Patent Application
20130111827
The present invention relates to a modular paneling system. In particular, the invention pertains to assembling a modular wall using modular panels.
Commercially available panel-based divider systems are of relatively complicated construction with expensive connecting means requiring detailed and skilled assembly. Many employ multiple mechanical fasteners to join and/or support the divider panels typically requiring tools and specialized mechanical knowledge or experience and frequently specialized training and certifications. Others attempt to use captive hooks and/or brackets in the joinery which limited configuration flexibility and/or panel joint security and rigidity. Repairs, replacements or reconfigurations can require significant time and labor and disassembly of the system or major sections or portions of the system in order to accomplish a desired or necessary change.
Accordingly, there exists a need for a paneling system that can be easily assembled and/or reconfigured without requiring a skilled technician.
A non-limiting exemplary embodiment of a paneling system includes a plurality of panels wherein each panel includes a frame defined at least in part by top and bottom frame members and first and second side frame members. The paneling system also includes a plurality of panel mounting brackets, each configured for attachment to one of the top, bottom, first side and second side frame members. Also included are a plurality of elongated posts, a plurality of end pieces, each configured for removably receiving and retaining at least a portion of one or more of the plurality of mounting brackets, and a plurality of caps, each configured for removably receiving and retaining at least a portion of one or more of the plurality of mounting brackets. Each mounting bracket includes a recessed front surface and a back surface, wherein the recessed front surface includes at least one contoured edge configured for abutment with or straddling at least a portion of an elongated post. In some embodiments of the mounting bracket, the at least one contoured edge includes a ridge. Each end piece defines at least a portion of a first trough surrounding a first end of an elongated post, and each cap defines at least a portion of a second trough surrounding a second end of one of the elongated post. The first and the second trough are configured for receiving and retaining at least a portion of at least one contoured edge of one or more mounting brackets.
In some embodiments of the paneling system, each panel includes a first and a second top mounting bracket, respectively, are attached to the first and the second frame member proximate top frame member; and each panel also includes a first and a second bottom mounting bracket, respectively, attached to the first and the second frame member proximate the bottom frame member. The mounting brackets are positioned or located such that the ridge of each contoured edge of the first top mounting bracket and the ridge of the first bottom mounting bracket are parallel to the first side member and are oriented towards respective top and bottom members; and the ridge of the second top mounting bracket and the ridge of the second bottom mounting bracket are parallel to the second side member and are oriented towards respective top and bottom members.
In certain embodiments of the paneling system, the cap includes a threaded shank and the second end of said post includes a threaded receptacle configured for receiving the threaded shank of the cap. In some embodiments of the paneling system, the cap and the second end of the post are spring-biased towards one another such that application of a pushing force on the second trough in a direction away from the second end of the post lifts at least a portion of the cap away from the second end (and away from the post), and removal of the pushing force at least partially returns the cap towards the second end of the post. Certain embodiments of the paneling system include a height adjustment foot having a threaded shank and a threaded receptacle in the end piece configured for receiving the threaded shank of the height adjustment foot for adjusting a height of the post by rotating the foot relative to the post.
In some embodiments of the paneling system, one or more mounting brackets secure a first post to the first side member, and one or more mounting brackets secure a second post to the second side member. Certain embodiments of the paneling system include one or more mounting brackets attached to the bottom frame member, and one or more modular components coupled to the one or more mounting brackets. In a non-limiting exemplary embodiment, the one or more modular components are selected from the group consisting of electrical outlets, communications ports, data ports, and any combination thereof.
Certain embodiments of the paneling system include one or more overlay panels that can be removably or permanently secured to one or both of a first and a second side of each panel. In some embodiments, the one or more panels include a core enclosed in the frame. In certain embodiments of the paneling system, the cross-section of at least the external surface or perimeter of the one or more elongated posts is selected from the group consisting of circular, elliptical, polygon, and any combination thereof.
A non-limiting exemplary embodiment of a method for assembling a modular wall includes providing a plurality of panel mounting brackets; providing a plurality of panels, each including a first side frame member having a first bottom mounting bracket and a first top mounting bracket at each laterally opposed first bottom and first top corners, respectively; providing a plurality of elongated posts, each including a first trough at a first end of each elongated post; providing a plurality of top caps, each defining at least a portion of a second trough at a second end of each elongated post; attaching together the first side frame member of a first panel to a first elongated post; and securing a first top cap to the first elongated post.
