationship between the heads and tunnels. The heads  114   a  move into and along the tunnel  70   a  and the heads  114   b  move into and along the tunnel  70   b . Similarly, the stalks  112   a  and  112   b  travel along the connector slots  68   a  and  68   b , respectively. The slot width and stalk width are preferably sized to provide a close fit between the parts. 
     As the recesses  132  approach the ramps  80 , the detente barrier walls  138  ride up the ramp surfaces  82 . When the detente barriers  138  reach the forward or front ends  84  of the ramps  80 , the barriers  138  snap over the forward ends to capture the ramps in the recesses  132 . The angle of the inclined surfaces  136  of the recesses  132  preferably match the angle of the ramp surfaces  82 . The detente structure assists in longitudinally holding the connectors in place. The dimensions of the slot  68 , stalks  112 , tunnels  70 , and heads  114  can also be such that static friction created between tightly fitting components also assists in holding the connectors in place. When the connectors  46  are installed, the relatively large size of heads  114  and the narrow width of the slots  68  retain the connectors in the installed position. 
     The forward ends  84  of the ramps and the inner sides of the detente barriers  138  that face the ramps, when the connector is installed, are preferably drafted, angled, or rounded slightly to assist in removing the connector  46  when desired. To remove the connector, the reverse of the above-described process is performed, but the detente barriers  138  must first snap back over the ramps  80  to accomplish removal. 
     Various dimensions for certain parts of the apparatus described herein can be selected to achieve desired functional characteristics. For example, if the panels  30  and connectors  46  are formed from plastic or thermoplastic materials, the parts can be designed to create slight interference fits or slight loads at points within the apparatus. The pins and/or the tunnels and slots can be appropriately spaced to draw the adjacent panels slightly together or force them slightly apart when installing the connector to create a fairly rigid joint or to form a seal at the lip and groove joint. Similarly, the detente barriers, ramps, and/or other elements can also be varied to achieve certain functional characteristics. Also, the tunnel, head, stalk, and slot sizes, and shapes, and positions can be designed to create desired characteristics. As an example, the engaging parts such as the pins can be formed progressively larger, moving from the leading end to the trailing end of the connector  46 . 
     The disclosed panels  30  are particularly well suited for the method and apparatus. The panels are hollow panels with space between the profile sides  40  and decorative sides  42 . Molding tools and operations can be utilized to form a wide variety of shapes and features into the panels. Points where the profiles side  40  and decorative side  42  are joined (called “tack offs”—see FIG. 12 at the bottom  59  of the docking section  54 ) can be created to provide strength enhancing characteristics as well as other features. 
     Although certain methods and apparatuses have been disclosed and described herein in accordance with the teachings of the present invention, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the invention fairly falling within the scope of the appended claims, either literally or under the doctrine of equivalents.