Abstract:
Support panels and modular assemblies thereof, the panels adapted for supporting removable load bearing members such as brackets. The panels comprise hollow bodies defining channels for receiving and supporting load bearing members. The hollow bodies further include support ribs extending between front and back walls of the panels to transfer forces exerted on flange portions of the channels by the load bearing members to the back walls and/or to other structural portions of the panels, the support ribs being offset from the perpendicular relative to the front and back walls of the panels. Pluralities of the panels may be joined by mating edges, which can define further channels for receiving and supporting load-bearing members, to form modular wall assemblies without the need for mounting overtop existing surfaces as said panels can be mounted directly on structural supports (e.g. stud walls).

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to a support panel and more particularly to a support panel for supporting brackets and the like. 
       BACKGROUND OF THE INVENTION 
       [0002]    Support panels are commonly used in office, commercial and other environments in order to position various items, goods and products within easy reach and/or sight of people. For example, specially-adapted support panels are often used as part of trade shows to display new products, in retail stores to display goods for sale, and in garages, workshops and other places where storage is required, to organize and make easily available various tools. 
         [0003]    Support panels define channels adapted for the mounting of various support members (for example, shelves, racks, hangers and the like). Typically, such support members are provided with brackets which engage the channels in order to securely hold the support members in place on the support panel. Hence, the mounting of shelves etc. is performed in an easy and efficient manner, without the use of screws or other types of fasteners. Support panels assembled from such walls are sometimes referred to as slat walls. 
         [0004]    A problem with existing support panels is that the panel structure is not adapted to fully support the load that can be placed upon the panel by the brackets. If the load placed on a bracket exceeds the structural strength of a structure defining the channel, the structure is likely to fail, not only dropping the load, but also damaging the channel rendering that channel unusable. Thus, it is desirable to have support panels with channel structures that optimize the load carrying ability of channels for both value and safety purposes. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention provides improved systems and methods for secure mounting of brackets and other load-bearing members on support panels. In preferred embodiments, the invention provides structures adapted for the removable mounting of such structures. 
         [0006]    In one aspect the invention provides support panels adapted for supporting removable load bearing members such as brackets. Panels according to such aspect can comprise hollow bodies having front and a back walls separated by voids, and one or more channels defined by the hollow bodies for receiving load bearing members. The channels can include openings defined in said front wall, and base and flange portions defined by the hollow bodies for engaging the load bearing members. Such panels further comprise one or more support ribs extending between the front and back walls to transfer forces exerted on the flange portions by the load bearing members to the back walls and/or to other structural portions of the panels. 
         [0007]    It has been found that superior load-bearing qualities can be achieved by providing the support ribs at angles offset from the perpendicular with respect to the front and back walls of the panels. 
         [0008]    In other aspects, the invention provides modular wall assemblies comprising pluralities of such panels, wherein the panels are joined by mating edges which can define further channels for receiving and supporting load-bearing members without any compromise in strength. 
         [0009]    The invention also provides for flat rear panel surfaces which allow mounting on stud walls without the need for backing (such as drywall), where joined panels act as an adequate sealing means for a wall especially at the corners where a void would be present. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The invention will now be described by example, and with reference to the accompanying drawings, in which: 
           [0011]      FIG. 1  is an isometric view of a modular support panel in accordance with an embodiment of the invention; 
           [0012]      FIG. 2  is a cross section of the modular support panel of  FIG. 1  viewed along lines  2 - 2 ; 
           [0013]      FIG. 3  is an enlarged partial view of the cross section of panel of  FIG. 2  as viewed in circle portion  3 . 
           [0014]      FIG. 4  is an enlarged, partial view of a modular support panel having two support ribs in accordance with another embodiment of the invention; 
           [0015]      FIG. 5  is an enlarged, partial view of a modular support panel having two support ribs in accordance with yet another embodiment of the invention; 
           [0016]      FIG. 6  is an enlarged, partial view of a modular support panel having a T-shaped channel in accordance with another embodiment of the invention; 
           [0017]      FIG. 7  is a portion of a wall formed from multiple modular support panels  30  of  FIG. 1  in accordance with another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]    Referring to  FIG. 1 , an embodiment of a modular support panel is indicated generally at  30 . As will be described further below, one or more modular support panels  30  can be used in combination with each other or with other suitable devices or materials to form a support panel wall or a portion thereof. Moreover, as will also be described in greater detail below, modular panels  30  include channels  58  for receiving and securely supporting load-bearing members such as brackets. 
         [0019]    Referring to  FIG. 2 , each modular panel  30  has a front wall  34  and a back wall  38  that are substantially parallel to each other and separated by distance D. Front wall  34  and back wall  38  are spanned by first edge  42  and second edge  46  to form one or more hollow bodies  72 . Front wall  34  and back wall  38  are also spanned by one or more separation ribs  50  defining one or more voids  54  within hollow body(ies)  72 . In the embodiment shown in  FIG. 2 , modular panel  30  includes three separation ribs  50 , one for each of hollow bodies  72 . Each separation rib  50  is connected to its respective front wall  34  and back wall  38  in a substantially perpendicular configuration. Moreover, each separation rib  50  runs substantially parallel with ends  42  and  46 . In other embodiments, the configuration of ribs  50  can vary based on a variety of criteria such as costs, desired panel strength and other criteria as would be understood by persons skilled in the relevant arts. 