In some embodiments, wherein each of the plurality of panels includes a second side frame member having a second bottom mounting bracket and a second top mounting bracket at each laterally opposed second bottom and second top corners, respectively, the method further includes attaching together the second side frame member of the first panel to a second elongated post and securing a second top cap to the second elongated post. In certain embodiments, the method includes attaching together the first side frame of a second panel and a third elongated post; securing a third top cap to the third elongated post; and attaching together the second side frame member of the second panel and the first elongated post prior to securing the first top cap to the first elongated post.
In a non-limiting exemplary embodiment, the method includes adjusting an angle between the first and the second panel by rotating the first and the second panels relative to one another about the first elongated post prior to securing the first top cap to the first elongated post.
In some embodiments, adjusting the angle between the first and the second panel includes unsecuring the first top cap from the first elongated post; rotating the first and the second panels relative to one another about the first elongated post; and securing the first top cap to the first elongated post.
In a non-limiting exemplary embodiment, the method for attaching together the first side frame member of the first panel to the first elongated post includes placing at least a portion of the first bottom mounting bracket of the first panel in the first trough of the first elongated post; and placing at least a portion of the first top mounting bracket of the first panel in the second trough of the first elongated post. And, the method for attaching together the second side frame member of the first panel to the second elongated post includes placing at least a portion of the second bottom mounting bracket of the first panel in the first trough of the second elongated post; and placing at least a portion of the second top mounting bracket of the first panel in the second trough of the second elongated post.
In another non-limiting exemplary embodiment, the method for attaching together the first side frame member of the first panel to the first elongated post includes placing at least a portion of the first top mounting bracket of the first panel in the second trough of the first elongated post; and placing at least a portion of the first bottom mounting bracket of the first panel in the first trough of the first elongated post. And, the method for attaching together the second side frame member of the first panel to the second elongated post includes placing at least a portion of the second top mounting bracket of the first panel in the second trough of the second elongated post; and placing at least a portion of the second bottom mounting bracket of the first panel in the first trough of the second elongated post. In such embodiments, one or both of the first and the second top caps are spring-biased with their respective first and second elongated posts such that in absence of an external force the spring-biased first top cap abuts with the second end of the first elongated post and the spring-biased second top cap abuts with the second end of the second elongated post.
In some non-limiting exemplary embodiments, the method includes attaching one or more overlay panels on one or more panels.
While multiple embodiments are disclosed herein, still others may become apparent to one skilled in the art. In the following, certain illustrative and non-limiting embodiments are described in detail with reference to the accompanying drawings wherein like elements are designated by like numerals. It should be clearly understood that there is no intent, implied or otherwise, to limit the invention in any form or manner to that illustrated and described herein. All alternative embodiments are considered as being within the metes and bounds of the instant invention.
As used herein, “attaching” should be understood to include mechanical attachment as well as bringing two or more components into an abutting or straddling relationship relative to one another.
In certain embodiments, paneling system 10 includes one or more bottom trim pieces 34. In a non-limiting exemplary embodiment, bottom trim piece 34 is a “living hinge” which can be slid underneath panel 12 and folded or formed into a “U”-shaped configuration having vertical faces abutting each side of panel 12. “Holes” 36 in bottom trim piece 34 can be covered or left open for electrical outlets, data and/or communications ports, etc. In some embodiments, paneling system 10 includes top trim 38 placed along top frame member 14.
Mounting bracket 24 is configured for attachment or securement to panel 12. In a non-limiting exemplary embodiment of paneling system 10, one or more mounting brackets 24 are attached or secured to any one of the panel frame members, viz., top, bottom and side frame members 14, 16, 18 and 20. In certain embodiments, mounting bracket 24 and one of the panel frame members are attached to one another via a snap-fit connection. In some embodiments, mounting bracket 24 and one of the panel frame members are attached to one another with one or more screws extending through one or more holes 52 in mounting bracket 24. In other embodiments, mounting bracket 24 and one of the panel frame members are attached to one another with an adhesive. In alternate embodiments, mounting bracket 24 is attached to a core or some other component of panel 12 and not to one of the frame members. All alternate means for attaching or securing one or more mounting brackets 24 to panel 12 are considered as being within the metes and bounds of the instant invention.
