US20070294975A1

US20070294975A1 - Support panel for removable brackets and the like

Info

Publication number: US20070294975A1
Application number: US11/425,754
Authority: US
Inventors: Paul Nadar; Antonio DI GINOSA
Original assignee: Individual
Current assignee: Royal Group Inc USA
Priority date: 2006-06-22
Filing date: 2006-06-22
Publication date: 2007-12-27

Abstract

Support panels and modular assemblies thereof, the panels adapted for supporting removable load bearing members such as brackets. The panels comprise hollow bodies defining channels for receiving and supporting load bearing members. The hollow bodies further include support ribs extending between front and back walls of the panels to transfer forces exerted on flange portions of the channels by the load bearing members to the back walls and/or to other structural portions of the panels, the support ribs being offset from the perpendicular relative to the front and back walls of the panels. Pluralities of the panels may be joined by mating edges, which can define further channels for receiving and supporting load-bearing members, to form modular wall assemblies without the need for mounting overtop existing surfaces as said panels can be mounted directly on structural supports (e.g. stud walls).

Description

FIELD OF THE INVENTION

The present invention relates generally to a support panel and more particularly to a support panel for supporting brackets and the like.

BACKGROUND OF THE INVENTION

Support panels are commonly used in office, commercial and other environments in order to position various items, goods and products within easy reach and/or sight of people. For example, specially-adapted support panels are often used as part of trade shows to display new products, in retail stores to display goods for sale, and in garages, workshops and other places where storage is required, to organize and make easily available various tools.
Support panels define channels adapted for the mounting of various support members (for example, shelves, racks, hangers and the like). Typically, such support members are provided with brackets which engage the channels in order to securely hold the support members in place on the support panel. Hence, the mounting of shelves etc. is performed in an easy and efficient manner, without the use of screws or other types of fasteners. Support panels assembled from such walls are sometimes referred to as slat walls.
A problem with existing support panels is that the panel structure is not adapted to fully support the load that can be placed upon the panel by the brackets. If the load placed on a bracket exceeds the structural strength of a structure defining the channel, the structure is likely to fail, not only dropping the load, but also damaging the channel rendering that channel unusable. Thus, it is desirable to have support panels with channel structures that optimize the load carrying ability of channels for both value and safety purposes.

SUMMARY OF THE INVENTION

The invention provides improved systems and methods for secure mounting of brackets and other load-bearing members on support panels. In preferred embodiments, the invention provides structures adapted for the removable mounting of such structures.
In one aspect the invention provides support panels adapted for supporting removable load bearing members such as brackets. Panels according to such aspect can comprise hollow bodies having front and a back walls separated by voids, and one or more channels defined by the hollow bodies for receiving load bearing members. The channels can include openings defined in said front wall, and base and flange portions defined by the hollow bodies for engaging the load bearing members. Such panels further comprise one or more support ribs extending between the front and back walls to transfer forces exerted on the flange portions by the load bearing members to the back walls and/or to other structural portions of the panels.
It has been found that superior load-bearing qualities can be achieved by providing the support ribs at angles offset from the perpendicular with respect to the front and back walls of the panels.
In other aspects, the invention provides modular wall assemblies comprising pluralities of such panels, wherein the panels are joined by mating edges which can define further channels for receiving and supporting load-bearing members without any compromise in strength.
The invention also provides for flat rear panel surfaces which allow mounting on stud walls without the need for backing (such as drywall), where joined panels act as an adequate sealing means for a wall especially at the corners where a void would be present.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by example, and with reference to the accompanying drawings, in which:

FIG. 1 is an isometric view of a modular support panel in accordance with an embodiment of the invention;

FIG. 2 is a cross section of the modular support panel of FIG. 1 viewed along lines 2-2;

FIG. 3 is an enlarged partial view of the cross section of panel of FIG. 2 as viewed in circle portion 3.

FIG. 4 is an enlarged, partial view of a modular support panel having two support ribs in accordance with another embodiment of the invention;

FIG. 5 is an enlarged, partial view of a modular support panel having two support ribs in accordance with yet another embodiment of the invention;

FIG. 6 is an enlarged, partial view of a modular support panel having a T-shaped channel in accordance with another embodiment of the invention;

