MODULAR COMPONENTS FOR BUILDING STRUCTURES

Abstract

A method of constructing a first interior building structure includes providing a first panel, the first panel including a first plurality of evenly spaced reinforcement structures and providing a second panel, the second panel including a second plurality of evenly spaced reinforcement structures. A first mounting structure is mounted on at least one of the reinforcement structures of the first panel. A second mounting structure is mounted on at least one of the reinforcement structures of the second panel. The first panel is coupled to the second panel by interlocking the first mounting structure with the second mounting structure, wherein, when the first panel is mounted to the second panel, the first and the second mounting structures are hidden from an exterior of the first and the second panels.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/823,272, filed on Aug. 23, 2006, which application is incorporated herein by reference.

FIELD

The principles disclosed herein relate generally to modular components for constructing building structures such as cabinetry, desks, shelving, closet systems, and furniture, and, to a method of constructing building structures using modular components.

BACKGROUND

Interior building structures such as cabinetry and office furniture are generally constructed at a predetermined site such as a cabinetmaker's shop and delivered to the job site preassembled. Preassembled interior units are generally of a closed architecture design.

Preassembled interior building structures, wherein a majority of the components are integrally formed, tend to have some shortcomings. Some of these structures tend to be heavy and may be difficult to maneuver through doorways or around objects such as preexisting furniture or preexisting cabinets. Flexibility of design is limited generally to the preassembled form.

Another shortcoming of preassembled interior units is that, since the major components of a unit may be integrally formed, the entire unit may need to be replaced if damaged, rather than replacing only the damaged component.

What is desired is an open architecture design that allows the user or installer to customize the cabinetry, desk, shelving, closet system, or furniture to the desired end result.

SUMMARY

According to one particular aspect, the principles disclosed herein relate to modular components for constructing building structures (e.g., interior building structures) such as cabinetry, desks, shelving, closet systems, and furniture.

According to another particular aspect, the disclosure herein relates to a method of constructing building structures, such as cabinetry, desks, shelving, furniture, walls, floors, etc., using modular components.

Using modular components to construct building structures promotes standardization of components for lower manufacturing costs, facilitates replacement and transport of the units and/or expands options for customization using open architecture by the end user.

A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an isometric view of a modular component in the form of a panel having features that are examples of inventive aspects in accordance with the principles of the present disclosure, the panel illustrated with an exposed end showing the interior structures such as the reinforcement structures of the panel;

FIG. 1B is another isometric view of the panel of FIG. 1A, the panel provided with mounting bores on a face of the panel, the mounting bores provided along the reinforcement structures of the panel;

FIG. 2 illustrates an embodiment of an interior building structure in the form of a shelving unit formed by using a plurality of the panels illustrated in FIGS. 1A and 1B;

FIG. 3 illustrates another embodiment of an interior building structure formed by adding additional panels to the structure of FIG. 2;

FIG. 4 illustrates an example fastener in the form of a bolt configured for use with the panels of FIGS. 1A and 1B in constructing interior building structures using modular components in accordance with the principles of the present disclosure;

FIG. 5 illustrates an example fastener in the form of a bracket configured for mating with the bolt of FIG. 4 in constructing interior building structures using modular components in accordance with the principles of the present disclosure;

FIG. 6 illustrates the panel of FIGS. 1A and 1B with a plurality of the bolts of FIG. 4 inserted within the mounting bores on the face of the panel;

FIG. 7 illustrates the panel of FIGS. 1A and 1B with a plurality of the brackets of FIG. 5 mounted to an end of the panel;

FIG. 8 diagrammatically illustrates the coupling of the panel of FIG. 6 including the bolts of FIG. 4 to the panel of FIG. 7 including the brackets of FIG. 5, the panels coupled along a path indicated by the arrows in the drawing;

FIG. 9 is a side view of the panel of FIG. 1A, showing the reinforcement structures of the panel;

FIG. 10A diagrammatically illustrates the mounting of a removable nosing having features that are examples of inventive aspects in accordance with the principles of the present disclosure to a panel such as the panel of FIG. 9;

FIG. 10B illustrates the removable nosing of FIG. 10A mounted to the panel of FIG. 10A;

FIG. 11 illustrates a bracket configured for use in mounting a panel such as the panel of FIG. 9 to a preexisting wall;

