Interlocking Molding with Sightline Elimination Flange for Toilet and Other Partitions

Abstract

A flanged interlocking molding is provided for use in toilet partitions or other partitions, and which eliminates the sight lines along each edge of the partition door. The flanged interlocking molding, formed of a single piece of material can be arranged on a component of the partition, such as a door and/or a pilaster. The flanged interlocking molding comprises a body portion; a first arm extending from a first edge of the body portion; a flange comprising include parallel layers of the metallic material including a first layer extending in a first direction away from the body portion, and a second layer extending from the first layer in a direction opposite the first direction; and a second arm extending from the second layer of the, the second arm including an edge arranged parallel to an edge of the first arm with a gap formed therebetween.

Claims

1. An apparatus, formed of an elongated and contiguous strip of a metallic material, comprising: a body portion; a first arm opposing an inner surface of the body portion and extending from a first edge of the body portion; a flange comprising parallel layers of the metallic material, the parallel layers comprising: a first layer extending in a first direction away from the body portion at a second edge of the body portion opposite the first edge of the body portion, and a second layer extending at a first edge from the first layer in a second direction opposite the first direction; and a second arm extending from a second edge of the second layer of the flange and opposing the inner surface of the body portion, the second arm comprising an edge arranged parallel to an edge of the first arm with a gap formed therebetween.

2. The apparatus according to claim 1, wherein the body portion comprises an outer surface having a convexly curved cross-sectional profile.

3. The apparatus according to claim 1, wherein the flange comprises a first end and a second end, and at least one of the first end or the second end is curved.

4. The apparatus according to claim 1, wherein the flange comprises a first end and a second end, and at least one of the first end or the second end is beveled.

5. The apparatus according to claim 1, wherein the flange comprises a first end and a second end, and at least one of the first end or the second end is straight and comprises a substantially right angle.

6. The apparatus according to claim 1, wherein the first arm comprises a first end and a second end, and at least one of the first end or the second end are beveled.

7. The apparatus according to claim 1, wherein the second arm comprises a first end and a second end, and at least one of the first end or the second end are beveled.

8. The apparatus according to claim 1, wherein the metallic material is stainless steel, aluminum, or galvanneal.

9. The apparatus according to claim 1, wherein the first arm and the second arm collectively form a locking mechanism configured to engage locking elements on a structure to secure the apparatus to the structure.

10. The apparatus according to claim 1, wherein the length of the body portion is greater than the length of each of the flange, the first arm, and the second arm.

11. The apparatus according to claim 1, wherein the apparatus has a uniform cross-sectional profile along the entire length of the apparatus.

12. The apparatus according to claim 1, wherein the flange is formed at a non-perpendicular angle relative to a reference plane through a base of the first arm and a base of the second arm.

13. A system, comprising: a door having a hinge side and a locking side; a first pilaster arranged adjacent to the hinge side of the door a second pilaster arranged adjacent to the locking side of the door; and a first apparatus secured to the hinge side of the door or the first pilaster, and a second apparatus secured to the locking side of the door or the second pilaster, each of the first and second apparatuses being formed of an elongated and contiguous strip of a metallic material, and comprising: a body portion; a first arm opposing an inner surface of the body portion and extending from a first edge of the body portion; a flange comprising parallel layers of the metallic material, the parallel layers comprising: a first layer extending in a first direction away from the body portion at a second edge of the body portion opposite the first edge of the body portion, and a second layer extending at a first edge from the first layer in a second direction opposite the first direction; and a second arm extending from a second edge of the second layer of the flange and opposing the inner surface of the body portion, the second arm comprising an edge arranged parallel to an edge of the first arm with a gap formed therebetween; wherein the first apparatus is provided along the height of the hinge side of the door and the flange of the first apparatus is configured to conceal a gap formed between the door and the first pilaster to prevent a sightline forming between the first pilaster and the door; and wherein the second apparatus is provided along the height of the locking side of the door and the flange of the second apparatus is configured to conceal a gap formed between the door and the second pilaster to prevent a sightline forming between the second pilaster and the door.

14. The system according to claim 13, wherein the first apparatus is secured to the first pilaster and the second apparatus is secured to the second pilaster.

15. The system according to claim 14, wherein the first pilaster comprises a pair of lengthwise slots configured to be engaged by the first arm and the second arm of the first apparatus to secure the first apparatus to the first pilaster.