         [0020]    In a preferred embodiment, panel  30  is integrally formed from PVC through an extrusion process. In other embodiments, panel  30  may be constructed from other plastics or materials, and formed through different processes, as understood by those with skill in the relevant arts. In yet other embodiments, one or more elements of panel  30  may be formed separately, and attached to panel  30  through additional processes. 
         [0021]    As will be apparent to those skilled in the relevant arts, the use of hollow panels offers a number of advantages including, for example, reduced structural weight, and potential for improved insulation and/or fire retardation by, for example, filling voids  54  with insulating or fire retarding foams or other materials. Materials used to fill voids  54  can be chosen based on numerous criteria such as desired panel strength, rigidity, fire retardation concerns, thermal and or audio insulation, cost and weight. 
         [0022]    Modular support panel  30  defines, by itself and/or in cooperation with one or more other support panels  30 , one or more channels  58  for receiving brackets or other removable load-bearing members. As shown in  FIG. 3 , channels  58  include respective openings  62  for receiving the load-bearing members, as well as respective base portions  66  and retaining flange  78  for supporting the load-bearing members.  FIG. 3  shows an embodiment of a channel  58  defined by an integral channel wall having a base portion  66  and a side portion  70 . In the embodiment shown, side portion  70  extends from base portion  66  and curves up to front wall  34 . A side portion  74  connected in a substantially perpendicular manner to front wall  34  and base portion  66  defines the other side of channel  58 . In this embodiment, base portion  66  is reinforced with separation rib  67 , one of which comprises a section of side portion  74 . 
         [0023]    Referring still to  FIG. 3 , flange  78  can be formed in various configurations, using different structures. For example, as shown in  FIG. 3 , flange  78  extends a distance D 1  from side portion  74  to form an integral u-shaped structure comprising inner surface  88  and outer surface  82 . Outer surface  82  is connected to front wall  34  and inner surface  82  is connected to side portion  74 . In this embodiment, side portion  74  comprises spanning rib  68 , which spans the distance between inner surface  88  and outer surface  82  of flange  78 . Preferably, flange  78  is configured to define at least a portion of receiving channel  58  and to support loads applied to an inner surface of the flange, the loads comprising at least a vector component normal to the front wall  34 . In the embodiment shown in  FIG. 3 , flange  78  is substantially parallel with front wall  34 , the outer surface  82  of flange  78  being in substantial alignment with the outer surface of front wall  34 . In other embodiments, flange  78  can take other shapes such as L-shaped protrusions or other configurations as would be understood by those skilled in the relevant arts. Flange  78  can be constructed from substantially the same material as the majority of panel  30 , or can be constructed of a different suitable material. In yet other embodiments, flange  78  can be aligned with front wall  34  in a non-parallel fashion, and/or connected at other locations on side portion  74 , such that front portion  82  is not aligned with front wall  34 . 
         [0024]    As will be understood by those of skill in the relevant arts, a suitable support member, such as a shelf (not shown) with a bracket that complements the shape of channel  58 , can be used with support panels  30 . In use, the bracket is inserted into channel  58  such that the shelf is held substantially perpendicular to support panels  30 . In order to support the shelf in this configuration, and any extra weight that the shelf itself must support, the bracket exerts a force, or a load, at least partially on inner surface  88  of flange  78  and at least partially on base portion  66 . 
         [0025]    Panels  30 , in accordance with the invention, can comprise additional structural members for providing support to load-bearing portions of panel  30 . For example, in some embodiments of the invention, panels  30  comprise one or more support ribs  86  located within void  54  for transferring torsional, bending, and/or other loads applied to flange  38  by, for example, a removable load-bearing support member. Support rib  86  can be proximate to side portion  74 , and extends between front wall  34  and back wall  38 . In general, support rib  86  supports the load-bearing capabilities of flange  78  and may allow for greater loads to be supported by support panel  30 . 
         [0026]    Referring now to  FIG. 4 , support rib  86  is shown connected to front wall  34  and back wall  38 . Support rib  86  and back wall  38  define angle  110  through their connection. Angle  110  is preferably less than about 90 degrees such that support rib  86  is closer to side portion  74  at front wall  34  than at back wall  38 . As will be understood by those familiar with such structures and the support of load-bearing members, the value of angle  110  and the orientation of support rib  86  in relation to back wall  38  can be varied. For example, angle  110  can be in the range of about 20 to about 85 degrees, more preferably in the range of about 40 to about 70 degrees, and even more preferably in the range of about 50 to about 70 degrees. An angle  110  of about 65 degrees has been found to serve particularly satisfactorily. 