FIG. 12 illustrates an exploded isometric view of the bracket of FIG. 11 and a panel such as the panel of FIG. 9;

FIG. 13A is an exploded side view of the panel and the bracket of FIG. 12, the bracket and the panel shown exploded from a preexisting wall that includes a mounting rail;

FIG. 13B illustrates the panel of FIG. 13A mounted to the preexisting wall via the use of the bracket of FIG. 13A;

FIG. 14A is an isometric view of a toe kick adjustable leg configured for use with an interior building structure formed from modular components having features that are examples of inventive aspects in accordance with the principles of the present disclosure;

FIG. 14B is a side view of the toe kick adjustable leg of FIG. 14A;

FIG. 15A is an isometric view of another embodiment of a toe kick adjustable leg for use with an interior building structure formed from modular components having features that are examples of inventive aspects in accordance with the principles of the present disclosure;

FIG. 15B is a side view of the toe kick adjustable leg of FIG. 15A;

FIG. 16A is an isometric view of top and bottom support structures of a toe kick assembly that are configured for use with the toe kick adjustable legs of FIGS. 14A and 14B;

FIG. 16B is an isometric view of a toe kick assembly formed from the top and bottom support structures of FIG. 16A and the toe kick adjustable legs of FIGS. 14A and 14B;

FIG. 16C is a front view of the toe kick assembly shown in FIG. 16B;

FIG. 17A is an isometric view of top and bottom support structures of a toe kick assembly that are configured for use with the toe kick adjustable legs of FIGS. 15A and 15B;

FIG. 17B is a side view of a toe kick assembly formed from the top and bottom support structures of FIG. 17A and the toe kick adjustable legs of FIGS. 15A and 15B;

FIG. 18 illustrates the use of a toe kick assembly such as the toe kick assembly of FIG. 17B in supporting an interior building structure formed from modular components having features that are examples of inventive aspects in accordance with the principles of the present disclosure against a preexisting wall;

FIG. 19 illustrates a partial isometric view of a molded rail configured to be used for hanging panels similar to the panels of FIGS. 1A and 1B vertically on a preexisting wall;

FIG. 20 illustrates an example fastener in the form of a spring clip configured for attachment to a panel similar to the panels of FIGS. 1A and 1B for vertically hanging the panel from the molded rail of FIG. 19;

FIG. 21 illustrates two of the spring clips of FIG. 20 fastened on a panel similar to the panels of FIGS. 1A and 1B, the panel having features that are examples of inventive aspects in accordance with the principles of the present disclosure;

FIG. 22A is a side view of the panel of FIG. 21 and two of the molded rails of FIG. 19, the panel and the molded rails shown in a disengaged configuration;

FIG. 22B illustrates a partial close-up view of the panel and one of the molded rails of FIG. 22A;

FIG. 23A illustrates the panel and the molded rails of FIG. 22A in an engaged configuration; and

FIG. 23B illustrates a partial close-up view of the panel and one of the molded rails of FIG. 23A.

DETAILED DESCRIPTION

The principles disclosed herein relate generally to modular components for constructing building structures, such as interior building structures including cabinetry, desks, shelving, and furniture, and, to a method of constructing building structures using modular components.

More particularly, the disclosure relates to lightweight, high-strength panels that are formed as modular, standardized components for constructing a variety of different building structures using similar panels. The panels are also configured to hide fastening hardware. The fastening hardware allows the finished product to be assembled on site, whether it is cabinetry, desks, office furniture, bookcases, closets, etc., while the hardware itself remains hidden.

FIG. 1A is an isometric view of a modular component in the form of a panel 10 having features that are examples of inventive aspects in accordance with the principles of the present disclosure. The panel 10 illustrated in FIG. 1A, as will be described hereinafter, can be used to construct a variety of different kinds of building structures such as cabinetry, desks, office furniture, bookcases, etc.

The panel 10, as illustrated in FIG. 1A, is generally formed from a top panel skin 12, a bottom panel skin 14, and a plurality of reinforcement structures 16 positioned between the top skin 12 and the bottom skin 14. The reinforcement structures 16 extend lengthwise along each panel 10. The panel 10 is illustrated in FIG. 1A with an exposed end 19 showing the reinforcement structures 16 of the panel 10.

