Interlocking panel

Abstract

Interlocking panel. The present invention relates to an interlocking panel. The panel has a first edge and a second edge. The first edge is provided with a plurality of outwardly projecting tabs. The second edge is located on the opposite side of the first edge and is provided with a plurality of grooves. The plurality of grooves formed along the second edge are positioned to correspond to the position of the plurality of tabs and are adapted to receive a complementary plurality of tabs from another adjacent panel. When the panels are to be assembled, the tabs of the adjacent panel are guided into the corresponding complementary grooves of the panel, and the tabs passing through them engage securely in the grooves, creating a flush joint and locking the panels in place, thus conferring a seamless visual appeal to the panel assembly.

Description

Interlocking panel TECHNICAL FIELD The subject matter herein refers, in general, to false ceiling panels used in modern architecture and, more specifically, to false ceiling panels that are equipped with coupling structures formed in one piece, enabling the interconnection of panels within the false ceiling. BACKGROUND In today's world, the aesthetics of professional and personal spaces, especially offices, commercial complexes, residential complexes, and theaters, play a significant role in providing a visually pleasing experience. Suspended ceilings are a popular design element used in modern architecture to enhance the overall appearance of a space. Suspended ceilings are, for the most part, secondary ceilings suspended below the main ceiling using ropes or suspension struts. They are commonly used to conceal unsightly electrical wiring, plumbing, fire alarm conduits, structural elements, and other structural features.In addition, suspended ceilings can also improve a space's acoustics by reducing sound reverberation, and enhance the room's lighting by allowing the installation of recessed lights, track lighting, or other types of fixtures. To create a lightweight ceiling, suspended ceilings are manufactured from panels made of a variety of materials such as plaster of Paris (POP), gypsum board, asbestos sheets, particleboard, aluminum panels, polyvinyl chloride (PVC), or wood, among others. In a conventional suspended ceiling system, metal or wooden tracks are arranged in a grid pattern and spaced at regular intervals. The panels are inserted into the grid and secured in place using fasteners such as nails, screws, staples, or clamps. In suspended ceiling installations, T-molding plays a crucial role, acting as an accessory to connect and conceal the joints between ceiling panels. Its primary purpose is to establish a stable framework by connecting the secondary profiles within the suspended ceiling grid system. Furthermore, it conceals the joint lines between the ceiling panels, resulting in a unified surface. BRIEF DESCRIPTION OF THE DRAWINGS The detailed description is provided with reference to the accompanying figures. In the figures, the leftmost digit(s) of a reference number identify the figure in which the reference number first appears. The same numbers are used throughout all the drawings to refer to similar features and components. Figure 1 illustrates an assembly of panels of the prior art, wherein two panels are connected using a T-molding. Figure 2 illustrates an interlocking panel, according to an example from the present subject matter. Figure 3 illustrates another example of Figure 2 in which the tabs are protruding from the flat portion of the panel edge. Figure 4 illustrates another example of Figures 2-3 in which the tabs are protruding from both the flat portion and the grooved portion of the panel edge. Figure 5 illustrates how a plurality of panel tabs are inserted as illustrated in Figures 2-4 through complementary slots in another adjacent panel. Figure 6 illustrates another example of Figures 2-5 in which a plurality of panel tabs are provided with a trapezoidal end profile. Figure 7 illustrates another example of Figures 2-5 in which a plurality of panel tabs are provided with a semicircular end profile. Figure 8 illustrates another example of Figures 2-7 in which a plurality of panel tabs form an alternating pattern of end profiles of different shapes. Figure 9 illustrates another example of Figure 7 in which a plurality of tabs are protruding from both the flat and the slotted portion of the panel forming an alternating pattern of end profiles of different shapes. Figure 10 illustrates another example of Figures 2-9 in which a plurality of tabs on a panel have a variable width. Figure 11 illustrates another example of Figures 2-10 in which a plurality of tabs forms a grouping pattern comprising a repeating sequence of at least two groups of tabs. DETAILED DESCRIPTION As previously mentioned, in conventional approaches, when two ceiling panels are joined, there is a small gap or seam between them. The T-molding is installed within this seam area, with its T-shaped profile fitting over the edges of the panels. The horizontal portion of the T-molding covers the seam, while the vertical stem extends downward between the panels. The T-molding typically has tabs or lips on either side of the horizontal portion, which grip the panels, holding them together. By effectively joining the panels and concealing the seam between them, the T-molding creates a cohesive surface, contributing to both the overall appearance and functionality of the installation. However, it is important to consider the limitations regarding the appearance of T-moldings in suspended ceilings. One of the main drawbacks of T-moldings in terms of