Modular panel assembly

A modular panel assembly that allows for rapid and relatively simple installation, while also providing flexibility for easy adaptation to any of a variety of constructions types. In some embodiments, the modular panel assembly involves panels which are prefabricated with panel connectors. Additionally, in some embodiments, the assembly involves two panel types that are substantially similar in their outward appearance, but differ internally so as to enable each of straight and non-straight surfaces for a structure being built.

BACKGROUND

1. Field of the Invention

The present invention relates to a multi-panel system for use in applications necessitating partitions and backdrops.

2. Description of the Related Prior Art

A typical problem associated with most known multi-panel systems is that when they are assembled at a building site, they are not sufficiently flexible to allow for easy adaptation to various architectural plans. Generally, panels are precut into dimensions such as 4′×8′, 6′×10′, etc. In addition, the panels are typically rigid in construction across their widths and lengths. Consequently, if architectural plans call for any deviation from the pre-existing dimensions or for structures having any sort of non-straight or curved surfaces, it is very difficult to adapt the panels to the building specification.

Another dilemma often faced in building structures (such as displays) with prefabricated panels is the mechanism by which the panel members are held together as a frame. In a typical panel display, each structural panel member has a generally rectangular central channel extending lengthwise there through and a pair of longitudinally-extending channels, each on an opposing side of the central channel. In turn, these longitudinally-extending channels are generally configured to mate with panel connectors, or vice versa, so as to join adjacently-positioned panels together. However, problems can often be experienced with the connectors. For example, in some cases, the connectors are configured with a variety of different components, thereby making them complex and time-consuming to use as well as expensive to purchase. In addition, with the manner in which the components of the connectors are configured together, such connectors can often be prone to falling apart if not handled properly. Finally, such connectors, if separately provided from the panels, require multiple steps for joining them to a first panel and then securing a second panel thereto.

The present invention solves these and other problems.

SUMMARY OF THE INVENTION

Embodiments of the invention provide a modular panel assembly that allows for rapid and relatively simple installation, while also providing flexibility for easy adaptation to any of a variety of constructions types. In certain embodiments, the modular panel assembly involves panels which are prefabricated with panel connectors. Additionally, in certain embodiments, the assembly involves two panel types that are substantially similar in their outward appearance, but differ internally so as to enable each of straight and non-straight surfaces for a structure being built.

In one embodiment, a modular panel system is provided which can be used to meet varying structural requirements for different construction applications. The system comprises a plurality of prefabricated panels. The panels comprise two panel types. A first panel type is for constructing straight construction surfaces and has a generally rectangular central channel defined between front and rear sheets thereof and has a pair of frame members on opposing vertical ends thereof. The central channel of the first panel type is packed with filler material. A second panel type is for constructing non-straight construction surfaces and has a generally flexible rectangular central channel defined between front and rear sheets thereof and has a pair of frame members on opposing vertical ends thereof. The central channel of the second panel type lacks filler material. The system further comprises a plurality of connection means integrally formed with the frame members of each of the panels of the first panel type and the second panel type. Each connection means is partially concealed within the frame members of unjoined panels of the first panel type and the second panel type and completely concealed by the frame members when used in joining any panels of either the first panel type or the second panel type. Each connection means is manipulated for joining or unjoining the panels of the first panel type and the second panel type via rotation of a fastener stemming from the connection means. Each fastener protrudes from one of the front or rear sheets of the panels of the first panel type and the second panel type.

In another embodiment, a modular panel system is provided which can be used to meet varying structural requirements for different construction applications. The system comprises a plurality of prefabricated panels. The panels each have a generally rectangular central channel defined between front and rear sheets thereof and each have a pair of frame members on opposing vertical ends thereof. The central channel defines a space there between the front and rear sheets. The system further comprises a plurality of panel connectors integrally formed with the frame members of each of the panels. Each panel connector is partially concealed within the frame members of unjoined panels and completely concealed by the frame members when used in joining the panels. Each panel connector is manipulated for joining or unjoining the panels via rotation of a fastener stemming from the panel connector. Each fastener protrudes from one of the front or rear sheets of the panels. Each panel connector comprises a first locking bar that is rotatably linked with a second locking bar. The first locking bar having a proximal end that forms a seat within which a proximal end of the second locking bar fits and aligns.

DETAILED DESCRIPTION

The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. The drawings depict selected embodiments and are not intended to limit the scope of the invention. It will be understood that embodiments shown in the drawings and described below are merely for illustrative purposes, and are not intended to limit the scope of the invention as defined in the claims.

