Patent Publication Number: US-10323412-B2

Title: Wall-mount system for hanging modules

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of and priority to U.S. Provisional Application Ser. No. 62/403,294, filed on Oct. 3, 2016, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to wall-mount systems and, more specifically, to a wall-mount system for hanging modules. 
     Modular wall-mount systems are generally known. However, because of the increasing premium on square-footage, there is a continuing need for visually appealing, space-saving, and easy-to-install wall-mount system for hanging modules. 
     SUMMARY 
     To the extent consistent, any of the aspects and features detailed herein may be utilized with any of the other aspects and features detailed herein. 
     Provided in accordance with aspects of the present disclosure is a wall-mount system including a frame assembly and a module. The frame assembly includes a plurality of horizontal ledgers configured for attachment to a wall and first and second vertical struts releasably engagable with the plurality of horizontal ledgers. Each of the first and second vertical struts includes a mounting surface defining a first receiver slot. The module is releasably mountable on the frame assembly and includes first and second cleats disposed towards opposite sides of the module. The first and second cleats are configured to releasably engage the first and second vertical struts, respectively. Each of the first and second cleats includes a base and an upright extending from each side of the base to define a U-shaped configuration. The base includes a first spring finger extending therefrom between the uprights. Each upright includes a first hook disposed towards a first end thereof. The first hooks of the first and second cleats are configured for receipt with the first receiver slots of the first and second vertical struts, respectively, to engage the module with the frame assembly. The first spring fingers of the first and second cleats are biased into contact with the mounting surfaces of the first and second vertical struts, respectively, to maintain the engagement of the module with the frame assembly. 
     In an aspect of the present disclosure, the first spring fingers are cut-out from the bases of the first and second cleats and deflected therefrom between the uprights. 
     In another aspect of the present disclosure, each of the first and second cleats is formed from a single piece of steel. 
     In another aspect of the present disclosure, the uprights of the first and second cleats include second hooks disposed towards respective second ends thereof. The second hooks are configured for receipt within second receiver slots of the first and second vertical struts, respectively. 
     In still another aspect of the present disclosure, the bases of the first and second cleats include second spring fingers extending therefrom between the uprights. The second spring fingers of the first and second cleats are biased into contact with the mounting surfaces of the first and second vertical struts, respectively. In such aspects, the first spring fingers may be disposed towards the first ends of the uprights and the second spring fingers may be disposed towards the second ends of the uprights. 
     In yet another aspect of the present disclosure, the module further includes a latch mechanism having first and second spring posts movable from an inwardly retracted position to an outwardly extended position. In such aspects, each of the first and second vertical struts defines a transverse aperture configured to receive one of the first or second spring posts in the outwardly extended position thereof to releasably lock the module in engagement with the frame assembly. 
     In still yet another aspect of the present disclosure, the latch mechanism includes a lever configured for selective manipulation to transition the first and second spring posts between the inwardly retracted position and the outwardly extended position. The first and second spring posts may be biased towards the inwardly retracted position. 
     In another aspect of the present disclosure, the latch mechanism extends transversely between the first and second cleats towards second ends of the uprights of the first and second cleats. 
     In another aspect of the present disclosure, the uprights of the first and second cleats include nubs towards the second ends thereof. The nubs are configured for receipt within second receiver slots of the first and second vertical struts, respectively, to align the module for receipt of the first and second spring posts within the transverse apertures of the first and second vertical struts. 
     In yet another aspect of the present disclosure, each of the plurality of horizontal ledgers includes a pair of base flanges configured to abut a wall surface and a mounting surface raised relative to the pair of base flanges. 
     In still another aspect of the present disclosure, the mounting surface of each of the plurality of horizontal ledgers defines a plurality of mounting arrangements along a length thereof. 
     In another aspect of the present disclosure, each of the plurality of horizontal ledgers is formed from a single piece of steel. 
     In still yet another aspect of the present disclosure, the first vertical strut is a single vertical strut and/or the second vertical strut is a double vertical strut. 
     In another aspect of the present disclosure, each of the first and second vertical struts is formed from a single piece of steel. 
