AU5121093A

AU5121093A - Wall panel assembly

Info

Publication number: AU5121093A
Application number: AU51210/93A
Authority: AU
Inventors: Knud Clausen; Murray Robert Fitzsimmons
Original assignee: Individual
Current assignee: Individual
Priority date: 1992-10-23
Filing date: 1993-10-15
Publication date: 1994-05-24
Also published as: CN1104701A; FR2697274A1; ZA937752B; WO1994010404A1

Description

WALL PANEL ASSEMBLY

TECHNICAL FIELD OF THE INVENTION

The present invention relates to the general field of cladding systems, with particular application to wall cladding which provides a shelf support system.

BACKGROUND

A variety of systems have been known for fastening panels to a support structure, either for providing a wall covering or for constructing a ceiling. The systems have generally fallen into either of two broad categories:

Point fastener systems, using fasteners such as screws or spot welds, as shown for example in US Patent No.4,450,970 - Shepherd;

Spring clipping systems, using resilient clips to grasp the support structure, as shown for example in US Patent No. 3,293,819 - Heirich, US Patent No. 3,412,516 or UK

Patent Application No.2052594A - Metal Ceilings (H & E) Ltd

The first category of systems generally suffer the disadvantage of being slow and difficult to assemble, and (particularly in the case of welding) requiring some skill to assemble properly.

The second category of systems are generally easy to assemble, but allow the panel to be removed again, simply by pulling on it

This is useful with regard to ceiling panels, in that it allows easy access to wiring or pipes above, but is not appropriate in respect of wall panels, which may be required to support weights such as shelves.

Our earlier US patent No. 5,081,323 disclosed a new system, by which a panel is slideably fitted into engagement with an overhanging lip on a support element, and then locked in that engaged position with a clip fitting over a detent at the other end of the panel. No point fasteners are required, and the engagement system is not able to resiliently disengage under any normal circumstances. OBJECT

It is an object of the present invention to go at least partway towards providing a novel or improved wall cladding system, or at least to provide the public with a useful choice.

SUMMARY OF THE INVENTION

In one aspect the present invention provides a panel assembly including a plurality of elongate support elements; and a plurality of elongate wall panels arranged in use transversely relative to said support elements; wherein each said wall panel is comprised of a face, a first part of a channel along a first edge of said face, and a complementary second part of a channel parallel to said first part along a second edge of said face, opposite said first edge; said first part of a channel including two oppositely recurving portions in the general form of an S-bend in cross-section, a first recurving portion forming a hollow flange and a second recurving portion underlying the first to form an undercut and a rear section behind said first recurving portion; said rear section terminating with a projecting edge; and wherein each said support element includes a plurality of retaining sections each including a hooked, overhanging lip; and each said support element further includes a plurality of detents each having a bearing face opposing a said hooked overhanging lip; whereby in use said first part of a channel can be engaged with a said retaining section, and said projecting edge of said rear section engaged with a said detent to bear against said bearing face, and thereby hold said first part of a channel in engagement with said retaining section.

Preferably each said detent comprises a tooth projecting from said support element, with said bearing face projecting substantially orthogonally from said support element.

Preferably said first part of a channel further includes an intermediate section between said first and second recurving sections, comprising a section extending substantially parallel to said face, and wherein said rear section extends substantially parallel to said face and said intermediate section; such that both said hollow flange and said undercut comprise sharply-defined pockets having substantially parallel walls.

PREFERRED EMBODIMENT

The following is a description of one preferred form of the present invention, given by way of example only, with reference to the accompanying drawings, in which:

Figure 1 : - illustrates elements of the preferred embodiment in perspective view.

Figure 2: - illustrates the elements of Figure 1 in side view and section.

Figure 3: - illustrates the elements of Figure 1 in combination as in use.

As described in our earlier US Patent No. 5,018,323, there are a number of advantages to be gained from the use of a wall cladding system having a plurality of elongate horizontal panels fixed onto elongate vertical support elements. The system described in that specification is however somewhat time-consuming to install although in general quicker than other systems hitherto available. The present invention includes an alternative fastening system, which may allow cladding to be installed more quickly and easily than formerly, or may at least offer a choice of systems to the public.