In certain embodiments, the panels 10 may be between 9 inches and 36 inches in width W and between 6 inches and 96 inches in length L. In other embodiments, the panels 10 may be between 9 inches and 48 inches in width W. The panels 10 may be provided at 1½ inch increments between the 9 inches and the 36 inches for the width W (or between the 9 inches and 48 inches for the width W) and may be provided at 1½ inch increments between the 6 inches and the 96 inches for the length L. In certain other embodiments, the panels 10 may be provided at 3 inch increments between the 9 inches and the 36 inches for the width W (or between the 9 inches and 48 inches for the width W) and may be provided at 3 inch increments between the 6 inches and the 96 inches for the length L.

The equal increments for the width W and the length L of the panels 10 promote standardization and modularity of the components when using the panels 10 to construct different types of building structures. It should also be noted that the increments the panels 10 are provided at in length L and in width W may be dictated by the thickness T of the panels 10 to promote standardization of the modular components. In certain embodiments, for example, wherein the panels 10 are 1½ inches in thickness T, the width W and the length L of the panels 10 may also be provided in 1½ inch increments. In other embodiments, wherein the panels 10 are ¾ inches in thickness T, the width W and the length L of the panels 10 may also be provided in ¾ inch increments. It will be understood that this is a preferred embodiment of the system, and, in other embodiments, the increments for the width W and the length L of the panels 10 do not necessarily have to be the same as the thickness T of the panels 10. The values given above are just example values and it should be understood that other width, length, spacing, thickness values and appropriate increment values may be used depending upon the purpose of the panels 10.

Still referring to FIG. 1A, the reinforcement structures 16 (i.e., cores) may also be located at evenly spaced intervals along the width W of the panel 10 to promote standardization. Please also see FIG. 9 for a side view of the panel 10. For example, in some embodiments, the reinforcement structures 16 may be provided at 1½ inch increments. In other embodiments, the reinforcement structures 16 may be provided at 3 inch increments. In yet other embodiments, the reinforcement structures 16 may be provided at ¾ inch increments along the width W of the panels 10.

It should be understood that the increments for reinforcement structures 16 may also be dictated by the thickness T of the panels 10 as described above for the length L and the width W. In other embodiments, the increments of the reinforcement structures 16, as long as they are evenly spaced, may be different than the increments the length L and the width W are provided at for the panels 10. Having reinforcement structures 16 positioned at equal intervals promotes standardization and modularity of the components when customizing interior building structures.

As will be described hereinafter, the panels 10 can be used to modularly build interior building structures or be fastened to preexisting walls to form structures such as shelving, cabinetry, etc.

The predetermined increments for the panel widths W and the panel lengths L as well as the predetermined increments for the reinforcement structures 16 promote standardization and modularity of the panels 10 in constructing interior building structures. For example, if a portion of an interior building structure such as a desk formed from the panels 10 of the present disclosure gets damaged, only the damaged panel 10 would have to be replaced. The damaged panel 10 can be replaced with an identical panel 10 that is formed based on the same standard increments provided on the damaged panel.

Still referring to FIG. 1A, the panel skins 12, 14 can be formed from composition board. The skins 12, 14 can be sanded, painted or finished. The skins 12, 14 can be of any color, either solid or otherwise, or veneered. Edges of the panel 10 can be edge-banded with veneer or plastic, left plain, or sanded and painted.

The reinforcement structures 16 can be made of any solid material that fits the design needs of the customer. In one embodiment, the reinforcement structures 16 may be made from maple that has been molded to size.

Referring now to FIG. 1B, the panel 10 is provided with mounting bores 18 on a face 20 of the panel 10. The mounting bores 18 are preferably provided along the reinforcement structures 16 of the panel 10. As with the increments of the length L, the width W and the spacing of the reinforcement structures 16, the mounting bores 18 may also be provided in a line at an even increment along the length L of the panels 10. In certain embodiments, the mounting bores 18 may be provided at 1½ inch increments, which may or may not be dictated by the thickness T of the panels 10, as discussed above.

The mounting bores 18 may be drilled through the composition board skins 12, 14 and into the reinforcement structures 16 to create a panel 10 that can accept the appropriate hardware for modular construction of the building structures, as will be described in further detail herein.