As described in the foregoing with reference to
Also as described in the foregoing with reference to
Referring now to
End piece 56 further includes stand-off or leg 68 extending away from bottom 70 of cup 64. In some embodiments of paneling system 10, leg 68 is configured for rotatable coupling or engagement with foot 72. In a non-limiting exemplary embodiment, leg 68 includes a threaded receptacle configured for receiving a threaded shank of foot 72. As such, a height of end piece 56, and therefore a vertical extent of post 26, can be adjusted by rotating foot 72 to extend or retract the threaded shank into or out from leg 68. Alternate height adjustment components, mechanisms, systems, etc., as are well known in the art, are considered as being within the metes and bounds of the instant invention.
While end piece 56 is described in the foregoing as if it were a component separate from post 26, it may not always be the case. For instance, in a non-limiting exemplary embodiment, post 26 and end piece 56 are integrated at first end 58 as a single unitary component. In certain embodiments of paneling system 10, post 26 is manufactured with end piece 56 at first end 58 such that end piece 56 is a part of post 26 and not a separate unit. In some embodiments, post 26 and end piece 56 are manufactured as two separate components, but are then fixedly attached to one another at first end 58 as one of the final steps in the manufacturing process.
In an embodiment of paneling system 10, top cap 60 includes recessed under-surface 74 defined at least in part by ridge 76 extending away from surface 74. In a non-limiting exemplary embodiment, a diameter of surface 74 is substantially equal to an outside diameter of post 26 at second end 62 and ridge 76 “flares” from surface 74. In other words, ridge 76 extends at an obtuse angle from surface 74. As such, cap 60 defines at least a portion of a second trough surrounding post 26 at second end 62 configured to receive and retain one or more ledges 50 of a respective number of mounting brackets 26. The distance between an outside diameter of post 26 at second end 62 and a rim of ridge 76 is substantially equal to the thickness of ledge 50. In certain embodiments of paneling system 10, the second trough is wedge-shaped and, as such, ledge 50 is also wedge-shaped. However, this is not a strict requirement. All that is required is that the second trough be configured to receive and retain post 26 at second end 62 and concurrently receive and retain one or more ledges 50.
In a non-limiting exemplary embodiment, second end 62 includes threaded receptacle 78 extending into post 26. Threaded receptacle 78 is configured for rotatable coupling or engagement with nut 80 extending through hole 82 in cap 60. As such, cap 60 can be removable secured to second end 62 of post 26 and retain the one or more ledges 50 received within the second trough. In some embodiments of paneling system 10, threaded receptacle 78 is not a separate piece, but instead is a part of post 26. In other words, post 26 and threaded receptacle 78 are integrated as a single unitary component. In a non-limiting exemplary embodiment of paneling system 10, nut 80 is a wing nut or a thumb nut configured for securing top cat 60 to threaded receptacle 78 of post 26 without the use of or need for a tool such as a wrench or pliers.
In a non-limiting exemplary embodiment of paneling system 10, top cap 60 and post 26 are spring-biased against one another at second end 62. In some such embodiments, cap 60, which abuts post 26 in a normal state, a force can be exerted on cap 60 to raise it a predetermined distance over second end 62. Cap 60 returns to the normal state, or to approximately the normal state, when the force is removed. In certain embodiments of paneling system 10, both the inside surface of ridge 76 and the outside surface of contoured edge 46 are threaded with the threads on ridge 76 configured for threaded engagement with the threads of contoured edge 46. As such, cap 60 can be “screwed on” or “rotated around” contoured edge 46. In some embodiments of paneling system 10, contoured edge 46 and cap 60 are configured for a “snap-fit” connection.
Although not explicitly illustrated or described, it should be amply apparent that embodiments of paneling system 10 include trims such as post trims or side trims for covering the joints, and the mounting brackets, between adjacent panels 12 and/or the joints between panel 12 and post 26.
With reference to
In a non-limiting exemplary embodiment, cap 60 and post 26 are spring-biased to another at second end 62. In such instances, the afore described method of assembly is modified somewhat in that ledge 50 of first (or second) top mounting bracket 26 is positioned within the second trough defined by the spring-biased cap. Ledge 50 of first (or second) bottom mounting bracket 26 is positioned adjacent first (or second) post 26 with contoured edge 46 and/or 48 abutting the external surface of post 26. When panel 12 is lifted with ledge 50 within the second trough, the spring-biased cap and recessed surface 74 are lifted away from second end 62 of post 26. Panel 12 is lifted in this manner until an edge of ledge 50 of first (or second) bottom mounting bracket 26 clears over a rim of cup 64. Then, panel 12 is lowered while maintaining contact between contoured edges 46 and/or 48 and the external surface of post 26. As such, ledge 50 of first (or second) bottom mounting bracket 26 “slides” into first trough 66. In some embodiments, the spring-biased top cap includes a nut for retaining ledge 50 of first (or second) top mounting bracket 26 by securing the top cap to second end 62 of post 26.
Ledge 50 of a first bottom mounting bracket 24 is set or positioned within first trough 66 of a first post 26. As such, contoured edges 46 and/or 48 of first bottom mounting bracket 24 abut with an external surface of first post 26. Ledge 50 of a first top mounting bracket 24 opposite first bottom mounting bracket 26 is positioned
First top cap 60 is positioned over second end 62 of first post 26 and nut 80 is at least partially tightened to retain ledge 50 of first top corner mounting bracket 24 within the second trough defined by first top cap 60 and first post 26. One or more additional panels 12 may be similarly mounted to first post 26. Also similarly, second bottom and top mounting brackets 26 at the corners opposite which first bottom and top mounting brackets 26 are located, are mounted to second post 26. One or more additional panels 12 may be similarly mounted to second post 26. Either during or after the assembly process, all nuts 80 are tightened to secure each top cap 60 to its respective post 26. Overlay panels 30 of different colors, material, utility, etc., can be attached to panels 12 during and/or after assembly.
In certain embodiments, additional mounting brackets 24 may be attached at other locations on first and/or second side frame members 18 and 20. In such embodiments, contoured edges 46 and/or 48 are also positioned abutting the external surface of the corresponding post 26.
In a non-limiting exemplary embodiment, elongated posts 26 are cylindrical wherein the external surface has a circular cross-section. Accordingly, contoured edges 46 and/or 48 are also curved having a radius of curvature substantially the same as that of the external surface of post 26. In view of the foregoing illustrations and descriptions, it will be apparent that two or more panels 12 mounted to the same post 12 can be oriented at different angles relative to one another. In certain embodiments of paneling system 10, the angle between adjacent panels 12 is adjusted and fixed or set during the assembly process and prior to tightening nut 80. In some embodiments of paneling system 10, the angle between adjacent panels 12 is changed after the assembly process, for example in the future, by first untightening or loosening nut 80, changing the relative orientations of one or more panels 12, and then tightening nut 80.
In some embodiments of paneling system 10, it may be desirable to limit or restrict the number of possible orientations in which the modular wall can be reconfigured. In one non-limiting embodiment, this is accomplished by providing posts 12 and complimentary contoured edges 46 and/or 48 of non-circular shapes. For instance, the cross-section of the external surface of post 12 can be elliptical or any polygon with appropriately contoured edges 46 and/or 48.
In a non-limiting exemplary embodiment, the process of assembling a modular wall includes the attachment or abutment of one or more overlay panels as previously described.
Based on the incorporated illustrations and description of certain non-limiting exemplary embodiments, various modifications thereof and/or alternate embodiments may become apparent without departing from the spirit, scope or intent of the instant invention. For instance, while the illustrated and/or described embodiments refer to particular features and/or functions, the invention is considered to also include embodiments having different structures and/or combinations that result in features and/or functions that are the same as or substantially similar to described and/or eluded to and/or illustrated. Accordingly, the metes and bounds of the invention embraces all alternatives, modifications, variations, etc., as may become apparent to one skilled in the art.
This application claims the benefit of U.S. Provisional Patent Application Serial No. 61/553,857 filed Oct. 31, 2011 which in its entirety is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61553857 | Oct 2011 | US |
