US20150121774A1

US20150121774A1 - Arrangement for attaching panels to support structures, a construction support structure and fastening means, and their use in modular building elements

Info

Publication number: US20150121774A1
Application number: US14/533,138
Authority: US
Inventors: Seppo Pienimaa
Original assignee: DaSeiNa Oy
Current assignee: DaSeiNa Oy
Priority date: 2013-11-05
Filing date: 2014-11-05
Publication date: 2015-05-07
Also published as: FI128535B; FI20136084L

Abstract

The invention concerns an arrangement for attaching panels to support structures, a construction support structure, fastening means for panel elements and the use of such panel elements to create modular room building elements, e.g. wet-rooms. The inventive arrangement is based on fastening means having an skillet attachment strip made of a sheet-like material having a first edge and an integral tab having a second edge. The tab is then formed as a clip protruding transversally from the strip and having a first side and a second side and with a generally nose-shaped tab on the first side. In the support structure is provided a notch for receiving the clip in a locking engagement, with a cross-section having a first side and a second side, a waist part that is narrower than the dimension of the clip and including an integral element formed as a tongue on said first side. The panel element is engaged with said support structure by aligning the clip with the notch and by the appliance of force to move the panel element towards the support structure, whereby the nose-shaped tab of the clip is caused to slide over the tongue-shaped element to attach the panel to the support structure with a snap-like action.

Description

FIELD OF THE INVENTION

The present invention relates to mechanisms for fastening boards or wall elements to support structures. More specifically, the invention describes an arrangement for attaching panels to support structures comprising wall-forming panel elements having fastening means with an elongate attachment strip, for an interlocking arrangement for the fastening of wall elements to support structures. The inventive wall elements are suitable for all kinds of building activity, including wet-room facilities.

BACKGROUND OF THE INVENTION

Snap and interlocking mechanisms for joining boards or wall elements together in a planar fashion is well known in the art. U.S. Pat. No. 5,125,204 describes a snap-in-place mounting arrangement for securely attaching generally flat panels to a support structure. US Patent Application 2011173914 relates to interlocking floor panels having a separate clip in a retaining profile. Canadian Patent No CA2776113 concerns a building panel having a device for connecting the building panel to at least one further similar building panel on a sub-surface.
It is also known to provide joints based on extruded aluminum profiles without any intermediate parts. Solutions permitting easy disassembly are also available, e.g. in key-locked joints.
However, efficient solutions for fastening larger panels not to each other, but to framework parts or at corners, in building structures where the materials cannot be worked upon at that stage, like glass and wetroom materials. An important aspect of such a construction is that the wall assembly may be made from inside the room, leaving the interior surfaces free from any fastening fixtures, seams or any other discontinuity on the wall surfaces. The prior art solutions does not provide for such, and it is thus the object of the present invention to solve the problems related to simple and secure wall element fastening in a demanding context involving fragile and/or sensitive wall structures.

SUMMARY OF THE INVENTION

The inventive arrangement is designed to be used when assembling complete room modules, for example. Other non-exclusive applications examples include decorative glass walls, dividing walls, exhibition structures etc. The panels used in the invention are designed to be assembled from the inside. This makes it possible to assemble e.g. wall panels also on existing walls, making the panels suitable both for in construction or remodeling. Special advantages emerge when using the inventive components in wet-room modules like complete bath- and restroom modules. Such modules do not need waterproofing elsewhere in the construction, once they are built to be waterproof. These modules will thus shorten construction time remarkably, prevent humidity related problems in construction and provide well designed high quality interior. The modular construction may easily include also bath room fixtures, heating/cooling piping, ventilation, illumination, audio, water & waste handling. Currently known modules have not all these combined features and benefits of easy-set-up and modular construction.
The room wall panels may be of any material, including fragile ones like glass, tile or marble, because of the gentle assembly method, and the panels can be used in any kind of buildings including wood, log, brick or concrete houses. A big advantage is the provision for easy remodeling as the wall panels are quickly replaceable with new ones. Then invention allows to build constructions which need only minimal cleaning by using surface designs and finishes which have no or only a small amount of seams. Finally, the inventive components and arrangement will provide modules incurring lower total cost due to savings in maintenance and simplicity of construction.
The invention is related to an arrangement for attaching panels to support structures, including:

- a panel element;
- fastening means attached to said panel element comprising at least one elongate attachment strip made of a sheet-like material having a first edge:
- said attachment strip having at least one integral tab having a second edge, said tab being formed as a clip protruding transversally from said attachment strip and having a first side and a second side,
- a support structure having an elongate receiving means for said clip forming a notch with a cross-section having a first side 3 a) and a second side,
- said notch being arranged to receive said clip in a locking engagement to fasten the panel element to said support structure.

