The invention is generally related to panel mounted accessory devices, and more particularly to an apparatus and a method for mounting accessory devices to panels.
Plastic and other panels are used in many different applications for a wide variety of modular or multi-component products. In many of these applications, a plurality of panels and/or components are interconnected to one another to form a finished product assembly. A number of different structures and methods have been devised that are useful to interconnect or attach two adjacent components to one another. A number of different accessory devices have also been devised that attach or otherwise mount to the panels that are useful for hanging or otherwise suspending objects from the panels.
In one example, a typical panel may provide a plurality of access holes therein. A typical hanger has prongs or hooks that are adapted for receipt in selected ones of the access holes. The prongs or hooks are inserted in the selected holes to suspend the hanger from the panel. In other examples, hangers, hooks, or mounting brackets are simply fastened to a panel utilizing conventional fasteners such as screws, bolts, or the like.
Problems associated with such accessory devices and mounting methods are abundant. Conventional threaded fasteners result in use of a number of component parts (nuts, bolts, washers, and the like) that can be easily lost or misplaced and that require significant labor to install. The hook-on accessory devices typically hang relatively loosely and, thus, can be easily dislodged and do not provide a sturdy mount for hanging objects. The fastener mount accessory devices can easily come loose if not properly fastened. Also, the fasteners can become loosened if the hanger is used over and over again, again resulting in a less than sturdy mount for hanging objects.
Exemplary mounting apparatuses and mounting methods in accordance with the teachings of the present invention are described and explained in greater detail below with the aid of the drawing figures in which:
The disclosed apparatuses and methods for mounting accessory devices to a panel solve or improve upon the above-mentioned problems in the prior art. The disclosed apparatuses and methods are especially well suited for mounting accessory devices to plastic panels, although they can be easily adapted for use with other panel materials, if desired. A sturdy mounted accessory device and method is disclosed and described that utilizes no mounting fasteners. A portion of an accessory device slides within and interlocks with a portion of a panel to secure the device in place. The disclosed apparatuses and methods for mounting accessory devices render such a device easy to install on a panel and result in a sturdily mounted device that is relatively difficult to dislodge.
Also shown and described herein are an exemplary apparatus and method for interconnecting adjacent panels. The disclosed interconnecting apparatus and method result in panels being connected in a simple, efficient manner. The disclosed apparatus and method for mounting accessory devices generally follow the same principles as the methods and apparatuses described herein for interconnecting two panels. The illustrated accessory installation is strong, secure, and easy to install and can support a wide variety of objects.
In order to simplify the description herein, a general element is given a base reference number. If a number of essentially identical elements are shown or referred to herein, the discrete, identical elements are each given the same base reference number and a unique sub-reference character. As an example, and with reference to
Also, terms of orientation, location, or part relationship are used herein, such as “top,” “bottom,” “front,” “back,” or other such descriptive terms. Such terms are utilized solely for ease of description and are not intended to specifically limit a component in any way. The panels and other components can be oriented and arranged in virtually any desired manner without being unnecessarily limited or restricted by the use of such terms herein.
As a further preliminary matter, the panels illustrated herein are for a modular shed or storage structure. However, the features of the disclosed examples have a much wider applicability. The panels and the accessory device and its illustrated mounting features can be used for other products including storage devices, units, enclosures, bins, boxes, containers, display panels, boards, totes, and other object storage and organization products. The connectors can be used for any of a variety of containers and the like as well.
The particular materials used to construct the exemplary panels are also illustrative. For example, blow molded, high density polyethylene is one preferred material and method for fabricating the disclosed panels. However, other materials can be used, such as other thermoplastic resins including polypropylene, acrylonitrile butadiene styrene (ABS), polyurethane nylon, homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, and the like. Also, molding or part forming operations other than blow molding can be used to form the various disclosed components, such as injection molding, rotational molding, and the like.
Further, injection molded, high density polyethylene is a preferred material and method for fabricating the connectors disclosed herein. However, other materials can certainly be used, such as other thermoplastic resins including polypropylene, acrylonitrile butadiene styrene (ABS), polyurethane nylon, homopolymer plastics, copolymer plastics, plastics with special additives, filled plastics, and the like. Still further, other molding operations or part forming operations can be used to form the connector components.