visual appearance is their potential to disrupt the visual continuity of the installation. The presence of a T-molding along the edges of a panel can create visible lines that interrupt the smooth, seamless flow of the surface. These lines can be noticeable and draw attention, detracting from the desired aesthetic appeal of a cohesive and uninterrupted visual appearance. Therefore, the molding lines create a sense of compartmentalization or division between panels. Instead of perceiving a unified and expansive surface, attention may be drawn to the molding lines, resulting in a fragmented or segmented visual effect. Furthermore, the presence of a T-molding can impose limitations on design possibilities for the installation. Achieving intricate or complex patterns that require continuous, uninterrupted surfaces can be challenging due to the visible molding lines. To this end, this subject matter discloses an interlocking panel equipped with one-piece coupling structures. These one-piece coupling structures enable the interconnection of panels with adjacent panels in a suspended ceiling. Although the subject matter herein has been described with reference to suspended ceilings, it should be understood that the scope of the invention is not limited to suspended ceilings. Instead, the subject matter herein 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. According to an example from the subject matter herein, the interlocking panel may have two distinct portions forming the panel, namely, a portion of the panel having notches or channels running on 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. These are hereafter referred to as the first edge and the second edge, respectively. The first edge is provided with a plurality of outwardly projecting tabs. The second edge is present on the opposite side of the first edge and is provided with a plurality of grooves.The plurality of grooves formed along the second edge are positioned so as to correspond to the position of the plurality of tabs and are adapted to receive a complementary plurality of tabs from another adjacent panel such that, when the panels are to be assembled, the tabs of the adjacent panel are guided into the corresponding complementary grooves of the panel, the tabs passing through them fitting securely into the grooves, creating a flush joint and locking the panels in place. In another example related to this subject matter, the interlocking panel may have a plurality of tabs projecting outward from the first edge, and the plurality of tabs may have trapezoidal, semicircular, or square end profiles. As a further illustration related to this subject matter, the tabs may have end profiles of the same shape or form an alternating pattern of end profiles of different shapes. As a further illustration of the subject matter herein, the interlocking panel may have a plurality of tabs projecting outward from the first edge, forming a grouping pattern. This grouping pattern may then be repeated sequentially along the length of the panel edge, and the groups of tabs are evenly spaced along it. The groups of tabs may contain the same number of tabs. For example, the number of tabs in a group of tabs may be two, but it may not be limited to two, and they are evenly spaced. Furthermore, the spacing between tabs within a group may be less than the spacing between groups of tabs. Therefore, this subject matter discloses an interlocking panel with a one-piece tongue-and-groove locking mechanism that offers several advantages over traditional T-moldings in butt-joint suspended ceiling panels. First, the one-piece tongue-and-groove locking mechanism ensures a tight fit between panels, preventing sagging or bowing of the ceiling over time. Additionally, the one-piece tongue-and-groove locking mechanism eliminates the need for visible moldings and fasteners, resulting in a streamlined and aesthetically pleasing appearance.Furthermore, the interlocking panels, equipped with a one-piece tongue-and-groove locking mechanism, are easy to install and require no special tools or equipment, making them a cost-effective and efficient solution for butt-joining panels in a false ceiling. The foregoing and other features, aspects, and advantages of the subject matter will be further explained with reference to the following description and accompanying figures. It should be noted that the description and figures merely illustrate the principles of the subject matter herein, along with the examples described herein, and should not be construed as limiting the subject matter. It is understood, therefore, that various arrangements may be devised which, although not explicitly described or shown herein, embody the principles of this disclosure. Furthermore, all statements herein that state principles, aspects, and examples thereof are intended to encompass equivalents thereof. Additionally, for the sake of simplicity, and without limitation, the same numbers are used throughout all drawings to refer to similar features and components. Figure 1 illustrates a prior art panel assembly where two panels, namely panel 11a and panel 11b, are connected using a T-molding 10. The approach involves cutting a notch (not shown) in the edges of each panel to be joined and inserting the T-molding into the notches. It may involve the use of additional fasteners or adhesives to reinforce the connection. However, as explained above, this connection method has limitations, such as the visible seam created by the T-molding, which can be less aesthetically pleasing. Therefore, there is a need for improved approaches to connecting suspended ceiling panels that can address the aforementioned drawbacks