Patent Grant
11280085
Structural panels may be used to construct a variety of enclosures, including but not limited to shelters, buildings, enclosures, and divider walls. While many different types of connections are used to assemble a series of structural panels, many of these connections suffer from an inability to readily disassemble, failure to maintain an adequate strength in resisting movement in one or more directions, and difficulty in creating or maintaining a proper connection between panels, for example.
A series of panels may also be used to create a partial enclosure for food preparation or other activities. In activities where cross-contamination of materials or working surfaces is a liability, such barriers that contain contaminates may be beneficial. Prior enclosure solutions are often built-in-place solutions. They may include washable panels mounted to walls surrounding a work surface, sometimes in combination with permanently mounted dividers. Other prior enclosure solutions may rely on low profile backsplashes built into associated work tables. These options do not offer versatility for configuring different contained workspaces. Further, prior enclosure solutions are often difficult to clean and sanitize.
Implementations described herein provide an interlocking panel system comprising a first panel including a first finger joint occupying an edge surface of the first panel and a second panel including a second finger joint occupying an edge surface of the second panel. The first finger joint and the second finger joint each have an interlocking plan and an interlocking profile. The first panel is slidably connectable to the second panel by interfacing the first finger joint with the second finger joint.
Implementations described herein further provide a workspace barrier comprising a left-rear panel, a right-rear panel, a left panel, and a right panel. The left-rear panel includes a first finger joint occupying an edge surface of the left-rear panel, the first finger joint having an interlocking plan and an interlocking profile. The right-rear panel includes a second finger joint occupying an edge surface of the right-rear panel, the second finger joint also having an interlocking plan and an interlocking profile. The first panel is slidably connectable to the second panel by interfacing the first finger joint with the second finger joint. The left panel is selectively interlocked with the left-rear panel and extends in a different plane from the left-rear panel and the right-rear panel when assembled. The right panel is selectively interlocked with the right-rear panel and extends in another different plane from the left-rear panel and the right-rear panel when assembled.
Implementations described herein still further provide a method of assembling a workspace barrier. The method includes selectively interlocking a left-rear panel including a first finger joint occupying an edge surface of the left-rear panel to a right-rear panel including a second finger joint occupying an edge surface of the right-rear panel. Each of the first finger joint and the second finger joint has an interlocking plan and an interlocking profile. The first panel is slidably connectable to the second panel by interfacing the first finger joint with the second finger joint. The method further includes selectively interlocking a left panel to the left-rear panel, the left panel extending in a different plane from the left-rear panel and the right-rear panel. The method further includes selectively interlocking a right panel to the right-rear panel, the right panel extending in a different plane from the left-rear panel and the right-rear panel. The method further includes positioning the interlocked workspace barrier in a self-supporting vertical orientation upon a workspace.
Implementations described herein further still provide an interlocking panel system that may function as a shield, guard, and/or containment around the sides of a workspace. The interlocking panel system may include three or more interlocking panel pieces, a left panel, a rear panel, and a right panel arranged in a self-supporting manner. In some implementations, there may be additional panels to lend additional modularity or portability to the interlocking panel system, or serve as a work surface (i.e., a bottom panel).
Once disassembled, the interlocking panel system panels may be light and small enough for a person to hand carry. In some implementations, a slot is cut out of the top of each panel to provide a built-in handle for carrying the panel. This allows for the individual panels to be transported to a sink for cleaning and disinfecting or to another location for use or storage. The various joinery linking the individual panels is designed to make the interlocking panel system easy to construct and deconstruct quickly and without special tools. The joinery is further designed to minimize the collection of contaminates, allowing for the interlocking panel system panels to be easily cleaned and sanitized.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more particular written Detailed Description of various implementations and implementations as further illustrated in the accompanying drawings and defined in the appended claims.
The following figures may include example dimensions, combinations of joinery, thickness of material, specifications for hardware, specific shapes of profiles, for example. Any or none of which may be included unless explicitly claimed otherwise or inherently necessitated by the claim language.