As will be evident to those having ordinary skill in the art, the various parts and components disclosed herein can be formed from other materials such as metal, wood, and the like, if desired and yet fall within the spirit and scope of the present invention. The components can also be fabricated utilizing a variety of manufacturing techniques such as stamping, casting, machining, and the like, as desired.
With the above in mind and with reference to
In the disclosed example, one or more accessory devices in the form of utility hangers 44 can be mounted to the profile side 40 of each panel. The accessory devices can be added to perform any number of desired functions, such as to provide shelving supports, tool hangers, and the like. As shown in
Details of the various structures and methods to interconnect the panels are now described. In general, a pair of adjacent panels, such as the panels 30a and 30b, can be interconnected by one or more connectors 46 that engage a portion of the profile side 40 of each adjoining panel. The adjacent panels 30a and 30b are first attached or interlocked with one another and then secured or connected to one another utilizing one or more of the connectors 46.
As shown in
As illustrated in
As shown in
Details of both the method and the apparatus in accordance with the teachings of the present invention are described, beginning with reference to FIG. 4. Each of the panels has an interlocking element at all of the edges that are adapted to interconnect with an adjacent panel. The interlocking elements of the panels to be joined are first interlocked to one another. Then a connector is utilized to secure the adjacent panels together.
In this disclosed example, each adjacent panel edge to be joined, such as the side edges 38a of the panel 30a and 36b of the panel 30b, has an interlocking lip 60a and 60b, respectively, that extends from the corresponding panel edge. Each lip 60 extends from the panel edge at an angle, and in this example, is generally perpendicular to a plane of the corresponding panel. Each lip 60a and 60b defines a groove 62a and 62b, respectively, between the lip and the panel edge. The lips 60 and grooves 62 of the respective panels are arranged in opposite directions so that the lip of one panel is received in and engages the groove of the adjacent panel in an interlocking relationship. For example, as shown in
Once the two adjacent panels, such as the panels 30a and 30b, are engaged or interlocked in this manner, the two panels, and thus the channels 50a and 50b are properly spaced apart laterally across the joint. However, the two panels 30a and 30b should also be aligned longitudinally so as to accommodate installation of a connector 46. In the disclosed example, the connector 46 requires that the corresponding docking sections 54a and 54b and engaging sections 56a and 56b of the adjacent channels 50a and 50b be directly across from one another. In an alternative example, though not shown or described in detail herein, the connector 46 can be designed to require a different, non-mirror image alignment of the adjacent channels 50, if desired.
Details of the channel segments 52 are described with particular reference to
The connector interface of one or both of the adjacent panels can include a detente mechanism to provide a positive fully installed feel or indication. The detente mechanism can also assist in holding a connector in an installed position. In this example, a detent ramp 80 is provided on at least one of the bearing surfaces 66 adjacent the connector slot 68. In the present example, a ramp 80 is provided on the side of the bearing surface 66 furthest from the panel edge so that when the connector 46 is installed, its outer most forward edges each engage a detent ramp to assist in holding the connector in the installed or engaged position. In the present example, the detent ramps 80 each have an inclined ramp surface 82 that can be inclined at a desired angle to make installation of the connector relatively easy. The ramps 80 in this example are located near the forward, narrowed end or stop surfaces 72 of the latching tunnel 70. However, the ramps can alternatively be provided anywhere along the bearing surfaces and yet provide the attendant function. Each ramp surface terminates at its inclined end at a front end 84.
Referring now to
The disclosed connector 46 has a body or base 100, which in this example is generally rectangular, and nearly square. The disclosed base 100 is a molded thermoplastic component having a wall thickness and a structural design sufficient to render the base substantially rigid. In the present example, the base has a top wall or surface 102, an annular depending skirt 104, which in this example is in the form of a plurality of depending skirt walls 104a, 104b, and 104c, and 104d necessitated by the polygonal shape of the base. The wall 104a is positioned at a leading end of the connector 46 and the wall 104b is positioned at a trailing end. The walls 104c and 104d define sides of the connector. The height of the annular skirt or side walls 104 creates a bottom well or depression 106 in the connector 46. A plurality of structural ribs 108 extend both longitudinally and transversely across the well 106 to provide additional structural rigidity to the connector 46 while minimizing the weight of the part and the amount of material necessary to form the part. The bottom well 106 and the ribs 108 of the base 100 are shown in simplified form in
The engaging parts of the connector 46 in this example each include a plurality of discrete engaging or locking pins 110 that extend generally perpendicular from the top wall 102. Each of the locking pins 110 has a narrow stalk section 112 connecting the pin to the base and an engagement head 114 spaced from the top wall by a respective stalk. The transverse width of the stalk essentially corresponds to the width of the connector slot 68 described previously for the channels 50. Similarly, the size and contour of the heads 114 correspond in size and shape to the cross sectional shape of the connector tunnel 70. In the present example, the pins 110 are open at the top and thus have a partly open interior 116 to reduce the weight of the part and to reduce the amount of material needed to fabricate the part.
