Wall panel system

Abstract: In its preferred form the present invent provides a system of interconnecting wall panels (10), which in normal use provide horizontal parallel recesses (21) along the length of the wall, into which shelf brackets (22) can be fitted, the converse face of the recesses providing detents by which the panels can be attached to a supporting structure (11) on the wall behind.

Description: The present invention relates to the general field of shelf support systems, with particular application to wall cladding which provides a shelf support system. Hitherto it has been known to provide wall panel systems which comprise a number of large square or rectangular panels, which are joined at the edges by vertical retaining strips, these retaining strips including a vertical channel or the like into which a shelf bracket can be affixed at any desired height. A problem is often encountered with such systems in that the shelf brackets must be in some way held at a particular position in the channel and be prevented from sliding down it, while still being adjustable as required. Furthermore, installation of such a system can present a number of difficulties. The spacing of the retaining strips is fairly rigidly prescribed by the width of the wall panels, and this spacing may be found inappropriate to a particular wall, taking into account the spacing between corners, and features such as pillars, windows or wall sockets. The two or more shelf brackets supporting any particular shelf must be positioned at the same height in the channel, and this may be difficult or time consuming to achieve. The spacing between channels may be inappropriate to the desired lengths of shelf, and while this problem is less likely to occur if the system uses narrower wall panels, and consequently increases the number of channels available, this solution increases the work required to install the system. As illustrated by US Patent No. 4,674,240 - M.A.Strausheim 1987, it has been known to go partway towards overcoming these problems with the use of an extruded plastic panel having horizontal channels therein, which are flanged and shaped to retain shelving brackets in normal use. Such a system is however relatively expensive, and is more difficult to install on a wall surface than systems hitherto available. The span of the panel between adjacent channels is very limited, unless the plastic is thickened or otherwise braced in the intermediate zones, and the overall width of each panel is limited by the extrusion process. Furthermore in the system illustrated, a number of panels must be fitted together on "stiffener strips", which must then be attached by undisclosed means to a wall surface. The interconnected panels therefore in practice must be formed into a single large sheet, which presents many of the same installation difficulties as the panels described above. US Patent No. 4607753 discloses another system of fixing panels, which provide for shelf mounting, to a support structure. The assembly disclosed includes a plurality of elongate support elements arranged in use transversely relative to said elongate wall panels, wherein each said wall panel is comprised of sheet material folded to provide a first part of a channel along a first edge of said panel, a complementary second part of a channel parallel to said first part along a second edge opposite said first edge, and a raised face between said parts of channels, said first part including two oppositely recurving portions in the general form of an S-bend in cross-section, a first said portion forming an overhanging hollow flange and the second said portion recurving behind the first to provide an undercut behind said first portion, wherein an intermediate wall extends behind and substantially parallel to said raised face between said first and second recurving portions, and a rear face extends behind and substantially parallel to said raised face and said intermediate wall from said second recurving portion, whereby a channel can be formed by the association of said first edge of one said panel with said second edge of a second said panel, said channel having an overhanging hollow flange formed by said first recurving portion. However, the respective panels which provide the channels are, in this prior disclosure, mounted onto the support elements by point fasteners such as screws or welds, so the assembly takes a relatively long time and some skill to put together. It is an object of the present invention to provide a novel and improved wall panel and shelf support system, or at least to provide the public with a useful choice. The present invention provides a panel assembly according to the pre-characterising part of claim 1 having features specified in US-A-4607753 and further characterised in that each said elongate support element includes a plurality of recesses, each said recess being undercut to provide an overhanging lip at a mouth of said recess, and the dimensions of said channel parts and said recesses provide that, with a said panel extending transversely across a said support element, said first channel part can be fitted into a said recess and is moveable along said support element within said recess to an engaged position at which said first recurving portion passes around said overhanging lip of the recess, and said intermediate wall, said second recurving portion and said rear face underlie said overhanging lip of the recess, an overlap between said overhanging lip and said intermediate wall acting to engage said first channel part in said recess, further including means engageable to retain said first channel part in said engaged position, said means being engageable with a detent on said support element. Other preferred features of the present invention will be made apparent in the following description of a preferred embodiment, which is given by way of example only. In the drawings: Figure 1: shows in perspective view a preferred panel support element of the present invention Figure 2 : shows a