BACKGROUND OF THE INVENTION
There are many applications for molded plastic structures, such as benchtop or tabletop panels, which require lightweight yet high strength and which structures should be provided in so-called standard dimensions. Benchtop panels are usually of rectangular configuration with lengths and widths in predetermined dimensional units, such as four feet by two feet, etc., but which also should be modifiable to be of reduced widths or lengths. There has also been a need to provide such panels which may be easily mounted on and connected to a frame or substructure. All of the above-mentioned desiderata are difficult to meet in prefabricated panels, particularly panels formed of injection molded plastics, or the like. However, the present invention does provide advantages and desired features in prefabricated benchtop panels as will be appreciated by those skilled in the art.
SUMMARY OF THE INVENTION
The present invention provides an improved benchtop panel which is lightweight, easily fabricated of molded plastic or the like, may be cut to various lengths and widths, is easy to mount on and connect to a frame or substructure and may be joined to adjacent panels by an improved connector system.
In accordance with an important aspect of the present invention, a benchtop panel is formed as a generally rectangular grid-like member having a predetermined length and width but which is fabricated to be cut in half lengthwise or widthwise to form separate panels or to reduce the overall length or width of a benchtop without sacrificing strength of the panel.
In accordance with another aspect of the invention, a benchtop panel is provided with spaced apart mounting flanges which are conveniently located for securing the panel to a frame or substructure by conventional mechanical fasteners, and particularly self-threading or self-tapping fasteners.
Still further, the present invention provides an improved benchtop panel which has requisite strength for typical benchtop panel applications while minimizing the amount of material required in the panel.
Still further, the present invention provides a benchtop panel assembly including two or more panels which are adapted to be connected to each other by an improved retainer or connector device for rapidly assembling two or more panels to form a benchtop.
Those skilled in the art will further appreciate the advantages and superior features of the invention, as mentioned herein, together with other important aspects thereof upon reading the detailed description which follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of an improved benchtop panel in accordance with the present invention;
FIG. 1
a is a detail section view taken generally along the line 1a-1a of FIG. 1;
FIG. 2 is an end view of the panel shown in FIG. 1;
FIG. 3 is an opposite end view of the panel shown in FIG. 1;
FIG. 4 is a section view taken along the line 4-4 of FIG. 1;
FIG. 5 is a detail section view taken along the line 5-5 of FIG. 1;
FIG. 6 is a detail section view taken along the line 6-6 of FIG. 1;
FIG. 7 is a detail section view taken along the line 7-7 of FIG. 1;
FIG. 8 is a perspective view showing one arrangement of panels in accordance with the invention as a benchtop;
FIG. 9 is a perspective view showing a different arrangement of panels in accordance with the invention as a benchtop;
FIG. 10 is a detail section view taken along the line 10-10 of FIG. 9;
FIG. 11 is a top plan view of a connector for connecting adjacent panels to each other as shown in FIG. 10;
FIG. 12 is a side elevation of the connector shown in FIGS. 10 and 11; and
FIG. 13 is a detail section view illustrating a typical connection between a panel and a frame member in accordance with the invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
In the description which follows like parts are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain elements may be shown exaggerated in scale or in generalized form in the interest of clarity and conciseness.
Referring to FIGS. 1, 1a and 4, in particular, there is illustrated a benchtop panel in accordance with the invention and generally designated by the numeral 20. The panel 20 is of generally rectangular configuration having spaced apart, elongated, outer, longitudinal, parallel edge webs 22 and 24 and transverse parallel end edge webs 26 and 28. Longitudinal intermediate webs 30 and 30a extend between the end webs 26 and 28 and transverse intermediate webs 32 extend between the longitudinal edge webs 22 and 24 to form a rectangular grid defining many rectangular openings 33. The grid defining the panel 20 is also provided with a pair of closely spaced longitudinal center webs 34 and a pair of centrally located transverse webs 36 which are also closely spaced adjacent each other. Webs 34 are parallel and substantially coextensive with webs 22, 24, 30 and 30a and webs 36 are coextensive with and parallel to webs 26, 28 and 32. As shown in FIG. 1a, end or edge web 26 and center webs 36 extend the full depth of panel 20 between top and bottom surfaces 20a and 20b. Intermediate webs 32, however, extend from surface 20a approximately one-half the full depth of the panel 20 between surfaces 20a and 20b. Edge web 28, not shown in FIG. 1a, also extends the full depth of the panel 20.
