The present invention relates to an organizer wall panel assembly, and more particularly an organizer wall panel assembly formed from a number of stackable, modular panels which are configured for use and securement as a wall section in substitution for part or all of a conventional dry wall sheet.
The construction of organizer wall panel assemblies by securing in place, a series of stacked, individual wall panels is well known. U.S. Pat. No. 7,306,107 to Secondino describes an earlier panel construction which individual wall panels are adapted for interconnection with horizontally adjacent panels in the erection of an organizer wall. Conventional panels used in organizer wall applications are typically formed as an elongated hollow extrusion and have variable lengths of between about six and twelve feet, a vertical height of about 8 inches, and lateral thickness of about % inches. The panels are formed with a longitudinal, “L-shaped” mounting groove which is sized to receive the bent end of a hangar member or bracket used to hang power or garden tools, garden equipment as well as other items, and which is formed with normally extending horizontal and vertical segments configured for complementary placement within the groove.
The applicant has appreciated that organizer walls formed from conventional panels suffer the disadvantage that the wider thickness of the profile frequently necessitates the assembly of conventional panels as a whole-wall application, where the panels are arranged to extend vertically fully from the floor to the ceiling. In particular, the added thickness of the panel extrusion prevents the easy integration of the wall panel assembly with conventional dry wall sheets, as part of a finished wall section. As a result, conventionally such panels are installed either over the top, or in place of conventional dry wall sheets, at increased costs.
In addition, the erection of organizer wall panel assemblies with panels arranged in a whole-wall arrangement results in the presence of mounting grooves in areas adjacent to the floor and ceiling with no practical functionality to the user. In addition to significantly increased production costs compared to the cost of securing conventional dry wall sheets, the requirement to install individual organizer wall panels individually, is far more labour intensive and time consuming.
To at least partially overcome some of the difficulties associated with conventional organizer wall panel constructions, the present invention provides an organizer wall panel assembly which is adapted for integration into a conventional wall construction, in place of part or all of a conventional half inch thick sheet of dry wall or gypsum board.
In one embodiment, the present invention provides for an organizer wall panel assembly which is formed at least in part from a series of horizontally stacked, longitudinally elongated panels. Each of the panels is most preferably from plastic or aluminum and are extruded or molded with a constant horizontal profile and variable longitudinal length of up to 20 feet, and preferably between 8 to about 16 feet. Most preferably, the panels have a generally modular construction, allowing the panels to be secured in place in a horizontal edge-to-edge arrangement in no particular order. The panels are formed having a generally rectangular body, an upper connecting portion which with the body forms an elongate mounting groove, and a lower covering flange portion.
Although not essential, the body is preferably formed as a mostly hollow construction having a generally planar front and rear surface. The rear surface is adopted for juxtaposed placement and mounting to a wall or wall studs. The front surface is generally parallel to the rear surface and is spaced therefrom to provide the panel body with a lateral thickness substantially corresponding to a thickness of a conventional dry wall sheet. Most preferably, the lateral thickness of the body is selected at between about 0.4 and 0.7 inches, most preferably between about 0.5 and to about 0.6 inches.
The lower covering flange portion projects downwardly past the lower extent of the panel body. Preferably, the covering flange portion is formed as a resiliently deformable web which is integral with the lower edge of the front panel surface. With the panel in a mounted arrangement, the covering flange portion most preferably extends downwardly below the body by a distance selected to overlie at least part of the connecting portion of a next lower adjacent panel or dry wall sheet. The covering flange portion further includes a rearwardly tapering lowermost edge portion. The tapering edge portion bends or curves rearwardly downwardly towards the rear of the panel. Most preferably, the lowermost edge of the covering flange portion is spaced rearwardly from the plane of the panel body front surface by a distance of between about 0.4 inches and 0.1 inches, and preferably about 0.3 inches and 0.15 inches, towards the panel rear.
The upper connecting portion is preferably integrally formed with the panel body as a single molding or extrusion. Although not essential, most preferably the panel is provided whereby the upper connecting portion is adapted for engagement with the lower edge of a next vertically adjacent panel in a mated fit arrangement. In one non-limiting construction, the upper connecting portion extends vertically from about 1 inch to about 2 inches from the upper edge of panel body. The connecting portion is provided with a fastener receiving portion which is sized to receive a nail, screw or other suitable mechanical fastener thereto, in the securement of the panel in place against the wall. The fastener receiving portion is connected to the panel body towards or along its rearward side by a vertical web. Horizontally extending shoulder and arm members, respectively project upwardly and downwardly along forward portions the fastener receiving portion. The fastener receiving portion, arm member and panel body comprise to define an L-shaped mounting groove sized to receive therein, the bent or hooked ends of one or more mounting brackets.