In order to include the features and to achieve the particular advantages of the present invention, the clip has a cross-section including a generally nose-shaped tab on said first side with said first edge being attached to the panel, said second side being slanted and ending at said second edge. Correspondingly, at the receiving end, the notch has a cross-section including an integral element formed as a tongue on said first side. The wall-forming panel element is then easily fastened to said support structure by means of aligning the clip or clips attached to the panel with the notches on the support structure, and by pressing the panel element against the support structure. The nose-shaped tab of the clip will then slide over the tongue-shaped element to become engaged with it in a snap-like action. Simultaneously, the second and free side of the clip may become and remain spring-loaded against the second side of the notch.
In an embodiment of the invention, the arrangement may include release means for detaching the wall-forming panel element from the support structure. The release means may consist of an expandable tube of e.g. rubber included in the original installation of the wall panel, or inserted from above or below, between the first sides of said clip and said notch. When the tube is inflated, it will expand and push the nose-shaped tab off the tongue to release the interlocking engagement between the clip and the notch, whereby the wall pane can be removed.
In another embodiment of the invention, the arrangement may include assembly means for assembling the wall-forming panel element to the support structure. The assembly means may consist of an expandable tube of e.g. rubber included in the original installation of the wall panel, or inserted from above or below, between the second sides of said clip and said notch. When the tube is inflated or expanded e.g. by activation of an expandable material inside the tube, it will expand and push the nose-shaped tab of said clip towards said tongue to secure the interlocking engagement between the clip and the notch.
In a further embodiment of the invention, the tongue-shaped element on the first side of the notch is at least partly grooved on the upper side facing the clip in order to increase friction between the contact surfaces of the clip and the notch when assembled.
One aspect of the invention concerns a construction support structure. Such structures are often, but not necessarily, elongate aluminum or plastic extruded profiles. They have according to the invention one or several integral notches that extend along the length of the profile and have a first side and a second side. The notch has a cross-section that has a waist section formed on the first side of the notch by a tongue-shaped section pointing inwards, i.e. towards the second side. The notch is arranged to receive fastening means for constructional elements to be fastened to the support structure. The fastening means when inserted in the notch is supported by the tongue element and held in place in a shape-locked joint formed by the fastening means and the waist section. Preferably, the tongue-shaped element is at least partly grooved on its upper surface for increasing the friction between the fastening means inserted into the notch and the tongue-shaped element.
The construction support structure may include a recess for a gasket beside and parallel to the notch in order to ensure that a wall built with panel elements is waterproof.
A further aspect of the invention concerns fastening means for panel elements to be attached to constructional elements, which are intended to fit into the support structure explained above. The fastening means comprise an elongate strip made of a sheet-like material having a first edge and at least one integral tab having a second edge. The tab is formed as a clip protruding transversally from the strip and has a first side and a second side with a cross-section that includes a generally nose-shaped tab on the first side. The second side is slanted and ends at the second edge. The clip is fastened to the panel element at its first edge.
The clip is fastened to the inventive construction support structure by inserting the clip into a notch having a waist section that is narrower than the clip. Because of the spring-loaded second side the clip will fit into the notch and engage with it in a snap-like action as the nose-shaped tab passes the waist section.
The invention also concerns the use of panel elements in connection with fastening means and construction support structures according to the invention, and a method of manufacturing modular building elements defining a room, including the steps of assembling wall-forming panel elements to construction support elements by the inventive arrangement.
The elongate strip is fastened to a panel element by having its first edge inserted in a U-shaped bend of the sheet-like material of the panel and bolting the edge part and the panel together, or by pressing or gluing the panel material from both sides around the panel first edge in order to attach the fastening means to the panel.
These and other embodiments of the invention are defined in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an embodiment of the present invention,

FIG. 2 shows alternative embodiments of the present invention,

FIG. 3 shows in cross-section an example of a support structure of the present invention,

FIG. 4 shows an section of a wall structure showing the construction principles of the present invention;

FIG. 5 shows a wet-room module built according to the present invention;

FIG. 6 shows an enlarged detail of FIG. 5;

FIG. 7 shows a further embodiment of the inventive support structure;

FIG. 8 shows a wall seam structure to be used in connection with the present invention;