16. The system according to claim 15, wherein the first pilaster comprises: an inner core; a first skin covering a first side of the inner core; and a second skin covering a second and opposite side of the inner core; wherein each of the first skin and the second skin comprise a lengthwise hook element, each defining one of the lengthwise slots therein; and wherein the first apparatus is configured to clamp the first skin to the second skin of the first pilaster.

17. The system according to claim 13, wherein the first apparatus is secured to the hinge side of the door and the second apparatus is secured to the locking side of the door.

18. The system according to claim 17, wherein the hinge side of the door and the locking side of the door each comprise a pair of lengthwise slots configured to be respectively engaged by the first arm and the second arm of the first apparatus to secure the first apparatus to the hinge side of the door and by the first arm and the second arm of the second apparatus to secure the second apparatus to the locking side of the door.

19. The system according to claim 18, wherein the door comprises: an inner core; a first skin covering a first side of the inner core; and a second skin covering a second and opposite side of the inner core; wherein each of the first skin and the second skin comprise a lengthwise hook element on each of the hinge side of the door and the locking side of the door, each defining one of the lengthwise slots therein; and wherein the first apparatus and the second apparatus are configured to clamp the first skin to the second skin of the door.

20. The system according to claim 13, wherein the door is configured for rotation of at least ninety degrees about the hinge side from a first, closed position to a second, opened position.

21. A system comprising: an apparatus, formed of an elongated and contiguous strip of a metallic material, comprising: a body portion; a first arm opposing an inner surface of the body portion and extending from a first edge of the body portion; a flange comprising parallel layers of the metallic material, the parallel layers comprising: a first layer extending in a first direction away from the body portion at a second edge of the body portion opposite the first edge of the body portion, and a second layer extending at a first edge from the first layer in a second direction opposite the first direction; and a second arm extending from a second edge of the second layer of the flange and opposing the inner surface of the body portion, the second arm comprising an edge arranged parallel to an edge of the first arm with a gap formed therebetween; and a panel structure to which the apparatus is secured.

22. The system according to claim 21, wherein the panel structure is a door, and the apparatus is secured to the door on one vertical edge of the door along the height of the door.

23. The system according to claim 21, wherein the panel structure is a pilaster, and the apparatus is secured to the pilaster on one vertical edge of the pilaster along the height of the pilaster.

24. The system according to claim 21, wherein the panel structure is a partition wall, and the apparatus is secured to the partition wall on one vertical edge of the partition wall along the height of the partition wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIGS. 1A-1C show various views of a toilet partition according to the prior art;

[0024] FIGS. 2A-2C show cross-sectional views of a door of a toilet partition according to the prior art;

[0025] FIGS. 3A-3D show various views of an interlocking molding of a toilet partition according to the prior art;

[0026] FIG. 4A shows a front perspective view of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0027] FIG. 4B shows a cross-sectional perspective view of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0028] FIG. 4C shows a front view of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0029] FIGS. 4D-4G show various close-up views of sections of the toilet partition including a flanged interlocking molding identified in FIG. 4C;

[0030] FIGS. 4H-4J show various cross-sectional views of the toilet partition including a flanged interlocking molding according to an embodiment of the present application;

[0031] FIG. 4K shows a close-up, partial top view of the toilet partition including a flanged interlocking molding identified in FIG. 4B;

[0032] FIG. 5A shows a front view of a door of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0033] FIG. 5B shows an edge view of a door of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0034] FIG. 5C shows a front perspective view of a door of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0035] FIG. 5D shows a bottom view of a door of a toilet partition including a flanged interlocking molding in accordance with an embodiment of the present application;

[0036] FIGS. 5E-5F show various close-up bottom views of sections of the toilet partition including a flanged interlocking molding identified in FIG. 5D;

[0037] FIG. 6A-6H show various views of flanged interlocking moldings for a toilet partition in accordance with an embodiment of the present application;

[0038] FIGS. 7A-7B show a diagram of the profile changes in the process of creating the flanged interlocking molding from a metallic strip in accordance with an embodiment of the present application;

[0039] FIG. 8A shows a top view of a roll forming assembly apparatus used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application;

[0040] FIG. 8B shows a side view of a roll forming assembly apparatus used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application;

[0041] FIGS. 9A-9O show side views of the different tooling dies and sheet configurations created by the tooling dies from the process of creating the flanged interlocking molding in accordance with an embodiment of the present application;

[0042] FIGS. 10A-10E show various views of a no-sight double straight die used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application;

[0043] FIGS. 11A-11E show various views of a no-sight double miter die used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application;

[0044] FIGS. 12A-12D show various views of a jog die of a no-sight double miter die used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application; and

[0045] FIGS. 13A-13D show various views of a punch of a no-sight double miter die used in the process of creating the flanged interlocking molding in accordance with an embodiment of the present application.