The applicant has appreciated that a number of panels may be assembled in a horizontally stacked, side-by-side arrangement together with one or more conventional dry wall sheets. Such an arrangement may provide a finished wall section which incorporates into part of the wall only, an organizer panel wall assembly which provides for hangar member retaining mounting grooves only in selected or preselected areas, having regard to customer preferences.
In one non-limiting possible mode of use, a number of stackable panels of the present invention may be adapted for securement directly to wall studs in place of a conventional dry wall sheet to provide an organizer wall panel assembly which extends vertically as only part of a conventional wall section. Where the lower extent of the wall section is finished with a conventional dry wall sheet, the covering flange portion of a lowermost positioned wall panel is provided overlying a horizontal upper edge of the conventional dry wall sheet. In such an arrangement, the rearwardly tapering portion of the covering flange portion is urged into resilient contact against the adjacent dry wall panel, to provide a visually finished edge.
Although not essential, the organizer wall panel assembly is preferably adapted for use with hangar members/brackets which incorporate a hooked mounting end sized for mated placement within the mounting groove in an edge-fit manner. Most preferably, the hooked end includes a generally horizontal web portion which extends inwardly from a rear portion of the hangar bracket adapted for juxtaposed placement against the panel front surface to an upwardly extending finger portion. The finger portion most preferably extends angularly upward from the innermost edge of the horizontal web at an angle selected at between about 55 to about 85 degrees, preferably about 65 to 75 degrees, and most preferably about 70 to 80 degrees relative thereto. The extent and angular orientation of the finger portion is selected to engage a rearwardmost portion of the arm member, and assist in maintaining bearing contact between the panel body and rear portion of the hangar member when under load.
Optionally, the upper connecting portion may be provided with a guide groove or other visual indicia for use guiding placement of mechanical fasteners through the fastener receiving portion at desired positions. The upper connecting portion may further be provided with one or more longitudinally extending channels, slots or recesses which are adapted for mated engagement with complementary formed members provided on the covering flange portion of a next adjacent upper panel.
Accordingly, in one aspect the present invention resides in an organizer wall panel assembly comprising a plurality of stackable panels having the substantially the same height and width, each said panel comprising a generally rectangular panel body having front surface, a wall engaging rear surface and horizontally extending upper and lower edges; an horizontally extending upper connecting portion, and a lower horizontally extending covering flange portion, the rear surface extending generally in a first plane, the front surface extending generally in a second plane parallel to and spaced laterally forward from the first plane by a distance selected at between about 0.5 and 0.65 inches, the upper connecting portion including, a vertical connecting web extending vertically upward from the upper edge and having a rear portion substantially coplanar with the rear surface and adapted for juxtaposed placement with said wall, a fastener receiving portion joined to the vertical connecting web, the fastener receiving portion being spaced rearwardly from the second plane and including a fastener pierceable body adapted to receive a mechanical fastener therethrough, and upwardly extending shoulder member and a downwardly extending arm member, the shoulder member projecting upwardly from the pierceable body to define at least in part a longitudinally extending channel groove therewith, the arm member projecting downwardly from the pierceable body a distance part way towards the upper edge, wherein the arm member, pierceable body and panel body define at least in part a longitudinally extending retention groove seized for receiving an end portion of a hooked member therein, the covering flange portion being integral with and extending downwardly from the front surface a distance selected to substantially overly the fastener receiving portion of a next lower panel when positioned adjacent thereto, the covering flange portion tapering rearwardly to a bottom panel edge portion, the bottom panel edge portion being resiliently deformable between an unbiased position, wherein the bottom edge portion is spaced a distance selected at between about 0.03 inches and 0.15 inches, preferably about 0.04 inches and 0.1 inches, rearwardly from the second plane, and a biased position wherein the bottom edge portion is moved towards coplanar alignment with the second plane.