The portable workspace barriers disclosed herein may function variously as a shield, guard, and/or containment around the sides of a workspace that can be easily assembled and disassembled without the use of tools. In various implementations, the portable workspace barriers include four interlocking panels, a left panel, two rear panels, and a right panel. In some implementations there may be additional left, rear, or right panels to lengthen or deepen the portable workspace barrier or provide modularity to the portable workspace barrier size. In still other implementations, the portable workspace barriers include a bottom panel that forms a work surface. While many of the example implementations provided herein are described in detail as portable workspace barriers, similar features may be included in other products, such as structural panels and other types of interlocking panels.
In an example implementation, the interlocking panel systems described in detail herein are constructed of ½″ thick high-density polyethylene (HDPE), polypropylene, or other plastic materials that are strong, rigid, stable, durable, and moisture resistant. In other implementations, the interlocking panel systems can be constructed of closed cell foams or solid plastics, various metal alloys, or natural materials (e.g., wood). The interlocking panel systems may also include additional rubberized features that give the individual panels a nonslip characteristic. The interlocking panel system material may also include anti-microbial and/or fire-resistant characteristics.
The thickness of the interlocking panel system may vary depending on desired rigidity considering the material used for construction and overall size of the interlocking panel system. In various implementations, the material thickness may vary from ⅛″ to 2″. The interlocking panel system may be of any overall size that makes it functional for its intended task. In an example implementation, the interlocking panel system is 24 or more inches wide, 18 or more inches deep and 16 or more inches tall. Further, the interlocking panel system may be made of up individual panels of various sizes and shapes. For example, the individual panels may be generally rectangular, square, trapezoidal, or have other shapes or combinations of shapes.
The finger joint 107 includes an interlocking plan and an interlocking profile (each described in further detail below with reference to
The width (i.e., overall dimension along the y-axis), depth (i.e., overall dimension along the x-axis), and height (i.e., overall dimension along the z-axis) of the system 100 may vary widely. For example, the width may be 24″ to 72″, the depth may be 20″ to 32″, and the height may be 16″ to 48″.
The finger joint 207 includes an interlocking plan and an interlocking profile (each described in further detail below with reference to
The s-shaped plan may vary in size and shape from that depicted in
The finger joint 307 also includes an interlocking profile (described in further detail below with reference to
The interlocking finger joint 307 provides stability to longitudinal strain along the y-axis of the back wall 306. The depicted rounded-end configuration of the interlocking finger joint 307 helps the matched panels 303, 304 self-center when being joined, easing the action of aligning the interlocking finger joint 307 and sliding the panels 303, 304 together along the vertical z-axis. The interlocking finger joint 307 is cut laterally in the panels 303, 304 perpendicular to a face of each panel (in the y-z plane) in a configuration that includes a finger-shaped tab 307a in each of the panels 303, 304, to fit into a corresponding finger-shaped void 307b in the other of the panels 303, 304. The interlocking finger-shaped tabs 307a and the finger-shaped voids 307b keep the panels 303, 304 joined end-to-end under strain in the y-direction. To provide coplanar alignment and stability to lateral strain along the x-axis of the back wall 306, the edge surfaces 380, 382 of the interlocking finger joint 307 are routed with a s-shaped tenon and groove, as described in further detail below with reference to
In some implementations, the finger-shaped voids may increase in size in a direction away from their openings to provide a biased locking characteristic when the back wall 306 is assembled. Further, the interlocking finger joint 307 may create a splash-tight seal when assembled.
During assembly, panels 403, 404 are aligned in the y-z plane, the interlocking plan (not shown) of the panels 403, 404 is aligned in the z-direction, and the interlocking profile (e.g., the depicted s-shaped tenon and groove) is aligned in the x-direction. The panels 403, 404 are interlocked by moving the panels 403, 404 toward one another in the z-direction. Once assembled, the interlocking plan secures the panels 403, 404 from movement in relation to one another in the y-direction, as well as limits movement in the z-direction. The interlocking profile secures the panels 403, 404 from movement in relation to one another in the x-direction.
