PRIVACY PANEL AND SYSTEM

Abstract

An engineered privacy panel comprising a recycled rubber composition, where the panel comprises one or more integral reinforcement members for reinforcement and providing fastening means for fastening the back of the panel to a support. The privacy panel can be used to make partitions and partition systems, each of which can be provided as a kit.

Claims

1. A panel comprising a reinforced body, wherein the reinforced body comprises one or more integral reinforcement members each comprising means for fastening the panel to a vertical support.

2. The panel of claim 1, comprising two integral reinforcement members.

3. The panel of claim 1, comprising three integral reinforcement members.

4. The panel of claim 1, comprising four integral reinforcement members.

5. The panel of any one of claims 1 to 4, wherein each of the reinforcement members comprises two substantially adjacent apertures, each of said apertures fitted with a threaded insert.

6. The panel of any one of claims 1 to 5, wherein the reinforced body comprises a frame with a top member and a bottom member connected by side members, wherein the top member and/or the bottom member comprises an elongate integral reinforcement member comprising the adjacent apertures fitted with threaded inserts at each of its ends.

7. The panel of any one of claims 1 to 5, wherein the reinforced body comprises a frame with a top member and a bottom member connected by side members, wherein the top member comprises an elongate integral reinforcement member comprising the adjacent apertures fitted with threaded inserts at each of its ends and the bottom member comprises a discreet reinforcement member at each end with threaded inserts.

8. The panel of any one of claims 1 to 5, wherein the reinforced body comprises a frame with a top member and a bottom member connected by side members, wherein the bottom member comprises an elongate integral reinforcement member comprising the adjacent apertures fitted with threaded inserts at each of its ends and the top member comprises a discreet reinforcement member at each end with threaded inserts.

9. The panel of any one of claims 1 to 5, wherein the reinforced body comprises a frame with a top member and a bottom member connected by side members, wherein the top member comprises a discreet integral reinforcement member comprising the adjacent apertures fitted with threaded inserts at each of its ends and the bottom member comprises a discreet integral reinforcement member comprising the adjacent apertures fitted with threaded inserts at each of its ends.

10. The panel of any one of claims 1 to 4, wherein the reinforced body comprises a frame with a top member and a bottom member connected by side members, wherein the threaded inserts form the reinforcement members.

10a. The panel of any one of claims 6 to 10, wherein the side members comprise a top threaded insert and a bottom threaded insert at each end for mounting a wall bracket.

11. The panel of any one of claims 6 to 11, wherein the top member and/or the bottom member further comprise a substantially central connection member aperture.

12. The panel of any one of claims 1 to 11, wherein the reinforcement members are made of metal.

13. The panel of claim 12, wherein the metal is steel or a steel alloy.

14. The panel of any one of claims 1 to 13, wherein the panel comprises a front face and a back face with a decorative pattern.

15. The panel of claim 14, wherein the decorative pattern is three dimensional.

16. The panel of claim 15, wherein the decorative pattern permits the flow of air and/or sunlight to pass through.

17. The panel of any one of claims 14 to 16, wherein the decorative pattern comprises slats.

18. The panel of any one of claims 14 to 16, wherein the decorative pattern comprises a knot or cross-weave design.

19. The panel of any one of claims 1 to 18 formed from a recycled rubber composition.

20. The panel of claim 19, wherein the recycled rubber composition comprises ground crumb SBR and optionally EPDM.

21. The panel of claim 19 or 20, wherein the recycled rubber composition comprises polyolefin.

22. The panel of claim 21, wherein the polyolefin is selected from the group consisting of polyethylene, polypropylene, polybutene, polyisoprene, polypentene and mixtures thereof.

23. The panel of claim 22, wherein the polyolefin is polyethylene and/or polypropylene.

24. The panel of any one of claims 19 to 23, wherein the ground crumb rubber to polyolefin is provided in a ratio of about 20:80 to 80:20 crumb rubber to polyolefin by weight.

25. The panel of any one of claims 19 to 24, wherein the composition further comprises additives and/or colorants.

26. The panel of any one of claims 1 to 25, further comprising a fastening device affixed to each of the integral reinforcement members on a back side of the panel, said fastening device further comprising means to fasten the panel to the vertical support.

27. A partition comprising one or more of the panels of any one of claims 1 to 26 mounted in between two vertical supports.

28. A partition system comprising two or more partitions of claim 27.

29. The partition of claim 27, or the partition system of claim 28 provided as a kit with instructions.

30. An engineered privacy panel comprising a recycled rubber composition, wherein said panel comprises one or more integral reinforcement members each comprising means for fastening the back of the panel to a vertical support and optionally one or more connection member apertures.