The pair of engaging parts of the disclosed connector 46 are arranged as a pair of pin rows 120a and 120b disposed adjacent and arranged along the opposite edges or sides of the connector 46. Each pin row 120 can alternatively be replaced by a unitary elongate structure or engaging part with no discrete segments or pins, if desired. Elongate strengthening ribs 121 are arranged parallel to and spaced apart from one another and extend longitudinally between the discrete pins 110 in each of the rows 120a and 120b.
Suitable recesses, openings, and the like can be provided such as the openings 122 in the connector 146. Such features may be necessary or advantageous when molding or otherwise forming the connector. As will be evident to those having ordinary skill in the art, the shape, construction, and various features of the pins and base can vary considerably and yet fall within the scope of the present invention.
As shown in
Similarly, a recess 132 is provided near each forward corner 134 of the base 100. Each recess 132 has an inclined surface 136 and a front detent barrier wall 138. The recesses 132 are open both to the top wall 102 and the skirt or side walls 104c and 104d. However, each recess is closed off toward the front wall or skirt 104a by a part of the front wall that defines the detente barrier wall 138 for reasons described below.
The procedure for installing a connector 46 in order to interconnect two adjacent panels 30, and the corresponding component features, are now described with particular reference to
A connector 46 is then selected and oriented with the pins 110 facing the profile sides or surfaces 40a and 40b of the interlocked panels 30a and 30b. The connector is also oriented such that the connector leading end 124 generally faces toward the connector slot 68 and tunnel 70 into which the connector is to be installed. The pins 110 are then moved directly over the connector channels 50 and 50 of the panels. One row 120a of pins 110a is inserted into the docking section 54a of the channel 50a and the other row 120b of pins 110b is inserted into the docking section 54b of the channel 50b as shown in FIG. 12. In this pre-installation position, the pins 110 and base 100 essentially float freely within the docking sections 54 of the channels 50. The center part of the connector base wall 102 can be designed rest or bear against portions of the panels 30a and 30b between the channels 50a and 50b, if desired. These regions of the panels can be sized to precisely vertically position the connector relative to the depth of the channels.
To complete installation of the connector 46, the connector is moved in the direction of the arrow “A” toward the engaging sections 56a and 56b, as shown in FIG. 12. The notches 130 on the pin leading ends and the tapered entry 74 into the connector slot 70 each assist in guiding the heads 114 and stalks 112 of the pins 110 into and between edges of the tunnel 70 and slot 68, respectively. The heads 114 are then guided along the tunnel 70 by the close fitting and complimentary relationship between the heads and tunnels. The heads 114a move into and along the tunnel 70a and the heads 114b move into and along the tunnel 70b. Similarly, the stalks 112a and 112b travel along the connector slots 68a and 68b, respectively. The slot width and stalk width are preferably sized to provide a close fit between the parts.
As the recesses 132 approach the ramps 80, the detente barrier walls 138 ride up the ramp surfaces 82. When the detente barriers 138 reach the forward or front ends 84 of the ramps 80, the barriers 138 snap over the forward ends to capture the ramps in the recesses 132. The angle of the inclined surfaces 136 of the recesses 132 preferably match the angle of the ramp surfaces 82. The detente structure assists in longitudinally holding the connectors in place. The dimensions of the slot 68, stalks 112, tunnels 70, and heads 114 can also be such that static friction created between tightly fitting components also assists in holding the connectors in place. When the connectors 46 are installed, the relatively large size of heads 114 and the narrow width of the slots 68 retain the connectors in the installed position.
The forward ends 84 of the ramps and the inner sides of the detente barriers 138 that face the ramps, when the connector is installed, are preferably drafted, angled, or rounded slightly to assist in removing the connector 46 when desired. To remove the connector, the reverse of the above-described process is performed, but the detente barriers 138 must first snap back over the ramps 80 to accomplish removal.
