Panel mounting apparatus and related method of manufacture

A wall panel assembly includes at least one panel made from a steel sheet having a plurality of rear extending lateral edge flanges forming an enclosure and including a front surface. A cleat disposed within the formed enclosure includes a cleat body having a slot that is engageable with a support structure that is fixedly attachable to a wall. The support structure includes a plurality of engagement members that are releasably engageable in the at least one slot of the cleat. The support structure can be formed from a series of linear interconnectable sections.

TECHNICAL FIELD

The application generally relates to the field of display systems and more particularly to a panel having a dry-erase surface that is attachable to an assembly support, and wherein the assembly support enables a single panel or a plurality of panels to be releasably attached to a wall or wall-like structure.

BACKGROUND

Applicants presently manufacture and market various display boards, some of which are defined by steel dry-erase surfaces that further support magnets in combination therewith for tracking, calendaring, scheduling and other purposes. These display boards have been found to be superior and more versatile, as compared to conventional blackboards for the above purposes. Certain versions have included portable boards that are self-supporting, as well as larger dry-erase display boards having dedicated frame or supporting structures.

A growing need in the field now exists for larger display boards that can effectively be mounted to existing wall surfaces. The conventional method at least partially satisfying this need is to provide panels that are adhesively attached directly to wall surfaces. Though effective and preferred in certain situations due to the dry-erase features of these panels, adhesive mounting is permanent and does not easily permit modification or adjustability. In that regard, certain purchasers have become desirous of an assembly that enables enhanced versatility by permitting display panels to be releasably attached to a wall surface.

SUMMARY

According to one version, there is provided a wall panel assembly comprising at least one wall panel comprising a steel sheet having a front surface and rear extending side edge flanges forming an enclosure and a cleat which is fitted within said formed enclosure, said cleat including at least one longitudinal slot; and a support having means for enabling said support to be fixedly attached to a wall surface, said support including a plurality of spaced engagement members engageable in said at least one longitudinal slot of said at least one wall panel.

According to one version, the engagement members comprise a plurality of spaced tongues, which can be integral to the support. Preferably, the tongues are angled relative to the remainder of the support and aligned with the longitudinal slot, which is also angled to effectuate support of a panel when attached, the tongues being adequately spaced in order to provide a distributed load.

According to one version, the panel includes an intermediate core layer, including a pair of substrate sections that are sized to be secured within a portion of said formed enclosure and in which said cleat is disposed between the substrate sections. The cleat is secured between the substrate sections and according to one version can include at least one edge section for reinforcing the panel to prevent buckling.

In one version, the support structure can be an integrated section. In another version, the support structure can be defined by a plurality of interconnectable structure sections, thereby enabling selective expansion of the assembly, as needed, and permitting a plurality of panels to be releasably attached to a wall or wall-like structure. The panels are longitudinally or laterally movable, once assembled. based on the attachment between the tongues and the at least one slot, which extends along substantially the entire width dimension of the panel.

According to another version, the herein described support structure can be used to facilitate permanent mounting of at least one display panel to a wall or wall structure. The support structure lends itself to align and level at least one panel or a plurality of panels relative to one another and a wall structure as the panels are being adhesively mounted thereto.

According to another version, there is provided a wall panel comprising a steel sheet having a dry-erase front surface, a rear backing surface supported by said steel sheet and including at least one longitudinal slot disposed in the rear backing surface, said at least one slot being configured to releasably engage a wall structure. According to one version, the slot can be disposed within a cleat provided in either the rear backing surface or an intermediate layer of the panel. The cleat is configured for releasably receiving at least one engagement member from a support structure, the latter being fixedly attached to a wall or wall surface.

In at least one embodiment, the retention of the cleat within the slot enables a panel to be aligned with a support structure as attached to the wall or wall structure. This alignment facilitates overall assembly, whether the panels are permanently or releasably attached to the wall structure.

According to yet another version, there is provided a method for releasably attaching at least one panel to a wall or wall-like surface. The method can comprise providing a support structure having at least one planar support and a plurality of spaced tongues extending therefrom. Additionally, at least one panel is provided, the at least one panel including a rear backing surface and further including at least one longitudinal slot. The at least one slot is engaged with said tongues of the support structure, in which the support structure is fixedly attached to a wall or wall-like structure.

According to at least one version, a plurality of panels can be releasably attached to the support structure wherein the panels can be laterally shifted or otherwise repositioned over at least a predetermined distance while supported by the support structure or removed and repositioned thereon. In another version, the panels can be permanently attached to the wall or wall structure retaining the support structure and in which the support structure facilitates alignment of one or a plurality of panels attached thereto.