Referring to FIG. 4, it may be seen that longitudinal edge webs 22 and 24 extend the full depth of panel 20 between surfaces 20a and 20b while longitudinal webs 30 extend only about half the depth of panel 20 from surface 20a. However, webs 30a, which alternate with webs 30, extend the full depth of panel 20 as do the longitudinal center webs 34. Still further, panel 20 is provided with spaced apart longitudinal webs 30b which extend the full depth of panel 20 and are integrally joined to longitudinal flanges 30c, see FIGS. 1 and 4. Flanges 30c are substantially coplanar with surface 20b of panel 20, are disposed approximately equidistant from an edge web 22 or 24 and web 34 and are operable for securing the panel to a frame as will be described further herein.
Referring briefly to FIGS. 2 and 3, transverse end web 26 is formed integral with plural spaced apart projections or bosses 38, which are adapted to project into cooperating recesses in an adjacent panel. Such recesses are shown in FIG. 3 wherein transverse end or edge web 28 is provided with spaced apart recesses 40 which correspond in spacing to the spacing of the projections or bosses 38.
Panels 20 may be fabricated in different length and width dimensions and various thicknesses. Typically, panels 20 are advantageously fabricated in approximately two foot widths by four foot lengths, but may be modified as to length and width by cutting a panel 20 into two sections along a line between closely spaced webs 36, for example, or cutting a panel into two sections along a line between closely spaced webs 34 also. In this way, smaller or sub-panels may be formed as needed to satisfy the benchtop requirements of a panel application. Web thicknesses may vary, however, for a panel fabricated of ______ thermoplastic, web thicknesses in the range of 0.125 inches to 0.151 inches may be suitable. Also, for panels having the overall dimensions indicated above, a panel depth or thickness between surfaces 20a and 20b in the range of about 0.88 inches is also suitable. Spacings of webs 30 and 30a are typically about 1.14 inches and spacings of webs 32 are typically about 2.0 inches. Panel 20 is also provided with longitudinally spaced apart planar gussets 42, as shown in FIG. 1, extending along edge webs 22 and 24. Each of gussets 42 is provided with a recess 43, see FIG. 5, and an opening 44 therethrough for receiving a connector for connecting adjacent panels 20 to each other as will be described further herein.
Referring briefly to FIG. 6, the region of the panel 20 which includes the closely spaced webs 34 and adjacent full depth webs 30a is also reinforced by transverse webs 32a which are full depth between webs 30a and webs 34, as indicated. Webs 32a are coplanar with respective webs 32 throughout the length of the panel 20, see FIG. 1. In this way, if a panel 20 is separated into two elongated panel sections by cutting the panel to sever all of the webs 32a between closely spaced adjacent webs 34, the panel will still be of requisite strength after being split into separate sections.
One important advantage of panel 20 in accordance with the invention is with respect to the ease of mounting multiple panels on and securing such panels to a table, bench or frame, as shown in FIG. 8. Referring to FIG. 8, a table or frame 50, as illustrated, is characterized by spaced apart legs 52 and 54 supporting longitudinal frame members 56 and transverse frame members 58. Transverse frame members 58, are preferably spaced apart equidistant from each other but may be spaced as desired, because placing panels 20 on top of frame 50 will allow for securing the panels to the frame members 58, since flanges 30c extend the entire length of each panel and will directly overlie frame members 58. In this way, conventional mechanical fasteners may be driven through flanges 30c at the points of contact with the frame members 58 to properly secure the panels 20 to a frame, such as the frame 50. The exemplary frame 50 illustrated in FIG. 8 may be formed of metal or wood. Wood frame members 52, 54, 56 and 58 are illustrated.
