PANEL CONSTRUCTION AND CONNECTION SYSTEM
BACKGROUND OF THE INVENTION
This invention relates to simple light weight panel constructions, frame assemblies having connections to secure components to a perimeter frame of the panel and means to secure said panels in various arrangements in an office landscape.
Modern office landscaping systems, be they free standing or modular, typically comprise a panel with a structural frame enclosing a core. In these constructions, all loads are resolved within the frame which consists typically of wood or metal encasing a core usually having acoustic absorption properties. In larger panels, the frame may require substantial cross-bracing to maintain panel rigidity. This construction adds weight and reduces space for core material, thus reducing performance if the core material is acoustical in nature.
Panel frames are typically made from wood or steel. Wood frame components require substantial processing before they can be assembled into panel frames. In both cases the resultant panel is of considerable weight, and this imposes extra requirements and costs on the design of related components. This increased weight also increases the complexity of the system since heavy panels require strong fastening systems to hold them in place. The high weight and complex fastening systems also increase the difficulty in assembling and configuring the system.
The panels usually are constructed with flat or curved cores surrounded by a perimeter frame. Typically, the panels are assembled and interconnected in an edge to edge relationship to form an office workspace environment with combinations of continuous walls and corner joints. Common connection
systems, where a vertical edge is constructed with a male connection frame member which engages a vertical female frame member along the longitudinal axis on the adjacent edge are limited to configurations with standard panel sizes and set angles as disclosed for example by U.S. Pat. Nos. 5,054,255 and Can. Pat. Nos. 2,090,386. A significant drawback to this type of panel connection system is that panels must always be disposed in a similar manner thus limiting the flexibility of the system and any reconfiguration thereof.
In further typical office systems, changes in directions require the addition of transition posts to effect the angle change. While these posts offer limited flexibility, each variation of post must be fabricated, inventoried, and stored thus requiring extensive labour and cost to reconfigure such systems, reference being had to U.S. Pat. No. 4,101,838.
As noted above, most panels are constructed with a perimeter frame around the acoustic core. Typically the frame members are inter connected through means of a corner connector. These corner connections tend to be permanent and do not enable disassembly without damaging the adjacent frame members. This results from the corner connector having barbs which "lock" in the hollow cavities into which they are inserted. Examples of this type of component are disclosed by U.S. Pat. Nos. 5,054,255. The penalty for this type of construction is that it limits re-sizing of the panels during reconfiguration of the system.
Our Canadian Patent CA 2,188,858 published 27 April 1997 relates to a partition panel of generally rectangular outline having a plurality of marginal edges and a plurality of corners, and a perimeter frame assembly comprising a plurality of frame members extending along the marginal edges of the panel, and a plurality of corner connectors each located at a respective one of the corners of the panel and attaching between adjacent ends of said frame members, said frame members including spaced primary flanges, said frame members each further
including a double-walled web extending between said primary flanges and providing a lengthwise extending hollow cavity, each comer connector including a pair of tongues each fitting tightly into adjacent ends of the frame members via the associated hollow cavities to secure said frame members together at said comers of the panel. In a preferred embodiment each said comer connector has shoulders thereon which butt-up against respective adjacent ends of the perimeter frame members when the tongues of the comer connectors are fully inserted into said hollow cavities of said frame members, said tongues being in a close friction fit within said cavities. The comer connectors and the frame members are typically provided with grooves therein which engage marginal portions of fabric material extending over at least one of the major faces of the panel to provide an exterior covering therefor and/or to engage edge trim pieces to finish the edges of rigid panels. The frame members preferably comprise plastics extrusions of uniform cross-section throughout their lengths, said spaced primary flanges having a U-shaped groove therebetween directed outwardly of the panel and said corner connectors also having spaced comer flanges thereon mating with said primary flanges and having U-shaped recesses therebetween mating with the U- shaped recesses of said frame members. SUMMARY OF INVENTION Basic objectives of the invention are to alleviate disadvantages of and to improve on the prior art systems noted above by providing a partition panel and associated components as described hereafter.