31. A privacy panel comprising a recycled rubber composition, said privacy panel comprising: a unitary molded body defined by a rectangular frame having a top member and a bottom member connected at each respective end via side members, said frame enclosing and integral with a three dimensional pattern; a first elongate reinforcement member positioned within and spanning substantially the width of the top member and a second elongate reinforcement member positioned within and spanning substantially the width of the bottom member, wherein each of said first and second elongate reinforcement members comprise substantially adjacent threaded inserts at each of their respective ends, each of said threaded inserts are configured to receive a fastening means for fastening the back side of the panel to a vertical support.

32. A one piece molded privacy panel of a recycled rubber composition, said privacy panel comprising: a substantially rectangular continuous frame having a top member, a bottom member and side members, said frame defining a window enclosing and integral with a three dimensional pattern; a first elongate reinforcement member positioned within and spanning substantially the width of the top member of the frame, said first member comprising two adjacent threaded inserts at each end; a second elongate reinforcement member positioned within and spanning substantially the width of the bottom member of the frame, said second member comprising two adjacent threaded inserts at each end; the side members comprising a threaded aperture positioned substantially below and substantially above one of the threaded apertures of the first and second elongate reinforcement members; wherein each of the threaded inserts of said first and second elongate reinforcement members are configured to receive a fastening means for fastening the panel from the back side to a vertical support.

33. A partition comprising the panel of any one of claims 30 to 32.

34. A plurality of interconnected partitions of claim 33 or a plurality of interconnected panels of any one of claims 1 to 26 and 30 to 32.

35. A kit comprising a panel of any one of claims 1 to 26 and 30 to 32, and components selected from one or more posts, one or more brackets, one or more fasteners, one or more washers, one or more connection members, one or more wall mount brackets, a plurality of base post supports and combinations thereof.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0097] The following description of typical aspects described herein will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings aspects which are presently typical. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities of the aspects shown in the drawings. It is noted that like reference numerals refer to like elements across different embodiments as shown in the drawings and referred to in the description.

[0098] The description herein will be more fully understood in view of the following drawings:

[0099] FIG. 1A is a front perspective view of a privacy panel showing a three dimensional decorative design in accordance with a non-limiting embodiment of the invention;

[0100] FIG. 1B is a front elevational view of the privacy panel of FIG. 1A;

[0101] FIG. 1C is a back elevational view of the privacy panel of FIG. 1A/B;

[0102] FIG. 1C1 is a plan view of the privacy panel of FIG. 1A/B/C;

[0103] FIG. 1E is a further embodiment of the privacy panel of FIG. 1A that has centrally located connection member apertures on the top and bottom panel members;

[0104] FIG. 1F is an enlarged partial view of two vertically adjacent panels of FIG. 1E showing an example of a connection member for engaging with the connection member apertures;

[0105] FIG. 2A is a partial perspective view of portion “A” of the privacy panel of FIG. 1D, the privacy panel partially translucent show the two adjacent threaded holes that extend into the integral reinforcement member, shown in stippled lines, each for receiving a fastening device;

[0106] FIG. 2B is a partial perspective view of portion “B” of the privacy panel of FIG. 1D, the privacy panel partially translucent to show the two adjacent threaded holes that extend into the integral reinforcement member, each for receiving a fastening device;

[0107] FIG. 2C shows the privacy panel partially translucent to show a further embodiment of the reinforcement member, the two adjacent threaded holes still extend into the shorter (e.g. smaller) integral reinforcement member, each for receiving a fastening device;

[0108] FIG. 2D shows a further view of the embodiment of FIG. 2C, whereby the body of the integral reinforcement member is shown in its entirety;

[0109] FIG. 3A shows an L type bracket mounted to a post with screws suitable for securing/fastening the privacy panel to the post;

[0110] FIG. 3B shows a corner of the back of the frame of the privacy panel for lining up the adjacent threaded holes with the aperture of the L type bracket and the screws for fastening;

[0111] FIG. 3C shows the screws for fastening being driven through the back of the L type bracket to fasten the privacy panel to the bracket that is affixed/attached to the post;

[0112] FIG. 3D shows a back corner of the frame fastened via the L type bracket to the post;

[0113] FIG. 3E shows a front corner of the frame of the panel as it is fastened to the post, illustrating that the fastening points are concealed at the back of the panel and are configured such that esthetic look of the front of the panel is not affected;

[0114] FIG. 4 is partially translucent to show that the screws are driven into the threaded holes and into the reinforcement member, shown in stippled lines;

