Method and system for modular panels and their installation
A method and apparatus for mounting modular panels in elevators cabs and on building walls with a plurality of side assemblies including frame member for supporting modular panel and for wall mounting the panels. Devices and method are disclosed for alignment of multiple panels fitted to a wall.
This application claims priority of U.S. Provisional Patent Application Ser. No. 61/744,443 filed Sep. 25, 2012.
FIELD OF THE INVENTIONThis invention is related to the art of building and elevator cab construction, and more particularly related to the art of methods and systems for installing and replacing modular panels on building and/or elevator walls and portions thereof.
BACKGROUND OF THE INVENTIONOnce a wall is constructed or installed in a building or elevator cab, it may be necessary to repair and replace the interior elements of the wall. Typically in modular construction, a plurality of panels can be provided to cover all or a portion of a wall or the interior surfaces of an elevator. For example, an elevator cab having four walls, a door, a floor and ceiling, may have at least three the walls covered with decorative paneling. The decorative paneling can become damaged which can prompt the replacement of the decorative paneling. Alternately, it may be desirable to replace the decorative paneling for aesthetic reasons. Accordingly, it is often necessary to replace an entire decorative panel assembly when just a portion of a decorative panel is to be replaced. This can be expensive, complicated, and time consuming. For example, the value of undamaged portions of the decorative panel assembly is lost when the entire decorative panel must be replaced because a mere portion of the decorative panel is damaged.
In addition, the connection elements of a wall for connecting decorative panels to the wall may require the removal of the entire decorative panel, and therefore make the replacement of a decorative panel complicated and time consuming. Furthermore, it may be difficult to locate adequate replacement paneling since the dimensions and design of a panel portion can change.
As a consequence, walls requiring replacement paneling are typically unappealing, and out of service for an extended period while replacement panels are being obtained and installed.
In addition, or the alternative, it is often desirable to change the appearance of a wall. Accordingly, in order to provide different paneling having different aesthetic appearance, is often necessary to replace the entire panel, and therefore lose the value of other necessary structural elements of the panel, such as those components which attach the panel to the wall.
Accordingly, there is a need for method and system for installing replacement panels on building and/or elevator cab walls and portions thereof.
SUMMARY OF THE INVENTIONThe present invention provides a method of installing modular paneling and a modular panel which can be used in accordance with the method.
A method of installing modular interior paneling according to the invention includes providing at least one modular panel on wall or ceiling surface. A modular panel according to the invention, which can be used in accordance with the method, includes a plurality of side assemblies and a decorative front panel, wherein the decorative front panel is held by the plurality of side assemblies. Each of the plurality of side assemblies can include an inner support frame, a removable panel moulding, and a removable perimeter alignment panel. The removable panel moulding and the removable perimeter alignment panel are attached to the inner support frame.
A method of installing modular paneling according to the invention includes removing at least one of the components of the modular panel, and thereby providing for a quick and economical method of replacing visible parts of the wall, such as when the parts become damaged, or for other aesthetic reasons. The removable parts include the decorative front panel, the plurality of panel mouldings, and the plurality of perimeter alignment panels.
Thus, the method also includes replacing the part that has been removed with another part, configured to fit with the inner support frame, but which can otherwise have different form and construction.
A method of installing modular paneling according to the invention can also provide for removing one or more of the modular panels from wall or ceiling surface in order to remove at least one of the removable parts, and replacing the modular panels to the wall after one or more of the removable parts have been replaced.
A method of installing modular paneling according to the invention can also include removing one or more of the side assemblies of a modular panel prior to the step of removing one or more of the removable parts, and then replacing of side assemblies after the removable parts have been replaced. For example, it is possible to provide an embodiment of a modular panel which requires that the side assemblies first be removed in order to replace one or more of the replaceable parts, and thereby prevent unauthorized removal of the parts. Alternatively, an embodiment of a modular panel can be provided which does not require that the side assemblies first be removed.
The method of installing modular paneling according to the invention can also include removing and replacing all of the panel mouldings, and alternatively, or in addition, removing and replacing all of the perimeter alignment panels, and/or removing and replacing all of the side assemblies.