and provide a more effective and aesthetically pleasing solution. Figure 2 illustrates an interlocking panel, according to an example in the subject matter hereof. Referring to Figure 2, the interlocking panel 21a may include a portion of the panel forming notches or channels 24 running on axes parallel to the horizontal edge of the panel, and the remaining portion of the panel forming a flat portion 25. Furthermore, the interlocking panel 21a may include a first edge and a second edge. The first edge is provided with a plurality of outwardly projecting tabs (22a, 22b, 22c). The second edge is present on an opposite side of the first edge and is provided with a plurality of grooves (23a, 23b, 23c). The plurality of grooves 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) projecting outward from the first edge of the interlocking panel 21a are flat and evenly spaced along the first edge of the panel and may have the same thickness as the panel. The width of the tabs may vary between 10 and 80 mm and may be uniform or different. It can be observed that the plurality of tabs (22a-22c) projecting from the first edge are parallel to each other and project perpendicular to the width (the 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 they project, may vary between 20 and 30 mm. The plurality of grooves (23a-23c) are narrow openings that allow a complementary plurality of tabs from another panel to pass through them during assembly. These grooves are adapted to receive a complementary plurality of tabs from an adjacent panel such that, when the panels are assembled, the tabs of the adjacent panel are guided into the corresponding complementary grooves of the panel. The tabs passing through the grooves engage securely, creating a flush joint and locking the panels in place. The tabs that project outward from the first edge of the panel can protrude from the slotted portion of the panel and / or the flat portion of the panel. Figure 3 illustrates another instance of the interlocking panel exemplified in Figure 2, where the tabs are projecting from the flat portion of the panel edge. Consequently, the slots formed along the second edge are located within the flat portion of the panel, corresponding precisely to the position of the tabs. Referring to Figure 3, the interlocking panel 31a has a slotted portion 34, and the remaining portion forms a flat portion 35 of the panel. As can be seen, the plurality of tabs (32a-32c) are projecting from the flat portion of the panel. Consequently, the grooves (33a-33c) formed along the second edge are located within the flat portion of the panel, corresponding precisely to the position of the tabs (32a-32c) respectively. Furthermore, Figure 4 illustrates another instance of the interlocking panel exemplified in Figures 2-3, where the tabs protrude from both the flat and slotted portions of the panel edge. Consequently, the slots formed along the second edge lie within the flat and slotted portions of the panel, precisely corresponding to the position of the tabs. Referring to Figure 4, the interlocking panel 41a has a slotted portion 44, and the remaining portion of the panel forms a flat portion 45. As can be seen, the plurality of tabs (42a-42f) protrude from both the flat and slotted portions of the panel. In particular, tabs (42a-42c) protrude from the flat portion of the first panel edge. Similarly, tabs (42d-42f) protrude from the slotted portion of the first panel edge.Consequently, the grooves (43a-43f) formed along the second edge are located within both the flat and grooved portions of the panel, precisely corresponding to the position of the tabs (42a-42f). Specifically, the grooves (43a-42c) are formed along the flat portion of the second edge of the panel. Similarly, the grooves (43d-43f) are formed along the grooved portion of the second edge of the panel. Figure 5 illustrates how a plurality of panel tabs, as illustrated in Figures 2-4, are inserted through complementary grooves in an adjacent panel. Referring to Figure 5, the interlocking panels 51a and 51b, as illustrated in Figures 2-4, are represented herein. As shown in Figure 5, to assemble panels 51a and 51b, panel 51a is positioned adjacent to panel 51b. The plurality of tabs (52a-52c) projecting outward from the edge of panel 51a are first aligned and then inserted through the corresponding complementary plurality of grooves (53a-53c) formed along the edge of panel 51b. For example, the tab 52a that protrudes outward from the edge of panel 51a is inserted through the complementary groove 53a formed along the edge of panel 51b.Similarly, the tab 52b projecting outward from the edge of panel 51a is inserted through the complementary groove 45b formed along the edge of panel 51b, and so on. The tabs (52a-52c) fit snugly into the corresponding grooves (53a-53c), creating a secure and rigid flush joint. It should be noted that the fit between the tabs and grooves can be designed to be either a clearance fit, a sliding fit, or an interference fit. Furthermore, when the panels are in the assembled state, at least some portion of panel 51a overlaps the portion of panel 51b. The overlapping portion can vary in the range of 30-40 mm. Therefore, the panel assembly described herein provides an overlapping butt joint for panels. Therefore, the plurality of tongues and grooves formed as a single piece, as described herein, facilitates a seamless appearance by securely connecting the panels without visible misalignments or gaps. The tongues and grooves are designed to precisely interlock, ensuring that the panels align seamlessly and create a smooth surface. This seamless integration enhances the overall visual appeal