[0115] FIG. 5 is a partition made from three vertically positioned and fastened privacy panels shown in FIGS. 1A-1D, where each of the three privacy panels is fastened via brackets to the posts at each back corner of the frame of each privacy panel;

[0116] FIG. 6A shows the assembly of a system of partitions and positioning of the brackets with an additional post;

[0117] FIG. 6B shows an embodiment of a partition system using the privacy panel of FIG. 1A;

[0118] FIG. 7A shows a further embodiment of the invention where the privacy panels of the invention are be combined with wooden panels to form a partition of a different design;

[0119] FIG. 7B shows a partition system combining two partitions shown in FIG. 7A and connected at a 90 degree angle forming an L-shaped configuration;

[0120] FIG. 8A is a back perspective view showing that the wooden panels are mounted to the post using the same L type bracket and in the same manner as the privacy panel;

[0121] FIG. 8B is a front perspective view illustrating that the fastening points are concealed at the back of the wooden panel and are configured such that esthetic look of the front of the wooden panel is also not affected;

[0122] FIG. 9A shows a front perspective view of a privacy panel showing a different three dimensional decorative design in accordance with a further non-limiting embodiment of the invention;

[0123] FIG. 9B shows a back perspective view of the privacy panel of FIG. 9A showing the fastening points at each corner of the panel;

[0124] FIG. 9C is a partition made from three vertically positioned privacy panels shown in FIGS. 9A and 9B, where each of the three privacy panels is mounted via brackets to the posts at each corner;

[0125] FIG. 10A shows a front perspective view of a privacy panel showing a different three dimensional decorative design in accordance with a further non-limiting embodiment of the invention;

[0126] FIG. 10B shows a back perspective view of the privacy panel of FIG. 10A showing the fastening points at each corner of the panel;

[0127] FIG. 10C is a partition made from three vertically positioned privacy panels shown in FIGS. 10A and 10B, where each of the three privacy panels is mounted via brackets at each back corner of each panel to the posts;

[0128] FIGS. 11A to 11F show further non-limiting partition system constructions comprising two partitions each incorporating the privacy panel of the invention having different three dimensional decorative designs and combined with wooden panels;

[0129] FIG. 12A shows a partition system made of three interconnected partitions, each of the partitions comprising privacy panels having a classic shutter three dimensional design. The partitions are connected at right angles to enclose and thus conceal outdoor bins in this example;

[0130] FIG. 12B shows how one representative and non-limiting base shown in the partition system of FIG. 12A is ground mounted;

[0131] FIG. 12C shows that the base supporting the vertical post is screwed into the ground surface;

[0132] FIG. 12D shows the base cover over the plate to hide the screws;

[0133] FIG. 13A shows components of a kit for a partition system of the invention, the components comprise L shaped mounting brackets, associated hardware (screws and lock washers), posts and bases;

[0134] FIG. 13B shows a wall bracket for key hole mounting of the privacy panel against a vertical surface. The wall bracket may be sold as a kit with associated hardware (screws and lock washers) and panel;

[0135] FIG. 13C shows a translucent view of a back top corner of the frame of a privacy panel showing a wall bracket fastened by a screw into a pre-threaded hole that extends through the reinforcement member for key hole mounting to a vertical surface; and

[0136] FIG. 14 shows a representative brochure for use in conjunction with any of the embodiments of the invention including component parts, kits, assembly into partitions and partition systems.

DESCRIPTION

[0137] All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. The publications and applications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. In addition, the materials, methods, and examples are illustrative only and are not intended to be limiting.

[0138] Unless defined otherwise, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although any methods and materials similar or equivalent to those described herein can be used in the practice for testing of the present invention, the typical materials and methods are described herein.

[0139] It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting.

[0140] The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element.

[0141] As used herein, the terms “invention” or “present invention” are non-limiting terms and not intended to refer to any single aspect of the particular invention but encompass all possible aspects as described in the specification and the claims.

[0142] As used herein the terms ‘comprises’, ‘comprising’, ‘includes’, ‘including’, ‘having’ and their inflections and conjugates denote ‘including but not limited to’ and are to be understood to be open-ended, e.g., to mean including but not limited to.

[0143] As used herein, the term “about” refers to variation in the numerical quantity. In one aspect, the term “about” means within 10% of the reported numerical value. In another aspect, the term “about” means within 5% of the reported numerical value. Yet, in another aspect, the term “about” means within 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the reported numerical value.

[0144] Should a range of values be recited, it is merely for convenience or brevity and includes all the possible sub-ranges as well as individual numerical values within and about the boundary of that range. Any numeric value, unless otherwise specified, includes also practical close values and integral values do not exclude fractional values. Sub-range values and practically close values should be considered as specifically disclosed values.

