GB2507129A

GB2507129A - Tessellating panel with magnets to provide secure interface with adjacent panels.

Info

Publication number: GB2507129A
Application number: GB1218996.5A
Authority: GB
Inventors: Stewart Morley
Original assignee: VIIG Ltd
Current assignee: VIIG Ltd
Priority date: 2012-10-22
Filing date: 2012-10-22
Publication date: 2014-04-23
Also published as: GB201218996D0

Abstract

The panel 10 comprises a core layer connected or bonded between first 14 and second 16 layers and an interface 20 around the edge of the panel. The panel has at least one magnet 26 configured on each side of the panel for removably connecting the panel with a paramagnetic portion on an adjacent panel. Each side may have a number of magnets that are in use aligned with similar magnets on adjacent panels. The magnets may be configured to adjust their position within the panel, and may be biased towards the inside of the panel in the absence of a paramagnetic body, and then biased towards an outer edge of the panel when a paramagnetic body is in close proximity. The panel may comprise two sides with a tongue and a pair of sides with a groove for securing the panels together. A channel may be formed at the edge of a panel so that a tool can be inserted between panels to separate them. The panel may have supports on the second side to help form part of a floor.

Description

IMPROVED PANEL

The invention relates to a panel, a structure having a plurality of panels and to a method of manufacturing the panel. The panel can be used to create a planar structure such as a floor or a wall. The panel is particularly suited to temporary or portable installations that require rapid installation and extraction.

Background of the invention

Known portable floors can be provided in a sheet-format where the floor is stored as a roll and unravelled and rolled-up -like a carpet. These rolls come in fixed sizes and are often large and awkward to handle. Edges of the sheets are taped together to avoid tripping. Alternatively, known portable floors are provided in modules that are arranged in a tile-format, with each individual panel being manually connected to an adjacent panel using a hand-tool, which actuates a mechanism (through a hole in the surface of the panel) to prevent panels separating. Temporary installations such as floors or walls are heavy, expensive to manufacture and are complex to install, take apart and store.

Summary of the invention

From one aspect, the invention resides in a panel for engaging with another panel, preferably configured having similar or corresponding features, for :o assembly to form a tessellated or grid-pattern planar surface. The panel has a core layer sandwiched and/or bonded between a first layer configured to define an upper surface of the panel and a second layer configured to define a lower surface of the panel. The first and second layers are thin -typically less than 5 mm thick, whereas the core is typically greater than 15mm. The thickness of the core can be increased to adjust the mechanical characteristics of the panel, such as the planar mechanical strength. The panel can be described as a sandwich panel and, overall, the sandwich panel provides a light and strong panel suitable for providing a light and strong planar structure when connected to other similar panels. An interface is configured around the edge of the panel to substantially enclose the core layer, wherein the interface is configured to contact or engage with an edge on an adjacent panel. The panel has a magnet configured on each side of the panel for removably connecting the panel with a paramagnetic portion of an adjacent panel or structure. The panel is suitable for rapid installation and extraction from a location, such as a conference or exhibition stand.

The panel can be configured to connect to an identical panel to form a S tessellated or grid-pattern planar surface. The panel can also be configured to connect with a similar panel of a different size, but that has the same or a corresponding interface. In this way the size of the panel can vary such that panels of different sizes can also be connected to form a tessellated or grid-pattern planar surface.

The panel is configured to be light and manoeuvrable, and be quickly assembled to form a structure having a plurality of panels. The panels are also configured to enable quick separation or extraction.

The panel can have a plurality of magnets located on each side of the panel. The magnets can be configured to align with a magnet on another panel such that the panel can be removably connected to an adjacent panel to form a tessellated or grid-pattern planar surface. The magnets can be provided as individual units, and be disc shaped or cylindrical. Additionally or alternatively, the panel can have one or more magnetic strips located along its edge. The or each magnet component can be incorporated within the interface.

