SUPPORT PANEL FOR REMOVABLE BRACKETS AND THE LIKE
Support panels and modular assemblies thereof, the panels adapted for supporting removable load bearing members such as brackets. The panels comprise hollow bodies defining channels for receiving and supporting load bearing members. The hollow bodies further include support ribs extending between front and back walls of the panels to transfer forces exerted on flange portions of the channels by the load bearing members to the back walls and/or to other structural portions of the panels, the support ribs being offset from the perpendicular relative to the front and back walls of the panels. Pluralities of the panels may be joined by mating edges, which can define further channels for receiving and supporting load-bearing members, to form modular wall assemblies without the need for mounting overtop existing surfaces as said panels can be mounted directly on structural supports (e.g. stud walls).
The present invention relates generally to a support panel and more particularly to a support panel for supporting brackets and the like.
BACKGROUND OF THE INVENTIONSupport panels are commonly used in office, commercial and other environments in order to position various items, goods and products within easy reach and/or sight of people. For example, specially-adapted support panels are often used as part of trade shows to display new products, in retail stores to display goods for sale, and in garages, workshops and other places where storage is required, to organize and make easily available various tools.
Support panels define channels adapted for the mounting of various support members (for example, shelves, racks, hangers and the like). Typically, such support members are provided with brackets which engage the channels in order to securely hold the support members in place on the support panel. Hence, the mounting of shelves etc. is performed in an easy and efficient manner, without the use of screws or other types of fasteners. Support panels assembled from such walls are sometimes referred to as slat walls.
A problem with existing support panels is that the panel structure is not adapted to fully support the load that can be placed upon the panel by the brackets. If the load placed on a bracket exceeds the structural strength of a structure defining the channel, the structure is likely to fail, not only dropping the load, but also damaging the channel rendering that channel unusable. Thus, it is desirable to have support panels with channel structures that optimize the load carrying ability of channels for both value and safety purposes.
SUMMARY OF THE INVENTIONThe invention provides improved systems and methods for secure mounting of brackets and other load-bearing members on support panels. In preferred embodiments, the invention provides structures adapted for the removable mounting of such structures.
In one aspect the invention provides support panels adapted for supporting removable load bearing members such as brackets. Panels according to such aspect can comprise hollow bodies having front and a back walls separated by voids, and one or more channels defined by the hollow bodies for receiving load bearing members. The channels can include openings defined in said front wall, and base and flange portions defined by the hollow bodies for engaging the load bearing members. Such panels further comprise one or more support ribs extending between the front and back walls to transfer forces exerted on the flange portions by the load bearing members to the back walls and/or to other structural portions of the panels.
It has been found that superior load-bearing qualities can be achieved by providing the support ribs at angles offset from the perpendicular with respect to the front and back walls of the panels.
In other aspects, the invention provides modular wall assemblies comprising pluralities of such panels, wherein the panels are joined by mating edges which can define further channels for receiving and supporting load-bearing members without any compromise in strength.
The invention also provides for flat rear panel surfaces which allow mounting on stud walls without the need for backing (such as drywall), where joined panels act as an adequate sealing means for a wall especially at the corners where a void would be present.
The invention will now be described by example, and with reference to the accompanying drawings, in which:
Referring to
Referring to
In a preferred embodiment, panel 30 is integrally formed from PVC through an extrusion process. In other embodiments, panel 30 may be constructed from other plastics or materials, and formed through different processes, as understood by those with skill in the relevant arts. In yet other embodiments, one or more elements of panel 30 may be formed separately, and attached to panel 30 through additional processes.
As will be apparent to those skilled in the relevant arts, the use of hollow panels offers a number of advantages including, for example, reduced structural weight, and potential for improved insulation and/or fire retardation by, for example, filling voids 54 with insulating or fire retarding foams or other materials. Materials used to fill voids 54 can be chosen based on numerous criteria such as desired panel strength, rigidity, fire retardation concerns, thermal and or audio insulation, cost and weight.
Modular support panel 30 defines, by itself and/or in cooperation with one or more other support panels 30, one or more channels 58 for receiving brackets or other removable load-bearing members. As shown in
Referring still to
As will be understood by those of skill in the relevant arts, a suitable support member, such as a shelf (not shown) with a bracket that complements the shape of channel 58, can be used with support panels 30. In use, the bracket is inserted into channel 58 such that the shelf is held substantially perpendicular to support panels 30. In order to support the shelf in this configuration, and any extra weight that the shelf itself must support, the bracket exerts a force, or a load, at least partially on inner surface 88 of flange 78 and at least partially on base portion 66.
Panels 30, in accordance with the invention, can comprise additional structural members for providing support to load-bearing portions of panel 30. For example, in some embodiments of the invention, panels 30 comprise one or more support ribs 86 located within void 54 for transferring torsional, bending, and/or other loads applied to flange 38 by, for example, a removable load-bearing support member. Support rib 86 can be proximate to side portion 74, and extends between front wall 34 and back wall 38. In general, support rib 86 supports the load-bearing capabilities of flange 78 and may allow for greater loads to be supported by support panel 30.
Referring now to
Support rib 86 is preferably attached to front wall 34 at a distance from side portion 74 that is between zero to about 4 times D1 (the distance that flange 78 extends from side portion 74, as described above). It is even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 0.5 times to about 3.5 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 1.5 times to about 3.0 times D1, and even more preferred that support rib 86 is attached to front wall 34 at a distance from side portion 74 that is in the range of between about 2 times to about 2.7 times D1. In some embodiments, support rib 86 can be attached to front wall 34 at a position as close to side portion 74 as the corner formed by side portion 74 and front wall 34.