[0145] It will be understood that any component defined herein as being included may be explicitly excluded from the claimed invention by way of proviso or negative limitation.

[0146] As may be used herein the terms ‘close’, ‘approximate’ and ‘practically’ denote a respective relation or measure or amount or quantity or degree that has no adverse consequence or effect relative to the referenced term or embodiment or operation or the scope of the invention.

[0147] As may be used herein any terms referring to geometrical relationships such as ‘vertical’, ‘horizontal’, ‘parallel’, ‘opposite’, ‘straight’, “lateral”, “parallel”, “perpendicular” and other angular relationships denote also approximate yet functional and/or practical, respective relationships.

[0148] As used herein “vertical” can be interchanged with “upright”.

[0149] As used herein the term “panel” can be interchanged with “screen”. Further, the panel/screen as described herein comprises a selected decorative three dimensional design that partially obstructs a sightline due to the presence of openings throughout the selected design.

[0150] As used herein, “insert molding” is a process to describe how the elongate metal bars are formed integrally (embedded) within desired locations in the molded privacy panel.

[0151] As used herein, “integrally formed” means “formed as a single piece”. Refers to a part that is continuous in form and that any components making up the part have been rendered inseparable.

[0152] As used herein “embedded” means fixed firmly and deeply in a surrounding mass. With respect to the elongate reinforcement members in the privacy panel, these are embedded within the frame of the privacy panel in the top and bottom rails of the frame due to the insert molding/injection molding of the privacy panel.

[0153] As may be used herein, the terms ‘preferred’, ‘preferably’, ‘typical’, ‘typically’ or ‘optionally’ do not limit the scope of the invention or embodiments thereof.

[0154] As may be used herein the term ‘substantially’ (or synonyms thereof) denote with respect to the context a measure or extent or amount or degree that encompass a large part or most of a referenced entity, or an extent at least moderately or much greater or larger or more effective or more important relative to a referenced entity or with respect to the referenced subject matter.

[0155] As used herein the term ‘may’ denotes an option or an effect which is either or not included and/or used and/or implemented and/or occurs, yet the option constitutes at least a part of some embodiments of the invention or consequence thereof, without limiting the scope of the invention.

[0156] The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, e.g., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary.

[0157] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, e.g., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (e.g. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”

[0158] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0159] As used herein “a plurality” is understood to be any number greater than one. “Plurality” means “two or more”.

[0160] As used herein “partition” is a non-load-bearing and free standing wall that is divided into parts, each part being a privacy panel of the invention. In one representative example, the partition comprises three parts, thus three privacy panels of the invention. Alternatively, one or two of the parts may be other materials such as wooden panels and the like. A partition can be interconnected at each end represented by a post to another partition of the same or different esthetic to form a partition system.

[0161] As used herein, “engineered” is understood to mean that the privacy panel is deliberately constructed for function rather than arising naturally and includes molding of the shape/construction.

[0162] As used herein, the “window” of the privacy screen is a framed area (enclosed by the frame) that comprises the 3D pattern and further admits some light and air. The 3D pattern provides esthetics but also visual impairment properties. As the engineered privacy screen of the invention is a one piece molded structure, the “window” is integrally formed with the frame.

[0163] Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

[0164] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0165] Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) is a European Union regulation dating from 18 Dec. 2006. REACH addresses the production and use of chemical substances, and their potential impacts on both human health and the environment. In accordance with the present invention, compliance with REACH provides that the methods described herein produce less than 1 ppm PAH during the processes and the products contain less than 1.0 ppm PAH.

[0166] The invention in embodiments and in aspects provides engineered privacy panels, a partition including one or more of the engineered privacy panels and a partition system that may include a plurality of interconnected partitions forming a variety of configurations and arrangements.

[0167] Surprisingly engineered privacy panels comprising recycled rubber materials can be injected molded to comprise any desired decorative three dimensional pattern. The injection molding of crumb rubber and granular polyolefin is demonstrated to be suitable to form a one piece panel structure that includes a reinforced frame supporting a window of a three dimensional decorative pattern. The one piece panel structure is molded to include elongate reinforcement members embedded within the polymeric crumb rubber matrix of the top and bottom of the frame and as such provide strength and rigidity to the panel structure. The reinforcement members also comprise the concealed fastening means, threaded inserts at each of their respective ends, each for receiving a fastening device for coupling each of the back corners of the panel to a support structure. In this manner, the front of the privacy panel is free of any fasteners and esthetically more pleasing.