The support structure in at least one version can be assembled as a unitary component and/or can be formed of a plurality of interconnectable structure sections, enabling the overall assembly to be expanded as needed.

The panels can include a dry-erase front or facing surface according to at least one version or can be defined by a front surface having at least a portion that is defined with a dry-erase coating. In another version, the front surface can be formed with various features, including designs, maps, grids, markers and other designations. According to at least one version, the dry-erase surface enables the use of magnets and other attachments.

According to another aspect, there is described a method for manufacturing a panel assembly. This method comprises manufacturing at least one panel, wherein the panel manufacture includes the additional steps of providing a steel sheet, forming lateral side flanges in the steel sheet, forming an enclosure, securing an intermediate layer within the formed enclosure, the intermediate layer including at least two substrate sections, and positioning at least one cleat between the at least two substrate sections of the intermediate layer, the at least one cleat including a body having a longitudinal slot extending along the width dimension thereof. The method further comprises providing a support structure including at least one planar section configured for fixed attachment to a wall surface, and providing at least one engagement member extending from the at least one planar section of the support structure, the at least one engagement member being sized for engagement with the slot to enable releasable engagement with the panel.

In one version, the method further includes the step of providing at least a portion of a facing surface of the steel sheet with a dry-erase coating, such as a ceramic coating.

The at least one engagement member comprises a plurality of angled tongues according to one version, the tongues being sized, spaced and configured for engagement with the slot, and in which the slot is angled for receiving the tongues to permit distributed support of the at least one panel.

In one version, the plurality of tongues are integral to the planar section. In another version, the tongues or other engagement members can be separately attached to the support structure.

According to one version, the method includes the additional steps of providing a plurality of panels, wherein the panels are laterally adjustable while in an assembled position. To that end, the support structure can further comprises a plurality of planar sections that include features enabling linear interconnectability of the sections in order to permit expandability of an assembly.

The support structure can enable alignment of the panels as they are either releasably attached to the support structure and the wall or wall structure. The panels can also be aligned using the support structure for purposes of permanent fixation to the wall or wall structure.

One advantage that is realized by the herein described assembly is enhanced versatility in being able to mount dry-erase and other display boards to a wall or similar structure in releasable or permanent fashion.

In one version, the cleat can include a lateral reinforcing portion to prevent localized buckling of the panel. The lateral reinforcing portion can be integrated with the panel or can be otherwise provided.

Yet another advantage is that the overall assembly is fast and easy in terms of time and overall cost and in which the support structure improved versatility and enables universal assembly. A nearly limitless number of assembly combinations are possible.

Still another advantage is that the panels can be laterally shifted or positioned in relation to one another once attached to the support structure of the herein described assembly.

These and other features and advantages will become readily apparent from the following Detailed Description, which should be read in conjunction with the following drawings.

DETAILED DESCRIPTION

The following description relates to a preferred embodiment of at least one panel for releasable assembly to a wall or wall-like structure using a support adapter, including the assembly and manufacture of an exemplary panel. It will be apparent, as discussed herein, that numerous variations and modifications are possible including permanent fixation of at least one panel to a wall or wall surface having a surface adapter(s) mounted thereto. In addition and though a display panel having a steel dry-erase surface is herein discussed according to this embodiment, other panels can be constructed to include and/or support or retain additional features.

Various terms are herein used throughout the course of the discussion that follows in order to provide a suitable frame of reference in regard to the accompanying drawings. These terms, which include, for example, “upper”, “lower”, “inner”, “outer”, “top”, “front”, “rear” and the like are not intended to be overly limiting of the inventive concepts described herein, including the claims, except where so specifically indicated.

The drawings have been provided to provide a clear and sufficient detailing of the invention. However, it should be noted the drawings are not necessarily drawn to scale and therefore the drawings should not be narrowly interpreted in terms of dimensions depicted in this application.

Referring toFIG. 1, there is first depicted a comparative illustration of a panel which is made in accordance with the prior art with a panel made in accordance with the exemplary embodiment of the present invention. First, a known wall panel10is defined by a substantially rectangular configuration and comprising three (3) major components; namely, a top layer16, an intermediate core layer20and a backing layer24. This panel10is marketed under the tradename of Whitewall in which the top layer16is made from a steel sheet having a ceramic or other suitable dry-erase coating layer that is applied to a front facing surface thereof. The application process and formulations of dry-erase coatings are not a part of the present invention, except in regard to the overall utility that is afforded by a dry-erase wall surface. Examples of same are described, for example, in U.S. Pat. Nos. 7,985,472 and 6,620,500, the contents of which are herein entirely incorporated by reference, as well as those developed by W.A. Krapf, Inc., of Macedon, N.Y., among others.

