INTERLOCKING PANEL

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a national phase entry of PCT Patent Application No. PCT/IN 2024/050367, filed Apr. 9, 2024, which claims priority to IN Patent Application No. 202341042845, filed Jun. 26, 2023, the entire contents of which are incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present subject matter pertains, in general, to false ceiling panels used in modern architecture, and more specifically, to false ceiling panels that are equipped with an integrally formed coupling structures, enabling the interconnection of panels within the false ceiling.

BACKGROUND

In today's world, the aesthetics of the professional/personal space especially office, commercial complex, residential complex or theatres play a significant role in providing a visually pleasing experience for individuals. False ceilings are a popular design element utilized in modern architecture to enhance the overall appearance of the space. False ceilings are mostly secondary ceilings that are suspended below the main ceiling with the help of suspension cords or struts and are commonly used to conceal unsightly electrical wiring ducts, plumbing pipes, fire alarm ducts, structural elements, etc. In addition to this, false ceilings can also improve the acoustics of a space by reducing sound reverberation, enhance the lighting of the space by enabling the installation of recessed lighting fixtures, track lights, or other type of light fixtures. To obtain a lightweight ceiling, the ceilings are crafted from panels made from a variety of materials like POP (plaster of Paris), gypsum board, asbestos sheets, particle board, aluminium panel, polyvinyl chloride (PVC) or wood etc.

In a conventional false ceiling system, the metal or wood runners are arranged in a grid pattern and are spaced apart at regular intervals. The panels are inserted into the grid and secured in place using fasteners e.g., nails, screws, staples, etc. or clips. In false ceiling installations, T-trims play a crucial role as it acts as an accessory to connect and conceal joints between ceiling panels. Its primary purpose is to establish a stable framework by connecting the cross tees within the grid system of the false ceiling. In addition to this, it conceals joint lines between the ceiling panels, resulting in a unified surface.

BRIEF DESCRIPTION OF DRAWINGS

The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.

FIG. 1 illustrates prior art assembly of panels, where two panels are connected using a T-trim.

FIG. 2 illustrates an interlocking panel, in accordance with an example of the present subject matter.

FIG. 3 illustrates another example of FIG. 2 in which tabs are protruding from the flat portion of the edge of the panel.

FIG. 4 illustrates another example of FIGS. 2-3 in which tabs are protruding both from the flat portion and the grooved portion of the edge of the panel.

FIG. 5 illustrates the manner in which plurality of tabs of panel as illustrated in FIGS. 2-4 are inserted through complementary slots of another adjoining panel.

FIG. 6 illustrates another example of FIGS. 2-5 in which plurality of tabs of a panel are provided with trapezium shaped end profile.

FIG. 7 illustrates another example of FIGS. 2-5 in which plurality of tabs of a panel are provided with semi-circle shaped end profile.

FIG. 8 illustrates another example of FIGS. 2-7 in which plurality of tabs of a panel form an alternating pattern of different shaped end profiles.

FIG. 9 illustrates another example of FIG. 7 in which plurality of tabs of are protruding both from the flat portion and grooved portion of the panel forming an alternating pattern of different shaped end profiles.

FIG. 10 illustrates another example of FIGS. 2-9 in which plurality of tabs of a panel have varying width.

FIG. 11 illustrates another example of FIGS. 2-10 in which plurality of tabs form a grouping pattern comprising a repeating sequence of at least two groups of tabs.

DETAILED DESCRIPTION

As mentioned previously, in the conventional approaches, when two ceiling panels are connected, a small gap or joint exists between them. T-trim is installed within this joint area, with its T shaped profile fitting over the edges of the panels. The horizontal part of the T-trim covers the joint, while the vertical stem extends down between the panels. The T-trim typically has flanges or lips on either side of the horizontal part of the trim, which grip onto the panels, holding them together. By effectively joining the panels and concealing the joint between them, the T-trim creates a cohesive surface, contributing to the overall appearance and functionality of the installation. However, it is important to consider the appearance-related limitations of T-trims in false ceilings.

One of the major drawbacks of T-trims in terms of visual appearance is its potential to disrupt the visual continuity of the installation. The presence of T-trim along the edges of the panel can create visible lines that interrupt the smooth and seamless flow of surface. These lines can be noticeable and draw the eye, detracting from the desired aesthetic appeal of a cohesive and uninterrupted visual appearance. Thus, trim lines create a sense of compartmentalization or division between panels. Instead of perceiving a unified and expansive surface, the eyes may be drawn to the trim lines, resulting in a fragmented or segmented visual effect.

Additionally, the presence of T-trim can impose limitations on the design possibilities for the installation. Intricate or complex patterns that require continuous and uninterrupted surfaces may be challenging to achieve due to the presence of visible trim lines.