FIG. 7 is a portion of a wall formed from multiple modular support panels 30 of FIG. 1 in accordance with another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, an embodiment of a modular support panel is indicated generally at 30. As will be described further below, one or more modular support panels 30 can be used in combination with each other or with other suitable devices or materials to form a support panel wall or a portion thereof. Moreover, as will also be described in greater detail below, modular panels 30 include channels 58 for receiving and securely supporting load-bearing members such as brackets.
Referring to FIG. 2, each modular panel 30 has a front wall 34 and a back wall 38 that are substantially parallel to each other and separated by distance D. Front wall 34 and back wall 38 are spanned by first edge 42 and second edge 46 to form one or more hollow bodies 72. Front wall 34 and back wall 38 are also spanned by one or more separation ribs 50 defining one or more voids 54 within hollow body(ies) 72. In the embodiment shown in FIG. 2, modular panel 30 includes three separation ribs 50, one for each of hollow bodies 72. Each separation rib 50 is connected to its respective front wall 34 and back wall 38 in a substantially perpendicular configuration. Moreover, each separation rib 50 runs substantially parallel with ends 42 and 46. In other embodiments, the configuration of ribs 50 can vary based on a variety of criteria such as costs, desired panel strength and other criteria as would be understood by persons skilled in the relevant arts.
In a preferred embodiment, panel 30 is integrally formed from PVC through an extrusion process. In other embodiments, panel 30 may be constructed from other plastics or materials, and formed through different processes, as understood by those with skill in the relevant arts. In yet other embodiments, one or more elements of panel 30 may be formed separately, and attached to panel 30 through additional processes.
As will be apparent to those skilled in the relevant arts, the use of hollow panels offers a number of advantages including, for example, reduced structural weight, and potential for improved insulation and/or fire retardation by, for example, filling voids 54 with insulating or fire retarding foams or other materials. Materials used to fill voids 54 can be chosen based on numerous criteria such as desired panel strength, rigidity, fire retardation concerns, thermal and or audio insulation, cost and weight.
Modular support panel 30 defines, by itself and/or in cooperation with one or more other support panels 30, one or more channels 58 for receiving brackets or other removable load-bearing members. As shown in FIG. 3, channels 58 include respective openings 62 for receiving the load-bearing members, as well as respective base portions 66 and retaining flange 78 for supporting the load-bearing members. FIG. 3 shows an embodiment of a channel 58 defined by an integral channel wall having a base portion 66 and a side portion 70. In the embodiment shown, side portion 70 extends from base portion 66 and curves up to front wall 34. A side portion 74 connected in a substantially perpendicular manner to front wall 34 and base portion 66 defines the other side of channel 58. In this embodiment, base portion 66 is reinforced with separation rib 67, one of which comprises a section of side portion 74.
Referring still to FIG. 3, flange 78 can be formed in various configurations, using different structures. For example, as shown in FIG. 3, flange 78 extends a distance D1 from side portion 74 to form an integral u-shaped structure comprising inner surface 88 and outer surface 82. Outer surface 82 is connected to front wall 34 and inner surface 82 is connected to side portion 74. In this embodiment, side portion 74 comprises spanning rib 68, which spans the distance between inner surface 88 and outer surface 82 of flange 78. Preferably, flange 78 is configured to define at least a portion of receiving channel 58 and to support loads applied to an inner surface of the flange, the loads comprising at least a vector component normal to the front wall 34. In the embodiment shown in FIG. 3, flange 78 is substantially parallel with front wall 34, the outer surface 82 of flange 78 being in substantial alignment with the outer surface of front wall 34. In other embodiments, flange 78 can take other shapes such as L-shaped protrusions or other configurations as would be understood by those skilled in the relevant arts. Flange 78 can be constructed from substantially the same material as the majority of panel 30, or can be constructed of a different suitable material. In yet other embodiments, flange 78 can be aligned with front wall 34 in a non-parallel fashion, and/or connected at other locations on side portion 74, such that front portion 82 is not aligned with front wall 34.
As will be understood by those of skill in the relevant arts, a suitable support member, such as a shelf (not shown) with a bracket that complements the shape of channel 58, can be used with support panels 30. In use, the bracket is inserted into channel 58 such that the shelf is held substantially perpendicular to support panels 30. In order to support the shelf in this configuration, and any extra weight that the shelf itself must support, the bracket exerts a force, or a load, at least partially on inner surface 88 of flange 78 and at least partially on base portion 66.
Panels 30, in accordance with the invention, can comprise additional structural members for providing support to load-bearing portions of panel 30. For example, in some embodiments of the invention, panels 30 comprise one or more support ribs 86 located within void 54 for transferring torsional, bending, and/or other loads applied to flange 38 by, for example, a removable load-bearing support member. Support rib 86 can be proximate to side portion 74, and extends between front wall 34 and back wall 38. In general, support rib 86 supports the load-bearing capabilities of flange 78 and may allow for greater loads to be supported by support panel 30.