The method of installing modular paneling according to the invention can also provide use of a panel lock which can be unlocked to allow one or more modular panels to be removed from a wall or ceiling, and then re-locked once the panels are replaced. For example, several modular panels can be provided on an interior side of an elevator cab, and can be attached to the side such that one panel must be removed to gain access to a second panel, and thus a single lock may be employed to prevent unauthorized removal of the panels. The elevator side lock can be incorporated into one or more of the panels, or disposed on the wall whereby the panels can be locked into place on their mountings. In addition, or in the alternative, a lock can be provided for one or more of the components of the modular panels.
A modular panel according to the invention includes side assemblies and a decorative front panel which is held by the side assemblies. Each of the side assemblies can include an inner support frame, a panel moulding, and a perimeter alignment panel. The panel mouldings and perimeter alignment panel are attached to inner support frames for corresponding side panels. The decorative front panel is preferably held by a cavity in side assemblies of the modular panel so that the decorative front panel can be installed or removed by simply sliding the decorative panel in and out of the cavity once a side assembly is removed. It can be appreciated that the decorative front panel can also be attached to the modular panel by a number of other attachment means, and can be configured such that the removal of a side assembly is not required.
The inner support frame can also be provided with attachments for affixing the inner support frame to a wall or an interior side of an elevator cab, as well as a locking mechanism to prevent unauthorized removal of the panel from the wall or the interior side of an elevator cab. In addition, the modular panel can be provided with an intermediate panel behind the decorative panel, such as may be useful for providing tighter fit for the decorative panel in the cavity of the modular panel, or for the incorporation of other features such as to provide insulation or lighting behind the decorative panel. In addition, or in the alternative, a back panel can be provided which is not held by the cavity.
OBJECTS OF THE INVENTIONIt is an object of the invention to provide a method and system for installing modular panels that is economical, efficient, and easy.
It is a further object of the invention to provide a method for installing modular panels that permits the replacement of altered components having different aesthetic characteristics.
It is a further of the object of the invention, to provide a modular panel that is easily removable, and that has components that are readily replaceable.
It is a further object of the invention to provide a modular panel having visible components that are replaceable with a wide variety of alternative components having different aesthetic characteristics.
It is a further object of the invention to provide a modular panel having a construction that provides economical, efficient, and easy replacement of its component parts.
Other and further objects of the invention will become apparent with an understanding of the following detailed description of the invention or upon employment of the invention.
A preferred embodiment of the invention has been chosen for detailed description to enable those having ordinary skill in the art to which the invention appertains to readily understand how to construct and use the invention and is shown in the accompanying drawing. Throughout the figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. Moreover, while the subject invention will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments. It is intended that changes and modifications can be made to the described embodiments without departing from the true scope and spirit of the subject invention.
A detailed description of the devices and methods for installing modular panels is provided below for general applicability. In addition, several specific embodiments are provided as examples of the devices and methods with which one of ordinary skill in the art may apply these teachings to address specific problems and to illustrate the benefits and improvements of the system and method over known solutions.
Referring to the drawing,
The decorative front panel (101) can be a material having the aesthetic characteristics desired for the wall or the interior of the elevator cab and sized to substantially fit within a plurality of the side assemblies (106) which are arranged around a perimeter of the decorative front panel (101). One non-limiting example of the decorative front panel (101) is a wood panel that is rectangular in shape and sized to substantially fit within a plurality of the side assemblies (106).
In addition, the decorative front panel (101) can be a composite of different materials, such as a composite of the different layers. Thus, the composition of the decorative front panel (101) can be any number of materials as known by one of ordinary skill in the art appropriate for use in elevator panels.
The panel moulding (102) can be a material having the aesthetic characteristics desired for the wall or the interior of the elevator cab and sized to substantially fit as a frame-like portion on a plurality of the side assemblies (106). In a preferred embodiment shown in
Each inner support frame (103) can be comprised of a substantially rigid material to provide support for the parts of a corresponding side assembly (106), including a panel moulding (102), a decorative front panel (101), and a perimeter alignment panel (104), among other things.