FIG. 2 illustrates an embodiment of an interior building structure in the form of a shelving unit 22 formed by using the panels 10 illustrated in FIGS. 1A and 1B. FIG. 3 illustrates another embodiment of an interior building structure 24 formed by adding additional panels 10 to the structure 22 of FIG. 2. The shelving units 22, 24 shown in FIGS. 2 and 3 illustrate an example use of the panels 10 in creating modular interior building structures. As shown in FIGS. 2 and 3, the interior building structures may be changed in size or style just by adding additional panels 10. The panels 10 are preferably provided at standard lengths L and widths W and include evenly spaced reinforcement structures 16 and include evenly spaced mounting bores 18 such that the panels 10 can be easily added to change the design of the units. Replacement of a damaged panel 10 or addition of panels 10 is facilitated by the standardization of the construction components.

The system illustrated in the present disclosure provides the advantage of integrally adding modular components to existing components. In the prior art systems, for example, a shelving unit such as the unit 24 shown in FIG. 3, would be constructed from two separate units placed next to each other, rather than integrally formed by adding panels 10 to a preexisting structure.

In building structures such as the ones shown in FIGS. 2 and 3, if the panels 10 are to be mounted to a wall, skins can be cut to fit the cabinet openings out of composition board to match the panel skin 12, 14 and placed inside the cabinet flush with the wall to create a finished look. Methods of attaching the composition board to the wall include adhesive, double sided tape, hook and loop fastening system, etc.

FIG. 4 illustrates an example fastener in the form of a bolt 26 configured for use with the panels 10 of FIGS. 1A and 1B in modularly constructing building structures in accordance with the present disclosure. The bolt 26 shown in FIG. 4 is commercially available under the name “Easy Bolt.”.

The bolt 26 shown in FIG. 4 includes a head portion 28 and a threaded portion 30. The threaded portion 30 is threaded into the mounting bores 18 provided along the reinforcement structures 16 of the panels 10. Please see FIG. 6. The bolt 26 is threaded into the panel 10 until stopped by a flange 32 provided on the bolt 26.

FIG. 5 illustrates an example fastener in the form of a bracket 34 configured for mating with the bolt 26 of FIG. 4 for constructing building structures according to the present disclosure. The bracket 34 shown in FIG. 5 is commercially available under the name “Mod-Eez®” by Modular Systems, Inc.

The bracket 34 includes a middle interlock portion 36 and two side mounting flanges 38. The mounting flanges 38 are provided with fastener openings 40 for fastening the bracket 34 to a panel 10. The middle portion 36 of the bracket 34 includes a longitudinal slot 42 for slidably receiving the head portion 28 of the bolt 26 shown in FIG. 4.

As shown in FIG. 7, a slot 44 may be cut at the end 19 of the panel 10 to place and fasten an end bracket 46 on the panel 10 and the brackets 34 may be fastened to the end bracket 46.

Once the brackets 34 are mounted on the panel 10, another panel 10 including the bolts 26 may be coupled to the panel 10 with the brackets 34, as shown in FIG. 8. Two panels 10 may be coupled in a perpendicular arrangement as shown in FIG. 8 to create, for example, an interior building structure such as the one shown in FIG. 2. The panels 10 may be coupled along a path indicated by the arrows A in FIG. 8. Once coupled, the bolt 26 and the brackets 34 are hidden from view to create a more attractive look.

FIGS. 10A and 10B illustrate another aspect of the modular building structure construction system of the present disclosure. FIGS. 10A and 10B diagrammatically illustrate the mounting of a removable nosing 48 to a panel such as the panel 10 shown in FIGS. 1-8.

The removable nosing 48 illustrated in FIGS. 10A and 10B is simply one example embodiment that can be used with the panels 10. The nosing 48 is not limited to a square shape, as shown, but could have countless profiles molded for the face. Depending upon the style desired by the customers, a component such as the nosing 48 can be switched to create a different style. For example, a different style nosing component 48 can be provided for each of the different styles of furniture such as, Mission, Victorian, Modern, etc. By simply replacing the nosing 48, the interior building structures can be given different styles.

In the embodiment shown in FIGS. 10A and 10B, the nosing 48 is coupled to a panel 10 via a nosing bracket 50. The nosing bracket 50 is fastened to a reinforcement structure 16 of the panel 10 and leg portions 52 of the nosing bracket 48 are inserted into slots 54 formed on the nosing 48. In this manner, the hardware (e.g., nosing bracket 50) used for creating the style of the furniture may be completely hidden from view for a more attractive look.