According to one feature of the present invention each comer of a partition panel of a type generally according to that described in the above-noted Canadian Patent CA 2, 188,858 preferably has, adjacent a proximal end of at least one of said tongues, an associated boss, said boss extending normal to its associated tongue, which boss is adapted to non-rotatably mate with a recess of complimentary shape in a panel connector for securing panels together or to a
post or other fixtures (e.g. coat hook, legs or work surface brackets). Each comer connector also preferably has at least one aperture therein which is adjacent an associated one of said bosses and being adapted to receive a lug of a panel connector to further inhibit any tendency toward relative rotation. As a further feature of the invention each frame member preferably includes a flexible rib extending therealong intermediate said primary flanges and projecting outwardly of the margins of the partition panel for contacting a frame member of an adjacent panel when in use to prevent light and inhibit sound transmission therebetween. In one embodiment of the panel said primary flanges of the frame members are each provided with an outwardly directed ledge, said ledges being disposed adjacent the marginal edges of the panel such that said ledges encompass a rectangular area, and a sheet of rigid material seated in said rectangular area in close juxtaposition to said primary flanges to define a major face of the panel with said ledges extending along the perimeter of the rigid sheet and encompassing the latter.
In another embodiment of the panel a wall of said double-walled web of each frame member has a spaced pair of further flanges extending therealong and defining a center channel supporting one or more rigid panels in a plane intermediate the planes defined by said major faces of the panel either within said center channel or to one or both sides thereof in engagement with a respective one of said further flanges.
A panel assembly according to one embodiment of the invention comprises a plurality of panels and further includes panel-to-panel connectors securing adjacent pairs of panels together, each said panel-to-panel connector extending between an adjacent pair of said panels and having a pair of recesses each receiving a respective one of the bosses on said comer connectors of the adjacent panels and also having a pair of lugs thereon mating in special apertures
of the comer connectors to prevent rotation of the panel-to-panel connectors about the bosses of the comer connectors.
Another aspect of the invention provides a comer connector adapted to be located at a comer of a partition panel to secure together elongated frame members disposed generally at right angles to one another, said comer connector having a pair of tongues at right angles to one another adapted to be snugly fitted into end portions of lengthwise extending hollow cavities in said frame members, each comer connector having shoulders defined thereon which butt-up against respective adjacent ends of the elongated frame members when said tongues are fully inserted into said hollow cavities, each comer connector having, adjacent a proximal end of each of said tongues, a respective boss, said bosses extending normal to their associated tongues and thus being at right angles to one another and either of which bosses (depending on panel orientation) is adapted to mate, in use, with a corresponding recess in a panel connector for securing adjacent partition panels together or to a post.
The comer connector is preferably adapted for use with frame members having primary flanges defining a U-shaped groove therebetween, said comer connector having spaced comer flanges thereon defining said shoulders adapted to abut the ends of the frame members, said comer flanges defining U-shaped recesses adapted to mate with the U-shaped recesses of the frame members and said bosses being located between said spaced comer flanges.
The comer connector preferably has a pair of apertures therein each of which is located adjacent a respective one of said bosses for simultaneously receiving therein a lug of a panel connector as and when the latter is engaged with the boss next adjacent thereto thereby firmly securing said panel connector relative to said comer connector.
Other aspects of the invention include special panel-to-panel straight and perpendicular connectors, panel-to-post connectors and transition panel connectors as well as a special vertical post construction adapted to cooperate therewith.
Thus a further aspect of the invention provides a panel-to-panel connector adapted to extend between adjacent comers of adjacent panels to secure them together, each of which panels comprises a plurality of frame members extending along the marginal edges of the panel with a plurality of comer connectors each located at a respective comer of the panel and forming an attachment between adjacent ends of said frame members, each comer connector having at least one boss thereon, and wherein the panel-to-panel connector defines a body having a pair of sockets therein spaced apart and located adjacent opposing ends of said connector body, each socket adapted to non-rotatably receive therein a respective boss of each of the panel comer connectors associated with the adjacent panels.