Referring also to FIG. 9, another embodiment of a table or frame 60 is illustrated for supporting plural side by side panels 20, as shown. Table or frame 60 is characterized by vertical leg members 62, longitudinal and transverse perimeter members 64 and 66 and intermediate transverse frame members 68. Frame members 64, 66 and 68 may be formed of metal angle mill shape members arranged as shown. Again, by constructing a simple table or frame, such as the frame 60, with spaced apart transverse frame members 68, panels 20 may be placed on top of the frame members 68 and secured thereto at the flanges 30c with suitable mechanical fasteners. FIG. 13 illustrates a typical connection between a flange 30c and a frame member 68, for example. In FIG. 13, flange 30c is secured to a frame member 68 by a conventional self tapping hexhead screw 70 of a type which may be conveniently and rapidly driven through the thermoplastic flange 30c and into or through the metal or wood frame member 68, as shown by way of example. Accordingly, the panels 20 may be quickly and easily secured to a table or frame, such as the tables or frames 50 and 60, by placing the panels on the frames and conveniently driving mechanical fasteners, such as screws 70 through the flanges 30c at the points of contact with the respective frame members 58 or 68. As shown in FIG. 9, one row of panels 20 has been cut along a line between webs 34 to form a row of panels of one half the width of the other two rows of panels.
In addition to the advantageous features of the support or connecting flanges 30c formed on each panel 20, adjacent panels 20 may be connected to each other with an improved connector, as illustrated in FIGS. 10 through 12. Referring to FIGS. 10 through 12, a panel connector 80 is illustrated comprising two spaced apart parallel legs 82 which include adjacent arcuate ends 82a, see FIG. 12, and are interconnected by an integral tab 84. Legs 82 are each provided with aligned and opposed projections 86 which have a tapered sidewall 87. Projections 86 include a panel engaging surface 88. When two panels 20 are placed adjacent each other and aligned at their transverse ends, respective gussets 42 on each panel are also aligned with gussets 42 on an adjacent panel. Adjacent panels 20 may be connected to each other by projecting the legs 82 of a connector 80 through the adjacent openings 44 in adjacent gussets 42 and rotating the connector into the position shown in FIGS. 10 and 12 so that connecting tab 84 resides in adjacent recesses 43 formed in the respective gussets 42. The connectors 80 may be snapped into place by slightly deflecting the gussets 42 as well as the connector legs 82 until the retainer surfaces 88 of the respective bosses move through the opening 44 and engage downwardly facing surfaces 42b of the gussets 42 as illustrated in FIG. 10.
With suitable force exerted thereon, the tabs 84 may also be lifted to remove connectors 80 from their working positions, if needed. Accordingly, adjacent panels 20 may be also quickly and conveniently joined to each other by placing connectors 80 in the openings 44 of adjacent panels, and rotating the connectors into the working position, as shown in FIGS. 10 and 12, to aid in securing the panels to each other to maintain a rigid support surface, such as the upper surface 20a. The spacings of openings 44 and recesses 43 on adjacent gussets 42 may be varied, as shown in FIG. 1, so that adjacent ones of connectors 80 face in opposite directions.
The construction and use of the benchtop panel 20 described herein, as well as the use of plural panels connected to each other by the connectors 80 and mounted on tables or frames, such as described, is believed to be understandable to those of ordinary skill in the art based on the foregoing description. Any number of panels 20 may be used to make up a benchtop support surface, depending only on the constraints of the space allocated for the underlying frame or table structure and by the dimensional intervals between the side edges of a panel and the closely spaced webs 34 and 36 which allow a panel to be subdivided in several ways.
Although a preferred embodiment of the invention has been described in detail herein, those skilled in the art will recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.
Patent Application
20060162272