Referring now to FIG. 4, support rib 86 is shown connected to front wall 34 and back wall 38. Support rib 86 and back wall 38 define angle 110 through their connection. Angle 110 is preferably less than about 90 degrees such that support rib 86 is closer to side portion 74 at front wall 34 than at back wall 38. As will be understood by those familiar with such structures and the support of load-bearing members, the value of angle 110 and the orientation of support rib 86 in relation to back wall 38 can be varied. For example, angle 110 can be in the range of about 20 to about 85 degrees, more preferably in the range of about 40 to about 70 degrees, and even more preferably in the range of about 50 to about 70 degrees. An angle 110 of about 65 degrees has been found to serve particularly satisfactorily.
Support rib 86 is preferably attached to front wall 34 at a distance from side portion 74 that is between zero to about 4 times D1 (the distance that flange 78 extends from side portion 74, as described above). It is even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 0.5 times to about 3.5 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 1.5 times to about 3.0 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 2 times to about 2.7 times D1. In some embodiments, support rib 86 can be attached to front wall 34 at a position as close to side portion 74 as the corner formed by side portion 74 and front wall 34.
Front wall 34 and back wall 38 may be generally parallel to each other and are separated by distance D2. A suitable distance D2, as well as suitable thicknesses of the walls and other components of the panel, can be determined by a person skilled in the relevant arts, and will generally be dependent on the materials used to construct them, as well as the desired loads that they are expected to bear, and various manufacturing practicalities.
In another embodiment of the present invention, a second support member 86 is used, as shown in FIG. 4. Second support member 86 can be attached to front wall 34 at a distance anywhere along void 54, but it is preferred that it is attached to front wall 34 at a distance from side portion 74 that is between zero to about 4 times D1. It is even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 0.5 times to about 3.5 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 1.5 times to about 3.0 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 2 times to about 2.7 times D1.
It is not required that each support member 86 has the same angle 110. The angles will be determined by the particular load requirements. For example, an embodiment is shown in FIG. 5 where second support member 86 has a smaller angle 110 than the first support member. In this embodiment, second support member 86 is shown attached to front wall 34 at the same distance from side portion 74 as the first support member. In other embodiments, second support member 86 can have a different able 110 and be attached to front wall 34 at a different distance from side portion 74.
In theory, there is no limit to the number of support ribs 86 that could be used; however, a skilled person could determine a practical number of support ribs 86, and their relative location, useful to support a desired load.
Referring back to FIG. 2, multiple panels 30 can be joined, at their respective mating ends 42 and 46, to form a continuous modular wall assembly. Ends 42 and 46 can comprise male-female or other mating configurations such as that shown, which includes a female joint portion 112 at end 42 and a male joint portion 114 at end 46. The embodiment shown in FIG. 2 further comprises flange portion 118 and wall structures 119, 120, 121 at ends 42, 46, such that when an end 42 is joined or otherwise placed in a proximate configuration to an end 46 to form a wall assembly, a channel 58 for receiving a load-bearing member can be formed by the respective ends 42, 46.
FIG. 5 shows a portion of a modular wall assembly, or modular support panel system, 200 in accordance with such an embodiment of the invention. Panel system 200 is formed by joining two modular panels 30 a and 30 b. Modular panel 30 a and modular panel 30 b are similar to modular panels 30, and like elements in modular panel 30 a and modular panel 30 b bear reference numbers similar to those of like elements in modular panels 30.
In the embodiment shown, a channel 122 is formed, or defined, where an end 42 meets an end 46. Accordingly, as shown in FIG. 5, the opening 62 of channel 122 is defined by front wall(s) 34 and flange 118. Furthermore, portion 119 of end 42 between front wall 34 a and female joint 110 a forms one side portion of channel 122. Portion 121 of end 46 between front wall 34 b and male joint 114 forms another other side portion. A portion 120 of male joint 114 that remains outside female joint 110 forms a base portion for channel 122.
In the embodiment shown, a support rib 130 is located proximate to end 46. As should be apparent to those skilled in the relevant arts, all variations discussed above for support rib 86 are also applicable to support rib 130 and are within the scope of the invention.
Modular wall assembly 200 can be secured to an existing wall system, or suitably supported by other means known in the art. For example, modular wall assembly 200 can be mounted directly on structural supports (e.g. stud walls). Alternatively, modular wall assembly 200 may comprise suitable supporting means to enable it to be self supporting such that minimal extra supporting means are required.
As shown, for example, in FIG. 2, it can be advantageous in some embodiments for panel 30 to include a plurality of channels 58. As will be understood by those skilled in the relevant arts, the relative spacing and configuration of channels 58 can be selected to accommodate desired loading configurations when load-bearing members are installed.
In another embodiment of the present invention, a panel 30 with opposing flanges 78 forming a “T” channel, as shown in FIG. 6, is provided. In this embodiment, an opening 300 is defined between opposing flanges 78. Opening 300 leads into channel 310, which is defined by side portions 320 and base portion 330. Support members 86 are provided to support each flange 78 and may be mirror reflections of each other or different. The parameters for support members 86 are as already described. In this embodiment, support member 86 can support only one flange 78 of the “T” channel or both.
While the invention has been described in some detail for purposes of clarity and understanding, it will be appreciated by those skilled in the relevant arts that various changes in form and detail can be made without departing from the true scope of the invention in the appended claims. The invention is therefore not to be limited to the exact components or details of methodology or construction set forth above.