An apparatus and method for mounting accessory devices to such panels constructed in accordance with the teachings of the present invention generally includes an accessory device and an accessory interface on a surface of the panel. Referring now to
As illustrated in
Each accessory channel segment 202 in the disclosed example has an accessory docking section 204 that is adapted for insertion and removal of a portion of the accessory device, or in this example, a hanger 44. Each accessory channel segment 202 also has an accessory engaging section 206 that is adapted for installation of an accessory device 44. Each accessory segment 202 can accommodate mounting of one accessory device in this example and as described below.
Details of the accessory segments 202 and sections 204 and 206 are now described with reference to
One end 222 of the accessory latching tunnel narrows to define an accessory stop surface 224 that limits travel along the tunnel of the accessory device when installed. In one example, this end 222 of the tunnel 220 can be a blind end instead of a narrowed open end. The opposite end of the accessory tunnel 220 and the accessory slot 218 can be tapered slightly radially outward, as shown, to define an entry opening 226 into the accessory slot and latching tunnel.
The accessory interface of the panels 30 can also include a detent mechanism to provide a positive and fully installed feel or indication for the accessory device 44. Such a detent mechanism can also assist to hold the accessory device in the installed position. In the disclosed example, and similar to the panel connector apparatus described above, a detent ramp 230 is positioned on a top side of at least one of the bearing surfaces 216 adjacent the accessory slot 218. In the disclosed example, one ramp 230 is positioned on each side of the accessory slot 218. Each of the ramps 230 as shown are located near the forward, narrowed end 222 adjacent the accessory stop surfaces 224 of the accessory tunnel 220 and the slot 218. However, the ramps 230 can be positioned anywhere along the bearing surfaces 216 and yet provide the attendant function. In addition, the detent feature can be provided with an alternative construction and yet perform the same function when installing the accessory device 44 as described below.
Each of the detent ramps 230 disclosed herein has an inclined ramp surface 232 that can be inclined at a desired angle to render installing the accessory device relatively easy and yet adequately provide the detent or “positive home” feel when the accessory device is installed. As with the ramps 80 described above, each of the detent ramps 230 terminates at its inclined end at a front end 234.
Details of one example of an accessory device in the form of the hanger 44 are now described with periodic reference to
With that in mind, the utility part 302 has a coupling section 304 which connects the utility part and the engaging part 300. In the disclosed example, the utility part 302 has a base or support section 306 providing structural rigidity to the device 44 and a wire hanger section 308 for supporting an object. The hanger section 308 in this example has a pair of spaced apart horizontal wires 309 that extend forward from the support section 306 and that define a gap 310 between them. A pair of suitably bent support wires 312 extend one each at an angle from respective distal ends of the hanger wires 309. In this example, the support wires are curved or bent and meet at a joint 314 fixed to a part of the support section 306. Proximal ends of the horizontal hanger wires 309 are suitably joined to an upper end of the mounting section 306 at separate joints 316. In this example, the wire mounting section 306 and hanger section 308 of the utility part 302 are formed from steel or a suitable metallic material and the joints 314 and 316 between the mounting section and hanger section are weld joints.
As illustrated, the mounting section 306 is a single wire shaped or formed in a rectangular configuration. The hanger section 308 is a single wire bent to form the angled support wires 312 and the horizontal wires 309. As will be evident to those having ordinary skill in the art, the wire structure can be formed or bent to virtually any desired configuration and yet provide some utility as a utility part 302. Similarly, other materials and constructions are also possible. For example, instead of using wire, the utility section 302 can be formed from molded plastic materials, sheet metal, or the like and include simple or complex surfaces that provide the desired utility as well as other shapes and configurations to provide structure and rigidity for the part.
To illustrate, the utility part 302 in this example provides an upper resting surface defined by the spaced apart horizontal wires 309 on which parts of an object can be rested. For example, a shovel or a rake handle can be placed in the gap between the horizontal wires 309 with the shovel or rake head resting on and supported by the wires 309. Alternatively, each horizontal wire 309 and its respective support wire 312 can define a separate hook for hanging an object such that one or more objects can be supported by each discrete hook. Many other configurations and constructions are certainly possible. The utility part 302 can also be in the form of a single hook or a single horizontal support surface (see FIG. 21 and description below) for supporting objects.