FIG. 9 shows a billet of a fastening means according to the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In FIG. 1 is shown in cross-section an embodiment of the present invention, where a clip denoted by a general reference number 1 is fastened to a wall-forming panel element 2, and which clip is inserted in a notch 3 of a support structure 4. The clip 1 is an integral part of an elongate strip made of a sheet-like material, and has a first edge S1, a second edge S2, and a first side 1 a and a second side 1 b. The first edge S1 is inserted in a U-shaped bend of a panel 2 of a sheet material of e.g. steel or aluminum, which is bolted, glued or pressed to form a joint between the panel and the clip. The joint is preferably continuous along the length of the panel and the strip, see also FIG. 9. The second side 1 b of the clip is slanted and ends at the second edge S2 that remains open and is not fastened to the panel 2. The support structure 4 may consist of a pole of an extruded aluminum profile.
In the support structure 4, the notch 3 is thus provided as a receiving means for clip 1, and has a corresponding first side 3 a and a second side 3 b. The notch 3 is arranged to receive the clip 1 in a locking engagement to fasten the panel element 2 to the support structure 4. A panel element usually has a number of clips spaced along the length of the vertical element side (see FIG. 9). Depending on the purpose, size and materials of the panel the amount of clips may vary, while the support structure usually takes the form of a continuous profile to which the clips can be attached anywhere. Typically the wall panel 2 is attached by its two ends to two vertical support structure profiles 4, whereby one panel 2 has one clip 1 at each end of it. The horizontal seams between stacked similar or identical wall-forming panels are also discussed later, but are not part of the invention as such.
The clip 1 has a cross-section that including a generally nose-shaped tab 1 c on the first side 1 a. Correspondingly, at the receiving notch 3, it has an integral element 6 formed as a tongue on its first side 3 a. The wall-forming panel element 2 is fastened to the support structure 4 by means of aligning the clip or clips 1 attached to the panel with the notches 3 on the support structure 4, and by pressing the panel 2 element against the support structure. The nose-shaped tab 1 c of the clip will slide over the tongue-shaped element 6 and become engaged with it in a snap-like action. Simultaneously, the second and free side 1 b of the clip 1 will become and remain spring-loaded against the second side 3 b of the notch 3. As is shown in more detail in FIG. 7, the surface of element 6 is provided with grooves to increase friction and thus to keep the clip 1 firmly in its place once inserted.
The spring-loading and secure fastening of the clip in the notch is based on a very precise design of the clip and the notch. The design considerations includes the shapes of the tab and tongue elements 1 c and 6, the largest width A of the clip 1 and the smallest width B of the waist portion of the notch, and their internal relations, and the fact that the second edge S2 of the clip is free to yield during insertion of the clip into the notch, and will act as a spring-loaded fixture against wall 3 b, once assembled. The spring load on the clip and the snap-action like fastening depend on the combination of all features mentioned above, and the assembly needs to be carefully designed for each particular construction.
The support structure 4 may have a recess 5 in the form of a longitudinal groove along the support structure profile, to accommodate e.g. a rubber gasket 9. The purpose of the gasket is to make sure the panel structure is waterproof, not allowing any moisture to enter the inner side (here the upper side) of the panel and the clip fastening means as shown.
Reference is now made to FIG. 2 that shows another embodiment of the clip and notch arrangement of FIG. 1. Here, the panel 2A may consist of a sheet of glass or some other material that cannot be bent like the metal sheet 2 of FIG. 1 In this case, a separate fastener 2B is provided, that secures the second edge S2 of clip 1 to the panel 2A. The inventive arrangement may also include release means 10 for detaching the wall-forming panel element from the support structure. The release means may consist of an empty but inflatable tube 10 of e.g. rubber. It may be included in the delivery of the wall panel, or it may be inserted from above or below, whatever is more convenient. The first side 3 b of the notch 3 includes a recess 3 c, against which the tube 10 may rest and it also provides the necessary space for sliding it in between the notch and the clip 1. When the tube is inflated, hydraulic fluid or air is pumped into it through a valve (not shown), whereby it will expand and push the nose-shaped tab 1 c of the clip off the tongue 6. The pressure in tube 10 need to work against the spring force exerted on the clip at its second edge S2, but once it is sufficient, it will release the interlocking engagement between the clip and the notch, and the wall panel 2 can be removed by pulling it outwards from the support structure 4. This enables an easy change of wall elements.
Similarly the arrangement may also or alternatively include assembly means 11 for assembling the wall-forming panel element to the support structure. The assembly means may consist of a similar empty but inflatable tube of rubber 11 as the release means 10, included in the original installation of the wall panel or inserted from above or below. In this case, the pace for the tube is provided between the second sides 1 b and 3 b of the clip 1 and notch 3, respectively. When the tube 11 is inflated, it will expand and push the nose-shaped tab 1 c of the clip towards the tongue 6 to secure the interlocking engagement between the clip and the notch, e.g. to secure that the fastening is not coming loose or is damaged during the assembly work or transfer of a wet-room module. After assembly the tube may be removed.
In FIG. 3 is shown a support structure 12 having four notches 13 a-13 d carved out. In any one or all of these, wall elements 14 a-14 d with clips 15 a-15 d may be fastened as shown like in FIG. 1. The versatility of the inventive arrangement and the simple fastening thus offered becomes apparent from FIG. 3. It is clear that both fastening and detachment of the wall panels 14 a-14 c may be carried out from the inside, i.e. the front side of the panel itself. No destructive or difficult operations behind the panel are needed. Inner corners and outer corners are equally well and easily covered. This is further demonstrated in FIG. 4, where a wall structure is shown, including two support structure members, a corner pole 12 and an intermediate pole 16, with wall panels 17 a and 17 b attached to form an inner corner of a wall, and a panel 18 on the outside. In a typical wet-room facility, the wall panels 17 a, 17 b may be attached as such and instantly providing a waterproof wall structure. On the outside, a decorative or otherwise suitable covering panel 18 may be attached, to conceal the support structure and e.g. electrical installations that may be present in the space 19 between the fastened elements. This construction also enables a room module to be installed in open space, where decorative panels may be needed on the outside surface. Such outside panels may be made of large glass, composite stone, or of decorative plate in any material.