A further aspect of the inveniton provides a panel-to-post connector adapted to secure a panel to a vertical post having a channel defining a re-entrant groove extending along at least one face of the post and wherein the panel comprises a plurality of frame members extending along the marginal edges of the panel with a plurality of comer connectors each located at a respective comer of the panel and forming an attachment between adjacent ends of said frame members, each comer connector having at least one boss thereon, said panel-to- post connector defining a body with a socket located adjacent one end thereof shaped to non-rotatably receive the boss of the panel comer connector therein, and the opposing end of the body having a head adapted to be received and retained in the re-entrant groove defined by said channel.
A further aspect of the invention provides a snap-in connector for effecting panel-to-panel, panel-to-post and post-to-post connections and comprising a central web having opposing spaced pairs of ramped shoulder- defining formations extending outwardly from opposing faces of said central web
to define an H-shaped configuration, said shoulder defining formations being adapted for snap-fit engagement with similarly spaced lengthwise extending formations on the margins of panels and/or posts for assisting in securing the same together. A further aspect of the invention provides a transition panel connector for securing adjacent panels together, each of which panels comprises a plurality of frame members extending along the marginal edges of the panel with a plurality of comer connectors each located at a respective comer of the panel and forming an attachment between adjacent ends of said frame members, each comer connector having at least one boss thereon, and wherein the transition connector defines a body having a socket adjacent a first end portion thereof and a second end portion being at right angles to said first end portion and having an aperture therethrough for receiving a threaded fastener for securing said second end portion at a selected point along a frame member of one panel while the boss of the comer connector of another panel is received in said socket of the transition connector, said socket having a non-circular shape corresponding to the boss to provide non-rotatable engagement therebetween.
A still further aspect of the invention provides a comer post for use in a panel system, said post having a plurality of comers and having, as seen in cross- section, a central core and a plurality of spaced apart tubular comer elements each defining one of the comers of the post and secured to said central core and extending parallel thereto, and a plurality of channel defining means extending lengthwise of said core and secured thereto intermediate associated pairs of said tubular comer elements and defining re-entrant grooves for receiving connector elements therein.
The foregoing and other advantages of the invention will be discussed in the following specification and claims, combined with reference to the appended drawings.
BRIEF DESCRIPTION OF THE VIEWS OF DRAWINGS
Fig. 1 is an exploded perspective view of an embodiment of the partition panel;
Fig. 2 is an exploded partial perspective view showing the manner in which the comer connector cooperates with the panel marginal frame members;
Fig. 3 is a perspective view of an end portion of a marginal frame member;
Fig. 4 is a cross-sectional view of the frame member showing panels associated therewith; Figs. 4A and 4B are further cross-sectional views of modified forms of marginal frame members;
Figs. 5, 6 and 7 are perspective views from different angles showing the modified comer connector;
Fig. 8 is a partially exploded end elevation view of a marginal frame member with certain panels associated therewith illustrating the various ways in which panels may be fastened or secured to the frame member;
Figs. 9A -9P are cross-section views taken through the frame member showing various panel constructions and illustrating the many variations and locations of panel boards, core boards, acoustic fillers, glazing panels, covering materials and fabrics etc. which may be utilized depending upon requirements;
Figs. 10, 11, 12 and 13 are perspective views of a panel-to-panel straight connector, a panel-to-panel perpendicular connector, a panel-to-post connector and a transition panel connector respectively;
Figs. 14, 15, 16 and 17 are top plan views of a modified form of the four connectors referred to in connection with Figs. 10-13 in the same order;
Fig. 18 is a perspective view illustrating application of a panel-to-panel straight connector;
Figs. 19, 20, 21, 22 and 23 are top plan, side elevation, first and second
end elevation views and bottom plan views respectively of a panel-to-panel straight connector as previously illustrated in Fig. 10 for example;
Figs. 24-27 are perspective views illustrating the manner in which the panel-to-panel perpendicular connector of Fig. 1 1 is utilized to secure panels together at right angles to one another;