[0168] The privacy panels of the invention are engineered to be easily reversibly fastened to vertical supports such as to fence posts and vertical walls without affecting the esthetic appeal of the panel. Fastening is reversible. Fastening of one panel does not affect the ability to fasten or unfasten a vertically adjacent panel. The back of the frame of the panel has fastening locations at each of the four corners of the frame where the elongated reinforcement members are embedded that comprise fastening means at each of their ends for receiving a fastening device to fasten the panel via a bracket to a vertical support. The position of the fastening means at each corner of the back of the frame provides a secure connection of the top and bottom of each side of the panel to a vertical support. Furthermore, as the connection means are concealed at the back corners of the panel they do not distract or affect the decorative esthetic appearance of the panel.

[0169] The privacy panels of the invention are unique in that their structure and design allows for the panel to be affixed to a vertical support using different types of brackets such that the panel can be fastened to a support in different spatial arrangements, such as by one side to a vertical post, at each side by vertical posts (panel perpendicular to bracket mounted on vertical post), or parallel and substantially parallel and flush against a wall (panel is positioned parallel with its vertical support member). The reinforcing members that provide strength and rigidity to the panel also comprise the concealed fastening means such that the panel can be securely fastened from the back of the panel without disturbing the esthetic appeal of the 3D pattern of the front of the panel and minimally noticeable on the back of the panel. Indeed, as wall mounted, the fastening means are not visible.

[0170] For purposes of description herein, the terms “top”, “bottom”, “right”, “left”, “side”, “back”, “front”, “vertical”, “horizontal” and derivatives thereof shall relate to the invention as oriented in FIGS. 1A-1F. However, it is to be understood the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific panels, partitions, partition systems and components illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0171] FIGS. 1A-1D show one design of an engineered privacy panel embodying the present invention with reference numeral 1 generally designating the privacy panel. The privacy panel 1 has a frame 10 that is continuous and has a top member 12, a bottom member 14, side member 16 and other side member 18. The frame 10 defines a window 20 that has a 3D pattern 22. The front of the panel 22 has a pattern 24 that is a conventional shutter pattern. Openings 25 are found in the 3D pattern that permit some air flow and light to pass through the 3D design.

[0172] FIG. 1C shows the back 26 of the panel and that the 3D pattern of the panel is the same or very similar to the front 22 of the panel. Fastening points 28 are provided at each corner 30 of the panel. The fastening points 28 are the areas of the corners 30 of the panel where the threaded inserts are located. Threaded inserts 32 are positioned in the top member 12 at each top corner 30a. Threaded inserts 34 are positioned in the bottom member 14 of each bottom corner 30b. In addition the side member 16 also contains a top threaded insert 34 and a bottom threaded insert 36 and the other side member 18 contains a top threaded insert 38 and a bottom threaded insert 40.

[0173] FIG. 1E shows a further embodiment of the panel 1 where a connection member aperture 41 is provided substantially central in the top member 12 and in the bottom member 14. A connection member aperture 41 can be formed within any panel design of the invention. As shown in FIG. 1F, an example of a connection member 41a functions to engage within apertures of two vertically adjacent panels to help to secure as desired.

[0174] As shown in FIGS. 2A and 2B, the elongate reinforcement member 42 is shown in phantom stippled to better illustrate the configuration of the threaded inserts 32 of the elongate reinforcement member 42. The configuration of the threaded inserts is the same in each corner 30 of the panel. FIGS. 2C and 2D show the discreet version of the reinforcement member 42a with threaded inserts 32a. It is within the scope of the invention to provide a combination of an elongate reinforcement member running along the entire length within the top and/or bottom member of the panel and also discreet elongate reinforcement members at each end corners. In this manner, an elongate reinforcement member can be integrally formed within for example the top member of the panel and two discrete reinforcement members 42a can be provided at each bottom corner, at each end of the bottom member—or vice versa. In further embodiments, the threaded inserts 32 and 34 can form the reinforcement member.

[0175] FIGS. 3A-3E show mounting of one corner 30 of the back of the panel 26 to a vertical post 46 using an L shaped bracket 48 with apertures 50 and screws 52. The L shaped bracket is shown fastened to the post using screws. The ease of fastening the panel to the post using the L shaped bracket is shown. The back of the panel 44 is mounted to the front of the L shaped bracket using two screws one into each threaded insert. As clearly shown in FIG. 3E, the fastening is discrete and does not draw attention away from the 3D pattern of the panel.