     In another aspect of the present disclosure, each of the first and second vertical struts defines a C-shaped configuration including feet extending from side legs thereof. The feet are configured for receipt within slots defined within the plurality of horizontal ledgers to releasably mount the first and second vertical struts on the plurality of horizontal ledgers. 
     In still another aspect of the present disclosure, the first and second vertical struts and the plurality of horizontal ledgers each further include apertures configured to enable bolting of the first and second vertical struts to the plurality of horizontal ledgers. 
     In yet another aspect of the present disclosure, the module includes a panel having the first and second cleats mounted on a backside thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects and features of the present disclosure are described hereinbelow with reference to the drawings, wherein: 
         FIG. 1  is a front, perspective, exploded view of a frame assembly of a wall-mount system provided in accordance with the present disclosure; 
         FIG. 2  is a rear, perspective view of a panel configured for releasable mounting on the frame assembly of  FIG. 1 ; 
         FIG. 3  is a rear, perspective view of another panel configured for releasable mounting on the frame assembly of  FIG. 1 ; 
         FIG. 4  is a rear, perspective, partially-exploded view of still another panel configured for releasable mounting on the frame assembly of  FIG. 1 ; 
         FIG. 5  is a rear, perspective, partially-exploded view of yet another panel configured for releasable mounting on the frame assembly of  FIG. 1 ; 
         FIG. 6  is a side, perspective view of a latch mechanism configured for use with the panels of  FIGS. 4 and 5  and having the cover removed therefrom; 
         FIG. 7  is a front, perspective view of the wall-mount system provided in accordance with of the present disclosure illustrating engagement of panels with the frame assembly; 
         FIG. 8  is a front view of the wall-mount system of the present disclosure; 
         FIG. 9  is a cross-sectional view taken along section line “E-E” in  FIG. 8 ; 
         FIG. 10  is a cross-sectional view taken along section line “D-D” in  FIG. 8 ; 
         FIG. 11  is a cross-sectional view taken along section line “B-B” in  FIG. 8 ; 
         FIG. 12  is an enlarged view of the area of detail indicated as “H” in  FIG. 11 ; 
         FIG. 13  is an enlarged view of the area of detail indicated as “F” in  FIG. 9 ; 
         FIG. 14  is an enlarged view of the area of detail indicated as “G” in  FIG. 9 ; 
         FIG. 15  is a top view of a cleat configured for use with the wall-mount system of the present disclosure; 
         FIG. 16  is a side view of the cleat of  FIG. 15 ; 
         FIG. 17  is a cross-sectional view taken along section line “R-R” of  FIG. 15 ; 
         FIG. 18  is a cross-sectional view of another cleat configured for use with the wall-mount system of the present disclosure; 
         FIG. 19  is a top view of the cleat of  FIG. 18 ; and 
         FIG. 20  is a side view of still another cleat configured for use with the wall-mount system of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Detailed embodiments of the present disclosure are disclosed herein; however, the disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure. 
     Referring generally to  FIGS. 1-20 , provided in accordance with the present disclosure is a wall-mount system  10  ( FIG. 7 ). Wall-mount storage system  10  ( FIG. 7 ) includes a frame assembly  100  and a plurality of modules, e.g., panels “P” and/or panels  200 - 500 , releasably mountable on frame assembly  100  in any suitable arrangement. Although panels “P” are illustrated as modules configured for use with system  10 , it is contemplated that the modules may include any suitable structures including and/or mounting components thereon such as, for example, fixed shelves, pivoting shelves, single or double-door cabinets, drawers, Murphy beds, cubby boxes, hooks, pegs, and the like. 
     Referring to  FIG. 1 , frame assembly  100  includes a plurality of horizontal ledgers  110  and a plurality of vertical struts  120 ,  130 . Horizontal ledgers  110  and vertical struts  120 ,  130  may each be formed from a single piece of cold rolled steel. Horizontal ledgers  110  are similar to one another and, thus, are described below in the singular with reference to one horizontal ledger  110 . 
     Horizontal ledger  110  defines a generally C-shaped configuration and is configured for mounting horizontally on a wall (not shown). Horizontal ledger  110  includes a pair of base flanges  112  configured to abut the wall and defines a plurality of spaced-apart slots  114  along the length thereof to enable mounting of horizontal ledger  110  to studs (not shown) supporting the wall, e.g., using suitable screws or other hardware (not shown). 