Figs. 28-31 are top plan, front elevation, end elevation and bottom plan views respectively of the panel-to-panel perpendicular connector;
Figs. 32 amd 33 are perspective views illustrating the manner in which the panel-to-post connector of Fig. 12 is utilized to secure a panel to a comer post;
Figs. 34, 35 and 36 are perspective views taken from differing angles of the panel-to-post connector;
Fig. 37 is a further perspective exploded view illustrating various components, including the panel-to-post connector, panels and the like associated with the comer post;
Fig. 38 is a further perspective view illustrating a panel secured to the comer post by way of the panel-to-post connector;
Fig. 39 is a top plan view of a comer post illustrating its several features and the manner in which it cooperates with an H-connector as well as the panel- to-post connector;
Fig. 40 is a further to plan view of the comer post illustrating further the manner in which it cooperates with the panel-to-post connector;
Fig. 41 is a further top plan view of a comer post illustrating the manner in which it cooperates with various decorative trim sections and/or H-connectors; Figs. 42 and 43 illustrate a modified comer post profiles;
Figs. 44-47 together with Figs. 45 A and 47A are perspective views illustrating the manner in which transition panel connectors may be utilized to connect together panels of the same or differing height;
Figs. 48 and 49-1-2-3 are perspective views illustrating the sequence of steps for joining panels horizontally using the H-connector referred to previously;
Fig. 50-1-2-3 comprises perspective views illustrating the sequence of steps involved for joining panels vertically utilizing the aforementioned H connector; and
Fig. 51-1-2-3-4-5 comprises a series of perspective views illustrating the steps involved in assembling panels utilizing the aforementioned H connector, the panel-to-panel straight connector and the panel-to-post connector. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Fig. 1 is an exploded perspective view of a panel construction 100 showing a number of components somewhat similar to those illustrated in Fig. 2 of our above-noted Canadian Patent CA 2,188,858 to which reference may be had for further details including methods of manufacture etc. The partition panel is of generally rectangular outline and includes opposed major faces each comprising one or more layers such as a hardboard panel 102, a layer of foam
104 and a fabric covering 106. The perimeter frame assembly comprises elongated frame members 108 which, as in CA 2,188,858, comprise plastic PNC extrusions which extend along the marginal edges of the panel 100. A plurality of comer connectors 110 are each located at a respective one of the comers of the panel and they serve to attach together the adjacent ends of the frame members
108. These comer connectors 110 will be described in further detail hereafter.
As best seen in Figures 2, 3 and 4, the frame members include spaced apart generally parallel primary flanges 112 with a double walled web 114 extending between the primary flanges and providing a lengthwise extending hollow cavity 116. These spaced primary flanges as well as the spaced secondary flanges 118 define relatively wide U-shaped grooves therebetween which, when assembled, are directed outwardly of the periphery of the panel. Also, as described in CA 2,188,858, the frame members include groove defining
elements in the form of spaced pairs of secondary flanges 1 18 provided with retaining means in the form of tooth-like projections 120 formed on the interior distal end portions of both the primary and secondary flanges 112, 118 and directed into the interior or mouth portions of the grooves 122 to provide a re- entrant shape for retention of marginal edge portions of panel coverings therein. As in our Canadian patent, the free distal edges of the secondary flanges 118 are provided with enlargements 119 to enable snap-fit of various connectors into the U-shaped grooves between secondary flanges 118. Additionally, the distal ends of the primary flanges 112 are provided with outwardly directed ledges 124 which, in the assembled condition, are disposed adjacent the marginal edges of the panel such that the ledges substantially encompass a rectangular area. This enables a sheet of rigid panel material 102' to be seated in the rectangular area in close juxtaposition to the primary flanges 112 thereby to define a major face or faces of the panel with these ledges 124 extending along the perimeters of the rigid sheet and substantially encompassing the same.
Another feature of the frame members is the presence of a centrally located parallel pair of further flanges 126 extending away from the inner wall of the double walled web 114 with the parallel further flanges 126 defining a central channel. As will be seen hereinafter these further flanges are utilized to support one or more rigid panels in a plane generally intermediate the planes defined by the outer or major faces of the panel.