As shown in Figure 1, the cladding system of the present invention is comprised of wall panels 10, and support elements 11. The support elements comprise pressed and roll- foimed metal bars, including a generally flat elongate strip 12 with a turned-back lip 13 along either side edge, and possibly one or more ribs or corrugations running along its length, to increase its rigidity. Apertures 14 are punched in the strip at intervals, whereby screws or other fasteners may be used to fix the support elements 11 to a wall or subframe. The elements 11 are further provided with hooks 15 and detents 16, by which the panels 10 are fastened to the support elements 11, as described hereafter.

The hooks 15 project outward and downward as shown, and may have a central rib 17 to strengthen them against bending. The detents 16 are preferably comprised of a tooth projecting from the support element 11, formed by making a small tangential slit in the element 11 below each hook 15, the lower lip of which is pressed to jut sharply outward a distance slightly greater than the thickness of the material of the panels 10. The upper or cut face 16a of the detent 16 projects substantially orthogonally out from the support element, while the lower face 16b comprises a more shallow slope.

Bracing arms 18 may also be provided to bear against the rear face of the panels 10, and support parts of the panels against buckling.

The panels 10, as shown in Figure 1, may be approximately 90mm wide, and 12mm deep, although it should be appreciated that these dimensions might be altered considerably to suit any particular purpose or application. The panels 10 are comprised of an elongate flat face 20, extending horizontally across the wall in normal use, with complementary parts of an undercut channel 21 along the top and bottom edges.

The bottom edge is recurved to provide a hollow overhanging lip 22 with a recess 23 behind it in the general form of an S-bend in cross-section. Preferably the S-bend is relatively deep and sharply defined, so that the intermediate, central portion between the two recurving portions comprises a substantially vertical wall 28, parallel to the face 20. In use, the hooks 15 of the support elements 11 fit into the lip 22, with the recess 23 extending in behind the hooks 15. The edge of the panel then extends back downward, forming a rear wall 24 of the recess 23, and terminating in a simple straight edge 25, preferably without any form of beading or lip.

The top edge is also folded back, at approximately 90" to the face of the panel, and then bends up to form a rear wall 26 parallel to but set back from the face 20. This terminates in a lip 27 folded forward again, at approximately 90^*. The lip 27 is less wide than the recess 23, such that the top edge is able to nest inside the recess 23 at the bottom edge of another panel.

To fix the panels 10 to a wall, the support elements 11 are first fastened to the wall, extending vertically, at intervals along the length of the wall. The topmost panel 10 is then fitted in place, with the lip 27 at the top edge fitting under the topmost hook 15 on each support element, and the recurving lip 22 at the bottom edge fitting around another hook 15 below. The panel 10 is pushed upwardly until the bottom edge 25 clicks over the detent 16, such that the panel is prevented from moving back downward and is locked in engagement with the hooks 15. Because the recurving lip 22 is relatively sharply defined with parallel vertical walls, it can not in normal use resiliently flex into or out of position around the hook 15. Accordingly, it must be slideably pushed upwards into the engaged position, and can only be removed by moving slideably back down out of that position. The detent 16, engaging with the edge 25 of the panel, prevents this. Although the detent 16 is relatively small, it can engage positively with the thin edge 25 of the downwardly projecting rear wall 24. The hook 15 inside the adjacent recurving lip 22 prevents the panel 10 from being pulled away from the support element 11, and thereby effectively prevents the edge 25 from disengaging from the detent 16, unless the rear wall 24 is bent or prised away from the support element 11.

A second panel 10 is then fitted in place, with the top edge first being fitted into the recess 23 at the bottom edge of the first panel 10, and then the recurving lip 22 at the bottom edge of the second panel 10 being fitted onto another hook 15 and pushed upwardly, until the bottom edge 25 of the second panel clicks into place over a detent 16. The top edge of the second panel is positively locked in place by fitting into the recess 23, and also covers the rear wall 24 and bottom edge 25 of the first panel, preventing it from being disengaged from the detent 16. The two panels in combination also present a neat appearance, with no visible seam or join, and a horizontal channel 21 with an overhanging upper lip 22. Shelf brackets 30 can be suspended from this channel, as illustrated in Figure 3.