     Horizontal ledger  110  further includes a mounting surface  116  raised relative to base flanges  112  (and the wall) due to the C-shaped configuration of horizontal ledger  110 . Mounting surface  116  defines a plurality of spaced-apart mounting arrangements  118  therethrough. One or more mounting arrangements  118  may be spaced-apart from one or more other mounting arrangements  118  and/or one or more mounting arrangements  118  may be disposed adjacent one or more other mounting arrangements  118 . For example, each end of horizontal ledger  110  may include a single mounting arrangement  118  while a plurality of adjacent-pairs of mounting arrangements  118  are spaced-apart along horizontal ledger  110  between the ends thereof. Mounting arrangements  118  may define any suitable configuration such as, for example, a pair of spaced-apart vertical slots  119   a  having a vertically-aligned pair of apertures  119   b  disposed therebetween. 
     Vertical struts  120 ,  130  include single vertical struts  120  and double vertical struts  130 , each defining a C-shaped configuration and configured for mounting to two or more of the horizontal ledgers  110 . Alternatively or additionally, vertical struts  120 ,  130  may be mounted to a U-channel secured to a floor or ceiling (not shown). Single vertical struts  120  are similar to one another and, thus, are described below in the singular with reference to one vertical strut  120 . Likewise, double vertical struts  130  are similar to one another and, thus, are described below in the singular with reference to one double vertical strut  130 . 
     Single vertical strut  120  includes features suitable for engaging a single mounting arrangement  118  of each of two or more horizontal ledgers  110 , while double vertical strut  130  includes features suitable for engaging an adjacent pair of mounting arrangements  118  of each of two or more horizontal ledgers  110 . 
     Single vertical strut  120  includes a mounting surface  122  and a pair of side legs  124  depending from either side of the mounting surface  122 . Each side leg  124  includes a plurality of spaced-apart feet  126  extending therefrom along the length thereof. Each foot  126  is aligned with a foot  126  foot on the other side leg  124  such that feet  126  are provided in horizontally-aligned pairs. Side legs  124  are spaced-apart a distance equal to the spacing between the vertical slots  119   a  of one of the mounting arrangements  118  of horizontal ledger  110  such that an aligned pair of feet  126  may be inserted through the aligned vertical slots  119   a  of one of the mounting arrangements  118 . Each foot  126  may further defines a toe (not explicitly shown) such that, upon insertion of feet  126  into vertical slots  119   a  and downward translation of vertical strut  120  relative to horizontal ledger  110 , the toes catch on horizontal ledger  110  to engage vertical strut  120  with horizontal ledger  110 . Side legs  124  further define aligned pairs of transverse apertures  128  therethrough and disposed in spaced-apart relation along the length thereof, as detailed below. 
     Mounting surface  122  of vertical strut  120  defines a plurality of spaced-apart receiver slots  123   a  along the length thereof and one or more apertures  123   b  disposed along the length thereof. The one or more apertures  123   b  are configured for alignment with one or more of the vertically-aligned pair of apertures  119   b  of one of the mounting arrangements  118  of horizontal ledger  110  when vertical strut  120  is engaged thereon to enable bolting of vertical strut  120  to horizontal ledger  110  to securely lock vertical strut  120  in engagement with horizontal ledger  110 . Receiver slots  123   a  are detailed below. 
     Vertical strut  130  includes a mounting surface  132  and a pair of side legs  134  depending from either side of the mounting surface  132  and is similar to vertical strut  120  except that mounting surface  132  generally takes the form of a pair of abutting mounting surfaces  122  formed together. As such, side legs  134  are spaced-apart a distance equal to the spacing between the outer-most vertical slots  119   a  of an adjacent pair of mounting arrangements  118  of horizontal ledger  110 . 
     Turning now to  FIGS. 2-6 , various panels  200 - 500  are configured for releasable mounting on frame assembly  100 . Panels  200 ,  300  are similar to one another in the manner in which they are engaged with frame assembly  100  but differ in terms of dimensions. Likewise, panels  400 ,  500  are similar to one another in the manner in which they are engaged with frame assembly  100  but differ in terms of dimensions. 