section of a preferred panel in perspective view. Figure 3 : schematically illustrates preferred panels in conjunction with a support element and shelf brackets, in side view and cross section. As shown in Figures 1 to 3, the present invention in its preferred form provides a system of interconnecting wall panels 10, which provide means for attaching shelf brackets at any of a range of desired heights, and also at substantially any desired horizontal spacing. As shown in Figure 1, the present invention provides a system using retaining elements 11 which are in normal use vertically mounted on a wall, onto which elongate horizontally extending panels 10 are fitted. The retaining element 11 in its preferred form comprises a substantially U-section channel member which can be fixed to a wall 20 by nails, screws or the like through apertures 12. The projecting side walls 13 of the retaining element 11 are provided with recesses 14, at regular intervals substantially corresponding to the height of panels 10. Further such recesses 14 might be provided in the element 11, to facilitate use of the retaining element with panels 10 of other heights, or for use with combinations of panels 10 of different heights. The recesses 14 are undercut, to provide projecting lips 15 and 16. The panels 10 preferably comprise roll-formed metal sheets or strips, approximately 15cm in height, and of any suitable length. It may be found preferable to cut the panels 10 to a desired length as ordered, rather than to provide them in predetermined sizes. It will be appreciated that the height of the panels may be varied considerably. Panels of, for example, 5 cm or 30 cm height might be used, with correspondingly altered retaining elements 11, but it should be appreciated that panels with a greater height will generally provide a lesser ranger of heights at which shelves can be attached, and those of lesser height will be more time consuming to install, as a greater number of panels will be required to cover the same wall area. The height of the panel is preferably selected so that a whole number of panels will make up standard wall heights, to avoid the cutting or trimming of panels to fit the wall. Each panel is folded on the lower and upper edges to provide co-operating parts of a channel. A first part 17 at the lower edge is in the form of an S-bend, so that in normal use as shown in Figure 3, it hooks under the projecting lip 15 of a recess 14 in the retaining element and turns in behind it, and recurves to form the rear wall of the channel. The lowermost portion hooks behind the other lip 16 of the recess 14, as shown. A second part 18 at the upper edge is bent to form a clip, which in normal use clips over the projecting lip 16, which provides a detent, and thereby fastens in place not only the second part 18 at the upper edge, but also the first part 17 at the lower edge of the panel 10 above. Thus, when a wall is to be covered with panels 10, in normal use the top panel will be fitted in place first, and then each subsequent panel fitted in place below it. By this means each panel except the lowermost panel is locked in place by those below. As shown in figure 3, the first part 17 at the lower edge of the panel 10 does not extend all the way into the undercut behind the lower projecting lip or detent 16. This space facilitates fitting of the panels onto the retaining element 11. The first part 17 at the lower edge is firstly fitted into a recess 14, and pushed downwardly as far as possible into the space behind the lower projecting lip 16. In this position there is sufficient clearance for the recurving portion 19 of the S-bend to pass under the upper projecting lip 15. The recurving portion 19 can then be pushed up behind the lip 15, and the second part 18 at the upper edge clipped into another recess 14 above. It should be noted that this system provides a finished channel which has a substantially flat base surface and rear wall, which is relatively easy to clean and will not in normal use tend to trap and collect dust. The upper surface of the channel is undercut to provide a flange with which a shelf bracket can engage. It will be appreciated that the spacing between the vertical retaining elements 11 is not critical, and as long as at least one retaining element is positioned at or near each end of the panels 10, a stable wall cladding will be formed. Preferably however one or more additional retaining elements 11 are fixed to the wall at positions between the ends of the panels, to provide additional support. The channel 21 provided by the co-operating parts at the edges of the panels 10 can be used to retain a shelf bracket 22, such as that illustrated in figure 3. The shelf bracket 22 includes a hook element 23 which in normal use engages with the channel 21, and a foot 24 which bears against the face of the panel 10. It will be appreciated that a wide variety of brackets could be produced to engage with and be supported by the channel 21 in a similar fashion. If the retaining elements 11 and wall panels 10 are correctly fitted on the wall 20, shelves can relatively quickly and easily be put in place where desired. Two or more brackets engaged with the same channel 21 will naturally be at the same elevation, and consequently a shelf supported by them will be horizontal. No measurement of heights is required to provide horizontal shelves, or a number of shelves at the same elevation. The horizontal distance between brackets at the same level can be easily adjusted to exactly suit a particular length of shelf. The use of metal panels 10 can provide fire safety advantages, and allows a wide range of colours and textures to be used. It will be appreciated that the metal panels may be contoured or perforated during the roll forming process, to give desired decorative or acoustic properties. Insulation panels or the like could be mounted behind the panels 10 if required. Materials other than roll formed metal could be used, although metal panels as described are preferred at present.