It should be noted that the removable nosing 48 is simply one example component that may be used to modularly vary the style of the furniture created with the panels 10. Other components are possible. It should also be noted that the hardware shown and the mounting method used to couple removable nosing 48 to the panel 10 is simply one example. Other hardware and mounting methods can be used with the modular components to instantly change the style of the building structures, wherein the hardware is hidden from view to create an attractive appearance.

As discussed above, in addition to constructing stand-alone structures, the panels 10 can also be mounted to preexisting walls to create certain other types of interior building structures such as shelving, cabinets, etc.

FIG. 11 illustrates a wall bracket 56 configured for mounting a panel 10 to a preexisting wall 58. The wall bracket 56 includes a C-shaped main body 60 with a top horizontal wall 62, a bottom horizontal wall 64, a vertical wall 66 interconnecting the top and bottom walls 62, 64, and a flange portion 68 integrally formed therewith and extending downwardly from the main body 60. The main body 60 is configured and sized such that it fits into an open end 19 of a panel 10 between the skins 12, 14. Please see FIGS. 12, 13A, and 13B. When inserted, the vertical wall 66 of the main body 60 rests against a reinforcement structure 16 of the panel 10. The horizontal walls 62, 64 of the bracket 56 can then be fastened to the top and bottom skins 12, 14 of the panel 10 via fasteners.

Once fastened to the panel 10, the wall bracket 54 and the panel 10 are slid over a rail 70 provided on the preexisting wall 58 and the bottom flange 68 of the wall bracket 56 is fastened to the wall 58. The rail 70 may be a two by two made of pine and may be fastened to the preexisting wall 58 through the studs to span the desired cabinet length. The exposed flange 68 can be covered with a composition board skin back. Screws can also be inserted through the panel 10 into the rail 70 for added stability.

FIGS. 14-18 illustrate the construction of example toe kick assemblies that can be used with interior building structures formed from the modular panels 10. The toe kick assemblies can be used for supporting the interior building structures against a preexisting wall, as shown in FIG. 18.

FIGS. 14A and 14B illustrate one example of a toe kick adjustable leg 72 to construct a toe assembly. A plurality of the legs 72 shown in FIGS. 14A and 14B is used with top and bottom support structures 74, 76 shown in FIG. 16A to form the toe kick assembly 78 shown in FIGS. 16B and 16C. The legs 72 are adjustable in height along a direction indicated by the arrow B in FIG. 16C. The leg 72 shown in FIGS. 14A and 14B is known in the prior at and is available under the name “Titus®” by Titus International PLC.

FIGS. 15A and 15B illustrate another example of a toe kick adjustable leg 80 to construct a toe assembly for use with the modular interior building structures. A plurality of the legs 80 shown in FIGS. 15A and 15B are used with top and bottom support structures 82, 84 shown in FIG. 17A to form the toe kick assembly 86 shown in FIG. 17B. The legs 80 are also adjustable in height along a direction indicated by the arrow C in FIG. 17B.

The toe kick assembly 78 shown in FIGS. 16B and 16C uses top and bottom support structures 74, 76 that include openings 75 for mounting the toe legs 72 in preset discrete positions along the toe kick assembly 78. The toe kick assembly 86 shown in FIG. 17B uses top and bottom support structures 82, 84 that include longitudinal grooves 83 for slidably positioning the legs 80 along the grooves 83 at non-discrete positions.

FIG. 18 illustrates the use of a toe kick assembly such as the toe kick assembly 86 of FIG. 17B in supporting an interior building structure 92 (e.g., cabinet) formed from modular components of the present disclosure. The front toe kick assembly 86 allows for an installer to use the adjustable legs 80 to level the cabinet 92. Once the cabinet 92 is leveled, toe kick assembly 86 can be covered with a composition board skin 88 or other toe kick materials. The toe skin 88 can be applied to the assembly 86 by adhesive or finishing nails through the skin and into the top and bottom structures 82, 84. The back rail 90 is the screwed into the studs of the back wall similar to that described in reference to FIGS. 13A and 13B.

FIGS. 19-23B illustrate a method of hanging a panel similar to panel 10 of the present disclosure vertically from a preexisting wall.