     Referring to  FIGS. 2-3 , panels  200 ,  300  include bodies  210 ,  310 , respectively, and a pair of cleats  220 ,  320  mounted to the back face of the respective body  210 ,  220  via screws  240 ,  340 . Embodiments of cleats suitable for use as cleats  220 ,  320  are detailed below. 
     With reference to  FIGS. 4-6 , panels  400 ,  500  are similar to panels  200 ,  300  and include bodies  410 ,  510 , respectively, and a pair of cleats  420 ,  520  mounted to the back face of the respective body  410 ,  520  via screws  440 ,  540 . Panels  400 ,  500  differ from panels  200 ,  300  in that panels  400 ,  500  each further include a latch mechanism  600  engaged thereon. Latch mechanisms  600  are similar to one another and, thus, are described below in the singular with reference to one latch mechanism  600 . 
     Latch mechanism  600  includes a base plate  610 , a pair of spring posts  620 , a pair of connector rods  630 , a pivoting lever  640 , and a cover  650 . Base plate  610  may be formed from a single piece of cold rolled steel and includes an elongated body  612  and a spring finger mount  660  at each end of the elongated body  612 . Elongated body  612  defines a U-shaped configuration having a pair of upright walls  614  interconnected by a floor  616 . Floor  616  defines apertures  617  to enable mounting of base plate  610  to the backside of a panel, e.g., panels  400 ,  500 , using screws or other suitable hardware. Floor  616  further pivotably supports pivoting lever  640  thereon. Upright walls  614  define opposed slots  618  adjacent the position where pivoting lever  640  is pivotably coupled to floor  616  and receive the opposing ends of pivoting lever  640  therethrough to permit pivoting of pivoting lever  640  relative to base plate  610  while defining the range of pivoting motion thereof. Pivoting lever  640  further includes a grasping extension  642  extending from one end thereof. 
     Each spring finger mount  660  defines apertures  661  to enable mounting of spring finger mounts  660  to the backside of a panel, e.g., panels  400 ,  500 , using screws or other suitable hardware. Each spring finger mount  660  further includes a pair of spaced-apart support brackets  662 ,  664  configured to slidably support spring posts  620  therethrough. 
     Spring posts  620 , as noted above, are slidably supported through support brackets  662 ,  664  of spring finger mounts  660 . Spring posts  620  include biasing members  624 , e.g., coil springs, disposed about the bodies  622  thereof and disposed between the support brackets  662 ,  664  of the corresponding spring finger mounts  660 . A collar  626  is engaged about the body  622  of each spring post  620  such that as bodies  622  are slid inwardly through support brackets  662 ,  664 , biasing members  624  are compressed. In this manner, biasing members  624  bias bodies  622  of spring posts  620  outwardly. 
     Connector rods  630  interconnect bodies  622  of spring posts  620  with pivoting lever  640  on opposite sides of the position where pivoting lever  640  is pivotably coupled to floor  616  of base plate  610 . As such, rotation of pivoting lever  640  in a first direction, e.g., in response to pivoting of grasping extension  642  in a first direction, slides both spring posts  620  inwardly relative to base plate  610  against the bias of biasing members  624 , while pivoting of pivoting lever  640  in a second, opposite direction, e.g., in response to release or return of grasping extension  642  in the second direction, slides both spring posts  620  outwardly relative to base plate  610 . 
     Cover  650  may be formed from a single piece of cold rolled steel and is configured to surround the internal components of latch mechanism  600 . Cover  650  defines a slot  652  through which grasping extension  642  of pivoting lever  640  extends to enable external manipulation of grasping extension  642 . Cover  650  may be screwed or otherwise secured to base plate  610  and/or the panel, e.g., panel  400 ,  500 . 
     Referring to  FIGS. 1-7 , in use, grasping extension  642  is moved in the first direction to retract spring posts  620  inwardly relative to base plate  610 . Once this has been achieved, the panel(s)  400 ,  500 , may be engaged between a pair of vertical struts  120 ,  130  using the pairs of cleats  420 ,  520  thereof, as detailed below. Grasping extension  642  may then be released or returned in the second direction to extend spring posts  620  outwardly relative to base plate  610  and through transverse apertures  128  of the pair of vertical struts  120 ,  130  to lock the panel(s)  400 ,  500  in engagement between the vertical struts  120 ,  130 . However, as with panels  200 ,  300 , latch mechanisms  600  need not be provided, depending upon a particular purpose, e.g., the load and/or use expected, depending upon the particular cleats utilized, etc. 