Claims: A panel assembly including: a plurality of elongate wall panels (10): and a plurality of elongate support elements (11) arranged in use transversely relative to said elongate wall panels; wherein each said wall panel is comprised of sheet material folded to provide a first channel part (17) along a first edge of said panel, a complementary second channel part (18) parallel to said first part along a second edge opposite said first edge, and a raised face between said channel parts; said first channel part including two oppositely recurving portions in the general form of an S-bend in cross-section, a first said portion forming an overhanging hollow flange and a second said portion (19) recurving behind the first portion to provide an undercut behind said first portion; wherein an intermediate wall extends behind and substantially parallel to said raised face between said first and second recurving portions, and a rear face extends behind and substantially parallel to said raised face and said intermediate wall from said second recurving portion; whereby a channel (21) can be formed by association of said first edge of one said panel with said second edge of a second said panel, with said overhanging hollow flange formed by said first recurving portion extending into said channel; CHARACTERISED IN THAT each said elongate support element includes a plurality of recesses (14), each said recess being undercut to provide an overhanging lip (15) at a mouth of said recess; and the dimensions of said channel parts and said recesses provide that, with a said panel extending transversely across a said support element, said first channel part can be fitted into a said recess and is moveable along said support element within said recess to an engaged position at which said first recurving portion passes around said overhanging lip of the recess, and said intermediate wall, said second recurving portion and said rear face underlie said overhanging lip of the recess, an overlap between said overhanging lip and said intermediate wall acting to engage said first channel part in said recess; further including means engageable to retain said first channel part in said engaged position, said means being engageable with a detent (16) on said support element. A panel assembly as claimed in claim 1, CHARACTERISED IN THAT said means on said panel, engageable with said detent (16) on said support element to retain said first channel part in said engaged position, comprises said second channel part at said second edge of the panel. A panel assembly as claimed in claim 1 or claim 2, CHARACTERISED IN THAT said detent (16) comprises a second lip at the mouth of a said recess. A panel assembly as claimed in any one of claims 1 to 3, CHARACTERISED IN THAT said rear face of said first channel part (17) is provided with a transversely projecting flange, arranged to engage with said second channel part (18) at the second edge of another panel in use. A panel assembly as claimed in any one of claims 1 to 4 CHARACTERISED IN THAT said first channel part (17) is at a lower edge of each said wall panel (10) and the first said recurving portion forming the overhanging hollow flange extends downwardly, and wherein said complementary second channel part (18) is at an upper edge of each said wall panel. A panel assembly as claimed in any one of claims 1 to 5 CHARACTERISED IN THAT each said recess (14) in said elongate support elements (11) has a depth not less than the depth of said channel (21) relative to said raised faces of said panels (10), such that unrecessed portions of the elongate support elements lie against or near a rear surface of said raised faces of the panels and act to brace and support said raised faces against denting or buckling. A panel assembly as claimed in any one of claims 1 to 6 CHARACTERISED IN THAT said elongate panels are formed from sheet metal.

Inventors: CLAUSEN KNUD, CLAUSEN, KNUD
Applicants: CLAUSEN KNUD, FITZSIMMONS MURRAY ROBERT, CLAUSEN, KNUD, FITZSIMMONS, MURRAY ROBERT
Application year: 1990
Main classification: A47F5
IPC codes: E04F13, G09F15, A47F5, E04B2, E04F19