The inner support frame 103 shown in
In a preferred embodiment, inner support frame comprises a generally L-shape beam of fixed cross-section with a face plate 103f having a top surface defining a modular panel mounting face 103b. Panel arm 103e extends along an edge of the face plate for positioning a modular panel on the mounting face. The face plate has a bottom surface 103g with first 103h and second 103i downwardly extending appendages from the bottom face. The appendages respectively support first 103m and second 103n elongate bars with each bar having wall mounting face 103c, 103d generally parallel to the panel mounting face 103b. The first and second appendages and bars define interior space 108 for connection of support frames to each other to form a modular panel. One of the bars 103n cooperates with the face plate to define a recess 103p for connecting modular panels to elevator cabs and building walls with connector or cleat 308. The other bar 103m cooperates with the face plate to define a recess 103r for receiving an intermediate alignment piece 112 which cooperates with alignment bar 111 (
Alignment bar 111 (
Panel faces 103b of an assembled inner support frame define the outer margin or perimeter of the area occupied by a modular panel situated within the frame 103.
The inner support frame of
The perimeter alignment panel (104) can be a material having the aesthetic characteristics desired for the wall or the interior of the elevator cab and is sized to substantially fit as a frame-like portion along as well as between a plurality of the side assemblies (106) to ensure vertical and horizontal alignment of adjacent modular panels. One example of the perimeter alignment panel (104) is a thin metal panel with parallel sides designed to fit closely with adjacent panel moulding (102) and inner support frame (103). In addition, the perimeter alignment panel (104) can be a composite of different materials, such as a composite of the different layers.
Each of the side assemblies (106) can be provided with other connection means for connecting several components of the side assemblies (106). For example, each panel moulding (102) can be provided with connection means, such as moulding connector (119) for connecting a panel moulding (102) to an inner support frame (103). It can appreciated by one of ordinary skill in the art that a moulding connector can be a screw, a clip, a bolt, or other such connectors.
Each of the perimeter alignment panels (104) can be provided with connection means, such as an alignment panel connector (120), for connecting a perimeter alignment panel (104) to an inner support frame (103). It can appreciated by one of ordinary skill in the art that and alignment panel connector (110) can be a screw, a clip, a bolt, or other such connectors.
A front view of a modular elevator panel (100) according to the invention is shown in
The side assembly (400) can be provided with one or more panel locks (405) which can be used to secure the modular panels (100) and prevent unauthorized removal of the panels. Locks (405) are preferably mounted to bridge adjacent panels as in
In an embodiment of panel assembly (400) having stacked modular panels (100), a single panel lock (405) can be used to secure a stack of modular panels (100). Accordingly, the modular panels (100) can be individually removed by unlocking a corresponding panel lock (405) for each modular panel (100), or for a stack of modular panels (100). Once a modular panel (100) is removed, individual portions of the modular elevator panel can be accessed.
A side assembly (106) of a modular panel according to the invention can be readily replaced. The modular panel (100) can be readily disassembled by removing one or more of its component parts. For example, a side assembly (106) can be first removed in order to access various components. Thereafter, the side assembly (106) can be replaced.
In addition, a decorative front panel (101) of a modular panel (100) can be replaced. Once a side assembly (106) is removed the decorative front panel (101) can be removed and replaced. The decorative front panel (101) can rest within a panel moulding recess (113) of the modular panel (100).
In one embodiment of the invention, it is preferable to provide a frame connector cavity (108) to hold the decorative front panel (101) in order to provide cost effective connection means, and to provide means for holding the decorative front panel (101) which is hidden from view for aesthetic reasons. The decorative front panel (101) is preferably provided such that it cannot be removed without first removing the modular panel (100) from the side assembly (400). This arrangement prevents unauthorized tampering or removal of the decorative front panel (101).