The position of the magnet can be adjustable with respect to a surface of the panel. The position can also be adjusted with respect to the edge of the panel. The magnet can be movable between: an inner position, in which the magnet is biased away from the edge of the panel when no paramagnetic body, such as another panel, is located adjacent the panel; and an outer position, in which the magnet is biased towards the edge of the panel when a paramagnetic body, such as another panel, is located adjacent the panel. By way of example, the magnet can be sprung biased away from the edge, and drawn to the exterior surface of the panel by a paramagnetic surface, or magnet, in another panel.

The or each magnet can be substantially aligned in parallel to a plane defined by the panel, such as the plane defined by the first layer. The or each magnet can be configured to provide a fixing to secure the interlace to the panel.

The or each magnet can provide a holding force of at least 12kg. In a panel structure, the combination of connected magnet pairs can provide, by way of example, a holding force of 12kg, or each magnet pair can provide a holding force of 12kg, such that three magnets connected to three corresponding S magnets on an adjacent panel provides 36kg of holding force. The holding force can be adjusted by increasing the size of the magnet, changing the type of the magnet or adjusting the distance between the magnets when connected.

The materials used for the core and the skins layers can be selected according to the performance required of the panel. Core layers of different densities can be used to adjust the energy absorbing properties of the panel.

Additionally or alternatively, the shape and form of the surface of the core, sandwiched between the skins, can be configured to adjust the mechanical characteristics of the panel i.e. the deflection or energy absorption of the surface.

The core layer can involve isolated cavities or interconnected cavities, regularly or irregularly distributed throughout the core material.

The panel can be configured to interface with another panel to increase the planar strength of the structure.

The panel can be configured with a recess on a side, or edge, of the panel for allowing a tool to be inserted between the panel and another panel or object such that the tool can prise or separate the panel from another panel or object.

When aligned with another panel, aligned recesses can define a slot between the panels, such that a panel structure comprising a plurality of panels can have slots located on the surface for deconstructing the panel structure. The slot, or elongate slit, can be configured to enable a blade-shaped tool to separate the panel from another panel or object.

The edge of the panel, or interface, can have a tongue and groove configuration. The panel can have three or more sides. One or more sides of the panel can be non-linear.

The panel can substantially cuboid in form, and can have a rectangular or square footprint. The interface can have a tongue on two sides, and a groove on other two sides. The tongue can be on two adjacent sides and the groves can be on the other two adjacent sides. The interface can be an extrusion connected to the core and the first layer and the second layer. The interface can be formed by the or each skin folded over the core.

The interface can be provided with a seal to inhibit fluid passing from one side of the panel to the other when connected to adjacent panels.

The second or lower surface of the panel can be configured with a plurality of supports.

The invention also resides in a planar structure having a plurality of panels, according to any preceding claim, connected in a tessellated or grid-like pattern. The structure can be a floor, or wall or partition. The panels can be portable such that the structure is a temporary installation.

The invention further resides in a method of manufacturing a panel for engaging with another substantially identical panel for assembly to form a tessellated or grid-pattern planar surface, the method comprising: sandwiching a core layer between a first layer and a second layer; providing an interface around the edge of the panel to substantially enclose the core layer, wherein the interface is configured to engage with an edge on an adjacent identical panel; and installing a magnet on each side of the panel such that the panel can be removably connected to an adjacent paramagnetic portion of a panel or structure.

--:o The position of the magnet can be is adjusted to modify the strength of the ferromagnetic connection to an adjacent paramagnetic portion of a panel or structure.

The components of the core, first and second layers and interface are described as being connected or bonded to each other. This connection or bond can include: a bond, such as an adhesive bond: a weld, such as a vibration weld; andlor a fixing, such as a screw. The connection or bond functions to hold the layers together.

In light of the teaching of the present invention, the skilled person would appreciate that two or more aspects or objects of the invention can be combined to form an improved panel, or a structure comprising two of more panels. Further aspects of the invention will be appreciated from the following description.