As shown in
The structure and nature of the engaging part 300 can vary considerably and yet fall within the scope of the present invention. In this example, the blade is in the formed from bent wire with two elongate parallel wire segments 336 that are joined at the distal end 332. In alternative examples, the blade can be formed as a solid part from molded plastic, metal, or the like. The size and shape of the blade can vary considerably and yet fall within the scope of the present invention. The blade 330 is preferably complimentary to the accessory latching tunnel. The engaging part 300 need not be in the form of a blade 330, but instead can be in other elongate forms (see FIG. 21 and description below) without departing from the spirit and scope of the invention.
The connection 304 between the engaging part 300 and the utility part 302 can also vary. It can be a fixed, welded connection between metal or plastic parts. It can alternatively be an integrally formed plastic interconnection between the parts sections. It can also be a tightly or loosely fastened connection between the sections, as in this example. As shown herein, the proximal ends of the wire segments 336 are angled, in this example, generally perpendicular to the wire segments 336 and form legs 338 extending from the segments. A transverse bar 340 is connected to both of the legs 338 and extends between the legs. A bore is formed in the connector bar 340 generally perpendicular to the bar and the segments 336. A complimentary bore 344 is formed in the upper end of the mounting section 306 of the utility part. One of the bores can be threaded to engage a traditional fastener. Alternatively, a nut and bolt arrangement can also be used, as in this example. A shown, a conventional threaded fastener 346 is passed through each of the bores 342 and 344 to interconnect the engaging part to the utility part and a nut 348 secures the fastener in place.
As noted above and shown in
As shown in
Referring now to
In this example, the accessory slot is provided for the detente mechanism 340. If an alternative detente mechanism were provided, such as within the accessory latching tunnel 220, no slot need be provided. The blade 330 could slide into a blind tunnel in the panel in such an example. A bump or protrusion within the tunnel 220 could engage the wire at the distal end 334 of the blade to provide the detente or “positive home” feel, for example.
Though one example of an accessory device in the form of a hanger 44 is illustrated and described herein, as will be evident to those having ordinary skill in the art, many modifications and changes to the disclosed device 44 can be made without departing from the spirit and scope of the present invention. For example,
In this example, a part of a shelf 420 rests on the upper surface 414. The support 412 can be provided with a means to secure the shelf in place, such a fastener opening or a snap-in feature, as desired. Alternatively, and as mentioned above, the shelf 420 can be an integrally molded or formed part of the device 400. Any accessory device that can be mounted to a panel and provide some utility is intended to be encompassed by the scope of the present invention.
Various dimensions for certain parts of the apparatuses described herein can be selected and manipulated to achieve desired functional characteristics. For example, portions of the panels 30, connectors 46, and accessory devices 44 can be designed to create slight interference fits or slight loads at points within the apparatus. The pins, blades, engaging parts, and/or the tunnels and slots can be appropriately spaced to draw the engaged components slightly together or force them slightly apart when installed. Such a slight interference between the installed or assembled components can be utilized to create a fairly rigid joint or to form a seal at the lip and groove joint of adjoined panels. Similarly, the detente barriers, ramps, and/or other elements can also be varied to achieve certain functional characteristics. Also, the tunnel, head, stalk, bladed, and slot sizes, and shapes, and positions can be designed to create desired characteristics. As an example, the engaging parts such as the pins can be formed progressively larger, moving from the leading end to the trailing end of the connector 46. The blade width can be similarly varied.
The disclosed panels 30 are particularly well suited for the method and apparatus. The panels are hollow panels with space between the profile sides 40 and decorative sides 42. Molding tools and operations can be utilized to form a wide variety of shapes and features into the panels. Points where the profiles side 40 and decorative side 42 are joined (called “tack offs”—see
Although certain methods and apparatuses have been disclosed and described herein in accordance with the teachings of the present invention, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the invention fairly falling within the scope of the appended claims, either literally or under the doctrine of equivalents.
The present patent is a continuation-in-part of U.S. patent application Ser. No. 09/860,381, which was filed on May 18, 2001, now U.S. Pat. No. 6,701,678 and Ser. No. 10/082,608, which was filed on Feb. 25, 2002 now U.S. Pat. No. 6,668,514.
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Number | Date | Country | |
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20020174532 A1 | Nov 2002 | US |
Number | Date | Country | |
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Parent | 10082608 | Feb 2002 | US |
Child | 10127949 | US | |
Parent | 09860381 | May 2001 | US |
Child | 10082608 | US |