To this end, the present subject matter discloses an interlocking panel provided with an integrally formed coupling structures. The integrally formed coupling structures enable the interconnection of panels with another adjoining panels in false ceiling.

Although the present subject matter has been described with reference to false ceilings, it is to be understood that the scope of the invention is not limited to false ceiling. Rather, the present subject matter can be applied to any type of ceiling or building architecture where similar panels are used without departing from the intended scope. Furthermore, the shape, size and material of the panel may vary depending on the specific application without departing from the intended scope.

In accordance with an example of the present subject matter, interlocking panel may have two different portions forming the panel i.e., a portion of the panel having grooves or channels running at axes parallel to the horizontal edge of the panel and the remaining portion forming a flat portion. The panel may have a first vertical edge and a second vertical edge. Henceforward referred to as the first edge and the second edge respectively. The first edge is provided with a plurality of tabs that protrude outward. The second edge is present on an opposite side of the first edge and is provided with a plurality of slots. The plurality of slots formed along the second edge are positioned such that they correspond to the position of the plurality of tabs and are adapted to receive a complementary plurality of tabs of another adjoining panel so that when the panels are to be assembled the tabs of the adjoining panel are guided into the corresponding complementary slots of the panel, the tabs passing through fit securely into the slots, creating a level joint and locking the panels into place.

In another example of the present subject matter, the interlocking panel may have plurality of tabs protruding outward from the first edge and the plurality of tabs may have end profiles of shape trapezium, semi-circle or square. As another illustration of the present subject matter, the tabs may have same shaped end profiles or form an alternating pattern of different shaped end-profiles.

By way of another illustration of the present subject matter, the interlocking panel may have plurality of tabs protruding outward from the first edge forming a grouping pattern. the grouping pattern may then be repeated as a sequence along the length of the edge of the panel and the groups of tabs are uniformly spaced therein. The groups of tabs may have same number of tabs provided therein. For example, the number of tabs in the group of tabs may be 2, but may not be limited, to 2 and are uniformly spaced. Further, the spacing between the tabs within the group may be lesser than the spacing between the groups of tabs.

Thus, the present subject matter discloses an interlocking panel provided with an integrally formed tab-slot lock mechanism and provides several advantages over traditional T-trims in butt joining panels in false ceilings. Firstly, the integrally formed tab-slot lock mechanism ensures a tight fit between the panels preventing sagging or bowing of the ceiling over time. Additionally, the integrally formed tab-slot lock mechanism eliminates the need of visible fasteners and trims rendering a streamlined and aesthetically pleasing appearance. Moreover, the interlocking panels provided with integrally formed tab-slot lock mechanism are easy to install and require no special tools or equipment, making it a cost-effective and efficient solution for butt joining of panels in false ceiling.

The above and other features, aspects, and advantages of the subject matter will be better explained with regard to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the present subject matter along with examples described herein and should not be construed as a limitation to the present subject matter. It is thus understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and examples thereof, are intended to encompass equivalents thereof. Further, for the sake of simplicity, and without limitation, the same numbers are used throughout the drawings to reference like features and components.

FIG. 1 illustrates prior art assembly of panels, where two panels i.e., panel 11a and panel 11b are connected using a T-trim 10. The approach involves cutting a groove (not shown) into the edges of each panel that will be joined and inserting the T-trim into the grooves and may involve use of additional fasteners or adhesives to strengthen the connection. However, as explained earlier, this connection method has limitations such as, the visible seam created by the T-trim may be less aesthetically pleasing. Thus, there is a need for improved approaches for connecting panels in false ceiling that can address the foregoing drawbacks and provide a more effective and aesthetically pleasing solution.

FIG. 2 illustrates an interlocking panel, in accordance with an example of the present subject matter. Referring to FIG. 2, the interlocking panel 21a may include a portion on the panel forming grooves or channels 24 running at axes parallel to the horizontal edge of the panel and the remaining portion of the panel forming a flat portion 25. Further, the interlocking panel 21a may include a first edge and a second edge. The first edge is provided with a plurality of tabs (22a, 22b, 22c) that protrude outward. The second edge is present on an opposite side of the first edge and is provided with a plurality of slots (23a, 23b, 23c). The plurality of slots formed along the second edge are positioned such that they correspond to the position of the plurality of tabs. For example, the position of slot 23a corresponds to the position of tab 22a and so on. The plurality of tabs (22a-22c) protruding outward from the first edge of the interlocking panel 21a are flat and are uniformly spaced along the first edge of the panel and may have thickness same as the panel. The width of the tabs may vary in the range of 10-80 mm and may be uniform or different. It may be noted that the plurality of tabs (22a-22c) protruding from the first edge are parallel to each other and are protruding perpendicular to the width (vertical dimension) of the panel. The length of the tabs i.e., the horizontal distance of the tabs from the edge of the panel from which the tabs are protruding may vary in the range of 20-30 mm.