In another aspect, the present invention resides in an organizer wall panel assembly comprising a plurality of stackable panels having the substantially the same height and width, said panels being secured to a wall in a stacked side-by-side arrangement, each said panel comprising a generally rectangular hollow panel body having front surface, a wall engaging rear surface and horizontally extending upper and lower edges; an upper horizontally extending connecting portion, and a lower horizontally extending covering flange portion, the rear surface extending generally in a first plane, the front surface extending generally in a second plane parallel to and spaced laterally forward from the first plane by a distance selected at between about 0.5 and 0.65 inches, the upper connecting portion including, a vertical connecting web extending vertically upward from the upper edge and having a rear portion substantially coplanar with the rear surface and adapted for juxtaposed placement with said wall, a fastener receiving portion joined to the vertical connecting web, the fastener receiving portion being spaced rearwardly from the second plane and including a fastener pierceable body adapted to receive a mechanical fastener therethrough, and upwardly extending shoulder member and a downwardly extending arm member, the shoulder member projecting upwardly from the pierceable body to define at least in part a longitudinally extending channel groove therewith, the arm member projecting downwardly from the pierceable body a distance part way towards the upper edge, wherein the arm member, pierceable body and panel body define at least in part a longitudinally extending retention groove sized for receiving an end portion of a hooked member therein, the lower edge, further including a horizontally extending boss, the boss sized for mated placement within the channel groove of a next lower-panel when positioned adjacent thereto, the covering flange portion being integral with and extending downwardly from the front surface a distance selected to substantially overly the fastener receiving portion of the next lower panel, the covering flange portion tapering rearwardly to a bottom panel edge portion, the bottom panel edge portion being resiliently movable from an unbiased position, wherein the bottom edge portion is spaced a distance selected at between about 0.03 and 0.15 inches, preferably about 0.4 and 0.1 inches, rearwardly from the second plane to a biased position wherein the bottom edge portion is moved forwardly by a deflected distance selected at least between about 0.03 and 0.3 inches, and preferably about 0.3 and 0.15 inches.
The present invention additionally provides various further non-limiting aspects, and which include without restriction as follows:
Reference may now be had to the following detailed description taken together with the accompanying drawings in which:
Reference may be had to
As is illustrated, the organiser wall panel assembly 8 is provided at a height spaced above the floor 4, and forms a section of the finished wall 6 and has an overall vertical extent selected at between about 2 and 6 feet, for increased efficiency, and reduced manufacturing and installation costs. It is to be appreciated however, that depending on individual user requirements, the organizer wall panel assembly 8 may be provided with a greater or lessened vertical height, or if desired, could extend the full vertical height of the wall 6.
Reference may be had to
Each panel 20 is preferably provided as interchangeable panels having a unitary construction, and for example are formed as a plastic, aluminum or most preferably polyvinylchloride (PVC) extrusions. The panels 20 have an overall vertical height of between about 5 and about 8 inches, preferably between about 6 and 7 inches, and may be provided with a variable longitudinal length. Typically, the panel 20 length ranges between about 6 feet to about 16 feet; and most preferably between about 8 feet to about 12 feet. Longer or shorter panels 20 may however be provided depending on the final applicator.
A horizontally extending arm member 62 extends downwardly from the forward edge portion of the pierceable body 54 generally vertically aligned beneath the shoulder member 56. The arm member 62 extends part way, and preferably approximately half way towards the upper edge 32a of the panel body 22. The shoulder member 56 and arm member 62 preferably extend to a forwardmost distance which is spaced rearwardly from the plane PF. The configuration of the fastener receiving portion 42 is selected to allow for the positioning of a covering flange portion 26 of a next upper adjacent panel 20, in a position substantially overlying the fastening receiving portion 52, in a generally co-planar arrangement with the plane PF.
The panel body 22, reinforcing wall 46, body 54 and arm member 62 define an L-shaped retention groove 64 therebetween. Preferably, the arm member 62 further includes a longitudinally extending notch 66, the notch 66 is adopted to receive therein in a complimentary fit arrangement therein, the rib 38 of the next horizontally adjacent panel 20.
Although not essential, most preferably the shoulder member 56 and arm member 62 define a fastener receiving groove 68 therebetween. The fastener receiving groove 68 is sized to substantially receive therein head portion 18 of the screw fasteners 16, when inserted through the fastener pierceable body 54 in the mechanical securement of the panel 20 to the wall studs 12.
A first organizer panel 20 is then mounted horizontally against the dry wall sheet 10 in the position shown in
The remainder of the wall panel assembly 8 may then be completed by assembling subsequent organizer panels 20 in a horizontally stacked edge-to-edge relationship to provide the wall panel assembly 8 of a desired vertical height. As each next panel 20 is positioned, the boss 34 of the next adjacent panel 20 received in the channel groove 60 of the underlying panel 20, and screw fasteners 16 are inserted through the fastener pierceable body 54 and into the studs 12 in the manner shown in
As shown best in
The applicant has appreciated that the angular orientation of the finger 90 relative to the horizontal web 86 facilitates the positioning of the hangar member back 82 more fully against the front surface 28 of the panel body 22, when a load is suspended from the hangar member 80.
Although the detailed description describes and illustrates various preferred embodiments, the invention is not limited to the specific preferred embodiments which are described. May modifications and variations will now occur to persons skilled in the art.