DETAILED DESCRIPTION OF THE INVENTION

[0046] The flanged interlocking molding of the present application and method of manufacturing the same will be described with reference to FIGS. 4A-13D.

[0047] FIGS. 4A-4B illustrate a toilet partition 50 comprising the flanged interlocking molding 80 of the present application. The toilet partition 50 can include several standard components of a toilet partition, such as a door 60 and pilasters 70a, 70b, but further includes two flanged interlocking moldings 80, one on each vertical edge of the door 60, which as shown in FIG. 4B, block the gaps 51, 52 along each edge of the door 60 so that there are no sight lines along the door 60 into the partition 50. Additional views of the flanged interlocking molding 80 arranged between the door 60 and pilasters 70a, 70b are shown in FIGS. 4C-4G. While the Figures may illustrate the flanged interlocking molding 80 used in combination with certain doors 60, pilasters 70a, 70b, and hinges 61a, 61b, it is noted that the flanged interlocking molding 80 is not limited to use with any particular type or structure of door, pilaster, or panel and the flanged interlocking molding 80 can be used in toilet partitions in which any type of door hinge or lock is used. The length of the flanged interlocking molding 80 can vary depending on the required length of the gap 51, 52 between the door 60 and pilaster 70a, 70b to be closed, and if necessary, multiple flanged interlocking moldings 80 can be used on one edge of a door 60 or pilaster 70a, 70b, such as above and/or below a hinge 61a, 61b. The ends of the flanged interlocking molding 80, shown for example in FIGS. 4D-4G, may be designed as beveled, square (i.e., flattened) 88a, 88b (shown for example in FIG. 6H), or rounded 84a, 84b (shown for example in FIGS. 6B-6C).

[0048] The manner in which the flanged interlocking molding 80 is secured to the toilet partition 50 can be seen for example in FIGS. 4I-4K. FIGS. 4I and 4K show the flanged interlocking molding 80 secured to the door 60 of the partition 50 on the hinge side of the door 60. The flanged interlocking molding 80 includes an interlocking molding 81 and a contiguous flange 82 extending away from the interlocking molding 81. The door 60 includes a front skin 63 and a rear skin 64, each skin 63, 64 being formed from a sheet of metal material, with a core 65 or membrane arranged in between the two skins 63, 64. The core 65 may be made of cardboard or other suitable material, and an adhesive can be provided between each skin 63, 64 and a respective side of the core 65 facing the skin 63, 64. Each skin 63, 64 includes lengthwise extensions on each lateral edge, which are hook-shaped in the cross-section so as to form slots 67a, 67b. The flanged interlocking molding 80 includes an interlocking molding 81 having two adjacent and opposing lengthwise wings or arms 85a, 85b. The interlocking molding arms 85a, 85b are configured to slide into the slots 67a, 67b of the door skin 63, 64, and function to clamp together the two skins 63, 64 of the door 60 and lock the door 60 components in place. When the interlocking molding 81 of the flanged interlocking molding 80 is in place and secured to the door 60, the flange 82 is positioned in between the door 60 and the pilaster 70a, 70b of the partition 50. The flange 82 may be planar with the door 60 or pilaster 70a, 70b or arranged at an acute angle relative to the door 60, such as a 10°±.

[0049] Similar to the door 60, the pilasters 70a, 70b may also similarly include a front skin 73a, 73b and a rear skin 74a, 74b, each skin 73a, 73b, 74a, 74b being formed from a sheet of metal material, with a core 75a, 75b or membrane arranged in between the two skins 73a, 73b, 74a, 74b and adhesive to adhere the cores 75a, 75b to the skins 73a, 73b, 74a, 74b. Similar to the construction of door 60, each pilaster skin 73a, 73b, 74a, 74b includes lengthwise extensions on each lateral edge, which are hook-shaped in the cross-section so as to form slots 77a, 77b. In constructions such as those shown in the FIGS. 4I-4K, where the door 60 has a flanged interlocking molding 80 on each edge, the pilasters 70a, 70b may each comprise a standard interlocking molding 76a, 76b engaged with the slots 77a, 77b.

