Interlocking structural members with edge connectors

#This invention relates to interlocking structural members, (e.g., display panels) connected together at their edges.

#Portable interlocking structural members such as display panels and room dividers, are frequently held together in the desired arrangement by connectors located along the edge of the panels. It is known to provide connectors consisting of bead and groove conformations in mating interfitting tongue and socket structures, oriented in the plane of the panels. The tongue and socket structures are interconnected by longitudinal movement of the adjacent panels towards each other.

#In one aspect the invention features an edge connector for connecting panel members at their adjacent edges, including a base extending transversely between edges of the base; a support wall integral with the base extending away from the base on one side thereof, the support wall extending generally parallel to the base edges and positioned between the transverse center of the base and one edge of the base; a tongue integrally connected at one end to the support wall and extending from the support wall to a free end thereof spaced away from the base and positioned between the support wall and the other edge of the base, the tongue and the base defining a recess therebetween to receive the tongue of a mating connector; and at least one detent or groove on a surface of the connector on the one side thereof to receive a bead or protrusion on a surface of a mating connector. Preferred embodiments include the following features. The edge connector comprises an elongated extrusion, and the base edges, support wall and tongue extend along the length of the extrusion. The base includes at least one leg integral with and extending away from the base on the other side opposite the support wall. Alternatively, the base includes two such legs and a crossbar spaced from the base and creating a groove between the legs, the base and the crossbar; the legs preferably extend away from the base beyond the crossbar. The tongue, in section, has parallel walls extending parallel to the base and is spaced from the base a sufficient distance to receive a similarly dimensioned tongue of a mating connector. The end of the support wall and the side of the tongue opposite the recess define a continuous outer surface that includes a protrusion or bead extending from the outer surface away from the recess between the transverse center of the base and the edge of the base near which the support wall is located. Preferably, the protrusion is located on the end of the support wall. The base includes a detent or groove located between the transverse center of the base and the other edge, and preferably between the free end of the tongue and the other edge of the base, and adapted to receive a protrusion on the support wall of a mating connector.

#FIG. 1 is a perspective view of a panel system according to the invention.

#FIG. 2 is a sectional view taken at line 2--2 of FIG. 1.

#FIG. 3a is a sectional view taken at line 3--3 of FIG. 1 prior to the assembly of two adjacent panels.

#A lightweight, sturdy, adaptable display panel system that is easily assembled and disassembled is made of edge protected, plastic laminate clad styrofoam panels held together in the desired angular arrangement by extruded plastic connectors secured to the edges of the panels. The panel system is assembled by snapping together or engaging the appropriate connectors in a lateral movement past each other, in a plane perpendicular to the plane of an adjacent panel. To disassemble the panels, the connectors are unlocked by deflection out of the local plane of the assembled system.

#Referring to FIG. 1, a system of structural members 10 comprises individual insulating foam panels (Branch River, Smithfield, R.I.) 12, typically 8.0' high.times.4' wide.times.1.5" thick, each having a two pound density expanded styrene styrofoam core, a 0.75" thick protective wood strip 14 top and bottom, and sides 16 laminated with a protective coating of 0.031" paper backed plastic laminate (not shown), the wood strip and the plastic laminate being attached to the foam core with a water-based resin (is set resin WD3-A322 and hardner CX47, manufactured by Ashland Chemical Co., Columbus, Ohio. At each vertical edge 18 of a panel 12, except for finish end edge 19, is an elongated, high-impact extruded styrene plastic edge connector strip 20, extending substantially the length of the panel edge 18.

#Referring to FIG. 2, elongated edge connector 20 has a 1.5" wide transverse base 22 extending the full width of a panel edge 18. The corners 23 of the base are chamfered at 45.degree.. Base 22 has an integrally connected central leg 24 extending into a groove 26 in the center of the panel and generally forming a T with the base. Leg 24 contains a plurality of striations or notches 28 for holding an assembly glue compatible with the styrofoam core (e.g., a two part solvent less epoxy resin, West System 105 Epoxy Resin, Group B, and Fast Epoxy Hardner 205 or Slow Epoxy Hardner 206, all manufactured by Gougeon Brothers, Inc., Bay City, Mich.). Beads of the glue are applied in the groove 26 and on the panel edges on each side of the groove 26 to securely bind the connector 20 to the panel 12. On the other side of the T an integrally connected short leg or support wall 30 (0.25" long), having a 0.031" high integrally connected protrusion or bead 32 on its end, is positioned between the transverse center of base 22 and one end of the base and extends away from panel end 18. Just below bead 32, a 0.125.degree. thick integrally connected tongue 34 extends 0.75" from support wall 30 parallel to base 22, a short distance beyond the transverse center of the base, so that the tongue is centered on the base, to form recess 42 between the tongue and the base. In the surface 36 of base 22 facing towards tongue 34, and just outside the projection of free end 40 of tongue 34 onto base surface 36, i.e., at a distance from the center of the tongue and, in the illustrated embodiment, from the center of the base equal to the distance of the bead from the centers, a 0.031" deep recessed detent or groove 38 is provided to receive the bead on the support wall of another connector.