It should be appreciated that the profile of the channel 21 might be altered considerably to suit a particular type or style of shelf bracket For example, the bottom lip might also be undercut, by providing a recurving portion at the top edge of the panel in addition to that at the bottom edge. This is considered to be less preferable at present because of the tendency with such an arrangement to collect dust

The panels are fitted in sequence from top to bottom. Irregularities such as power sockets and light switches can be accounted for as the wall is constructed by cutting holes in a panel at the appropriate point, or by cutting a panel into two sections and leaving a gap between the cut ends. A skirting board may be fitted between the lowest panel and the floor, possibly fitting into the recess 23, and nailed or otherwise fixed in place. By this means a solid and secure wall covering is provided, with every panel fastened along both top and bottom edges. It should be appreciated that if disassembly of the wall is ever necessary, the skirting board can be removed, and the bottom edge 25 of the lowermost panel can be prised out of engagement with the detents 16. The lowermost panel can then be slipped downwardly out of engagement with the hook 15, and removed. This reveals the bottom edge 25 of the next panel 10 above, allowing this panel in turn to be removed, and so on.

The panels are preferably coloured and given any desired surface texture prior to installation, so that little or no further work is required to finish the wall.

It is preferred that both the support elements 11 and the panels 10 are pressed and/or roll-formed from relatively inflexible sheet metal, such as 1mm galvanised steel. However, it should be appreciated that either or both components might be made from other materials, possibly by a moulding, extrusion, or cutting process rather than pressing and rolling. The dimensions and specific forms of the various parts of the invention illustrated in the above example might also be modified to suit a different manufacturing process, or end use.

In particular, the detents 16 might comprise any of a variety of structures presenting a face 16a against which an edge of the panel can bear. For example, the detent might comprise a short tongue, bent out from the support element at an acute angle or at 90°. Alternatively it could comprise a notch in the support element, with the projecting edge of the panel being bent rearwardly to engage with it. Various other means might similarly be used.

A variety of other changes and modifications might also be made within the general spirit and scope of the invention, which may be characterised by the following claims:

Claims

CLAIMS:

1. A panel assembly including: a plurality of elongate support elements; and a plurality of elongate wall panels arranged in use transversely relative to said support elements; wherein each said wall panel is comprised of a face, a first part of a channel along a first edge of said face, and a complementary second part of a channel parallel to said first part along a second edge of said face, opposite said first edge; said first part of a channel including two oppositely recurving portions in the general form of an S-bend in cross-section, a first recurving portion forming a hollow flange and a second recurving portion underlying the first to form an undercut and a rear section behind said first recurving portion; said rear section terminating with a projecting edge; and wherein each said support element includes a plurality of retaining sections each including a hooked, overhanging lip; and each said support element further includes a plurality of detents each having a bearing face opposing a said hooked overhanging lip; whereby in use said first part of a channel can be engaged with a said retaining section, and said projecting edge of said rear section engaged with a said detent to bear against said bearing face, and thereby hold said first part of a channel in engagement with said retaining section.

2. A panel assembly as claimed in claim 1 wherein each said detent comprises a tooth projecting from said support element, with said bearing face projecting substantially orthogonally from said support element

3. A panel assembly as claimed in claim 1 or claim 2 wherein said first part of a channel further includes an intermediate section between said first and second recurving sections, comprising a section extending substantially parallel to said face, and wherein said rear section extends substantially parallel to said face and said intermediate section; such that both said hollow flange and said undercut comprise sharply- defined pockets having substantially parallel walls.

4. A panel assembly as claimed in any one of claims 1 to 3, wherein said second part of a channel includes a rear wall, and is shaped to nest within the first part of a channel of an adjacent said panel, to cover said projecting edge of the rear section of said adjacent panel.

5. A panel assembly as claimed in any one of claims 1 to 4, further including a plurality of retaining members for suspending articles from the panel assembly, said retaining members each including a hook dimensioned and arranged to fit within a channel comprised of a said first and a said second part of a channel, whereby said hook can be inserted into said undercut and bear against said hollow flange, to suspend an article.

6. A panel assembly as claimed in claim 5, wherein said retaining member comprises a shelf bracket

A panel assembly as claimed in claim 1, wherein said panels are formed from metal.