by providing a clean, uninterrupted look. Furthermore, the interlocking mechanism adds to the visual appeal by concealing the joints. By effectively hiding the connection points, the mechanism eliminates any visible breaks or separations, contributing to a cohesive and polished surface. Figure 6 illustrates another example of Figures 2-5 in which a plurality of panel tabs are provided with trapezoidal end profiles, while Figure 7 illustrates another example of Figures 2-5 in which a plurality of panel tabs are provided with semicircular end profiles. Referring to Figures 2-7, the plurality of tabs projecting outward from the edges of the panels can have trapezoidal, semicircular, or square end profiles. Specifically in Figures 2-5, the plurality of tabs (22a-22c, 32a-32c, 42a-42c, 52a-52c) projecting from the edges of panels 21a, 31a, 41a, and 51a have square end profiles. Tabs with square end profiles are easier to manufacture and can provide a precise fit in grooves with square or rectangular openings. The straight edges of the tabs give the panel assembly a smooth appearance by preventing the tabs from deviating from their intended insertion direction within the grooves. Furthermore, as illustrated in Figure 6, the plurality of tabs (62a-62c) protruding from the edges of panel 61a have trapezoidal end profiles. The tabs with trapezoidal end profiles offer easy insertion and secure locking due to their tapered shape. The narrow end of the trapezoidal end profile provides ample space for the tabs to easily insert into the grooves, while the wider end creates a tight fit when fully seated in the grooves, preventing the tabs from being pulled out. This provides a secure interlock for the panels, enhancing the seamless appearance of the panels upon installation. Furthermore, as shown in Figure 7, the plurality of tabs (72a-72c) protruding from the edges of panel 71a have semicircular end profiles. The curved edges of the tabs' semicircular end profiles allow for smoother, more gradual insertion, which can be particularly useful where panels need to be installed quickly or where numerous tabs need to be inserted into grooves. Figure 8 illustrates another example of Figures 2-7, in which a plurality of tabs on a panel form an alternating pattern of end profiles of different shapes. Referring to Figure 8, panel 81a is provided with a plurality of tabs (82a-82c) projecting outward from the edge of panel 81a. The plurality of tabs (82a-82c) form an alternating pattern of tabs with trapezoidal and semicircular end profiles. By using tabs with end profiles of different shapes, it is possible to achieve a combination of the advantages, such as ease of insertion and the aesthetic appearance offered by each shape, while minimizing their disadvantages. Figure 9 illustrates another example of Figure 8, in which a plurality of tabs on a panel form an alternating pattern of end profiles of different shapes, and the tabs are projecting from both the flat and grooved portions of the panel. Referring to Figure 9, panel 91a is provided with a plurality of tabs (92a-92f) projecting outward from the edge of panel 91a. The plurality of tabs (92a-92f) form an alternating pattern of tabs with trapezoidal, semicircular, and square end profiles. As can be seen, the tabs are projecting from both the flat and grooved portions of the panel. Therefore, using tongues with differently shaped end profiles helps conceal any imperfections or irregularities that may arise during the assembly process. The intricate interlocking mechanism ensures that the panels fit together snugly, masking any potential misalignment or discrepancy. As a result, the overall appearance of the paneling or surface remains flawless and visually appealing. Figure 10 illustrates another example of Figures 2-9 in which a plurality of tabs on a panel have a variable width. Referring to Figure 10, panel 101a is provided with a plurality of tabs (102a-102c) that project outward from the edge of panel 101a. The tabs (102a-102c) have a variable width. By varying the width of the tabs, it is possible to fine-tune the locking mechanism in an assembly of panels. One advantage of varying the tab width is the ability to adjust the level of friction and resistance against the groove. 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 smoother and easier insertion into the groove. Furthermore, varying the width of the tabs can provide greater design flexibility and allow for customization of the panel system. By adjusting the tab width, it is possible to create a unique tab pattern or arrangement 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. Figure 11 illustrates another example of Figures 2-10 in which a plurality of tabs forms a grouping pattern comprising a repeating sequence of at least two groups of tabs. Referring to Figure 11, panel 111a is provided with a plurality of groups 112a and 112b of tabs projecting outward from the edge of panel 111a. As depicted, group 112a of tabs has a plurality of tabs. The tabs within group 112a are evenly spaced. Similarly, the plurality of tabs within group 112b are evenly spaced. As can be seen, groups 112a and 112b of tabs are evenly spaced, and the spacing between tabs within groups is less than the spacing between 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 the interlocking of the panels, creating a stronger and more stable connection between the panels. The subject matter herein has been disclosed in connection with certain examples, but is not limited to the particular constructions disclosed herein and shown in the drawings, but also includes any modification or equivalent within the scope of the subject matter herein.