[0050] FIG. 4J shows the flanged interlocking molding 80 secured to the door 60 of the partition 50 on the edge of the door 60 comprising lock 62, wherein the flanged interlocking molding 80 is secured to the door 60 in the same manner. A shoe 78a, 78b is arranged at the base of each pilaster 70a, 70b, surrounding the base of the pilaster 70a, 70b.

[0051] As illustrated in FIGS. 4I and 4K, the door 60 can be configured to open and rotate 90° or more from the closed position shown in the Figures inward (i.e., towards the toilet), and so the flanged interlocking molding 80 is secured to the door 60 such that the flange 82 is arranged on the lock side on the internal face of the door 60 and on the hinge side on the external face of the door 60, such that the flange 82 of the flanged molding 80 does not interfere with the opening and closing of the door 60 by contacting a pilaster 70a, 70b. For a door 60 that rotates in the opposite direction (i.e., away from the toilet), the orientation of the flanged interlocking molding 80 relative to the door 60 can be reversed. In the “closed” position, the locking element 62 of the door can engage a corresponding locking element 72 on the pilaster 70b to lock the door 60.

[0052] FIGS. 5A-5F show various views of a door 60 of a toilet partition 50 having the flanged interlocking molding 80 arranged on each edge of the door 60 in the manner previously described.

[0053] While the Figures primarily illustrate the flanged interlocking molding 80 being secured to each edge of the door 60 of the toilet partition 50, the flanged interlocking molding 80 can alternatively be secured to one or both pilasters 70a, 70b instead of the door 60. In such embodiments, the flanged interlocking molding 80 can be used in place of the standard interlocking molding 76a, 76b of the pilasters 70a, 70b to secure the two skins 73a, 73b, 74a, 74b of the pilaster 70a, 70b together, with the flange 82 still being arranged between the door 60 and the pilaster 70a, 70b to close the sight line gaps 51, 52.

[0054] Preferably, the toilet partition 50 comprises one flanged interlocking molding 80 on each side of the door 60, the hinge side (i.e., the side of the door comprising or connected to one or more hinges where a sightline gap 51 would form) and the locking side (i.e., the opposite side, generally adjacent to or comprising a closure or locking element such as lock 62, where a sightline gap 52 would form). For example, the toilet partition 50 may comprise: (i) a flanged interlocking molding 80 secured to each of the hinge side and the locking side of door 60; (ii) a flanged interlocking molding 80 secured to the hinge side of the door 60 and a flanged interlocking molding 80 secured to the pilaster 70b along the edge adjacent to the locking side of the door 60; (iii) a flanged interlocking molding 80 secured to the lock side of the door 60 and a flanged interlocking molding 80 secured to the pilaster 70a (the pilaster adjacent to the hinge side of the door 60); (iv) a flanged interlocking molding 80 secured to each of the pilasters 70a, 70b along their respective edges adjacent to the door 60.

[0055] Additionally, the flanged interlocking molding 80 can also be provided on one or both panel walls (not shown) of a toilet partition 50. The panel wall generally comprises a similar structure as the pilaster 70a, 70b or door 60, including a pair of skins having a core in between, with an interlocking molding locking the skins and core in place. A sightline may also be formed in between a panel wall and a pilaster 70a, 70b, which are arranged perpendicular to each other. A flanged interlocking molding 80 can be provided on an edge of a panel wall adjacent to the pilaster 70a, 70b to close this sightline and provide further privacy.

[0056] The flanged interlocking molding 80 can also be used in combination with other panel, door or wall like structures through which a sightline may form that can be blocked by the flange 82 of the flanged interlocking molding 80, such as shower partitions, urinal partitions, and other doors or panels.

[0057] FIGS. 6A-6H show various views of flanged interlocking moldings 80 combining as one piece an interlocking molding 81 and an integral flange 82. The flanged interlocking molding 80 is made from a single piece of metallic material, such as a stainless steel or other metal, including but not limited to galvanneal, 300 series stainless steel or other series of stainless steel, which is rolled into a shape illustrated in the Figures comprising the interlocking molding 81 and flange 82. The cross-sectional profile of the flanged interlocking molding 80 is consistent along its length.