The s-shaped tenon and groove profile is cut into the edge surfaces 480, 482 of the panels 403, 404, respectively, leaving flat shoulders (which may vary in size) on each side that creates a tight interlocking lateral bond when used in combination with the interlocking plan (not shown). In some implementations, the s-shaped tenon and groove profile cut into each of the edge surfaces 480, 482 is identical, but cut from a reverse x-direction. In other implementations, the s-shaped tenon and groove profile is unique to each of the panels 403, 404. The s-shaped tenon and groove interlocking profile may also vary in size and shape from that depicted in
During assembly, panels 503, 504 are aligned in the y-z plane, the interlocking plan (not shown) of the panels 503, 504 is aligned in the z-direction, and the interlocking profile (e.g., the depicted round-stub tenon and groove) is aligned in the x-direction. The panels 503, 504 are interlocked by moving the panels 503, 504 toward one another in the z-direction. Once assembled, the interlocking plan secures the panels 503, 504 from movement in relation to one another in the y-direction, as well as limits movement in the z-direction. The interlocking profile secures the panels 503, 504 from movement in relation to one another in the x-direction.
The round-stub tenon and groove interlocking profile may vary in size and shape from that depicted in
In various implementations, the round-stub tenon and groove profile of
To assemble the joint 608, the panels 602, 603 are placed at approximately 90 degrees to each other. The panel 602 is lifted and the D-tabs are inserted into the corresponding slots, then the panel 602 is lowered until the D-tabs interlock in the corresponding slots. Compared to a half-lap corner joint (not shown, see e.g., joint 1530 of
The expander panel 713 includes two interlocking finger joints 707 to interlock with the left-rear panel 703 and the right-rear panel 704 using the expander panel 713 to increase the width of back wall 706 of the system 700. Multiple expander panels permit the back wall 706 width to be modularly increased or decreased, while keeping the individual panel pieces small and light enough for a person to handle for transport to a sink for cleaning or elsewhere for storage. Additionally, the expander panel 713 width may be customized to create any desired specific width of the system 700, while keeping the left-rear panel 703 and the right-rear panel 704 consistently sized for manufacturing efficiency.
In various implementations, the center panel 815 is functional for systems less than 36″ wide and approximately 24″ tall. At this size or smaller dimensions, the panels 802, 805, 814 are small and light enough for a person to handle for transport to a sink or storage. Assemblies with wider rear walls may be made from multiple interlocking panels to reduce the size and weight of the individual panels (see e.g., system 700 of
The work surface panel 1021 may be used to further contains contaminates within the system 1000. A top of the work surface panel 1021 may feature a shallow trough 1059, which may be 1¼″ wide and ¼″ deep running ½″ inside the internal perimeter formed by the panels 1002, 1015, 1005, for example. The trough 1059 may function to retain spillage of liquid or solid matter.