In FIG. 19, a partial isometric view of a molded rail 92 is illustrated. The molded rail 92 is configured to be used as part of a quick-attach hanging system for hanging panels similar to the panels 10 of FIGS. 1A and 1B vertically on a preexisting wall. According to certain embodiments, the molded rail 92 is made from but not limited to hardwoods, such as maple, cherry, oak, etc. The molded rail 92 includes a curved, molded upper portion 93. The rear 94 of the molded rail is flat and is designed to rest flush against the wall. The rear 94 of the molded rail includes a recessed portion 91. As will be discussed in further detail below, the molded upper portion 93 is contoured to match the shape of an upper surface 97 of a cut-out 96 formed in the panel 10. When the panel 10 is hung from the rail 92, the molded upper portion 93 intermates with the upper surface 97 of the cut-out 96.

The flat rear 94 of the molded rail 92 is designed to be fastened to a preexisting wall. The molded rail 92 can be fastened to studs or other structural parts of the wall to provide a secure attachment. The recessed portion 91 is configured to leave a slot 99 between the wall and the panel 10. As will be described in further detail below, this slot 99 accommodates a spring clip 95 that is attached to the panel 10.

FIG. 20 illustrates an example fastener in the form of a spring clip 95 configured for attachment to the panel 10 for vertically hanging the panel 10 from the molded rail 92 of FIG. 19. According to one embodiment, the spring clip 95 is made from steel. A spring clip such as the clip 95 shown in FIG. 20 is commercially available under the name “Mod-Eez®” by Modular Systems, Inc. The spring clip 95 includes an upper plate 100 including fastener holes 101 and a lower plate 102 that is connected to the upper plate 100 by a middle portion 103. The upper plate 100 is fastened to the panel 10 with fasteners. The lower plate 102 is configured to flex with respect to the upper plate 100 to frictionally hold the panel 10 against the molded rail 92, as shown in FIGS. 22B and 23B.

FIG. 21 illustrates a panel 10 configured to be vertically hung from a preexisting wall using the quick-attach hanging system of FIGS. 19-23B. The panel, similar to the panels 10 shown in FIGS. 1A and 1B, includes mounting bores 18 for receiving bolts 26. Once hung vertically, horizontal panels 10 can be mounted to the vertical panel 10 to form shelving and other similar structures or other horizontal structures such as closet rods, etc. can be added.

The vertical panel 10 is prepared by first shaping the rear vertical end 105 of the panel 10. As shown in FIG. 22B, an upper portion 106 of the rear 105 of the panel (i.e., the portion located above the molded rails 92) is trimmed, leaving an offset that is the same width as the recess 91 at the back end of the molded rail 92. One, two, or more cut-outs 96 may be formed at the rear vertical end 105 for receiving the molded rails 92. As noted previously, the cut-outs 96 include upper surfaces 97 shaped to mate with the upper portions 93 of the molded rails 92. In the depicted embodiment, two cut-outs 96 are shown. Other numbers are certainly possible, depending upon the size of panel 10 being hung.

Before the spring clips 95 are fastened to the panels 10, as shown in FIG. 21, a recess 107 is formed at the rear vertical end 105. The upper plate 100 of the spring clip 95 is fastened within this recess 107 and is inset from the trimmed rear end 106 of the panel 10. In this manner, when the clips 95 are fastened, the lower plate 102 lies flush with the trimmed rear end 106, as shown in FIG. 22B.

FIGS. 22B and 23B illustrate the mounting of the panel 10 to the wall. The panel 10 is initially moved toward the molded rail 92, with the molded rail 92 received within the cut-out 96. Then, the panel 10 is slid downwardly in the direction of the arrow A until the upper portion 93 of the rail 92 mates with the upper surface 97 of the cut-out 96 of the panel 10. The lower plate 102 of the spring clip 95 is deflected by the upper portion 93 of the molded rail 92, toward the wall, in a biased fashion. In this manner, the spring clip 95 provides a biasing force on the molded rail 92 to frictionally hold the panel 10 against the rail 92. The bent portion 102 of the spring clip 95 fits into and is accommodated by the recess 91 at the back of the molded rail 92. Since an upper portion 106 of the vertical rear end 105 of the panel 10 had been trimmed, even though a portion 102 of the spring clip 95 protrudes rearwardly, everything lines up flush with the wall.

The molded rail 92, since oriented horizontally, allows the user to place a panel 10 at any horizontal location along the rail 92. The molded rails 92 can be sized according to need. The quick-attach hanging system including the molded rail 92, the panel 10 and the spring clip 95 provide a simple way to form vertical structures without the need for tools. Horizontal components can, then, be added to the vertical panels in accordance with the previous description above, such as by using bolts 26 within mounting bores 18, etc.