[0058] Examples of a flanged interlocking molding 80 formed with a processing step by a double straight die 122 are shown in FIGS. 6A, 6G, and 6H, and examples of a flanged interlocking molding 80 formed with a processing step by a double miter die 123 are shown in FIGS. 6B, 6C, and 6F, as discussed further below. As shown for example in the cross-sectional view of FIG. 6D and 6E, the interlocking molding 81 of the flanged interlocking molding 80 includes a curved body portion, which at one end includes a sharp bend where the flange 82 is formed as a wing off of outer surface the body portion by rolling the metal into a hairpin shape terminating in one arm 85a of the interlocking molding 81, the arm 85a opposing an inner surface of the body portion. The flanged interlocking molding 80 is formed from a contiguous material and profile from one arm 85a of the interlocking molding 81 to the opposing, adjacent arm 85b with the flange 82 formed therebetween. In the embodiment illustrated in the Figures, the width (D.sub.2) of the flanged interlocking molding 80 may be approximately one inch, the width (D.sub.1) of the flange 82 may be approximately 0.6 inches (with the actual length of the flange 82 being slightly greater) and the distance between the arms 85a, 85b of the interlocking molding (D.sub.3) may be approximately 0.2 inches. The flange 82 may be formed at an angle (Θ.sub.1) of approximately 10°±. In alternative embodiments of the flanged interlocking molding 80, the dimensions may vary. Further, while the Figures illustrate the body portion of the flanged interlocking molding 80 as having an outer surface having a convexly curved cross-sectional profile, the cross-sectional profile shape may vary flanged interlocking molding 80.

[0059] The flanged interlocking molding 80 may also be manufactured in alternative manners. For example, the flanged interlocking molding 80 can be made of aluminum and can further be made by way of an aluminum extrusion process.

[0060] In order to achieve the final profile for the interlocking molding 80 with flange 82, as shown in FIGS. 4A-6H and described above, a manufacturing process and system have been developed. There are several unique design characteristics that must be achieved by the flanged interlocking molding 80, which are attained through the process and system described herein and illustrated in FIGS. 7A-13D. In order to accomplish this process of creating the flanged interlocking molding 80, a roll forming assembly apparatus 100 is provided comprising a series of fourteen dies (101-114) to form the flat steel.

[0061] FIGS. 7A-7B show a diagram of the changes in the profile of the metallic strip 200 through the process of forming the flanged interlocking molding 80 shown and described herein. The strip 200 begins with a flat profile having a width (W) of 2.665 inches and progresses through a series of modified profiles 201-214 as the strip passes through the fourteen tools or dies (101-114) of the assembly apparatus 100.

[0062] As shown in FIGS. 8A-8B, the roll forming assembly apparatus 100 includes a roll former 115 comprising the fourteen dies 101-114. The assembly further includes a control panel 116, an electric panel 117 and a hydraulic power unit 118. Before the roll former 115 (in the direction of the flow of the strip 200 through the apparatus), a series of tools including a no-sight latch hole die 121, a no-sight double straight die 122, and a no-sight double miter die 123 is provided, as well as a series of tools including a traditional hanger hole die 124, a traditional latch hole die 125, and a traditional pre-notch die 126 is provided. The two series of tools can be used interchangeably depending on the final intended form of the flanged interlocking molding. After the roll former 115 (in the direction of the flow of the strip 200 through the roll forming assembly apparatus 100), a further series of tools including a no-sight cut off die 131, a traditional miter straight cut off die 132, a traditional double straight cut off die 133, and a traditional double miter cut off die 134 is provided.

[0063] Cross-sectional views of the tools 101 through 114 are shown in FIGS. 9A through 9O, including the cross-sectional profiles 201 through 214 created at each step by the tools 101 through 114 formed through the process. In FIG. 9O, the cross-sectional profile 214 of the final form is shown, with the transition shown between flange angle (Θ.sub.2) in cross-sectional profile 213 of approximately 79° to a further angle (Θ.sub.3) in cross-sectional profile 214 of approximately 82.5°.

[0064] FIGS. 10A-10E show a no-sight double straight die 122 used in the roll forming assembly apparatus 100. The no-sight double straight die 122 comprises: base shoe 122a, punch shoe 122b, top shoe 122c, die pin 122d, up stop, rod extension 122f, lifter button 122g, die ring 122h, punch 122i, punch backup 122j, punch holder 122k, stripper 122l, head cylinder 122m, die bushing 122n, die spring 122o, collar 122p, and shoulder bolt 122q. In FIG. 10A, the up stops and shoulder bolt shims are not shown for clarity. In the no-sight double straight die 122 shown in FIGS. 10A-10E, the height (D.sub.4) between the base shoe 122a and punch shoe 122b is 6.22 inches when open and 3.72 inches when shut, and the punch 122i includes a width (D.sub.5) of 0.7050 inches