Front wall 34 and back wall 38 may be generally parallel to each other and are separated by distance D2. A suitable distance D2, as well as suitable thicknesses of the walls and other components of the panel, can be determined by a person skilled in the relevant arts, and will generally be dependent on the materials used to construct them, as well as the desired loads that they are expected to bear, and various manufacturing practicalities.
In another embodiment of the present invention, a second support member 86 is used, as shown in
It is not required that each support member 86 has the same angle 110. The angles will be determined by the particular load requirements. For example, an embodiment is shown in
In theory, there is no limit to the number of support ribs 86 that could be used; however, a skilled person could determine a practical number of support ribs 86, and their relative location, useful to support a desired load.
Referring back to
In the embodiment shown, a channel 122 is formed, or defined, where an end 42 meets an end 46. Accordingly, as shown in
In the embodiment shown, a support rib 130 is located proximate to end 46. As should be apparent to those skilled in the relevant arts, all variations discussed above for support rib 86 are also applicable to support rib 130 and are within the scope of the invention.
Modular wall assembly 200 can be secured to an existing wall system, or suitably supported by other means known in the art. For example, modular wall assembly 200 can be mounted directly on structural supports (e.g. stud walls). Alternatively, modular wall assembly 200 may comprise suitable supporting means to enable it to be self supporting such that minimal extra supporting means are required.
As shown, for example, in
In another embodiment of the present invention, a panel 30 with opposing flanges 78 forming a “T” channel, as shown in
While the invention has been described in some detail for purposes of clarity and understanding, it will be appreciated by those skilled in the relevant arts that various changes in form and detail can be made without departing from the true scope of the invention in the appended claims. The invention is therefore not to be limited to the exact components or details of methodology or construction set forth above.
Claims
1. A support panel for supporting one or more removable load bearing members, said support panel comprising:
- a body having a front wall and a back wall;
- at least one channel defined in said body for receiving at least one load bearing member, said channel having an opening defined in said front wall, a base portion, and a flange portion for engaging said load bearing member; and
- at least one support rib extending between said front wall and said back wall, each support rib extending at an angle of between 30 and 85 degrees relative to the back wall.
2. The support panel of claim 1, wherein each support rib extends at an angle of between 40 to 70 degrees relative to the back wall.
3. The support panel of claim 1, wherein said support rib extends at an angle of between 50 to 60 degrees relative to the back wall.
4. The support panel of claim 1, wherein said support rib is connected to said front wall at a location zero to four times the width of the flange.
5. The support panel of claim 1, wherein said support rib is connected to said front wall at a location in the range of between about 0.5 times to about 3.5 times the width of the flange.
6. The support panel of claim 1, wherein said support rib is connected to said front wall at a location in the range of between about 1.5 times to about 3.0 times the width of the flange.
7. The support panel of claim 1, comprising at least one base reinforcement rib spanning said base portion and said back wall for reinforcing said base portion.
8. The support panel of claim 1 wherein said flange is u-shaped.
9. The support panel of claim 4, comprising a spanning member spanning two ends of the u-shape of said flange for strengthening said flange.
10. The support panel of claim 1, comprising edges adapted for modular connection to mating edges of other panel structures.
11. The support panel of claim 10, wherein the edges adapted for modular connection are configured such that when mated with edges of other panel structures the edges and mating edges form a channel for receiving at least one load bearing member, said channel having an opening, a base portion and a flange portion defined by the edges and mating edges.
12. The support panel of claim 1, comprising a plurality of support ribs extending between said front wall and said back wall, each of said support rib extending at an angle of between 30 and 85 degrees relative to the back wall.
13. The support panel of claim 12, wherein at least one of said support ribs is connected to said front wall at a location within approximately zero to four times the width of the flange.
14. The support panel of claim 12, wherein at least two of said support ribs define angles with the back wall that are not equivalent.
15. The support panel of claim 1, comprising a plurality of channels defined in said body for receiving load bearing members, each said channel having an opening defined in said front wall, a base portion and a flange portion defined by said body for engaging at least one load bearing member.
16. A support panel for supporting one or more removable load bearing members, said support panel comprising:
- a body having a front wall and a back wall;
- at least one channel defined in said body for receiving at least one load bearing member, said channel having an opening defined in said front wall, a base portion, and two flange portions such that the channel forms a “T” shape; and
- at least one support rib extending between said front wall and said back wall, each support rib extending at an angle of between 30 and 85 degrees relative to the back wall.
17. A modular support panel system for supporting at least one removable load bearing member,
- said system comprising a plurality of support panels, each said support panel comprising: a body having a front wall and a back wall; and first and second edges configured such that two adjacent panels can be linked by adjoining a first edge of one panel to a second edge of the second panel to form a wall structure;
- the first and second edges of adjacent panels defining, when joined, a channel for receiving said at least one load bearing member, said channel having an opening defined by the front walls of the adjacent panels, a base portion, and a flange portion for engaging said load bearing member;
- at least one of the support panels further comprising a support rib extending between its front wall and its back wall, said support rib extending at an angle of between 30 and 85 degrees relative to the back wall.
18. A support panel for supporting a removable load bearing member, said support panel comprising:
- a body having a front wall and a back wall;
- a channel defined in said body for receiving said load bearing member, said channel having an opening defined in said front wall, a side portion perpendicular to said front wall and said back wall, and a flange defined by said body for engaging said load bearing member; and
- a support rib extending between said front wall and said back wall to transfer force exerted on said flange by said load bearing member toward said back wall, said support rib extending at an angle of between 10 and 50 degrees relative to the back wall.
Type: Application
Filed: Jun 22, 2006
Publication Date: Dec 27, 2007
Inventors: Paul NADAR (Mississauga), Antonio DI GINOSA (Mississauga)
Application Number: 11/425,754
International Classification: E04B 2/30 (20060101);