     Turning to  FIGS. 8-20 , cleats suitable for use with panels “P,” which may be configured similar to any of panels  200 - 500 , to releasably mount panels “P” on frame assembly  100  (see  FIGS. 7 and 8 ) are detailed. 
     Referring to  FIGS. 15-17 , in conjunction with  FIGS. 8-14 , a cleat  700  is detailed. Cleat  700  may be configured for use with a panel “P” that lacks a latch mechanism  600  ( FIG. 6 ), e.g., panel  200 ,  300 , or may be used with a panel “P” that includes a latch mechanism  600  ( FIG. 6 ), e.g., panel  400 ,  500 . Cleat  700  may be formed from a single piece of cold rolled steel and includes a base  710  having an upright  720  extending from either side thereof to define a U-shaped configuration. 
     Base  710  defines a partial cut-out  712  wherein sides of a piece of material are cut-out from base  710  to define a cantilever spring arm  714  that deflects inwardly from the opening defined by partial cut-out  712 . Cantilever spring arm  714  defines a dog-legged free end  716  that deflects back towards partial cut-out  712 . In use, as detailed below, cantilever spring arm  712  is configured to abut the mounting surface  122 ,  132  of the vertical strut  120 ,  130  cleat  700  is engaged with to bias cleat  700  away from the vertical strut  120 ,  130  to help maintain engagement therebetween. Base  710  of cleat  700  further defines a plurality of apertures  718  to enable mounting of cleat  700  to the backside of a panel using screws or other suitable hardware. 
     Uprights  720  of cleat  700  define pairs of hooks  722  extending therefrom adjacent to or at the upper and lower ends thereof, although hooks  722  may be positioned at any suitable position and/or in any suitable spacing along uprights  720 . Hooks  722  define tangs  724  and notches  726 . The tangs  724  of each pair of hooks  722  are configured for insertion through a receiver slot  123   a  of one of the vertical struts  120 ,  130  and notches  726 , upon downwardly translation of cleat  700  relative to the vertical strut  120 ,  130 , are configured to receive a portion of the vertical strut  120 ,  130  to engage cleat  700  therewith. The bias of cantilever spring arms  714 , as noted above, helps maintain this engagement wherein tangs  724  are received within receiver slots  123   a  and notches  726  receive a portion of the vertical strut  120 ,  130 . 
     Turning to  FIGS. 18 and 19 , in conjunction with  FIGS. 8-14 , cleat  800  is similar to cleat  700  except that cleat  800  defines a longer length and includes a pair of partial cut-outs  812  and cantilever spring arms  814  formed therefrom. Cantilever spring arms  814  are disposed towards opposite ends of cleat  800  and are oriented in opposite directions. Providing a pair of cantilever spring arms  814  in a longer cleat  800  enables biasing force to be applied closer to each of the engagement points between the cleat  800  and a vertical strut  120 ,  130 . Additional cantilever spring arms  814  are also contemplated. 
     With reference to  FIG. 20 , in conjunction with  FIGS. 8-14 , cleat  900  is similar to cleat  700  except that, similarly as with cleat  800  ( FIGS. 18-19 ), cleat  900  includes a pair of cantilever spring arms  914  (although only one or more than two are also contemplated) and, further, cleat  900  includes a nub  923  extending from each of the uprights  920  thereof towards the upper end thereof. Nubs  923  are configured for insertion through a receiver slot  123   a  of one of the vertical struts  120 ,  130 ; however, unlike hooks  722  ( FIGS. 15-17 ), do not include engagement features to maintain nubs  932  in engagement within the receiver slot  123   a . Rather, cleat  900  is configured for use with a latch mechanism  600  positioned towards the upper end of cleat  900  such that nubs  932  function to position and align, while the latch mechanism  600  is utilized to engage. 
     As can be appreciated in view of the forgoing, wall-mount system  10  ( FIG. 7 ) provides modularity, secure engagement of components, and ease of assembly and dis-assembly with minimal tools required. 
     While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.