Brief description of the Figures

In order that the invention can be more readily understood, reference will now be made, by way of example, to the drawings in which: S Figure 1 is a perspective view of the upper surface of the panel; Figure 2 is a perspective view of the upper surfaces of a plurality of tessellated panels of Figure 1: Figure 3a is a schematic diagram showing, in cross-section, edges of two panels of the type shown in Figure 1, which are configured to mate together, while Figure 3b is a close-up view of the edge of the left-hand panel shown in Figure 3a; Figure 4a is a schematic diagram showing, in plan-view, the position of magnets located on a square-shaped panel, while Figure 4b shows the position of the magnets of the panel in Figure 4a in end-elevation view; Figure 5a is a schematic diagram showing, in plan-view, two square shaped panels similar to Figure 4a located adjacent each other such that the magnets on opposing edges of the panels are aligned, while also including slots indicated by arrows; and Figure 5b is a schematic sectional view of the slots of Figure 5a, wherein the bold lines represent the position of the panels when located adjacent one another, and the hashed-lines indicate the position of the panels when separated by a blade-tool (shown as a solid black line as viewed) that has been inserted in the slot and rotated by 90 degree to separate the edges of the panels.

Detailed description of embodiments

Figure 1 shows the main components of a panel 10 having a core 12 positioned between an upper skin or surface 14 and a lower skin or surface 16.

An interface 20 surrounds the edge of the panel 10. The interface has a tongue 22 on two adjacent sides of the panel and a groove 24 on the other adjacent sides. Magnets 26 (not shown in Figure 1) are located in the edge of the panel.

In the embodiment shown, the upper skin 14 is a 3.0mm thick sheet of polypropylene (PP) and the lower skin is a 2.0mm thick sheet of PP. The core 12 is made of an expandable foam, such as a thermoplastic polymer foam. In this embodiment, a 30mm thick panel of 120g/litre expanded polypropylene (EPP) was used. EPP is available from companies such as ARPRO ®. The magnets are, by way of example, 15 x 8 mm cylindrical magnets (6400 gauss /12kg pull force). The interface is, by way of example, formed of extruded PP. A plurality of panels can be configured to form a planar structure, such as a floor. Figure 2 shows, a structure formed from tessellated panels 10 of Figure 1. During assembly, the upper 14 and lower 16 skins of the panel 10 are bonded to the core 12. The interface 20 is bonded to the skins and/or the core 12. The panels are securely held together by the magnets located in the interface 20 of the panel.

Figure 3a shows in more detail the cross-section of the edges of two panels 10, and in particular the interface 20. The tongue 22 on one panel is configured to engage with the groove 24 of another panel. Magnets 26 mounted in the edge of the panel are configured to hold the panels in connection when the interfaces of the panels engage. The strength of the connection is determined by a number of factors including the size, strength and distance between the magnets. Adjustments to the connection force, influenced by the size and strength of the magnets, can be made in the design stage, while fine tuning :20 adjustments post-manufacture, and in-use, can be achieved by varying the distance between the magnets. Figure 3b illustrates, using doffed-lines, that the position of the magnet can be brought closer to the edge of the panel to change the pull, or connection, between the panels. The position of the magnets can be adjustable and can, optionally, be mounted in a holder (not shown) that enables the magnet, by way of example, to be rotatably screwed into and out of the panel to adjust the distance between corresponding magnets, thereby adjusting the holding strength. Other means of adjusting the position of the magnet with respect to the interface between the tongue and groove are possible. Note that the magnates can be configured not to touch, as shown, and sit behind an exterior surface of the edge of the panel. The portion of the edge, or interface, that forms a barrier between the magnet and the exterior edge of the panel can be very thing and/or strong. In this way the strength of the magnet can be efficiently utilised. The barrier can be formed of a thin, perhaps less than 1mm thick, piece of metal, such as aluminium.

The panels can be of different sizes and dimensions such that, when arranged in a grid, or tessellated, a panel structure can define a floor of a particular size i.e. to fit within a room, or to cover a specific area of an exhibition hall.