In use, the modular panel assembly of the present invention can be used in any of a variety of different applications. For example, such assembly may be used as a cordon or barrier for an area, e.g., to prevent access and/or block the view of persons in the surrounding area. Conversely, such assembly may be used for attracting attention, thereby enticing people to view and/or approach an area. For example, in the case of a store front, particularly in a mall, the modular panel assembly can be used in forming a display space behind the store's front window. In such enclosed space, the retailer would be able to display advertisements and/or new or select products on sale. Alternatively, the modular assembly can be constructed beyond the front window(s) to aesthetically enhance the store's entryway. As such, the panels could be painted or decorated so as to attract attention to the store and generate increased business. As alluded to above, it should be understood that description of these few applications are not meant to limit the uses of the embodied modular panel assembly, but conversely to provide a sense of these and other potential applications that the present invention avails itself to.

In general, the modular panel assembly of the present invention involves a plurality of wall panels which utilize a simplified, yet highly effective panel interconnection means, the structure and function of which will be described herein in greater detail. Additionally, in certain embodiments, the wall panels, while substantially similar with respect to their outer appearance and construction, have variation with respect to their internal composition. Consequently, when building desired structures, the panels can be interconnected in a like and relatively uncomplicated manner, while also enabling the panels to be easily adaptable to a variety of construction shapes.

FIG. 1Ais a cross-sectional elevation view of an end portion of a panel of a first panel type used in accordance with certain embodiments of the invention. As shown, the end portion of the panel10includes a main body12and a frame member14. The main body12has a generally rectangular central channel16defined between front and rear sheets18and20, respectively, of the panel10. As shown, the central channel16of the panel10is packed with filler material22. In certain embodiments, the front and rear sheets18,20are formed of a relatively flexible material, yet the filler material22there between is used to indirectly enhance the rigidity of the sheets18,20. In certain embodiments, the filler material22is of a honeycomb structure which defines a plurality of openings roughly a half inch in diameter or so extending perpendicularly of the sheets18,20; however, it should be appreciated that the make-up of the filler material22can be varied as desired. In certain embodiments, the honeycomb structure can be formed of one or more materials such as cardboard, aluminum, foam, plastic, or the like so as to limit the overall weight of the panel10.

By way of comparison,FIG. 1Bis a cross-sectional elevation view of an end portion of a panel of a second panel type used in accordance with certain embodiments of the invention. While similar in other respects to the panel10ofFIG. 1A, the panel10′ ofFIG. 1Bhas entirely no filler material in its central channel16. Benefits of such panel10′ lacking filler material will be described herein later. However, at this point, in describing the further characteristics of the panel10ofFIG. 1Abelow, it is to be understood that its characteristics hold true for the panel10′ ofFIG. 1B(such that the two are interchangeable), unless described otherwise.

With further reference to the panel10ofFIG. 1A, the outer planar surface sides of the sheets18, represent the exposed surfaces of a structure built with a plurality of the panels10. As such, it may be desirable for the outer surfaces of one or more of the sheets18,20to be made aesthetically pleasing. Accordingly, in certain embodiments, the outer surfaces of one or more of the sheets18,20can be pre-configured with fastening mechanisms, enabling the sheet(s) to be covered with a layer of fabric or other decorative material. However, in other certain embodiments, the outer surfaces of one or more of the front and rear sheets18,20can be preformed with decorative material, such as fabric, or other materials, such as ABS (Acrylonitrile-Butadiene-Styrene), vinyl, or aluminum, thereon or as an integral part thereof.

As described above, the end portion of the panel10includes a frame member14. Such frame member14is included on the vertical end24of the panel10. As shown, the sheets18,20of the panel10overlay opposing planar sides of the frame member14. In certain embodiments, the sheets18,20of the panel10completely overlay opposing planar sides of the frame member14. One benefit of such a configuration is to encase and conceal the frame member14from view when the panel10is adjoined to a further panel, as is depicted inFIG. 4. While not shown inFIGS. 1A and 1B, a further frame member14is included in like fashion on the opposing vertical end of the panels10and10′. Accordingly, each of the panels10,10′ has a pair of the frame members14, with one on each opposing vertical end of the panel's central channel16.

In certain embodiments, the frame member14is a longitudinally extending slotted channel. The frame member14, as its name implies, provides side structural support for the panel10as well as providing a conduit for connectional means between it and a further panel10or10′. In certain embodiments, as shown, the channel of the frame member14has a generally rectangular cross section with a plurality of slots70defined therein, as exemplified inFIG. 3. Such slots70are formed in the channel so as to provide for the connection means between adjoined panels10(or panels10′ or one each of panel10and panel10′). In certain embodiments, with reference toFIGS. 1A,1B, and2, each of the slots70opens internally to a cavity26within the channel of the frame member14, with such cavity26sized to house a panel connector. To that end,FIG. 2is a cross-sectional elevation view of the frame member14with a panel connector30integrally provided therein in accordance with certain embodiments of the invention. The cross-sectional view ofFIG. 2shows a cross section of one of the cavities26of the frame member14and the panel connector30therein.