The plurality of slots (23a-23c) are narrow openings and facilitate the complementary plurality of tabs of another panel to pass through them when assembled. The plurality of slots (23a-23c) are adapted to receive a complementary plurality of tabs of another adjoining panel so that when the panels are to be assembled the tabs of the adjoining panel are guided into the corresponding complementary slots of the panel, the tabs passing through the slots fit securely into the slots, creating a level joint and locking the panels into place.

The tabs so protruding outward from the first edge of the panel may be protruding from the grooved portion of the panel and/or the flat portion of the panel. FIG. 3 illustrates another instance of the interlocking panel exemplified in FIG. 2, wherein the tabs are protruding from the flat portion of the edge of the panel. Accordingly, the slots formed along the second edge are positioned within the flat portion of the panel, precisely corresponding to the position of the tabs. Referring to FIG. 3, the interlocking panel 31a has a grooved portion 34 and the remaining portion forming a flat portion 35 of the panel. As would be noted, the plurality of tabs (32a-32c) are protruding from the flat portion of the panel. Accordingly, the slots (33a-33c) formed along the second edge are positioned within the flat portion of the panel, precisely corresponding to the position of the tabs (32a-32c) respectively.

Further, FIG. 4 illustrates another instance of the interlocking panel exemplified in FIGS. 2-3, wherein the tabs are protruding both from the flat portion and the grooved portion of the edge of the panel. Accordingly, the slots formed along the second edge are positioned within the flat portion and the grooved portion of the panel, precisely corresponding to the position of the tabs. Referring to FIG. 4, the interlocking panel 41a has a grooved portion 44 and remaining portion of the panel form a flat portion 45. As may be noted, the plurality of tabs (42a-42f) are protruding both from the flat portion and the grooved portion of the panel. Particularly, the tabs (42a-42c) are protruding from the flat portion of the first edge of the panel. Similarly, the tabs (42d-42f) are protruding from the grooved portion of the first edge of the panel. Accordingly, the slots (43a-43f) formed along the second edge are positioned within the flat portion and the grooved portion of the panel, precisely corresponding to the position of the tabs (42a-42f). Specifically, the slots (43a-42c) are formed along the flat portion of the second edge of the panel. Similarly, the slots (43d-43f) are formed along the grooved portion of the second edge of the panel.

FIG. 5 illustrates the manner in which plurality of tabs of panel as illustrated in FIGS. 2-4 are inserted through complementary slots of another adjoining panel. Referring to FIG. 5, the interlocking panels 51a and 51b in accordance with an example illustrated in FIGS. 2-4 are depicted herein. As shown in FIG. 5, for assembling the panels 51a and 51b, the panel 51a is positioned adjacent to panel 51b. The plurality of tabs (52a-52c) protruding outward from the edge of the panel 51a are first aligned and then inserted through the corresponding complementary plurality of slots (53a-53c) formed along the edge of the panel 51b. For example, the tab 52a protruding outward from the edge of the panel 51a is inserted through the complementary slot 53a formed along the edge of the panel 51b. Similarly, the tab 52b protruding outward from the edge of the panel 51a is inserted through the complementary slot 45b formed along the edge of the panel 51b and so on. The tabs (52a-52c) snugly fit into the corresponding slots (53a-53c) creating a secure and rigid level joint. It is to be noted here that the fit between the tabs and slots may designed to be either a clearance fit, a sliding fit or an interference fit. Further, when the panels are in assembled state, at least some portion of the panel 51a overlaps the portion of panel 51b. The overlapping portion may vary in the range of 30-40 mm. Thus, the panel assembly described herein provides an overlapping butt joint for panels.

Thus, the integrally formed plurality of tabs and slots as described herein facilitate a seamless appearance by securely connecting panels without visible gaps and misalignments. The tabs and slots are designed to fit together precisely, ensuring that the panels align seamlessly and create a smooth surface. This seamless integration enhances the overall visual appeal by providing a clean and uninterrupted look. Furthermore, the interlocking mechanism adds to the visual appeal through the concealment of joints. By effectively hiding the connecting points, the mechanism eliminates any visible interruptions or separations, contributing to a cohesive and polished surface.

FIG. 6 illustrates another example of FIGS. 2-5 in which plurality of tabs of a panel are provided with trapezium shaped end profiles, while FIG. 7 illustrates another example of FIGS. 2-5 in which plurality of tabs of a panel are provided with semi-circle shaped end profiles.