         [0027]    Support rib  86  is preferably attached to front wall  34  at a distance from side portion  74  that is between zero to about 4 times D 1  (the distance that flange  78  extends from side portion  74 , as described above). It is even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 0.5 times to about 3.5 times D 1 , and even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 1.5 times to about 3.0 times D 1 , and even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 2 times to about 2.7 times D 1 . In some embodiments, support rib  86  can be attached to front wall  34  at a position as close to side portion  74  as the corner formed by side portion  74  and front wall  34 . 
         [0028]    Front wall  34  and back wall  38  may be generally parallel to each other and are separated by distance D 2 . A suitable distance D 2 , as well as suitable thicknesses of the walls and other components of the panel, can be determined by a person skilled in the relevant arts, and will generally be dependent on the materials used to construct them, as well as the desired loads that they are expected to bear, and various manufacturing practicalities. 
         [0029]    In another embodiment of the present invention, a second support member  86  is used, as shown in  FIG. 4 . Second support member  86  can be attached to front wall  34  at a distance anywhere along void  54 , but it is preferred that it is attached to front wall  34  at a distance from side portion  74  that is between zero to about 4 times D 1 . It is even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 0.5 times to about 3.5 times D 1 , and even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 1.5 times to about 3.0 times D 1 , and even more preferred that support rib  86  is attached to front wall  34  at a distance from side portion  74  that is in the range of between about 2 times to about 2.7 times D 1 . 
         [0030]    It is not required that each support member  86  has the same angle  110 . The angles will be determined by the particular load requirements. For example, an embodiment is shown in  FIG. 5  where second support member  86  has a smaller angle  110  than the first support member. In this embodiment, second support member  86  is shown attached to front wall  34  at the same distance from side portion  74  as the first support member. In other embodiments, second support member  86  can have a different able  110  and be attached to front wall  34  at a different distance from side portion  74 . 
         [0031]    In theory, there is no limit to the number of support ribs  86  that could be used; however, a skilled person could determine a practical number of support ribs  86 , and their relative location, useful to support a desired load. 
         [0032]    Referring back to  FIG. 2 , multiple panels  30  can be joined, at their respective mating ends  42  and  46 , to form a continuous modular wall assembly. Ends  42  and  46  can comprise male-female or other mating configurations such as that shown, which includes a female joint portion  112  at end  42  and a male joint portion  114  at end  46 . The embodiment shown in  FIG. 2  further comprises flange portion  118  and wall structures  119 ,  120 ,  121  at ends  42 ,  46 , such that when an end  42  is joined or otherwise placed in a proximate configuration to an end  46  to form a wall assembly, a channel  58  for receiving a load-bearing member can be formed by the respective ends  42 ,  46 . 
         [0033]      FIG. 5  shows a portion of a modular wall assembly, or modular support panel system,  200  in accordance with such an embodiment of the invention. Panel system  200  is formed by joining two modular panels  30   a  and  30   b . Modular panel  30   a  and modular panel  30   b  are similar to modular panels  30 , and like elements in modular panel  30   a  and modular panel  30   b  bear reference numbers similar to those of like elements in modular panels  30 . 
         [0034]    In the embodiment shown, a channel  122  is formed, or defined, where an end  42  meets an end  46 . Accordingly, as shown in  FIG. 5 , the opening  62  of channel  122  is defined by front wall(s)  34  and flange  118 . Furthermore, portion  119  of end  42  between front wall  34   a  and female joint  110   a  forms one side portion of channel  122 . Portion  121  of end  46  between front wall  34   b  and male joint  114  forms another other side portion. A portion  120  of male joint  114  that remains outside female joint  110  forms a base portion for channel  122 . 
         [0035]    In the embodiment shown, a support rib  130  is located proximate to end  46 . As should be apparent to those skilled in the relevant arts, all variations discussed above for support rib  86  are also applicable to support rib  130  and are within the scope of the invention. 
         [0036]    Modular wall assembly  200  can be secured to an existing wall system, or suitably supported by other means known in the art. For example, modular wall assembly  200  can be mounted directly on structural supports (e.g. stud walls). Alternatively, modular wall assembly  200  may comprise suitable supporting means to enable it to be self supporting such that minimal extra supporting means are required. 
         [0037]    As shown, for example, in  FIG. 2 , it can be advantageous in some embodiments for panel  30  to include a plurality of channels  58 . As will be understood by those skilled in the relevant arts, the relative spacing and configuration of channels  58  can be selected to accommodate desired loading configurations when load-bearing members are installed. 
         [0038]    In another embodiment of the present invention, a panel  30  with opposing flanges  78  forming a “T” channel, as shown in  FIG. 6 , is provided. In this embodiment, an opening  300  is defined between opposing flanges  78 . Opening  300  leads into channel  310 , which is defined by side portions  320  and base portion  330 . Support members  86  are provided to support each flange  78  and may be mirror reflections of each other or different. The parameters for support members  86  are as already described. In this embodiment, support member  86  can support only one flange  78  of the “T” channel or both. 
         [0039]    While the invention has been described in some detail for purposes of clarity and understanding, it will be appreciated by those skilled in the relevant arts that various changes in form and detail can be made without departing from the true scope of the invention in the appended claims. The invention is therefore not to be limited to the exact components or details of methodology or construction set forth above.