The panel connector30, as alluded to above, is configured to be rather simple in its construction, which enables its ease of use in adjoining together two panels10(or two panels10′ or one each of panel10and panel10′). As shown, in certain embodiments, the panel connector30is formed of four components involving first and second locking bars32and34, a resilient member36for limiting the amount of angular separation between the locking bars32and34, and a fastener38. In certain embodiments, the locking bars32and34each have proximal portions40and42, respectively, which allow for the bars32,34to be rotatably linked. To that end, in certain embodiments, as shown, the proximal portion40of the locking bar32forms a seat44within which the proximal portion42of the locking bar34fits and aligns. As shown inFIG. 2, the proximal portion42of the second locking bar34is curved and the seat44of the first locking bar32is curved so as to align with the curve of the second locking bar34, wherein the curves of the first and second locking bars32and34align in contacting fashion during rotation of the first locking bar32with respect to the second locking bar34. Consequently, such seat44enables the locking bar proximal portions40,42to be conjoined securely with each other, while permitting rotation there between. Such rotation, as further detailed below, enables angular movement of distal portions48,52of the locking bars32,34relative to each other.

The fastener38of the panel connector30functions to facilitate the angular manipulation between the locking bars32,34. As shown, in certain embodiments, a portion of the fastener38is adjustably retained within a threaded bore46defined in the distal portion48of the locking bar32. Such bore46opens to a space50defined between the locking bars32,34. When employed, the fastener38is threaded in the bore46of the locking bar32so as to extend across the space50and to contact the distal portion52of the locking bar34. Accordingly, when the fastener38is rotated in the bore46so as to be further advanced in a direction toward the space50, the locking bar distal portions48and52in effect are forced apart, with such distal portion48of bar32being angularly moved away from the opposing distal portion52of bar34. Conversely, when the fastener38is rotated in the bore46so as to be withdrawn in a direction away from the space50, the locking bar distal portions48and52in effect are drawn together, with such distal portion48of bar32being angularly moved toward the opposing distal portion52of bar34. The fastener38can be any of known varieties; however, in certain embodiments, it is of an Allen type (so as to be manipulated with an Allen wrench) in order to prevent stripping of such from repeated use.

As described above, a resilient member36is used with the locking bars32,34for limiting the amount of angular separation therebetween. As depicted inFIG. 2, the fastener38, by its linkage with the distal portion48of bar32and its contact with the distal portion52of bar34, keeps such distal portions48,52from being brought further together, i.e., further narrowing the space50there between, without corresponding manipulation of the fastener38. To provide additional stability for the panel connector30, the resilient member36is used to prevent the locking bar distal portions48,52from being free to further separate from each other, i.e., with the space50widening there between. In certain embodiments, as shown, the resilient member36is retained between adjacent outer edges54and56of the locking bars32and34, respectively. In turn, regardless of manipulation of the fastener38, the resilient member36serves to resiliently exert pressure upon such adjacent outer edges54,56of the locking bars32,34. Consequently, the space50between the bar distal portions48,52is kept from widening without further manipulation of the fastener38. The resilient member36can be formed of any such resilient material, such as rubber, plastic, or like materials. Additionally, the resilient member36can be formed of any shape so long as it can be wedged between the outer edges54,56of the locking bars32,34.

As described above with respect to the frame member14, each of its slots70opens internally to a cavity26within the frame member's channel, with such cavity26configured to house the panel connector30, as depicted inFIG. 2. As further shown, such slot70is sized to allow distal ends58and60of the locking bars32and34, respectively, to extend there through. Such is also illustrated byFIG. 3, which illustrates a side perspective view of the frame member14in accordance with certain embodiments of the invention. As shown byFIGS. 2 and 3, the panel connectors30are integrally formed in the panels10,10′. Consequently, extending from the frame member cavities26and further through the panels10,10′ are openings72which align with the fasteners38jutting out from the panel connectors30.

FIG. 4shows a cross-sectional elevation view of the frame members20of two panels joined via one of the panel connectors30in accordance with certain embodiments of the invention. It should be appreciated that the joined panels10ofFIG. 4can involve two panels10, two panels10′, or one each of panel10and panel10′. Defined within the locking bar distal ends58and60of the panel connector30are indentations62and64, respectively, which are sized to mate with slot edges74of the panel frame member14housing the connector30. These same indentations62and64further serve to hold corresponding slot edges74of a frame member14of a further panel10or10′ for connection purposes.

In certain embodiments, the frame members14of the panels10,10′ have slots70that are similarly positioned and spaced along their lengths. Accordingly, the panels10,10′, regardless of their distinct internal compositions, can be routinely secured together by bringing vertical ends of each of the panels10,10′ together so as to bring close the corresponding slots70of each, and then tightening the corresponding fasteners38(jutting out the sides of the panels10,10′) to adjoin the slot edges74of each of the panels10,10′, thereby adjoining those portions of the panels10,10′.