[0176] FIG. 4 shows a bracket 48 fastened to the back of the panel 26 in phantom illustrating that the screws 52 engage with the elongated reinforcement member providing a very strong/secure connection. This fastening is similarly done at each corner 30 of the back of the panel 26.

[0177] FIG. 5 shows a partition 54 formed with three privacy panels 1. The partition comprises two vertical posts 56 each with a base 58 that can be affixed to a ground material. The panels 1 are shown in a vertical orientation. Each panel is connected to each of the posts by each back corner as shown in FIGS. 3A-3E and FIG. 4 using four brackets per panel.

[0178] FIG. 6A shows a partition 54 and an intermediate of how a further partition can be added to form a partition system. FIG. 6B shows a completed partition system 60 in a side by side orientation.

[0179] FIG. 7A shows a different configuration of a partition 54. In this configuration wooden planks 62 are used to form part of the partition for a different esthetic look. In FIG. 7B the two partitions of FIG. 7A are interconnected at a right angle. FIGS. 8A and 8B show that the same type of bracket 48 used for affixing the privacy panel is also used to fasten the wooden planks 62 to the post 56 such that the fastening remains done to fasten the back of the wooden planks to the front of the bracket keeping a visually clean consistent esthetic look.

[0180] FIGS. 9A-9C show another engineered privacy panel 100 within a partition 101 having a different 3D pattern 124 described as a knit design. As with the shutter design, the knit design also has openings 125 to allow for airflow and sunlight to pass through the knit design and yet maintain restricted visual permission through the panel.

[0181] FIGS. 10A-10C show another engineered privacy panel 200 within a partition 201 having a different 3D pattern 224 described as a cross weave (x-weave) design. As with the shutter design and the knit design, the cross weave design also has openings 225 to allow for airflow and sunlight to pass through the knit design and yet maintain restricted visual permission through the panel.

[0182] FIGS. 11A-11F show a variety of different designs and arrangements of the privacy panel of the invention within a partition and within connected partitions forming a partition system. These are non-limiting as other designs and arrangements are within the scope of the invention. Any of the partitions shown can be connected by a 90 degree mount and one or more further partitions can be interconnected to any of the different designs to form enclosures or long partition systems.

[0183] FIG. 12A shows one enclosure configuration 300 using three partitions having a shutter design and connected at 90 degree angles. These types of configurations are suitable to use as enclosures. FIGS. 12B-12D show a representative type of base 70 and base cover 72 that can be used with a post 46. These can be affixed to any variety of ground surfaces such as grass, dirt, wood, concrete, tile, rubber. Further, these can be used with any material of post whether aluminum, wood, engineered wood, plastic, combinations thereof and the like. Thus the privacy panels of the invention can be mounted to any new or existing posts on any type of surface.

[0184] FIG. 13A shows non-limiting examples of components that can be sold as part of a kit including the privacy panels of the invention. Such components may include the posts, bases for the posts, brackets, connection members and hardware. As a kit exact numbers of brackets, hardware, posts and bases can be included for specific constructions. FIG. 13B shows a wall mount bracket 74 that can be used and further included in a kit for vertically hanging the panel against a wall or other vertical structure. FIG. 13C is provided in phantom to show a wall bracket fastened to one back corner of the panel showing the screw inside the threaded insert providing a tight and strong connection. This would be repeated on the other top corner 30A of the back of the panel.

[0185] FIG. 14 is a representative and non-limiting brochure that can be sold as part of a kit comprising one or privacy panels of the invention. The brochure can also be used for sales promotion.

[0186] The privacy panels are made as a one piece molded body and therefore the elongate reinforcement members and/or discrete reinforcement members are embedded within frame locations into the recycled crumb rubber composition. As such they are insert molded in the injection molding of the panel.

[0187] One non-limiting sequence for making the panel is as follows: [0188] 1. The injection mold tool is installed with a chosen panel aesthetic design (a tooling insert). Each injection mold tool can yield multiple “3D patterns” of panels, but all panels have the same ‘frame’ design. [0189] 2. The injection mold machine is prepared with a mixture of crumb rubber and granular polyolefin in desired amounts with optional additives and colourants. The injection mold machine is prepared for heating (and cooling for the tool) for injection of the mixture. [0190] 3. The core/cavity of the injection mold tool is opened to expose the core and cavity. [0191] 4. Two steel reinforcement bars are placed into pre-determined, static location(s) of the injection mold tool. Placement locations are to hold bars securely using any method such as magnets, clamps, friction fit pins, and the like or any other method prior to closing core and cavity side. [0192] 5. Once the two halves of the tool are closed, heated and now molten mixture is injected into the tool cavity ensuring it is filled. [0193] 6. One must ENSURE the threaded insert locations of the reinforcement bars are “sealed off” prior to their placement in the mold tool so that the molten mixture does not ‘fill’ the female machine thread of the insert. [0194] 7. Once the mold has had time to fill, cure and solidify, the tool is opened and the molded panel is safely ejected part from the injection molding machine. [0195] 8. Steps 3-7—constitute a single part cycle that is repeated.