The panel moulding recess (113) can be sized to fit the decorative front panel (101), or can be larger to also include an intermediate panel (107). An intermediate panel (107) can be used to ensure a snug fit of the decorative front panel (101) within the panel moulding recess. Thus, it is possible to quickly replace a damaged decorative front panel (101) without having to replace an entire modular panel (100). A perimeter alignment panel (104) of a modular elevator panel according to the invention can be replaced. Once a side assembly (106) is removed, it is also possible to remove and replace the perimeter alignment panel (104). In an alternative embodiment, perimeter alignment panels (104) can be connected to the modular panel (100) such that a side assembly (106) need not first be removed. Thus, it is possible to quickly replace a damaged perimeter alignment panel (104) without having to replace an entire modular panel (100). In addition, the perimeter alignment panels (104) cannot be removed without first removing the modular panel (100) from the side assembly (400), and thereby prevents unauthorized tampering or removal of the perimeter alignment panel (104).
A panel moulding (102) of a modular panel (100) can likewise also be readily replaced. Once a side assembly (106) is removed, it is also possible to remove and replace the panel moulding (102). Thus, it is possible to quickly replace a damaged panel moulding (102) without having to replace an entire modular panel (100). The panel moulding (102) cannot be removed without first removing the modular panel (100) from the side assembly (400), and therefore prevents unauthorized tampering or removal of the panel moulding (102).
In an alternative embodiment, the panel moulding and inner frame support can be combined into a single integral piece, as shown in
Referring to
The inner support frame 103 includes main plate 103f defining modular panel mounting face 103b, and upper 103i and lower 103h T-members together defining frame connector cavity 108 and wall mounting faces 103d, 103c. The lower T-member has inclined inner surface 103s forming recess 103p that cooperate with panel connector or cleat 308 for mounting modular panel on elevator or building wall. Upper T-member is provided with upwardly open recess 103r for cooperating with alignment bar 111 and intermediate alignment piece 112.
Inner support frame 103 also includes panel arm 103e having connector 129 for securing modular panel to the support frame. The panel arm further includes an inwardly directed cavity 103w defining an elongate interior recess for positioning an elongate LED strip 114 by which the decorative front panel or the border of the modular panel may be illuminated by diffuser panel 115 and laminated glass front 116.
As shown in
Referring to
The inner support frame 103 includes main plate 103f defining modular panel mounting face, and upper and lower T-members together defining frame connector cavity 108 and wall mounting face 103c, 103d. The upper T-member 103h has an inclined inner surface 103s forming a recess that can cooperate with panel connector 308 for mounting modular panel on elevator or building wall. Lower T-member 103i is provided with open recess 103r for cooperation with alignment bar 111 and intermediate alignment piece 112. Inner support frame 103 also includes panel arm 103e for securing modular panel 100 to the support frame.
As shown in
The inner support frame 103 is provided with locking lip 103v by which lock 405 (
A panel system according to the invention includes several desirable attributes, including the design of individual panels, how the panels can be installed, and how each of the panels cooperate with one another to form an overall panel structure having an aesthetic appearance. Aspects of the invention which contribute include the spacing mechanisms, the alignment mechanisms, cleat mechanism to hang one or more panels to a wall. The aforementioned construction permits a lightweight panel to be used instead of a heavier material, which material is typically heavy to support the weight of the panel after being pierced by a supporting connection, such as a screw, bolt or nail. A panel according to the invention also permits the use of thin glass, thereby permitting a number of additional improvement, including wall sections with varying opacity, such as may be variably controlled through the use of electric activation, as well as lit/backlit panels which can have light elements embedded within the panel or illuminated at one or more edges of a panel.
In the past heavy glass was problematic because of its weight and difficult to use architecturally because of the green tint that often accompanies use of glass. The use of thin glass permitted by a panel system according to the invention can provide a whiter appearance which is highly desirable. In one embodiment, it is possible to glue the decorative front panel (101), to glue as assembly including the decorative front panel (101) to a frame of side assemblies (106) and thereby avoid using a capture potion for the panel, which improves the aesthetic appearance of a panel. By painting or adding a laminated structure to the back of a clear panel product, then gluing the painted or laminated surface to the frame of side assemblies (106) it is possible to avoid the discoloration and the clear panel cause by contact with an adhesive, and avoids the problem of headlighting when the panel is back-lit. The panels can thus be prefabricated and brought to the field for installation.