Claims

1. A support panel for supporting one or more removable load bearing members, said support panel comprising:

a body having a front wall and a back wall;

at least one channel defined in said body for receiving at least one load bearing member, said channel having an opening defined in said front wall, a base portion, and a flange portion for engaging said load bearing member; and

at least one support rib extending between said front wall and said back wall, each support rib extending at an angle of between 30 and 85 degrees relative to the back wall.

2. The support panel of claim 1, wherein each support rib extends at an angle of between 40 to 70 degrees relative to the back wall.

3. The support panel of claim 1, wherein said support rib extends at an angle of between 50 to 60 degrees relative to the back wall.

4. The support panel of claim 1, wherein said support rib is connected to said front wall at a location zero to four times the width of the flange.

5. The support panel of claim 1, wherein said support rib is connected to said front wall at a location in the range of between about 0.5 times to about 3.5 times the width of the flange.

6. The support panel of claim 1, wherein said support rib is connected to said front wall at a location in the range of between about 1.5 times to about 3.0 times the width of the flange.

7. The support panel of claim 1, comprising at least one base reinforcement rib spanning said base portion and said back wall for reinforcing said base portion.

8. The support panel of claim 1 wherein said flange is u-shaped.

9. The support panel of claim 4, comprising a spanning member spanning two ends of the u-shape of said flange for strengthening said flange.

10. The support panel of claim 1, comprising edges adapted for modular connection to mating edges of other panel structures.

11. The support panel of claim 10, wherein the edges adapted for modular connection are configured such that when mated with edges of other panel structures the edges and mating edges form a channel for receiving at least one load bearing member, said channel having an opening, a base portion and a flange portion defined by the edges and mating edges.

12. The support panel of claim 1, comprising a plurality of support ribs extending between said front wall and said back wall, each of said support rib extending at an angle of between 30 and 85 degrees relative to the back wall.

13. The support panel of claim 12, wherein at least one of said support ribs is connected to said front wall at a location within approximately zero to four times the width of the flange.

14. The support panel of claim 12, wherein at least two of said support ribs define angles with the back wall that are not equivalent.

15. The support panel of claim 1, comprising a plurality of channels defined in said body for receiving load bearing members, each said channel having an opening defined in said front wall, a base portion and a flange portion defined by said body for engaging at least one load bearing member.

16. A support panel for supporting one or more removable load bearing members, said support panel comprising:

a body having a front wall and a back wall;

at least one channel defined in said body for receiving at least one load bearing member, said channel having an opening defined in said front wall, a base portion, and two flange portions such that the channel forms a “T” shape; and

17. A modular support panel system for supporting at least one removable load bearing member,

said system comprising a plurality of support panels, each said support panel comprising:

a body having a front wall and a back wall; and

first and second edges configured such that two adjacent panels can be linked by adjoining a first edge of one panel to a second edge of the second panel to form a wall structure;

the first and second edges of adjacent panels defining, when joined, a channel for receiving said at least one load bearing member, said channel having an opening defined by the front walls of the adjacent panels, a base portion, and a flange portion for engaging said load bearing member;

at least one of the support panels further comprising a support rib extending between its front wall and its back wall, said support rib extending at an angle of between 30 and 85 degrees relative to the back wall.

18. A support panel for supporting a removable load bearing member, said support panel comprising:

a body having a front wall and a back wall;

a channel defined in said body for receiving said load bearing member, said channel having an opening defined in said front wall, a side portion perpendicular to said front wall and said back wall, and a flange defined by said body for engaging said load bearing member; and

a support rib extending between said front wall and said back wall to transfer force exerted on said flange by said load bearing member toward said back wall, said support rib extending at an angle of between 10 and 50 degrees relative to the back wall.