The above specification, examples and data provide a complete description. Many embodiments can be made without departing from the spirit and scope of the disclosure.

Claims

1. A method of constructing a first interior building structure comprising:

providing a first panel, the first panel including a first plurality of evenly spaced reinforcement structures;

providing a second panel, the second panel including a second plurality of evenly spaced reinforcement structures;

providing a first mounting structure on at least one of the reinforcement structures of the first panel;

providing a second mounting structure on at least one of the reinforcement structures of the second panel;

coupling the first panel to the second panel by interlocking the first mounting structure with the second mounting structure, wherein, when the first panel is mounted to the second panel, the first and the second mounting structures are hidden from an exterior of the first and the second panels.

2. A method according to claim 1, wherein the first mounting structure includes a bolt and the second mounting structure includes a bracket with a longitudinal slot for slidably receiving the bolt.

3. A method according to claim 2, wherein the bracket is mounted on a recess formed at an end of the panel so as to not protrude out from the end of the panel to hide the bracket from view when the first panel is mounted to the second panel.

4. A method according to claim 1, wherein the first panel is between a range of 9 inches and 48 inches in width and between a range of 6 inches and 96 inches in length, and the panel includes a thickness, wherein the width and the length of the panel are provided in increments within the ranges for the length and the width, wherein the increments are determined by the thickness of the panel, wherein the increments are generally equal to a factor of the thickness of the panel.

5. A method according to claim 4, wherein the increments are generally equal to the thickness of the panel.

6. A method according to claim 1, wherein the first panel and the second panel are coupled in a perpendicular configuration.

7. A modular building structure comprising:

a first panel including a first plurality of evenly spaced reinforcement structures;

a second panel including a second plurality of evenly spaced reinforcement structures;

a first mounting structure mounted on at least one of the reinforcement structures of the first panel; and

a second mounting structure mounted on at least one of the reinforcement structures of the second panel;

wherein the first mounting structure is interlocked with the second mounting structure to couple the first panel to the second panel such that the first and the second mounting structures are hidden from an exterior of the first and the second panels when coupled.

8. A modular building structure according to claim 7, wherein the first mounting structure includes a bolt and the second mounting structure includes a bracket with a longitudinal slot for slidably receiving the bolt.

9. A modular building structure according to claim 8, wherein the bracket is mounted on a recess formed at an end of the second panel so as to not protrude out from the end of the second panel to hide the bracket from view when the first panel is mounted to the second panel.

10. A modular building structure according to claim 7, wherein the first panel is between a range of 9 inches and 48 inches in width and between a range of 6 inches and 96 inches in length, and the panel includes a thickness, wherein the width and the length of the panel are provided in increments within the ranges for the length and the width, wherein the increments are determined by the thickness of the panel, wherein the increments are generally equal to a factor of the thickness of the panel.

11. A modular building structure according to claim 10, wherein the increments are generally equal to the thickness of the panel.

12. A modular building structure according to claim 7, wherein the first panel and the second panel are coupled in a perpendicular configuration.

13. A method hanging a first panel to a preexisting wall, comprising:

providing a first panel, the first panel including a first plurality of evenly spaced reinforcement structures;

providing a horizontal rail;

fastening the rail to the wall with fasteners;

fastening a bracket to one of the reinforcement structures, wherein a portion of the bracket extends into the first panel and is hidden from view when the first panel is mounted to the wall; and

capturing the horizontal rail by at least a portion of the bracket to frictionally hold the panel against the wall.

14. A method according to claim 13, wherein the first panel is hung horizontally with respect to the wall.

15. A method according to claim 13, wherein the first panel is hung vertically with respect to the wall.

16. A method according to claim 13, further comprising inserting a screw through a major face of the panel, through the bracket, and into the rail.

17. A method according to claim 13, wherein the bracket includes a C-shape.

18. A method according to claim 13, wherein the bracket includes a Z-shape.

19. A method according to claim 13, further comprising cutting a cut-out at a rear face of the panel and hanging the panel so as to receive the rail within the cut-out.

20. A method according to claim 13, wherein the first panel can be hung against the wall at an infinite number of different points along the horizontal rail.