Various changes may be made to the structure embodying the principles of the invention. The foregoing embodiments are set forth in an illustrative and not in a limiting sense. The scope of the invention is defined by the claims appended hereto.
Claims
1. A modular panel for installation on elevator cab and building walls, the modular panel comprising a decorative front panel having a perimeter defining multiple sides, a plurality of side assemblies adjoining the panel sides for installation of the modular panel, means for connecting the side assemblies to each other to define a frame about the modular panel perimeter, each side assembly having an inner support frame, the inner support frame having a modular panel mounting face for engaging and positioning a modular panel, and a wall mounting face for positioning the modular panel on elevator and building walls, the panel mounting face and the wall mounting face having surfaces being generally parallel to each other, the panel mounting face and the wall mounting face being spaced from each other to define an interior space accessible through the wall mounting face, the interior space adapted to receive a wall panel connector by which the modular panel is secured to elevator cab and building walls.
2. A modular panel as defined in claim 1 in which each side assembly comprises an inner support frame, a panel moulding connected to the frame and extending along the perimeter of the front panel, the panel moulding having means for retaining the front panel to the support frame.
3. A modular panel as defined in claim 2 in which the inner support frame has a panel arm for positioning the panel moulding on the frame.
4. A modular panel as defined in claim 1 which further comprises a perimeter alignment panel extending along an outer margin of the panel for aligning adjacent modular panels when connected to elevator cab and building walls.
5. A modular panel as defined in claim 1 which further comprises an intermediate panel and a back panel between the decorative front panel and the modular panel mounting face.
6. A modular panel as defined in claim 1 in which each inner support frame has mitered ends abutting adjacent inner support frames, interior spaces of the inner support frames communicating across the mitered ends, and connectors positioned in interior spaces across mitered ends for connecting the side assemblies to each other to define a frame about the modular panel perimeter.
7. An inner support frame for positioning modular panels in elevator cabs and on building walls, the inner support frame comprising a generally L-shape beam of fixed cross-section, the frame having a face plate having a top surface defining a modular panel mounting face, a panel arm extending along an edge of the face plate for positioning a modular panel on the mounting face, the face plate having a bottom surface, first and second appendages extending from the bottom face, the appendages respectively supporting first and second elongate bars, each bar having a wall mounting face generally parallel to the panel mounting face, the first and second appendages and bars defining an interior space for connection of support frames to each other about a modular panel, one of the first and second bars cooperating with the face plate to define a recess for connecting modular panels to elevator cabs and building walls.
8. An inner support frame as defined in claim 7 in which the other of the first and second bars cooperate with the face plate to define a recess for receiving an intermediate alignment piece whereby adjacent modular panels are aligned.
9. An inner support frame as defined in claim 8 in combination with alignment bars mounted on elevator cab and building walls, the alignment bars having a recess in registry with the other bar recess to receive the intermediate alignment piece.
10. An inner support frame as defined in claim 8 in which the recess has an interior locking edge for cooperation with a lock for securing adjacent modular panels to each other.
11. An inner support frame as defined in claim 7 which further comprises a panel arm extending along an edge of the face plate for positioning a modular panel on the frame.
12. An inner support frame as defined in claim 11 in which the panel arm has a recess for receiving and positioning an LED strip along a margin of a modular panel.
13. An inner support frame as defined in claim 11 in which the panel arm has means for connection to a modular panel.
14. A method for installing modular panels in elevator cabs and on building walls comprising the steps of positioning inner support frames about the perimeter of a decorative panel, defining a connector cavity in each support frame, for connecting the support frames to each other at abutting edges, defining a mounting recess in each support frame for installing modular panel, and aligning modular panels along their perimeters.
15. A method as defined in claim 14 including the additional step of locking adjacent panels to each other.
Type: Application
Filed: Sep 24, 2013
Publication Date: Jun 19, 2014
Inventor: Harold S. Friedman (New York, NY)
Application Number: 13/998,030
International Classification: E04F 13/08 (20060101); E04B 2/72 (20060101);