Example

A typical 4 m²large wet-room cabinet or room module 20 is shown in FIG. 5. It consists of a floor element 21, with assembled heating pipes and floor drain pipe (not shown), that may be assembled and leveled on the intended installation site. The floor assembly, weighing about 80 kg, may include a steel sheet with a surface finish of vinyl flooring, plastic coating, ceramic tiling, composite stone plating, nano-ceramic plating, or some color treatment. The space under the floor element 20 is filled with wet concrete or with EPS (Expanded Polystyrene) cement on the construction site, and/or with a honeycomb strengthening structure next to the steel plate. Typical wet-room facilities are shown: a toilet 30, a wash basin with tap 31 and a shower 32.
The frame structure consists of vertical poles 22, horizontal beams 23 and joint modules (not shown). Here, seven poles each 2.4 m high and eight beams at the floor and ceiling levels make up the structure. The wall elements 24, piled two on top of each other and leaving a horizontal seam 24 a between them, may in this example be made of either 0.5-1.0 mm thick galvanized steel or aluminum plate formed and supported by hard mineral wool about 30 mm thick, or an aluminum structural panel with a honeycomb core. The surface finish options for the wall elements are plastic coating, ceramic tiling, artificial marble, composite stone, nano-ceramic plating or PVDF fluorocarbon resin coat, depending on the wall element material. Finally, a ceiling element (not shown) with illumination, ventilation and electricity fixtures is placed on top of the beam-reinforced support structure.
An enlarged section C of a corner of the cabinet 20 in FIG. 5 is shown in FIG. 6. The vertical corner pole 22 (see also FIG. 3) is supported by the C-beams 23 defining the floor space 21, and they are joined with joint pins 26 which are forced into the notch 3 of the poles 22. Leveling of the floor is done by height adjustment screws 27. The foundation 25 of the floor is done e.g. by concrete or EPS cement, as explained above. The same joint structure of the support construction is repeated for the ceiling. The joint structure is shown in detail in FIG. 7, where a notch in a support structure pole is schematically drawn. The first side of the notch is provided with an area 29 where the surface is rifled or grooved. The joint pin 26 shown in FIG. 6 may be inserted at the ends of the same notch 28 that stretches along the length of all the pole profile and which is also receiving the wall elements 24 for fastening. The grooved area 29 will keep the pins 26 firmly in place. The grooved area also keeps the clip 1 shown in FIGS. 1 and 2 in place, as has been earlier discussed.
In FIG. 8 is shown the seam 24 a between two vertically piled wall-forming panels 24. The seam structure is waterproof, and can be further secured by introducing a sealant in the cavity 33.
In FIG. 9 is shown a billet of a fastening means according to the invention. This exemplary fastening means consists of an elongate strip 1 d, with punched integral clip billets 1, which are to be bent to have a cross-section as shown in FIGS. 1 and 2. In the strip 1 d is also shown holes 1 e for bolt or dowels (not shown) to secure the clips to the panel element 2 as discussed in connection with FIG. 1.
It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.
Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment.
As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary. In addition, various embodiments and example of the present invention may be referred to herein along with alternatives for the various components thereof. It is understood that such embodiments, examples, and alternatives are not to be construed as de facto equivalents of one another, but are to be considered as separate and autonomous representations of the present invention.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
While the forgoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.