[0196] As can be appreciated by one of skill in the art, the injection mold tool is sized to accommodate a desired size of panel. Representative non-limiting examples are a width of up to about 48 inches, a length (height) of up to about 24 inches and a thickness (at the thickest point) of up to about 1.5 inches, or up to about 1 inch.

[0197] Based on a panel of 48″×24″ inches in size, weight of the panel may vary from about 5-9 lbs (not including weight of the steel bar reinforcing members). The weight may further vary, e.g. be decreased by incorporating the discreet sized reinforcement members that may for example be up to about 50 mm, up to about 100 mm in length, up to about 150 mm, up to about 200 mm, up to about 250 mm or more. The discreet sized reinforcement members are sized to accommodate the threaded inserts. The weight may be still further decreased should the panel be injected molded with sealed off threaded inserts as the reinforcement members or a combination of an elongate reinforcement member, discreet sized reinforcement member and threaded insert(s).

[0198] More specifically with respect to the mixture of crumb rubber and granular polyolefin for the injection molding, this is a dry composition comprising, or in aspects consisting of or consisting essentially of, crumb rubber and granular polyolefin where this dry ground composition is made such that the crumb rubber is relatively evenly dispersed with the granular polyolefin. This composition is fed into a barrel containing a feed extrusion screw. The polymer resin is heated to temperatures of between 140° C. to about 230° C. to a molten state by the combination of heating elements and shear heating from the extrusion screw. The polyolefin as it melts forms a matrix about the crumb rubber which remains intact. This mixture is worked by the screw such that it has the crumb rubber substantially evenly dispersed throughout the molten polyolefin and this mixture is conveyed by the screw, or screws as the case with twin screw extrusion, and injection molded into the cavity of the tool.

[0199] The resultant panel has substantially homogeneously dispersed crumb rubber with the matrix of the polyolefin throughout the formed panel. This substantially evenly dispersed mixture leads to more desirable properties of the panel and also a desired even esthetic look. As will be appreciated by one of skill in the art, the 3D pattern of the panel can have a complex design, however, the injection molding method used provides increased consistency in composition of matter throughout the panel.

[0200] In aspects, the compositions of the invention can comprise particles of crumb rubber comprising EPDM that is admixed with particulate polyolefin to form a mixture for molding, in one aspect injection molding. In aspects, each particle of crumb rubber can comprise SBR mixtures that may comprise EPDM.

[0201] The crumb rubber may be obtained from any variety of sources or suppliers and is often derived from old used tires or recycled rubber. In aspects rubber can be a synthetic rubber selected from styrene-butadiene rubber (SBR—a copolymer of styrene and butadiene), ethylene propylene diene rubber (EPDM—a terpolymer of ethylene, propylene and a diene-component), ethylene propylene rubber (EPR), butadiene rubber (BR) and mixtures thereof. Any rubber source can be of a recycled nature. In aspects the crumb rubber is granulated scrap/waste rubber from used tires (SBR). In further preferred aspects, the crumb rubber may comprise or consist of EPDM which has favorable properties in that it is a high density synthetic rubber that is extremely versatile and has desirable resistant properties against weathering, acids and alkali's. Some of EPDM's properties include: strong acid and alkali resistance; high temperature resistance up to 215° C.; flame retardant; excellent weathering properties; and a tensile range of 500-2500 P.S.I. EPDM is generally regarded as more environmentally friendly compared with crumb tire SBR rubber which contains higher zinc and polycyclic aromatic hydrocarbons (PAH) due to vulcanization and thus higher level of PAH are released due to the high aromatic oils used to mix the total recipe of the tire rubber. Oils and fats of the skin can absorb PAH's and therefore lower PAH release levels are desired with the use of EPDM. With the use of EPDM in the present invention PAH emissions are less than about 1.0 ppm or less than about 0.5 ppm (or up to but less than 1.0 ppm PAH) using methodology for measuring/quantitating PAH emission as is understood by one of skill in the art. In aspects, the crumb rubber may be any mixture of SBR and EPDM in ratios that provide less than 1.0 ppm PAH in a final product.