Figure 4a alternatively shows a square-shaped panel 10 that can be arranged in a grid-like pattern to form a planar structure in a similar manner to the panels in Figure 2. By way of example, three magnets 26 are provided on each side of the square panel. One magnet is located in the centre region of an edge between the corners, while the other two magnets 26 are located close to the corners, but not so close that they contact or interfere with the magnet installed on the adjacent edge of the panel. Figure 4b shows, schematically, the end-elevation view of the panel of Figure 4a.

Figure 5a shows two panels of Figure 4a located together such the magnets on corresponding sides are aligned such that the panels are securably held together. The magnets are configured such that the panels are retained in a fixed position during normal use i.e. for an exhibition stand. Figure 5a additional shows two slots 28, identified with arrows, on the side of the mating panels.

These slots 28 are for illustrative purposes only. In the example shown the slots are defined by elongate recesses in the edge of each panel. Such recesses can be formed on any side of a panel that is configured to be engaged to another panel to form a planar structure, and can equally be applied to the structure of Figure 2.

Two slots 28 are formed in Figure 5a. Recesses 29 on the edge of a panel correspond and align with recesses an-the edge of another panel such that a long and thin aperture is created there between, thus forming a slot 28.

Recesses 29 can be positioned on each edge of the panel such that slots are formed in a panel structure and provided to optimise the separation of the panels.

S

Additionally or alternatively, the recess can be provided only on one of the panels.

Figure 5b illustrates the edges of a connected (solid line) and unconnected (hashed-line) panel. In the connected position the recess on each panel is aligned to provide a slot into which a flat, blade-like tool 30 can be inserted (note: the direction of insertion is in to the page as viewed). The magnets 26 located in the panel edges hold the panels together. Rotation of the tool forces the edge of the panels apart thus overcoming the magnetic force holding the panels together.

The position of the tool 30 is shown, in cross-section, as a flat blade between the separated, unconnected panels.

Overall, a number of panels can be positioned ri a grid like manner or a tessellated manner to form a planar structure. Panels of different sizes can also be configured to form a planar structure, such as a floor, wall or partition.

By way of example, to form a floor, a first panel 10 is positioned on a surface to be covered. A second panel 10 is then positioned on the surface and placed or slid against the first panel such that the tongue 22 and groove 24 engage. Magnets in the or each panel edge function to pull or hold the edge of the first panel against the second panel. Preferably, a magnet in one panel is configured to align with a magnet in a second panel because this provides a stronger bond, as shown in Figure 5b. The first and second panel become secured together under the magnetic force. Further panels 10 are placed adjacent to the first and second panels until they are surrounded on each side by other panels. The magnets in the panels hold the plurality of panels together to form the planar surface. The tongue and groove configuration inhibits the edges of the panel becoming misaligned to create a trip-hazard.

To disassemble a planar structure having a plurality of connected panels, a tool 30 having a blade like edge is inserted between the edges of two panels located on the periphery of a structure. Ideally, recesses on the edges of the aligned panels allow a tool to be rotated to push the peripheral, or outermost, panel away from the structure. This step is repeated until all the panels are separated from one another.

In the manufacturing of a panel 10, the edge portion, or interface 20, is connected to the core by using, for example, a bonding glue. The skin layers 14, 16 are then secured onto the core and, at the edge, secured to the interface.

Assembled, the interface substantially encloses the core 12.

The type of connection between the core 12 and the skins 14, 16 and the interface 20 is selected according to the materials used. In the present embodiment an EPP core is sandwiched and bonded between polypropylene (PP) sheets and a PP extrusion is bonded to the edge of the core and the sheets.

Alternatively, welding techniques, such as vibration welding, can be sued to bond the interface 20 to the sheets 14, 16.

Alternatively, the skins 14, 16 can be made of aluminium, and the interface can be an aluminium extrusion. The sheets can be bonded to the EPP core, and welding can be used between the aluminium sheets and the aluminium edge extrusion.