Claims

1. An interlocking panel comprising: a first edge; a plurality of tabs projecting from the first edge; a second edge, wherein the second edge is present on an opposite side of the first edge; and a plurality of grooves formed along the second edge, wherein the plurality of grooves are positioned corresponding to the position of the plurality of tabs and are adapted to receive a complementary plurality of tabs from another adjacent panel when assembled to effect a panel interlock to form a flush joint.

2. The interlocking panel according to claim 1, wherein the plurality of grooves formed along the second edge are narrow openings, wherein the narrow openings facilitate the passage of the complementary plurality of tabs from another panel when assembled. 3.The interlocking panel according to claim 1, wherein the plurality of tabs projecting from the first edge are flat and have the same thickness as the panel.

4. The interlocking panel according to claim 1, wherein the plurality of tabs projecting from the first edge are evenly spaced along the first edge.

5. The interlocking panel according to claim 1, wherein the plurality of tabs projecting from the first edge have a grouping pattern comprising a repeating sequence of at least two groups of tabs.

6. The interlocking panel according to claim 5, wherein the spacing between tabs in each group is equal and the spacing between adjacent groups of tabs is greater than the distance between tabs within each group. 7.The interlocking panel according to claim 1, wherein the end profiles of the plurality of tabs projecting from the first edge are trapezoidal, semicircular, or square.

8. The interlocking panel according to claim 7, wherein the plurality of tabs projecting from the first edge either have end profiles of the same shape or form an alternating pattern of end profiles of different shapes.

9. The interlocking panel according to claim 1, wherein the width of the plurality of tabs projecting from the first edge is in the range of 10-80 mm and is either uniform or different.

10. The interlocking panel according to claim 1, wherein the flush joint formed between interlocking panels includes the overlap of at least some portion of one panel with another panel.

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