Claims

1. An arrangement for attaching panels to support structures including:

a panel element;

fastening means attached to said panel element comprising at least one elongate attachment strip made of a sheet-like material having a first edge:

said attachment strip having at least one integral tab having a second edge, said tab being formed as a clip protruding transversally from said attachment strip and having a first side and a second side,

a support structure having an elongate receiving means for said clip forming a notch with a cross-section having a first side and a second side, and

said notch being arranged to receive said clip in a locking engagement to fasten the panel element to said support structure,

wherein

the clip has a cross-section including a generally nose-shaped tab on said first side with said first edge being attached to the panel, said second side being slanted and ending at said second edge,

the notch has a cross-section having a waist part that is narrower than the dimension of the clip, including an integral element formed as a tongue on said first side, and

said panel element being intended to be engaged with said support structure by alignment of said at least one clip with said at least one notch, and by the appliance of force moving the panel element towards the support structure, whereby said nose-shaped tab of the clip is caused to slide over said tongue-shaped element to attach the panel to the support structure with a snap-like action.

2. An arrangement for attaching panels to support structures including:

a wall-forming panel element;

fastening means attached along the length of at least one vertical side of said panel element and comprising at least one attachment strip made of a sheet-like material having a first edge:

said attachment strip having at least one integral tab having a second edge, said tab being formed as a clip protruding transversally from said attachment strip and having a first side and a second side with a cross-section including a generally nose-shaped tab on said first side, with said first edge being attached to the panel and said second side being slanted and ending at said second edge,

a vertical support structure having a continuous receiving means for said clip forming a notch with a cross-section having a first side and a second side with a waist section that is narrower than the largest width of the clip, including an integral element formed as a tongue on said first side, and

said notch being arranged to receive and to be engaged with said clip in a locking engagement to fasten the wall-forming panel element to said support structure by appliance of force moving the panel element towards the support structure, whereby said nose-shaped tab of the clip is caused to slide over said tongue-shaped element to attach the panel to the vertical support structure with a snap-like action where said second edge will become and remain spring-loaded against the second side of the notch.

3. An arrangement according to claim 1, wherein the tongue-shaped element on the first side of said notch is at least partly grooved on the upper side in order to increase friction between the contact surfaces of the clip and the notch when assembled.

4. An arrangement according to claim 1, wherein the said second side of the clip is spring-loaded against said second side of the notch when assembled.

5. An arrangement according to claim 1, wherein support structure includes a recess along said elongate receiving means on the side being in contact with said panel element, said recess being adapted to receive a gasket.

6. An arrangement according to claim 1, including assembly means for assembling the panel element to the vertical support structure, wherein said assembly means consists of an inflatable tube situated between the second sides of said clip and said notch, whereby the assembly means when being inflated will push the nose-shaped tab of said clip towards said tongue to secure the interlocking engagement between the clip and the notch.

7. An arrangement according to claim 1, including release means for detaching the panel element from the support structure, wherein said release means consists of an inflatable tube situated between the first sides of said clip and said notch, whereby the release means when being inflated will push the nose-shaped tab of said clip off said tongue to release the interlocking engagement between said clip and said notch.

8. A vertical construction support structure for receiving wall-forming panels provided with clip-like fastening means along at least one edge of the panel, said structure comprising an elongate profile having at least one integral notch extending along the length of the profile for engagement with clip-like fastening means with a snap-like action, and having a cross-section with a first side and a second side, wherein said notch has a waist section formed on the first side by a tongue-shaped element pointing towards the second side.

9. A construction support structure according to claim 8, wherein the tongue-shaped element on the first side of said notch is at least partly grooved on its upper surface for increasing the friction between a fastening means inserted into the notch and the tongue-shaped element.

10. A construction support structure according to claim 8, wherein the support structure includes a recess for a gasket beside and parallel to said notch.

11. Fastening means for wall-forming panel elements to be attached to vertical support structures by engaging with an elongate notch provided in the support structures with a snap-like action, said fastening means comprising an elongate strip made of a sheet-like material having a first edge and at least one integral tab having a second edge, said tab being formed as a clip protruding transversally from said strip and having a first side and a second side, and wherein the clip has a cross-section including a generally nose-shaped tab on said first side, said second side being slanted and ending at said second edge, and wherein said clip is fastened to a wall-forming panel element at its first edge.

12. Fastening means for panel elements according to claim 11, wherein the elongate strip is fastened to a panel element by having said first edge inserted in a U-shaped bend of a sheet-like material of said panel and by securing the panel material from both sides to said first edge in order to attach said fastening means to said panel.