[0202] The crumb rubber for use in the invention can be of a variety of mesh sizes, for example up to about 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75 and 80 mesh including combinations thereof. In aspects, the crumb rubber is up to about 10 mesh or up to about 20 mesh including combinations of mesh sizes up to about 20 mesh. Such crumb rubber has particle sizes of about 0.15 to about 1.70 mm (Aldrich 2003-2004 Catalog/Handbook of Fine Chemicals).

[0203] The polyolefin for use in the composition to make the panels of the present invention is any polyolefin having a melt index ranging between about 5 g/10 minutes to about 50 g/10 minutes is suitable for use in the present invention. Representative examples are selected from the group consisting of polyethylene, polypropylene, polybutene, polyisoprene, polypentene and mixtures thereof. In aspects the polyolefin is polyethylene or polypropylene. In other aspects functionalized olefin polymers are not incorporated into the methods, compositions or panels of the invention. The polyolefin for use in the first dry grind composition is particulate and can be of any desired size up to about 80 mesh.

[0204] When heated at temperatures of about 140° C. to about 230° C., inclusive of any specific temperature in between, the polyolefin will melt about the crumb rubber. Any temperature within this range is suitable for use in the method. In aspects the temperature is about 180° C., about 181° C., about 182° C., about 183° C., about 184° C., about 185° C., about 186° C., about 187° C., about 188° C., about 189° C., about 190° C., about 191° C., about 192° C., about 193° C., about 194° C., about 195° C., about 200° C., about 205° C., about 210° C., about 215° C. and about 220° C.

[0205] The amount of crumb rubber to polyolefin used in the composition in the method to make the panels can range from about 20%:80% by weight to 80%:20% by weight. In aspects about 25% by weight of crumb rubber is used in the compositions. In further aspects, up to about 100% of the crumb rubber can be EPDM. In further aspects from about 25% to about 75% by weight EPDM. In further aspects about 5% by weight to about 60% by weight of the total amount of crumb rubber when mixed with other crumb rubber such as for example SBR.

[0206] The amount of polyolefin used to make the compositions of the invention, in the final shaped panel is about 15% to about 75% by weight, in aspects 15% to about 50% by weight, in aspects about 15% to about 40% by weight and in still further aspects at least about 50% by weight. One of skill in the art would understand that this would include amounts of about 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 58, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79 and 80% by weight.

[0207] The amount and type of crumb rubber and polyolefin selected for use may for example be a mix of about 50:50% by weight crumb rubber to polyolefin to achieve a desired shore harness A (where less than 70 is soft; 70 is standard and 90 is stiff) as would be understood by one of skill in the art. This is but one representative and non-limiting example. Other ratios such as 25:75% by weight crumb rubber to polyolefin is also desired to achieve a modified desired shore harness A.

[0208] Up to about 10% by weight additives can be incorporated as desired to improve certain properties of the end product, as would be understood by a skilled person. These are selected from the group consisting of titanium dioxide, UV stabilizers, calcium carbonate, talc, flame retardants and combinations thereof. The additives can be incorporated into the extruded sheet or within the composition of plurality of shaped particles. Thus the additives are incorporated into the final shaped product. It is also understood that in embodiments of the invention, no additives are incorporated.

[0209] Up to about 10% by weight colorant can be incorporated either into the sheet or within the composition of plurality of shaped particles. Thus into the final product. It is also understood that in embodiments of the invention, no colorants may be incorporated.

[0210] The engineered panels described herein have enhanced durability as being made of recycled crumb rubber composition, the panels are relatively unaffected by moisture and do not rot, rust or corrode. The panels of the invention are ecofriendly since they utilize recycled rubber (in aspects reclaimed from old tires) and can also incorporate reclaimed polyolefin. In addition, The recycled crumb rubber composition resists nicks and dents, does not peel, and when impacted, tends to return to its original shape.

[0211] Installation of the panels to vertical supports is simple and inexpensive, requiring only unskilled labor. No field cutting or special tooling is required nor any drilling. Fastening locations on supports are easy to determine.

[0212] Maintenance of the privacy panel is simple. In order to clean the privacy panel as described herein, one need only occasionally wash using a hose and optionally a light detergent. In addition, any damage such as damage by vandalism can be easily rectified by removing and replacing the damaged panels in the normal manner as described herein.

[0213] Advantageously, the privacy panels, partitions comprising one or more of the privacy panels disclosed herein and associated partition systems are easy to assemble, disassemble, ship, transport, and construct into a variety of suitable configurations and arrangements.

[0214] While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed.

[0215] The descriptions of the various embodiments and/or examples of the present invention have been presented for purposes of illustration but are not intended to be exhaustive or limited to the embodiments and/or examples disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.