Another feature of the frame member comprises the presence of a flexible rib 130 extending lengthwise thereof and disposed in the aforementioned U- shaped groove defined by the primary flanges. This rib 130 is of a relatively soft flexible PNC-coextruded and integrally formed with the more rigid PNC utilized for the remainder of the frame member. The flexible rib is sufficiently wide as to extend outwardly beyond the primary and secondary flanges 112, 118 such that when the panels are assembled together light is prevented and sound is
inhibited from passing through the joint between the two panels. It is also noted that the rib 130 is curved about its longitudinal axis to ensure that it will always deflect to one side when pressure is applied to it and the rib is also offset from the center of the frame member 108 so there is less chance of it interfering with a flexible rib provided on the other panel that it joins.
The modified frame member of Fig. 4 A is similar to that described previously with like but "primed" reference numbers, e.g. 108' , designating similar parts. The first main difference is that the further flanges 126 of Fig. 4 are absent. These flanges are not required when there is no internal core to support (see e.g. Figs. 9B and 9D). The second main difference is that the toothlike projections 120' on the distal portions of flanges 112', 118' actually engage and/or overlap each other slightly to create a friction fit for the fabric covering as it is rolled into the retaining grooves 122'. The fabric is thus held taut across the faces of the panel assembly. Fig. 4B shows a modification very similar to that of Figs. 3 and 4, i.e. it includes the further flanges 126" . However, in common with Fig. 4 A it also includes the engaging and/or overlapping projections 120" to effect a friction fit for the fabric covering exactly as described above. Another option is to use an edge strip 166 as described hereafter to secure a facing panel as in Fig. 8 and/or a fabric covering.
The comer connectors 110 as best shown in Figures 2 and 5-7, serve to secure together the elongated frame members 108 generally at right angles to one another. Each comer connector 110 includes a pair of tongues 132 at right angles to one another and sized and arranged to be snugly fitted into the end portions of the lengthwise extending hollow cavities 116 in the frame members as described above. Each comer connector has pairs of shoulders 134 defined thereon which abut up against the respective adjacent ends of the elongated frame members 108 when the tongues 132 are fully inserted into the hollow cavities. As shown in the
drawings, each comer connector 110 has spaced comer flanges 136 thereon defining the shoulders which abut the ends of the frame members, these shoulders 134 also being provided with the aforementioned groove-defining means including secondary flanges similar to those provided in the elongated frame members 108 with the grooves 138 defined by the comer connectors communicating, with and being generally coplanar with the grooves 122 in the frame members thereby to enable marginal edges of the covering fabric 106 to be engaged and held in the grooves all around the perimeter of the panel including its comers by suitable means such as splines 140 (Fig. 1). It is also noted that the comer flanges 136 together with their associated secondary flanges define generally U-shaped recesses adapted to mate with the U-shaped recesses defined by the frame members.
Each corner connector 110 also has, adjacent a proximal end of each of the tongues 132, a respective short projection or boss 142 extending normal to its associated tongue, the two bosses for each comer connector 110 thus being at right angles to one another and, as noted, either one of the bosses 142 being adapted to mate, in use (and depending on orientation of the panel), with a correspondingly shaped recess in a panel-to-panel or panel-to-post connector for securing partition panels (see Figs. 10-13). It will be noted here that the bosses 142 are of octagonal outline although other outline shapes are possible. This multi-sided shape prevents the connector from rotating about the axis of the boss. Each boss is also internally threaded with the threads 144 being either formed directly in the plastics material or in a metal insert disposed in the boss 142 for receiving connector screws to be described hereafter. Each comer connector further includes a pair of rectangular apertures 146 each of which is located adjacent a respective one of the bosses 142 for simultaneously receiving therein a lug of a panel connector (to be described hereafter) as and when the connector is brought into engagement with the boss next adjacent thereto thereby firmly
securing the panel connector against twisting and rotation relative to the associated comer connector 110.
The symmetry of the panel described is worthy of mention. The comer connectors, with their dual sets of bosses 142 and apertures 146 allow the panels to be installed in almost any desired orientation as the panel effectively has no defined top, bottom, left or right side, front or rear and hence can be rotated and joined in any direction and fastened.