Referring to FIGS. 2-7, the plurality of tabs protruding outward from the edges of the panels may have end profiles of shape trapezium, semi-circle, or square. Particularly in FIGS. 2-5, the plurality of tabs (22a-22c, 32a-32c, 42a-42c, 52a-52c) protruding from the edges of the panel 21a, 31a, 41a and the panel 51a have square shaped end profiles. The tabs with square shaped end profiles are easier to manufacture and can provide a precise fit in slots with square or rectangular openings. The straight edges of the tabs provide a smooth appearance to the panel assembly by preventing the tabs from deflecting/deviating from their actual direction of insertion within the slots.

Further, as illustrated in FIG. 6, the plurality of tabs (62a-62c) protruding from the edges of the panel 61a have trapezium shaped end profiles. The tabs with trapezium shaped end profiles offer easy insertion and secure locking due to their tapering shape. The narrow end of the trapezium shaped end profile of tabs provides clearance for the tabs to be easily inserted into the slots, while the wider end creates a tight fit when fully seated in the slots, preventing the tabs from being pulled out, thereby providing a secure interlocking for the panels, adding to the seamless appearance of the panels in the installation.

Furthermore, as depicted in FIG. 7, the plurality of tabs (72a-72c) protruding from the edges of the panel 71a have semi-circle shaped end profiles. The curved edges of the semicircular shaped end profiles of tabs allow for a smoother and more gradual insertion, which can be particularly useful where the panels need to be installed quickly or where there are numerous tabs to be inserted into the slots.

FIG. 8 illustrates another example of FIGS. 2-7 in which plurality of tabs of a panel form an alternating pattern of different shaped end profiles. Referring to FIG. 8, the panel 81a is provided with plurality of tabs (82a-82c) protruding outward from the edge of the panel 81a. The plurality of tabs (82a-82c) form an alternating pattern of tabs with trapezium and semicircular shaped end profiles. By using tabs of different shaped end profiles, it is possible to achieve a combination of the advantages like ease of insertion and aesthetic appearance offered by each shape while minimizing their disadvantages.

FIG. 9 illustrates another example of FIG. 8, in which plurality of tabs of a panel form an alternating pattern of different shaped end profiles and the tabs are protruding both from the flat portion and the grooved portion of the panel. Referring to FIG. 9, the panel 91a is provided with plurality of tabs (92a-92f) protruding outward from the edge of the panel 91a. The plurality of tabs (92a-92f) form an alternating pattern of tabs with trapezium, semicircular, and square shaped end profiles. As would be noted, the tabs are protruding both from the flat portion and grooved portion of the panel.

Thus, the use of tabs with different shaped end profiles helps to conceal any imperfections or irregularities that may arise during the assembly process. The intricate interlocking mechanism ensures that the panels fit snugly together, masking any potential misalignments or discrepancies. As a result, the overall appearance of the paneling or surface remains flawless and visually appealing.

FIG. 10 illustrates another example of FIGS. 2-9 in which plurality of tabs of a panel have varying width. Referring to FIG. 10, the panel 101a is provided with plurality of tabs (102a-102c) protruding outward from the edge of the panel 101a. The tabs (102a-102c) have varying width. By varying the width of the tabs, it is possible to fine-tune the locking mechanism in panel assembly. One advantage of varying the width of tabs is the ability to adjust the level of friction and resistance against the slot. A wider tab can provide more surface area for friction, creating a stronger and more secure locking mechanism. On the other hand, a narrower tab can provide a smoother and easier insertion into the slot.

Furthermore, varying the width of tabs can provide more design flexibility and allow for customization of the panel system. By adjusting the width of tabs, it is possible to create a unique pattern or arrangement of tabs that can complement the overall design of the panel system. This can be particularly important where the aesthetics of the panel system are a key consideration.

FIG. 11 illustrates another example of FIGS. 2-10 in which plurality of tabs form a grouping pattern comprising a repeating sequence of at least two groups of tabs. Referring to FIG. 11, the panel 111a is provided with plurality of groups 112a and 112b of tabs protruding outward from the edge of the panel 111a. As depicted therein, the group 112a of tabs has plurality of tabs. The tabs within the group 112a are uniformly spaced. Similarly, the plurality of tabs within the group 112b are uniformly spaced. As would be appreciated, the groups 112a and 112b of tabs are uniformly spaced and the spacing between the tabs within the groups is lesser than the spacing between the groups of tabs.

This arrangement of tabs forming a grouping pattern with at least two tabs in each group and alternating the groups can help with panel interlocking by creating a stronger and more stable connection between the panels.

The present subject matter has been disclosed in connection with certain examples but is not limited to the particular constructions herein disclosed and shown in the drawings, but also comprises any modifications or equivalents within the scope of the present subject matter.