[0065] FIGS. 11A-11E show a no-sight double miter die 123 used in the roll forming assembly apparatus 100. The no-sight double miter die 123 comprises: base shoe 123a, punch shoe 123b, top shoe 123c, die pin 123d, up stop, rod extension 123f, lifter button 123g, die ring 123h, punch 123i, punch backup 123j, punch holder 123k, stripper 123l, head cylinder 123m, die bushing 123n, die spring 123o, collar 123p, and shoulder bolt 123q. In FIG. 10A, the up stops and shoulder bolt shims are not shown for clarity. In the no-sight double miter die 123 shown in FIGS. 11A-11E, the height (D.sub.6) between the base shoe 123a and punch shoe 123b is 6.22 inches when open and 3.72 inches when shut, and the punch 123i includes a width (D.sub.7) of 0.7050 inches

[0066] A first unique characteristic of the design of the flanged interlocking molding 80 is the two wings or arms 85a, 85b, which act as both alignment guides as well as the male portion of the interlocking design concept when assembling metal partitions. The arms 85a, 85b comprise adjacent edges, which must be parallel to each other and uniform in length and angular alignment in order to center the molding 81 to the two female portions of the interlocking design concept which is found on the two outer skins of the metal partition (see, e.g., FIG. 4K). The length of each arm 85a, 85b is formed by tooling 101 and 102. The angular alignment of the arms 85a, 85b is formed by tooling 103, 104, and 105 with the final alignment occurring in tooling 106 through 114. The arms 85a, 85b may comprise straight ends 86a, 86b terminating the arms 85a, 85b with a substantially right angle, or may comprise beveled ends 87a, 87b

[0067] A second unique characteristic the design of the flanged interlocking molding 80 is that the flange 82 is designed to reduce the line of sight that is commonly created when installing a toilet partition, as well as achieving the requirements of what is commonly known as the stop for a toilet partition. In order to reduce the line of sight, while at the same time ensuring the successful installation of the components, both the length of the flange 82 and its angular alignment to the interlocking molding 81 of the flanged interlocking molding 80 are critical. In order to withstand the force that is enacted on the stop when a partition door 60 is closed, the characteristics of the flange 82 at two locations are critical. The flange 82 of the flanged interlocking molding 80 begins at the point where the radius of the domed feature of the interlocking molding 81 is descending. Due to the physical properties of the material, an intersecting radius formed in the opposite direction of the existing radius is required. The formation of this feature begins with tool 102 and due to the physical properties of the material is formed across tools 103, 104, 105, 106, 107, 108 and is completed in tool 109. At the peak of the flange 82, the material must be redirected 180 degrees in order to finalize the second arm 85b of the interlocking molding 81. In order to overcome the physical properties of the material, a radius must be formed at the peak of the flange 82 that does not introduce stress that will deform the flanged interlocking molding 80. The formation of these features begins with tool 102 and due to the physical properties of the material is formed across tools 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, and is finalized with tool 114.

[0068] A third unique characteristic of the design of the flanged interlocking molding 80 is the transition of the flanged interlocking molding 80 when it is cut to length. When installed on the toilet partition 50, the flanged interlocking molding 80 aligns with two additional interlocking moldings on the lock side of the door 60 and with two hinges 61a, 61b on the hinge side of the door 60 to finalize the toilet partition 50. In order to cut the flanged interlocking molding 80 correctly to ensure alignment and minimalize additional processing, the strip is first punched by the double miter die (123) or the double straight die (122). An example of a flanged interlocking molding 80 formed with a processing step by the double straight die 122 are shown in FIGS. 6A-5B, and examples of a flanged interlocking molding 80 formed with a processing step by the double miter die 123 are shown in FIGS. 6B, 6C, and 6F. After the strip is formed, a custom cutoff tool is provided as shown in FIGS. 12A-13D to finalize the strip in accordance to its final length. The die 131 also ensures that a safety hazard (sharp edge) to the end user is not introduced by cutting a sharp edge from the flange 82 to form the curved flange ends 83a, 83b, as shown for example in FIGS. 6B-6C. For contrast, FIG. 6A shows flanged interlocking molding 80 lacking the curved flange ends 83a, 83b. The no-sight cutoff die 131 includes a jog die 131a and a correspondingly shaped punch 131b.

[0069] While there have been shown and described and pointed out fundamental novel features of the invention as applied to embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods described may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice.