Support rail

Abstract

A support rail comprises a rail body having a front surface and a rear surface, wherein at least a portion of the rear surface is adapted to engage a fixed wall support member for attachment thereto. The support rail also includes a longitudinal channel portion that is at least partially defined by the front surface, wherein the channel is adapted to receive a longitudinal edge of a wall panel. Also disclosed are wall mounting systems and methods of installing a wall support rail system.

Description

RELATED APPLICATION

[0001] The present application claims priority of U.S. Provisional Application Serial No. 60/326,306 filed Oct. 1, 2001 and hereby incorporates the same Provisional Application by reference.

TECHNICAL FIELD

[0002] The present invention relates to support rails which may be affixed to a wall support member and configured for mounting one or more wall panels along a wall. Shelving, utility brackets, or other implements can then be selectively interfaced with the support rail.

BACKGROUND OF THE INVENTION

[0003] Items are often hung on the walls of residential, commercial and industrial buildings, including for example, homes, offices, garages, sheds, and retail establishments. Such items are often supported by shelving, for example. Shelving can be associated with a wall in a number of different configurations. For example, individual brackets can be attached to the wall (e.g., with screws) and a shelf can be associated with (e.g., such as by placement upon) those brackets. In another example, elongated support rails can be attached to a wall with screws or anchors, for example, and brackets for supporting shelving or other implements can be attached to the support rails. Shelving having wall-mounted support rails is often desirable for a variety of reasons, including for example, ease of assembly, ease of shelf-height adjustment, and ease of access.

[0004] Conventional shelving systems involving support rails are generally installed after the interior walls of a building are substantially finished (e.g., plastered, painted and/or wallpapered). However, this installation of such support rails can be time-consuming and expensive in-part because it can be difficult to locate adequate anchoring points along a finished wall such that the support rails will not separate from the wall when heavily-loaded shelving is attached. Also, the installation of support rails after the wall is substantially finished can create a significant mess in an otherwise clean environment. Furthermore, such support rails typically protrude from the wall in an aesthetically displeasing manner.

[0005] Accordingly, there is a need for a support rail system that can be installed more easily and quickly. In addition, there is a need for a support rail system which provides a more aesthetically pleasing effect. Even further, there is a need for a support rail that can be easily installed but that can provide sufficient strength to support shelving or other implements selectively attached thereto by a consumer.

SUMMARY OF THE INVENTION

[0006] Accordingly, it is an object of the present invention to provide improved support rail systems and methods. It is another object to provide systems and methods which may be easily and quickly installed. It is yet another object to provide support rails, systems and methods which provide an aesthetically pleasing effect and sufficient support strength.

[0007] To achieve the foregoing and other objects, and in accordance with the purposes of the present invention defined herein, a support rail is provided. In one embodiment, the support rail comprises a rail body having a front surface and a rear surface, wherein at least a portion of the rear surface is adapted to engage a fixed wall support member for attachment thereto. A longitudinal channel portion is at least partially defined by the front surface, wherein the channel is adapted to receive a longitudinal edge of a wall panel. The support rail is configured to effectively cover a longitudinal edge of a wall panel received in the channel.

[0008] In another embodiment, the support rail comprises a rail body having a front surface, a rear surface, and a cap having slots for selective attachment of hangers to the support rail. At least a portion of the rear surface is adapted to engage a fixed wall support member for attachment thereto. Also included is a longitudinal channel portion that is at least partially defined by the front surface wherein the channel is adapted to receive a longitudinal edge of a wall panel to be secured to the wall support member.

[0009] In another embodiment, the present invention is directed to a method of installing a wall support rail system including a support rail having a rail body and a longitudinal channel. A longitudinal edge of a wall panel is inserted into the channel and the rail body is engaged over a portion of a wall support member. The wall panel is affixed to the wall support member and to the rail body by inserting one or more fasteners through apertures in the rail body.

[0010] In accordance with yet another embodiment, the present invention is directed to a method of installing a wall support rail system comprising a plurality of support rails, wherein each support rail has a rail body and at least two longitudinal channel portions. The rail body has a front surface and a rear surface, wherein at least a portion of the rear surface is adapted to engage a wall support member for attachment thereto. The longitudinal channel portion is at least partially defined by the front surface and is adapted to receive a longitudinal edge of a wall panel. The method comprises abutting a proximal end of a first wall panel in a first longitudinal channel portion of a first support rail. The rail body of the first support rail is engaged over a portion of a first wall support member and the rail body of the first support rail is affixed to the first wall support member. The proximal end of a second wall panel is abutted in a second longitudinal channel portion of the first support rail and the distal end of the second wall panel is abutted in a first longitudinal channel portion of a second support rail. The rail body of the second support rail is engaged over a portion of a second wall support member and the rail body of the second support rail is affixed to the second wall support member.

[0011] In accordance with still another embodiment of the present invention, a wall mounting system comprises a support rail comprising a cap, the cap having longitudinal slots and configured to cover a seam between an adjacent wall panel and the support rail. The support rail is adapted to be substantially recessed into a wall except for a portion of the cap. Also included is a mount having at least one flange configured for insertion into at least one of the longitudinal slots. An implement is supported by the mount.

[0012] The support rails, systems and methods are advantageous for providing an efficient and aesthetically pleasing means for mounting shelving or other implements. Additional objects, advantages, and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:

[0014] FIG. 1 is a partial top cross-sectional view depicting a support rail system in accordance with one exemplary embodiment of the present invention;

[0015] FIG. 2 is an enlarged top cross-sectional view depicting the support rail of FIG. 1;

[0016] FIG. 3 is a front or face view depicting the support rail of FIG. 2;

[0017] FIG. 4 is an enlarged top cross-sectional view depicting another exemplary embodiment of a support rail in accordance with the present invention;

[0018] FIG. 5 is an enlarged top cross-sectional view depicting still another exemplary embodiment of a support rail in accordance with the present invention;

[0019] FIG. 6 is an enlarged top cross-sectional view depicting yet another exemplary embodiment of a support rail in accordance with the present invention; and

[0020] FIG. 7 is an enlarged top cross-sectional view depicting another exemplary embodiment of a support rail in accordance with the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0021] The present invention and its operation is hereinafter described in detail in connection with the views and examples of FIGS. 1-7, wherein like numbers indicate the same or corresponding elements throughout the views. As shown in FIG. 1, a support rail 30 may be attached to a wall support member, for example a fixed wall stud 20, and can be configured to secure one or more wall panels 25, 26 to the stud 20. Examples of wall panels might include drywall, masonry board, paneling, plywood, laminated lumber products, plastic sheeting, synthetic lumber materials, lattice, pegboard, hardware cloth, composites thereof and/or other suitable building material(s). More particularly, the panels might comprise four-foot by eight-foot sheets of sheet rock or peg board. The stud 20 can be formed from one or more pieces of lumber, metal or another material configured to support one or more wall panels. For example, the stud 20 can comprise a 1½″×3½″ piece of lumber (e.g., a “two by four”) or a similarly sized metal member. In another embodiment, the stud 20 can comprise a support member within a pre-manufactured shelving unit, such as those used within many retail establishments.

[0022] The support rail 30 can be configured to secure one or more of the wall panels 25, 26 to the stud 20 and can include a rail body 40 formed from any of a variety of materials. Examples of suitable materials for rail body 40 include but are not limited to steel, stainless steel, aluminum, wood, plastic, composites and/or any other material having sufficient strength to support implements upon a wall as disclosed herein. The type and configuration of the material forming rail body 40 (including thickness, size of slots and fasteners, and width of channels) can depend upon the location of support rail 30, types of implements to be supported by support rail 30, and consumer preference. As depicted in FIG. 2, rail body 40 can be manufactured from a single piece of formed or extruded material. Alternatively, rail body 40 can be manufactured from multiple pieces of material adhered or otherwise fastened together by any suitable technique, including but not limited to welds, rivets, screws, or the like. For example, rail body 40 might be manufactured by tack welding (e.g., a plate to a closed portion 74 shown in FIG. 2) or roll forming support rail 30.

[0023] Rail body 40 can comprise any of a variety of configurations. In one embodiment of the present invention, rail body 40 can comprise at least one leg member and at least one base member. However, rail body 40 might also comprise a cap and/or one or more side walls. For example, as depicted in FIG. 2, rail body 40 is shown to comprise a cap 80, two side walls 60 and 61, two base members 58 and 59, and two leg members 46 and 48. Also as depicted in FIG. 2, rail body 40 might also comprise one or more cap bottom members 62 and 63. Cap 80 is shown as attached to cap bottom members 62 and 63, wherein cap bottom members 62 and 63 are shown as attached to side walls 60 and 61, respectively. Side walls 60 and 61 are further shown as being attached to base members 58 and 59, respectively, and base members 58 and 59 are shown as being attached to first leg member 46 and second leg member 48, respectively. In some embodiments, as in FIG. 2, base members 58 and 59 can be extended into support rail 30 and away from first and second leg members 46 and 48, respectively.

[0024] In one embodiment as shown in FIGS. 2 and 3, rail body 40 can have a rear surface 44 and a front surface 42, wherein portions of rear surface 44 and front surface 42 can be associated with opposite sides of each component of rail body 40, including but not limited to cap 80, cap bottom members 62, 63, side walls 60, 61, base members 58, 59 and/or leg members 46, 48. At least a portion of rear surface 44 of rail body 40 can be adapted, for example, to engage stud 20 in order to facilitate attachment of rail body 40 to stud 20. More particularly, a portion of rear surface 44 corresponding to one or more base members 58, 59 can be configured to engage a top surface of stud 20 for attachment of support rail 30 thereto. Also, a portion of rear surface 44 corresponding to first leg member 46 and second leg member 48 can be configured to engage side surfaces of stud 20 for attachment of support rail 30 thereto.

[0025] The front surface 42 of the rail body 40 can be configured to define at least a portion of one or more longitudinal channels, wherein each channel is configured to receive a longitudinal edge of a wall panel, and in one embodiment may secure the wall panel to a stud. As shown in FIG. 2, rail body 40 might define an open portion width W1, a closed portion width W2, and a cap width W3. In the embodiment depicted in FIG. 2, where W2 is depicted as having a shorter length than both of W1 and W3, channels 70 and 71 can be formed on either side of support rail 30 and can generally assume a U-shape. U-shaped channels 70, 71 might be defined at least in-part by the front surface 42 corresponding to side walls 60, 61 and base members 58, 59. However, the front surface 42 corresponding to cap bottom members 62, 63 might also define a portion of the U-shaped channels 70, 71. In an exemplary embodiment of the present invention, channel 70 can have a U-shape defined by the portion of front surface 42 corresponding to cap bottom member 62, side wall 60 and base member 58.

[0026] A longitudinal edge 32 of wall panel 25 can be inserted into channel 70. The wall panel can be held in place within channel 70 by any suitable technique. In one embodiment, the wall panel is held in the channel by a fastener (e.g., nail 90) inserted sequentially through aligned apertures 53, 52, and 51 into the stud. Likewise, a channel 71 can have a U-shape defined by the portion of front surface 42 corresponding to cap bottom member 63, side wall 61 and base member 59. A longitudinal edge 33 of wall panel 26 can be inserted into channel 71 and can be held in place within channel 71 by a fastener inserted sequentially through apertures 56, 55, and 54 into the stud. In addition to securing the wall boards within channels 70 and 71, the fasteners (e.g., 90) can further secure the wall boards and support rail 30 to the stud. In some embodiments, as shown in FIG. 2, for example, rail body 40 might include an open portion 72 substantially defined by corresponding leg members 46 and 48. Open portion 72 can be configured to fit or slide over stud 20 (shown generally in FIG. 1). Also, rail body 40 might also include a closed portion substantially defined by side walls 60 and 61. In the exemplary embodiment depicted in FIG. 2, for example, rail body 40 is shown to have a staggered channel design wherein its open portion 72 has a different (e.g., larger) width W1 than its closed portion 74 having width W2.

[0027] In the embodiment depicted in FIG. 2, for example, rail body 40 is shown as having a first leg member 46 longer than a second leg member 48. First leg member 46 is also shown as having an aperture 50 for attaching support rail 30 to stud 20 (e.g., with a fastener 99). In an alternative embodiment, first leg member 46 may have the same length as second leg member 48 and/or second leg member 48 might include one or more apertures (e.g., 457 in FIG. 5, for example) for attaching support rail 30 to stud 20. By configuring second leg member 48 shorter than first leg member 46, as shown in FIG. 2, support rail 30 may be more easily interfaced with stud 20 (e.g., such as when installed onto a stud from an angled orientation). In this manner, open portion 72 may be pressed against a face of stud 20 diagonally relative to the stud. Hence, when wall panel 26 is seated within channel 71, additional clearance in open portion 72 caused by the shortened second leg member 48 enables easier sliding of rail body 40 over stud 20.

[0028] As shown most clearly in FIGS. 2 and 3, cap 80 is configured opposite open portion 72. In some embodiments, cap 80 might have a width W3 greater than the width W2 of closed portion 74. Also, cap 80 can be configured to effectively cover one or more longitudinal edges (e.g., 34 and 35) of wall panels (e.g., 25 and 26) and can also be configured to effectively cover side walls 60 and 61 when one or more wall panels (e.g., 25 and 26) are inserted into channels 70 and 71. In this manner, cap 80 may be configured as a seam flashing to cover a seam or gap between two wall panels (e.g., cap 80 substantially covers the seam between wall panels 24 and 25 in FIG. 1), thereby obscuring the seam from view by a consumer.

[0029] Cap 80 may be provided with slots 84 disposed along the length L of the support rail 30, as shown in FIG. 3, for example. Slots 84 can assume virtually any configuration within cap 80, provided that slots 84 can facilitate the selective attachment of hangers, brackets, mounts, hooks, pipes, or other mountings or implements. Slots 84 might also be configured to interface with and/or support storage devices, such as shelving, a folding work bench, various tool hangers, etc. A wall mounted system may also be attached to support rail 30 through association with slots 84. As depicted in FIG. 3, for example, a mount, such as a hanger 95, may have one or more flanges 96, 97 respectively configured for insertion into one or more slots 83, 85 in cap 80. An apparatus or implement can then be selectively supported by the mount and can comprise, for example, a shelf (e.g., 98 in FIG. 3), a tool, or a piece of work or exercise equipment.

[0030] Cap 80 may further have apertures (e.g., 53, 56) to aid in facilitating the attachment of rail body 40 and one or more wall panels to a stud with an appropriate fastener (e.g., 90). Each aperture in the cap (e.g., 53, 56) would generally align with an aperture in the cap bottom member (e.g., 52 and 55, respectively) and an aperture in the base member (e.g., 51 and 54, respectively). Support rail 30 may also be provided with one or more push plugs 94 to obscure the head of any fasteners (e.g., 90) that would otherwise be visible to a consumer.

[0031] In yet another embodiment, as depicted in FIG. 4, a support rail 230 is depicted having a rail body 240 and a cap 280. In this embodiment, rail body 240 can comprise a rear surface 244 and a front surface 242, wherein portions of rear surface 244 and front surface 242 can be associated with opposite sides of each component of rail body 240, including but not limited to cap support member 281, side walls 260, 261, base members 258, 259 and leg members 246, 248. As shown, cap 280 may not be integral with rail body 240 but may be adapted to engage cap support member 281 of rail body 240. In order to maintain attachment to rail body 240, cap 280 might comprise one or more protrusions configured to selectively engage one or more corresponding grooves in one or more side walls of rail body 240. For example, cap 280 can be attached to rail body 240 by interlocking engagement of protrusion 286 of cap 280 with groove 266 in side wall 260. Cap 280 may extend along the entire length of rail body 240 and may be provided with slots 284 to align with slots 285 in cap support member 281 to facilitate the selective attachment of implements as previously discussed.

[0032] When cap 280 is attached to rail body 240, channels 270 and 271 can be defined. More specifically, channel 270 can be defined by a cap bottom surface 262 and portions of front surface 242 corresponding to base member 258 and side wall 260. Similarly, channel 271 can be defined by a cap bottom surface 263 and portions of front surface 242 corresponding to base member 259 and side wall 261. In the embodiment depicted by FIG. 4, cap 280 can be formed of any plastic, wood, metal, composite, combination thereof, or other material suitable to engage rail body 240 and to at least partially obscure the seam between one or more longitudinal edges of wall panels and side walls 260, 261 of rail body 240. In addition to at least partially concealing the seam, cap 280 can be further configured to cover any fastener used to attach the wall panel(s) to rail body 240 and/or a stud. Such fasteners might be inserted through apertures 251 and 254 in rail body 240, for example.

[0033] In addition to being attached to a stud by fasteners inserted through apertures 251 and 254 in rail body 240, rail body 240 might also be fastened to a stud with one or more fasteners (e.g., nail 299) through aperture(s) (e.g., 250) in first leg member 246. Second leg member 248 might also comprise one or more similar apertures. In an exemplary embodiment, second leg member 248 has a different configuration than first leg member 246 in order that rail body 240 can be readily inserted over a stud from an angled orientation (e.g., diagonally). In one embodiment, leg 248 might be shorter than leg 246. However, in an alternate embodiment, as depicted in FIG. 4, second leg member 248 might comprise a protruded portion 249 so as to enable second leg member 248 to clear a corner of a stud as rail body 240 is engaged with the stud diagonally. By providing sufficient clearance, protruded portion 249 may therefore be especially helpful when a support rail 230 is attached to a stud from an angular direction (e.g., other than straight-on).

[0034] In an additional embodiment, as depicted by FIG. 5, a support rail 430 is shown as comprising a rail body 440 with caps 480 and 482. In this embodiment, rail body 440 can comprise a rear surface 444 and a front surface 442, wherein portions of rear surface 444 and front surface 442 can be associated with opposite sides of each component of rail body 440, including but not limited to cap support member 481, side walls 460, 461, base members 458, 459 and leg members 446, 448. Cap support member 481 may include slots 484 in cap support member 481 to facilitate the selective attachment of implements as previously discussed. Each cap (e.g., 480) can cover a longitudinal edge (e.g., 432) of a wall panel (e.g., 424) without covering the front surface 442 corresponding to the cap support member 481. As shown, caps 480, 482 may not be integral with rail body 440 but may be adapted to engage side walls 460, 461 of rail body 440. Caps 480, 482 may be formed from metal (e.g., thin sheet steel, aluminum), plastic, wood, a composite, or any other material having sufficient flex or spring to allow caps 480, 482 to mate with wall panels and rail body 440 at close tolerances under a variety of conditions. In order to maintain attachment to rail body 440, caps 480, 482 might comprise one or more protrusion configured to selectively engage or insert into one or more corresponding grooves in the side walls of rail body 440. For example, cap 480 can be attached to rail body 440 by interlocking engagement of the protrusion 486 with groove 466 in side wall 460. Likewise, cap 482 can be attached to rail body 440 by interlocking engagement of the protrusion 487 with groove 467 in side wall 461. Grooves 466, 467 can be oriented longitudinally along side walls 460, 461 of rail body 440, for example. Caps 480, 482 can be adapted to extend along the entire length of rail body 440.

[0035] To install cap 480, for example, end 488 of cap 480 can be slid between wall panel 424 and side wall 460 and protrusion 486 can then be inserted into groove 466 in side wall 460 of rail body 440. Similarly, to install cap 482, end 489 of cap 482 can be slid between a wall panel (not shown) and side wall 461 and the protrusion 487 can then be inserted into groove 467 in side wall 461 of rail body 440. When caps 480, 482 are attached to rail body 440, channels 470 and 471 can be defined. More specifically, channel 470 can be defined by a cap bottom member 462, a cap side member 474 and a portion of front surface 442 corresponding to base member 458. When a longitudinal edge 432 of a wall panel 424 is inserted into channel 470, cap side member 474 can become wedged between wall panel 424 and side wall 460, thereby maintaining cap bottom member 462 in contact with wall panel 424 and maintaining protrusion 486 within groove 466. Similarly, channel 471 can be defined by a cap bottom member 463, a cap side member 475 and a portion of front surface 442 corresponding to base member 459. When a longitudinal edge of a wall panel (not shown) is inserted into channel 471, cap side member 475 can become wedged between the wall panel and side wall 461, thereby maintaining cap bottom member 463 in contact with the wall panel and maintaining protrusion 487 within groove 467.

[0036] Each cap can be configured to engage rail body 440 and to at least partially obscure the seam between one or more longitudinal edges (e.g., 432) and an adjacent side wall. In addition to at least partially concealing the seam, each cap can be further configured to cover fasteners used to attach rail body 440 and/or the corresponding wall panel(s) to a stud. Such fasteners might be inserted through apertures 458, 459 in rail body 440, for example. In addition to being attached to a stud by fasteners inserted through apertures 458, 459 in the rail body, the rail body 440 might also be fastened to a stud with one or more fasteners through one or more apertures 450 and 457 in first and second leg members 446 and 448, respectively. It is to be understood that the cap configuration of FIG. 5 is suitable for association with a variety of rail body configurations, some of which are disclosed herein.

[0037] Though slightly extending from a wall, support rail 430 can offer a symmetrical and desirable appearance to a consumer. For example, caps 480, 482 can add a smooth and rounded edge to interface cap support member 481 with one or more wall panels (e.g., 424). Although small, hairline seams may be visible between caps 480, 482 and cap support member 481, these seams are typically quite small and should not provide significant visual distraction to a consumer. Furthermore, caps 480, 482 can typically be configured to cover any fasteners used to connect support rail 430 and/or wall panels to a stud.

[0038] In another exemplary embodiment depicted by FIG. 6, a support rail 530 is shown to include a rail body 540 comprising a base member 558 extending substantially across the entire width of support rail 530. Rail body 540 might, for example, be constructed of two separate pieces of metal welded or otherwise fastened together. Alternatively, rail body 540 might be molded, extruded or otherwise formed as a single piece of plastic, metal, or other material. Rail body 540 is also depicted as comprising a cap 580, wherein cap 580 can be configured to cover the seam or gap between the longitudinal edges of one or more wall panels. Furthermore, cap 580 can include slots 584 as previously discussed for association with shelving or other implements.

[0039] Base member 558 can be attached to each of side walls 560, 561 and each of leg members 546, 548. In use, leg members 546, 548 can be inserted over a stud 520 such that base member 558 can be pressed into contact with stud 520. In other embodiments, part or all of the base member and/or leg members may be eliminated and the support rail might otherwise be connected with the stud. However, as shown in FIG. 6, support rail 530 and the wall panel(s) can be attached to stud 520, for example, by inserting screws or other fasteners into apertures in cap 580, through a wall panel and then directly into stud 520.

[0040] Regardless of the configuration of the one or more base members (e.g., 558), rail body 540 might also include lances 598, such as tangs or barbs, along the portion of its rear surface 544 corresponding to the one or more base members (e.g., 558) and/or leg members (e.g., 546). Lances 598 can be configured to interface and secure support rail 530 to stud 520 without the need for additional fasteners (e.g., nails, screws). Furthermore, lances 598 can be angled with respect to rear surface 544 of rail body 540 in order that rail body 540 can be optimally inserted against stud 520 (e.g., such as when lances are directed parallel to the angle of insertion of support rail 530 to stud 520).

[0041] In one embodiment, lances might only be present upon the portion of the rear surface of a rail body corresponding to one or more base members, and may accordingly be absent any leg members. In still another embodiment, lances might be present upon a portion of the rear surface corresponding to a single leg member, but not otherwise present on any base members or other leg members. In still a further embodiment, lances might be present on portions of the rear surface corresponding to both a base member and a leg member. In such a case, it might be beneficial for such a leg member having lances to be formable such that it can be moved against the stud after the base member is brought adjacent to the stud. For example, as depicted in FIG. 6, support rail 530 has a formable first leg member 546. In this embodiment, first leg member 546 can be originally oriented longitudinally with base member 558, but after insertion of rail body against stud 520, can be bent into position (e.g., by hand or with a hammer) against the side of stud 520, as depicted in FIG. 6. In another embodiment, both leg members 546, 548 can be initially oriented longitudinally with base member 558 and would be similarly formable.

[0042] In yet another exemplary embodiment depicted by FIG. 7, a support rail 630 is shown to comprise a rail body 640 and a cap 680. Rail body 640 can include a cap support member 681 and side walls 660, 661, wherein each of these components can correspond with a front surface 642 and a rear surface 644 of rail body 640. Rear surface 644 can also include bottom surfaces 664 and 665 of side walls 660, 661, respectively, wherein bottom surfaces 664 and 665 can be configured to engage a wall support member (e.g., stud 620). When cap 680 is brought adjacent to cap support member 681 of rail body 640, a channel 670 can be defined by cap 680, stud 620, and front surface 642 of rail body 640 corresponding to side wall 660. Likewise, a channel 671 can be defined by cap 680, stud 620, and front surface 642 of rail body 640 corresponding to side wall 661. Once defined, each of channels 670 and 671 can receive longitudinal edges of wall panels such that support rail 630 can conceal the longitudinal edges from view by a consumer.

[0043] Cap 680 comprises slots (e.g., 684) that can be configured to receive hooks or other implements for attachment to a wall. These slots (e.g., 684) can also be configured to receive fasteners (not shown) for securing cap 680 and/or rail body 640 to a stud 620. Rail body 640 might also include slots (e.g., 685), whereby some of the slots in rail body 640 can align with certain slots in cap 680. In this manner, hooks, implements, fasteners or clips inserted through slots (e.g., 684) in cap 680 can further extend through aligning slots (e.g., 685) in rail body 640. For example, fasteners (e.g., screws) can be inserted sequentially through aligning slots (e.g., slots 684 and 685 in cap 680 and rail body 640, respectively) and into stud 620 in order to secure support rail 630 to stud 620. In an embodiment wherein fasteners are not inserted through slots (e.g., 684) in cap, but nevertheless are inserted into stud 620 through slots (e.g., 685) in rail body 640, cap 680 can be configured to at least partially conceal such fasteners from view by a consumer. In such an embodiment, after rail body 640 is secured to stud 620 with such fasteners, cap 680 can be secured to rail body 640 with clips (e.g., 699), for example, wherein each clip can be inserted sequentially through a set of unused aligning slots in both cap 680 and rail body 640, for example. In one embodiment of the present invention, stud 620 can optionally include a recess 622 in order to provide clearance for implements or hooks inserted through the slots, for example.

[0044] To install a support rail system of the present invention, as shown in FIGS. 1 and 2, for example, a proximal end (e.g., unattached longitudinal edge 35) of a first wall panel (e.g., 26) can be inserted into a first channel (e.g., 71) of a rail body (e.g., 40) of a first support rail (e.g., 30). The first support rail can then be aligned with a first stud (e.g., 20) and an open portion (e.g., 72) of the rail body having first and second leg members (e.g., 46 and 48) can be engaged over a portion of the first stud. The second leg member may be shortened (as in FIG. 2) to make it easier for a user to slide the open portion of the rail body over the first stud. Once the open portion is slid over the first stud, the second leg member may typically be hidden from view by the first wall panel. However, the first leg member will likely remain visible, that is, until the second wall panel (e.g., 25) is installed. The first support rail can then be secured to the first stud in any manner known in the art. For example, the first support rail may be secured to the first stud by inserting a screw, nail or other fastener (e.g., 90) sequentially through apertures (e.g., 56, 55 and 54) in the rail body of the first support rail. The first leg member may also be secured directly to the first stud by inserting a screw, nail, or other fastener (e.g., 99) through an aperture (e.g., 50) in the first leg and into the first stud. As will be apparent, the first wall panel may be secured to the first stud by the fastener(s) used to secure the first support rail to the first stud. In an alternate embodiment, additional fastener(s) may be employed to secure the first wall panel to the first stud. In yet a further embodiment, the first wall panel can be held securely in the first channel and accordingly may not be fastened to the first stud, except by the first support rail.

[0045] Next, the proximal end (e.g., unattached longitudinal edge 34) of a second wall panel (e.g., 25) may be inserted into a second channel (e.g., 70) of the first support rail. The second wall panel may be secured in the second channel of the first support rail and optionally to the first stud by any of the techniques discussed above. For example, a fastener can be sequentially inserted into apertures (e.g., 53, 52 and 51) within the rail body, through the second wall panel and into the first stud. The distal end (e.g., longitudinal edge 33) of the second wall panel can then be abutted or slid into a first channel of a second support rail (e.g., 130), wherein the first and second support rails might be similar. The rail body of the second support rail can then be aligned and fastened to a second stud (e.g., 120), for example, by fasteners inserted through one or more apertures in the rail body of the second support rail. The second support rail may be further attached to the second stud by one or more fasteners inserted through one or more apertures in the leg(s) of the rail body into the second stud. In some instances, a proximal end (e.g., longitudinal edge 32) of a third wall panel (e.g., 24) can also be inserted and fastened within a second channel of the second support rail. This process can be repeated as desired by the customer to install additional panels. In this manner, one or more support rails may be integrated as part of a substantially finished wall. Because of the ease of installation, such support rails are well suited for retail stores and for residential and commercial storage facilities, garages, laundry rooms, bathrooms, and kitchens.

[0046] A support rail system may include any of a variety of specific arrangements of support rails associated with one or more walls. In an exemplary embodiment, a support rail system can include a plurality of support rails. For example, a pair of support rails may be provided substantially parallel to each other and oriented horizontally or vertically along a wall. In some embodiments, one or more support rails might be mounted upon the wall centrally between the floor and the ceiling of a room. In another example, one or more support rails might extend vertically from the floor to the ceiling within a room.

[0047] Parallel support rails can be spaced to accommodate the intended implement(s) and/or the intended wall panels. In certain circumstances, implements (e.g., shelving) and/or wall panels can be specially manufactured to correspond with the desired spacing between the support rails. For example, if four-foot shelving is to be used, at least two parallel support rails should be spaced four feet apart. Similarly, if sheets of drywall having a four-foot width (and an eight-foot height, for example) are oriented vertically adjacent to wall studs spaced every sixteen inches, support rails can be mounted vertically and spaced at four-foot intervals (e.g., a support rail on every fourth stud). Such a configuration would accommodate the aforementioned four foot shelving. In other embodiments, the support rails may be attached to every stud (e.g., spaced sixteen inches apart) or every other stud (e.g., spaced thirty-two inches apart), thereby allowing greater flexibility in mounting brackets and/or other implements along the wall. Brackets may be provided and inserted into slots within each support rail and may, for example, be inserted at equal heights on two parallel support rails so as to support a shelf or a bench.

[0048] The foregoing description of exemplary embodiments and examples of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate the principles of the invention and various embodiments as are suited to the particular use contemplated. It is hereby intended that the scope of the invention be defined by the claims appended hereto.

Claims

1. A support rail comprising:

a rail body having a front surface and a rear surface, at least a portion of the rear surface adapted to engage a fixed wall support member for attachment thereto; and,

a longitudinal channel portion at least partially defined by the front surface wherein the channel is adapted to receive a longitudinal edge of a wall panel;

wherein the support rail is configured to effectively cover a longitudinal edge of a wall panel received in the channel.

2. The support rail of claim 1, further comprising slots configured to selectively engage shelving hangers.

3. The support rail of claim 1, further configured to receive longitudinal edges of two adjacent wall panels for attachment to the wall support member.

4. The support rail of claim 1, wherein the rail body further comprises a side wall configured to partially define the longitudinal channel.

5. The support rail of claim 4, wherein the rail body further comprises a base member attached to the side wall and configured to partially define the longitudinal channel.

6. The support rail of claim 5, wherein the rail body further comprises a first leg member attached to the base member.

7. The support rail of claim 6, wherein the first leg member is provided with at least one aperture for attaching the support rail to the wall support member in use.

8. The support rail of claim 6, wherein the rail body further comprises a second leg member.

9. The support rail of claim 8, wherein the second leg member has a length substantially less than the first leg member.

10. The support rail of claim 8, wherein the second leg member comprises a protruded portion adapted to mount over the wall support member for attachment.

11. The support rail of claim 8, wherein the first leg member and the second leg member are each provided with at least one aperture for attaching the support rail to the wall support member in use.

12. The support rail of claim 4, wherein the rail body further comprises an integral cap attached to the side wall and configured to cover a seam at the longitudinal edge of the wall panel.

13. The support rail of claim 12, wherein the cap is provided with at least one aperture configured to receive a fastener for attaching the wall panel to the wall support member.

14. The support rail of claim 13, further comprising at least one push plug configured to cover a fastener within the aperture in the cap.

15. The support rail of claim 1, wherein the support rail further comprises a cap separate from the rail body but adapted to engage the rail body, wherein the cap is configured to cover a seam at the longitudinal edge of the wall panel.

16. The support rail of claim 15, wherein the cap is further configured to partially define the longitudinal channel.

17. The support rail of claim 15, wherein the cap is further configured to cover a fastener within an aperture in said rail body.

18. The support rail of claim 15, wherein the cap comprises a protrusion, said rail body comprises a groove, and the cap is configured to attach to the rail body by interlocking the protrusion with the groove.

19. A support rail comprising:

a rail body having a front surface, a rear surface, and a cap having slots for selective attachment of hangers to the support rail, wherein at least a portion of the rear surface is adapted to engage a fixed wall support member for attachment thereto; and

a longitudinal channel portion at least partially defined by the front surface wherein the channel is adapted to receive a longitudinal edge of a wall panel to be secured to the wall support member.

20. The support rail of claim 19, wherein the cap is configured to effectively cover the longitudinal edge of a wall panel received in the channel.

21. A method of installing a wall support rail system including a support rail having a rail body and a longitudinal channel, the method comprising:

inserting a longitudinal edge of a wall panel into the channel;

engaging the rail body over a portion of a wall support member; and

affixing the wall panel to the wall support member and to the rail body by inserting one or more fasteners through apertures in the rail body.

22. The method of claim 21, further comprising the step of effectively covering the longitudinal edge of the wall panel received in the channel with a cap.

23. The method of claim 22, wherein the cap is provided as an integral extension of the rail body.

24. The method of claim 22, wherein the cap is provided as a separate piece which is attached to the rail body after the longitudinal edge is inserted into the channel.

25. A method of installing a wall support rail system comprising a plurality of support rails, each support rail having a rail body and at least two longitudinal channel portions, the rail body having a front surface and a rear surface, at least a portion of the rear surface adapted to engage a wall support member for attachment thereto, wherein the longitudinal channel portion is at least partially defined by the front surface and is adapted to receive a longitudinal edge of a wall panel, the method comprising:

abutting a proximal end of a first wall panel in a first longitudinal channel portion of a first support rail;

engaging the rail body of the first support rail over a portion of a first wall support member;

affixing the rail body of the first support rail to the first wall support member;

abutting the proximal end of a second wall panel in a second longitudinal channel portion of the first support rail;

abutting the distal end of the second wall panel in a first longitudinal channel portion of a second support rail;

engaging the rail body of the second support rail over a portion of a second wall support member; and

affixing the rail body of the second support rail to the second wall support member.

26. The method of claim 25, further comprising affixing the first and second wall panels to the first wall support member with fasteners.

27. A wall mounting system comprising:

a support rail comprising a cap, the cap having longitudinal slots and configured to cover a seam between an adjacent wall panel and the support rail, wherein the support rail is adapted to be substantially recessed into a wall except for a portion of the cap;

a mount having at least one flange configured for insertion into at least one of the longitudinal slots; and

an implement supported by the mount.

28. The wall mounting system of claim 27, wherein the implement comprises a shelf.