The intermediate core layer20is defined by a composite honeycombed material section, such as formed by paper or corrugated cardboard, which is appropriately sized to be fitted to the top layer16, and the rear or backing layer24is made from a thin sheet of material, such as aluminum, that is sized to cover the intermediate core layer20. In terms of assembly, the intermediate core layer20is adhered to the rear surface of the formed steel sheet. Lateral edge portions28of the front layer16are bent outwardly to permit overlap of multiple panels (not shown) and further to obscure the interior features of the formed panel10. The rear backing layer24is also adhered to the intermediate core layer20. As previously noted and when seeking to attach this panel10and/or a series of these panels to a wall surface (not shown), the rear backing layer24is permanently adhered thereto. Once attached, the position of the panel20cannot easily be adjusted or modified.

By contrast and in addition to other differences, the panel100made in accordance with the presently described embodiment includes a rear backing surface150permitting access to an intermediate insert or cleat140. A longitudinal supporting slot144spans the width dimension of the cleat140, the panel further including a frame160including a series of side trim sections164that are disposed between a core layer and lateral side edges of the panel100as discussed herein. The assembly of the panel100is now described in greater detail with reference toFIGS. 2-8.

According to a first step of manufacture,FIG. 2, a flat thin sheet104of steel is initially provided. Preferably and according to this embodiment, this sheet104already has a dry-erase coating that has been applied to a first or front side by means that are known in the field and in which the rear side108of the sheet104is herein exposed. According to this version, the entire front surface is provided with a suitable dry-erase coating, such as a polished ceramic coating as described for example, in U.S. Pat. Nos. 7,985,472 and 6,620,500, the contents of which have been herein entirely incorporated by reference, as well as those developed by W.A. Krapf, Inc., of Macedon, N.Y., among others. It will be readily understood that according to other versions, only a portion of the front surface can be provided with a dry-erase coating. In addition, other features can be inset within the front surface, such as columns, grids, rows, labels, headings, and the like.

In a second step, shown inFIG. 3, notches112are then individually cut into each of the four corners of the formed steel sheet104. These notches112are defined by orthogonal edges114that define grooves117, the latter each extending inwardly to a protrusion115to enable the fitting of individual corner pieces130, as discussed herein. These notches112can be inset into the sheet104using a sheet metal notcher or other appropriate metal forming tool.

Once the notches112have been formed and now referring toFIG. 4, a respective set of four (4) lateral or side flanges116of the steel sheet104are then foamed, such as through use of a suitable metal working apparatus, such as a finger brake or a press brake. Suitable examples of such apparatus capable of boxing the steel sheet are commercially sold by Mittler Bros and Baileigh Industrial, among others, the workings of these apparatuses being fairly well known to those in the field and not requiring further elaboration. Preferably and according to this embodiment, the lateral flanges116of the steel sheet104are flexed substantially perpendicular to the flat portion of the rear surface108thereof. Still more preferably and for reasons discussed herein, the lateral flanges116of the panel100are each retroflexed inwardly slightly less than 90 degrees relative to the rear surface108. As such, an enclosure119defined by the lateral flanges116and the rear surface108of the panel100is formed.

Referring toFIG. 5and once the lateral flanges116have been formed as described, the individual corner pieces130are inserted to cover the spacing formed by the grooves117and the folded sheet104and creating a solid exterior perimeter for the panel100. The corner pieces130include respective features that mate with the protrusion115and the orthogonal edges114when fitted within the grooves117defined by the formed flanges116.