In an example implementation, the magnetic butt joint 1225 is formed by a series of holes bored into the corresponding vertical edges of the rear panels 1223, 1224. The holes are drilled at approximately regular intervals and are centered longitudinally along the edges of the rear panels 1223, 1224. The holes on each of the edges of the rear panels 1223, 1224 are filled with magnets that align precisely when the system 1200 is assembled. Various additional features of the system 1200 are similar to that described above with reference to systems 100, 200 of
For example, the magnets may be cylinder-shaped neodymium magnets that are ⅜″ long and ⅜″ in diameter. The magnets are press-fit into each of the bored holes, being sure to properly orientate the magnet's polarity to cause attraction between the corresponding magnets within the panels 1323, 1324. The magnetic butt joint 1325 creates a coplanar rear wall 1306 that is self-joining and self-aligning. Various additional features of the system 1300 are similar to that described above with reference to systems 100, 200 of
To assemble the corner joint 1430, the slotted void 1431 is aligned above the slotted void 1432 at a 90-degree angle and then lowered into place. Additional corner panels (not shown) may also be manufactured and assembled in the same manner is depicted and described with reference to the system 1400. To disassemble the corner joint 1430, the panel 1402 is lifted straight up until the interlocking voids 1431, 1432 are freed. Various additional features of the system 1400 are similar to that described above with reference to systems 100, 200 of
In a specific example implementation, recesses are bored in each the panels 1639, 1640 to hold magnetic assemblies that align and attach the overlapping panels 1639, 1640. The bores for the magnetic cups are created in a back face of the right-rear panel 1640 to a depth equivalent to the depth of the magnet cups used. At the top of the panel overlap on the back face of the right-rear panel 1640, a 1.125″ hole is bored on center 1.25″ from the top and 1.25″ from the edge of the panel 1640. At the bottom of the panel overlap on the back face of the panel 1640, a 1.125″ hole is bored on center 1.25″ from the bottom and 1.25″ from the edge of the panel 1640. A bore for a washer is bored into the front face of the left-rear panel 1639 to a depth equivalent to the depth of the washer being used. At the top of the panel overlap on the front face of the left-rear panel 1639, a 1.125″ hole is bored on center 1.25″ from the top and 1.25″ from the edge of the panel 1639. At the bottom of the panel overlap on the front face of the left-rear panel 1639, a 1.125″ hole is bored on center 1.25″ from the bottom and 1.25″ from the edge of the panel 1639. Various additional features of the system 1600 are similar to that described above with reference to systems 100, 200 of
The batten panel 1947 is screwed to panel 1940 using screw 1961. Bore 1951 for washer 1956 is made into panel 1939 to a depth equivalent to the depth of washer 1956. The washer 1956 is inserted into the bore 1951 and is permanently affixed with a ½″ long, #10 flathead screw 1953 that is threaded into a corresponding predrilled hole. Magnetic force between the magnet 1954 and the washer 1956 automatically aligns panels 1939, 1940 and attaches them together via the batten panel 1947. To disassemble the panels 1939, 1940, they may be pulled apart by grasping the top of each of the panels 1939, 1940 and pulling them apart with opposing forces. In various implementations, the magnetic batten joint 1946 may include multiple magnet assemblies such as the magnet assembly 1960 depicted in
A cutting operation 2120 cuts an interlocking plan outline of at least one interlocking panel out of the stock material. The cutting operation 2120 may be achieved by one or more of sawing, drilling, milling, routing, fluid-jet cutting, and plasma cutting. The interlocking plan outline may include, for example, a finger joint plan, a D-tab and slot joint plan, or other interlocking plan described in detail herein. Other features described in detail herein may also be cut into the interlocking panel via the cutting operation 2120.
A routing operation 2130 routes an interlocking profile into the interlocking plan edge surface of the interlocking panel(s). The routing operation 2130 may be achieved by running a routing bit (also referred to as a profiling bit) along the interlocking plan edge surface of the interlocking panel. The routing bit has a profile that matches the desired profile of the interlocking plan edge surface. The interlocking profile may include, for example, a finger joint profile, a D-tab and slot joint profile, or other interlocking profile described in detail herein.
A rounding operation 2140 rounds off sharp edges on the interlocking panel(s). The rounding operation 2140 may be achieved by applying a chamfer or bevel to sharp edges on the interlocking panel. Further, the rounding operation 2140 may be achieved mechanically, or by hand. A logo cutting operation 2150 cuts a logo identifying the origin and/or individual interlocking panel(s) themselves. The logo cutting operation 2150 may be achieved by sawing, drilling, milling, routing, fluid-jet cutting, plasma cutting, laser cutting, burning, or etching. The resulting logo may include a variety of information, including but not limited to a source manufacturer name and location, and a product name and identifying number.