In light of the above description, the rest of the present invention can be detailed. As described above, the modular panel system involves a plurality of wall panels which utilize a simplified, yet highly effective panel interconnection means. This simplicity and effectiveness can be gleaned from that already described. For example, the embodied panel connectors30have limited parts, thereby limiting their complexity and enhancing the ease of their use. In addition, the connectors30are integrally provided in the frame members14of the panels10,10′. Accordingly, the panels10,10′ can be adjoined through a limited number of steps for the installer, i.e., bringing close the corresponding slots70of each to-be-joined panel10and/or10′, and then tightening the corresponding fasteners38of the panel connectors30. Further, in certain embodiments, only one vertical side of the panels10,10′ needs to be configured with the panel connectors30to join two panels10and/or10′ together.

As alluded to above, using two types of panels10and10′ with the same outward appearance and connection system (as described above) allows the panels10,10′ to be interconnected in a like and relatively uncomplicated manner, while also enabling the panels10,10′ to be easily adaptable to a variety of construction shapes. For example, if needing a straight surface for the construction, the panel10ofFIG. 1Acan be used; however, if any non-straight (e.g., curved and/or bent) surface is needed, the panel10′ ofFIG. 1Bcan be used. Such panel10′, because it lacks filler material in its central channel16, can be freely shaped so as to provide such non-straight surfaces.FIG. 5is a cross-sectional elevation view of a portion of a multi-panel structure80utilizing the panels10and10′ (with the separate panels10,10′ distinguished via dashed lines shown there between). The panels10(with filler material22) are used in forming straight wall sections82for the structure80; conversely, the panels10′ are used in forming non-straight wall sections84(i.e., in this embodiment, the wall sections84define curved corners) for the structure80. In certain embodiments, such non-straight wall sections84include one or more curved portions and/or one or more bent portions. As shown, because the panels10′ lack filler material, the panels10′ can be shaped so as to curve along the outer planar surface sides of its sheets18,20. As such, when forming an outer curve along a planar side of one of the panel sheets18,20, a segment of the other sheet opposing the curve freely collapses into the panel central channel16to allow for formation of the curve, e.g., such as forming a curved corner86, for the panel10′.

There are a variety of techniques that can be utilized when building multi-paneled structures using the panels10,10′. For example, one can initially install a panel10(with filler material22) using any of wall, floor, or ceiling brackets. While such brackets are not shown in the figures, these types of brackets, and the procedures generally followed when used with panels, are well known in the art. In general, such brackets are initially mounted as intended (to a wall, the floor, or the ceiling), and then the panel is joined thereto. In some cases, the joining of the panels to the brackets can involve fasteners and/or sliding connections. In certain embodiments, the panels10,10′ are configured to be joined to such brackets on their opposing upper and lower (or horizontal) ends.

Upon installing the panel10to one or more of a wall, the floor, or the ceiling (via brackets), the panel10forms a rigid structure for a next panel (either panel10or panel10′) to be joined thereto. As such, the next panel10or10′ would be joined to the installed panel10using the connectors30(protruding from either the installed panel10or the next panel10or10′) as described above. In cases where the next panel involves a panel10′, after joining such panel10′ to the installed panel10, the segment of the panel10′ extending away from the junction can be bent and/or curved over its length as desired. Subsequently, the distal or opposing end of such panel10′ is secured to a further panel10(or10′) so as to maintain the bend and/or curve formed in the panel10′. Such panel-to-panel construction is thereafter repeated until the installer reaches the last panel10or10′ to be installed, upon which the extending end of such panel would be mounted to the wall, floor, or ceiling (via brackets).

An alternative installation may involve initially installing a panel10′ of the multi-panel structure following steps similar to those described above. In turn, upon securing one of the ends of the panel10′ to wall, floor, and/or ceiling brackets, the segment of the panel10′ extending away from the junction can be bent and/or curved over its length as desired. Subsequently, the distal or opposing end of such panel10′ is secured to a further panel10(or10′) so as to maintain the bend and/or curve formed in the panel10′.

It should be appreciated that whileFIG. 5depicts only a single curve being formed with each of the panels10′ shown, the invention should not be so limited. Instead, the panel10′ can be used to form a plurality of distinct curves over its length and/or one or more sharp bends or corners over its length in adhering to the design of a multi-panel structure. Further, whileFIG. 5shows each of the panels10′ having a curvature, the panels10′ can just as well be utilized in multi-panel structures having only straight sides.

It will be appreciated the embodiments of the present invention can take many forms. The true essence and spirit of these embodiments of the invention are defined in the appended claims, and it is not intended the embodiment of the invention presented herein should limit the scope thereof.