Referring toFIG. 6, the cleat140can then be positioned in the center of the enclosure119formed by the lateral flanges116of the panel100and more specifically between two substrate sections124forming an intermediate core layer120. According to the herein described embodiment, the substrate sections124of the core layer120are preferably made from a dense foam, such as polystyrene. Alternatively, the core could be defined by other filler materials, for example, such as corrugated honeycombed cardboard, that are capable of providing a structural backing for the steel top sheet of the panel. Each of the substrate sections124are adhered or otherwise secured to the rear surface108of the panel100and are sized to be fitted tightly within the formed enclosure119as to their width dimensions. As to the cleat140and according to this embodiment, this component is defined by an integrated structure that includes a body142made from wood, thickened plastic or other suitable material, and including a longitudinal supporting slot144extending substantially along the entire width dimension of the panel100. According to this embodiment, opposing reinforcement rails148are formed on lateral sides of the cleat body142. The reinforcement rails148can be integral to the cleat body142or can be attached thereto by means such as fasteners and the like and are used to provide reinforcement against buckling due to the discontinuity of the core layer120created by the introduction of the cleat140. In passing and though the cleat140is introduced as a separate component for purposes of this embodiment, the cleat140could also be integral to the core layer in which a reinforcement rail would not be required. This latter feature may also not be needed depending on the overall size of the panel. As shown herein, the cleat140is effectively secured to the panel100by means of an interference fit between the substrate sections124and the lateral flanges116defining the formed enclosure119.

Referring toFIG. 7and following assembly of the cleat140, a rear backing layer150is secured to the rear side of the formed panel100. The rear backing layer150according to this embodiment is made from a thin sheet of aluminum or similar material that includes an access slot, which when assembled is aligned with the supporting slot of the cleat140. As shown herein, the access slot is effectively created by providing two adjacent sections154of the rear backing layer150, as shown, which are disposed on opposing sides of the cleat140, as shown inFIG. 8.

Referring to FIGS.1and8-10, and according to this embodiment, a lateral edge trim160is added to the each of the four (4) sides of the formed panel100and more specifically between the steel sheet104and the intermediate core layer120thereof. The lateral edge trim160comprises four separate trim sections164, each section including a first edge167that extends into the panel100and engages the lateral edge of the substrate sections124of the core layer120. A second orthogonal edge169includes a groove165that receives a protrusion136formed in each of the corner pieces130and enables interconnectivity of the edge trim sections164, as shown in the enlarged views ofFIGS. 9 and 10.

Referring now toFIGS. 11-16, at least one formed panel100, as discussed infra, can be releasably attached to a support structure200, the latter being fixedly secured to a wall or wall structure.

Referring toFIG. 11, the formed panel100can be attached to a support structure or support200. As shown, the support200is defined by at least one planar section204made from a structural material, such as steel or other suitable material. The support200is further defined, according to this embodiment, by a plurality of spaced holes and slots208that permit the passage of fasteners217as shown inFIG. 12to enable fixed attachment of the assembly to a wall surface240as shown inFIGS. 13(a)-13(c), the at least one planar section204including a plurality of spaced engagement members extending from an upper surface thereof. According to this embodiment, the spaced engagement members are tongues212that extend angularly upward from the support200and are configured, spaced and sized to engage the slot of the cleat140of the panel100. When assembled to the wall surface240, as shown inFIGS. 13(a)-13(c), the weight of the panel100is effectively distributed over the plurality of tongues212based on the relative spacing of the tongues. According to this embodiment, five (5) tongues engage the supporting slot144of the cleat140though the relative spacing between the tongues212can be suitably altered, as needed, to provide adequate support. As shown inFIGS. 11 and 14, the tongues212are integral and formed with the planar section204. However, alternatively the engagement members (e.g., tongues) could be separately attached to the support structure200to provide additional versatility.

A single planar section204is shown inFIG. 11. However and as shown inFIGS. 14 and 15, a plurality of planar sections204can be interconnected together in linear serial fashion, each of the planar sections including respective male and female end engagement features250,254enabling attachment thereto and permitting expandability of the assembly, as needed.

When releasably attached to a support structure200, as shown inFIGS. 15 and 16, the panels100can be laterally adjusted to permit alignment with each other as needed, based on the spacing of the tongues212and the extensive supporting slot144of the cleat140and as shown by arrow257. According to another version, the slot144can be abbreviated as to its length, although it is preferred the supporting slot extend over substantially the width dimension of the panel100to maximize adjustability. The number and spacing of the tongues212can also be suitably adjusted to better support loads and also increase adjustability of one or a plurality of supported panels100in the assembly. By retroflexing the lateral flanges116of the panels100, an improved fit is naturally created relative to the lateral edge trim160.

Moreover and by presetting the support structure200and leveling same relative to the wall structure first, wall panels can then be added in which engagement of the tongues with the cleat slots of the panel permit planar alignment of one or a plurality of panels whether the panels are releasably attached to the wall by virtue of the support structure or for permanently adhering the panels to the wall or wall structure.

It will be readily apparent that there are numerous variations and modifications that can be made within the spirit and scope of the inventive concepts described herein and according to the following claims.