The operations 2100 may be repeated to manufacture multiple interlocking panels to be used together in an interlocking panel system, as described in detail herein. Some of the manufactured interlocking panels may be identical, while others may be different. In an alternative method of manufacturing an interlocking panel system, the individual interlocking panels are molded in whole or in part rather than machined out of sheet stock as described in detail herein.
The first interlocking operation 2210 interlocks the left-rear panel to the right-rear panel extending in a common planar direction. In some implementations, the first interlocking operation 2210 is achieved with the left-rear panel and the right-rear panel interlocked lying flat and then the interlocked rear panel is stood upright for interlocking operations 2220, 2230. In other implementations, the first interlocking operation 2210 may instead be accomplished by mechanically interfacing a magnetic batten joint, a magnetic lap joint, or other type of joint together.
A second interlocking operation 2220 selectively interlocks a left panel to a left side of the interlocked rear panel. A third interlocking operation 2230 selectively interlocks a right panel to a right side of the interlocked rear panel. The left and right panels each extend in a different plane (e.g., each at approximately 90 degrees) from the interlocked rear panel. The interlocking operations 2220, 2230 may be accomplished by mechanically interfacing one or both of a D-tab and slot joint and a half-lap corner joint together. A positioning operation 2240 positions the interlocked panel system in a self-supporting vertical orientation upon a workspace. The interlocking panel system surrounds the workspace on three sides. The fourth side is open so that a user may access the workspace.
In various implementations, the structural panels and portable workspace barriers (collectively interlocking panels) disclosed herein are portable, self-supporting, and modular systems that form barriers to function as a shield, guard, or containment around the sides of a workspace. Advantages of the presently disclosed technology include, without limitation, the interlocking panel's ability to be easily deconstructed for storage and/or to be transported to another workspace or to a wash sink. The interlocking panels are easily de-constructed and re-constructed by one person. The design of the interlocking panels allows for easy cleaning and sanitation. The materials of the components are moisture resistant and can be anti-microbial and/or fire-resistant. Further, the interlocking panel size may be customized to suit multiple user needs.
The presently disclosed technology may be applicable to in a variety of fields or industries, for example, food service (e.g., kitchens, restaurants, butchers, food bars, as a food-allergy barrier (e.g., isolating foods containing gluten, nuts, or dairy or kosher foods)), medical (e.g., hospitals, doctor offices, dental practices, veterinary practices, and pharmacies), scientific (e.g., clean rooms and laboratories), care giving (e.g., childcare and senior care), privacy partitions (e.g., voting and standardized testing), and healthcare (e.g., manicure and pedicure salons and estheticians), environmental (e.g., as a wind breaks in outdoor work areas or while camping), construction (e.g., structural panels for constructing an enclosure, such as a building).
In some implementations, the material for the interlocking panels may be provided in multiple colors, with different colors on opposing sides of each panel. As many of the interlocking panel designs disclosed herein are reversible, the interlocking panels may be assembled with a desired one of the two colors visible to a user using a workspace and a different color visible on the exterior of the interlocking panel system. In an example implementation, a first color is defined for handling a first food product (e.g., raw chicken), while a second color is defined for handling a second food product (e.g., raw beef). The colors enable a user to consistently use the correct side of the interlocking panel system assigned to type of food the user intends to prepare. The colors also allow a supervisor to quickly confirm that the user is using the correct side of the interlocking panel system assigned to the type of food the user is preparing.
The above specification and examples provide a complete description of the structure and use of exemplary embodiments of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Furthermore, structural features of the different embodiments may be combined in yet another embodiment without departing from the recited claims.
The present application claims benefit of priority to U.S. Provisional Patent Application No. 62/488,240, entitled “Portable Workspace Barrier” and filed on Apr. 21, 2017, which is specifically incorporated by reference herein for all that it discloses or teaches.
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| Number | Date | Country | |
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| 20180305924 A1 | Oct 2018 | US |
| Number | Date | Country | |
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| 62488240 | Apr 2017 | US |