Magnets 26 can be configured within the interface 20 prior to assembly or can be added after the panel is assembled.

The interface 20 can alternatively, be formed from the skins 14, 16 being folded over the edge of the core 12 and shaped such that they interface in a tongue and groove, or tab and slot type arrangement.

The present invention has been described above purely by way of example, and modifications can be made within the spirit and scope of the invention, which extends to equivalents of the features described. The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or any combination of any such features or any generalisation of any such features or combination.

Claims

CLAIMS1. A panel for engaging with another panel for assembly to form a tessellated or grid-pattern planar surface or structure, the panel having: a core layer connected or bonded between a first layer configured to define an upper surface of the panel and a second layer configured to define a lower surface of the panel; and an interface configured around the edge of the panel to substantially enclose the core layer, wherein the interface is configured to contact or engage with an edge on an adjacent panel, wherein the panel has a magnet configured on each side of the panel for removably connecting the panel with a paramagnetic portion of an adjacent panel or structure.
2. A panel according to claim 1, wherein each side of the panel has a plurality of magnets.
3. A panel according to any preceding claim, wherein the or each magnet is configured to be aligned with a magnet on another panel or structure such that the panel can be removably connected to an adjacent panel to form a tessellated or grid-pattern planar surface.
4. A panel according to any preceding claim, wherein the position of the magnet is adjustable with respect to a surface of the panel.
5. A panel according to any preceding claim, wherein the magnet is movable between: an inner position, in which the magnet is biased away from the edge of the panel when no paramagnetic body, such as another panel, is located adjacent the panel; and an outer position, in which the magnet is biased towards the edge of the panel when a paramagnetic body, such as another panel, is located adjacent the panel.
6. A panel according to any preceding claim, wherein the or each magnet is substantially aligned in parallel to a plane defined by the panel.
7. A panel according to any preceding claim, wherein the or each magnet is configured to provide a fixing to secure the interface to the panel.
8. A panel according to any preceding claim, wherein a recess is configured on an edge of the panel for allowing a tool to be inserted between the panel and another panel or structure such that the tool can prise or separate the panel from the another panel or structure.
9. A panel according to claim 8, wherein the recess is an elongate slit configured to enable a blade-shaped tool to separate the panel from another panel or object.
10. A panel according to any preceding claim, wherein the interface has a tongue and groove configuration.
ii. A panel according to any preceding claim, wherein the panel has three or more sides.
12. A panel according to any preceding claim, wherein at least one side is non-linear.
13. A panel according to any preceding claim, wherein the panel is rectangular and the interface has a tongue on two sides, and a groove on other two sides.
14. A panel according to any preceding claim, wherein the interface is an extrusion connected to the core and the first layer and the second layer.
15. A panel according to any of claims ito 13, wherein the interface is formed by the or each skin folded over the core.
16. A panel according to any preceding claim, wherein the interface is provided with a seal to inhibit fluid passing from one side of the panel to the other when connected to adjacent panels.
17. A panel according to any preceding claim, wherein the second or lower surface is configured with a plurality of supports.
18. A planar structure having a plurality of panels, according to any preceding claim, connected in a tessellated or grid-like pattern.19 A planar structure according to claim 18, wherein the structure is a floor.20. A planar structure according to claim 18 or 191 wherein the panels are portable such that the structure is a temporary installation.21. A panel or a panel structure as hereinbefore described.22. A method of manufacturing a panel for engaging with another panel for assembly to form a tessellated or grid-pattern planar surface, the method 0 comprising: sandwiching a core layer between a first layer and a second layer; providing an interface around the edge of the panel to substantially enclose the core layer, wherein the interface is configured to engage with an edge on an adjacent panel; and installing a magnet on each side of the panel such that the panel can be removably connected to an adjacent paramagnetic portion of a panel or structure.23. A method according to claim 21, wherein the position of the magnet is adjusted to modify the strength of the ferromagnetic connection to an adjacent parama9netic portion of a panel or structure.