With further reference to Figs. 5-7 it will be noted that the comer connectors 110 possess a number of additional features. The tongues 132 are each provided with elongated openings 148 adjacent opposing sides thereof to provide a measure of flexibility allowing the tongue 132 to flex inwardly when being inserted into the hollow cavity 116 of the frame member. Outwardly extending shallow barbs 150 on the tongue edges provide a substantial factional fit. The tongue's distal end is also provided with bevelled comers for ease of insertion.
With reference to Fig. 7, the underside of the comer connector tongue shows a plurality of ribs 152 to provide for friction fit with the internal walls of the hollow cavity referred to above with suitable steps 154 being provided for engaging the frame member when fully inserted to provide additional support. The above-noted rectangular apertures 146 immediately adjacent the respective bosses 142, as previously noted, enable lugs on the connectors (to be described hereafter) to locate therein to prevent rotation of the connector on the octagon-shaped boss thus providing a solid panel-to-panel or panel-to-post connection. Additionally, these apertures provide for some ventilation of the interior cavity of the panel and allow for the possibility of routing small wires.
An additional notch 156 is provided on each comer connector intermediate the two bosses 142, again to receive a projection on the panel connectors used to further help prevent rotation of the connectors on the octagon-
shaped bosses 142.
Turning now to Fig. 8, the manner in which face boards 160 for defining the opposing major faces of the panel may be attached to the perimeter frame assembly will now be described. As will be seen, adhesive double sided tape 162 may be used or a layer of glue 164 or, alternatively, a rigid edge trim strip 166 of generally U-shape configuration may be arranged with the arrow shaped bead of the edge trim firmly engaged within the grooves which, in several other embodiments, are utilized to secure a covering fabric, including vinyl, material.
Thus, as a first example, double sided adhesive tape 162 is interposed between the margins of the face board 160 and the primary flange 112 of the frame member 108. Alternatively, in place of the double sided adhesive tape, a layer of glue 164, preferably one that does not dry out and become brittle so that it remains flexible to accommodate expansion and contraction, is interposed between the primary flange 112 and the margin of the face board 160 to hold the latter securely in place. Finally, by utilizing the edge trim 166 referred to above, the face board may be effectively secured to the frame members (as well as to the comer members) by means of the edge trim without the need for glue or double sided tape.
Figs. 9A-9P illustrate the tremendous number of varieties of combinations of panel configurations and coverings made possible by the present invention.
Fig. 9A shows an acoustic panel arrangement wherein there is disposed a central core board 170 located in the center channel 128 defined by the further flanges 126, with rectangular batts of glass fibre 172 being disposed in flanking relation to the core board 170. The major faces of the panel are defined by rigid glass fibre reinforced sheets 174 covered with an exterior layer of fabric 176, the marginal edges of which are secured in the previously noted retaining grooves.
Fig. 9B is a relatively simple structure with the interior of the panel being entirely hollow and the major surfaces being defined by a pair of rigid sheets 174
covered with any desired fabric material 176.
Fig. 9C is another variation wherein the panel is provided with cork facing boards 178 with a pair of rigid boards 180 being disposed in flanking relation to the further flanges 126 referred to previously. Relatively thick fibre boards 182 are provided on each side immediately inwardly of the cork facing boards 178.
Fig. 9D shows a simple arrangement employing either two glazing panels 182 or two vinyl faced panels 184, both of which are secured in place by the previously noted edge trim strip 166, glue 164 or tape 162. It is unnecessary to describe the structures illustrated in Figs. 9E-9P in further detail as the various permutations and combinations of structural arrangements will be readily apparent from the drawings and the notes thereon.
The various types of panel connectors will now be described, beginning with the panel-to-panel straight connector 190 illustrated in Figs. 10, 14, 18 and 19-23.
The function of the straight connector is best illustrated in Fig. 18. It will be seen here that the straight connector 190 secures two panels 100 together edge-to-edge in a straight or co-planar relationship. The connector 190 is used in the horizontal orientation illustrated in Fig. 18 as well as in a vertical orientation at the end of a panel section when one panel is stacked vertically on another panel (as will be seen hereinafter with reference to Fig. 51).
The connector 190 includes a somewhat elongated body having stiffening ribs as noted hereafter. The undersurface of the connector is provided with a spaced apart pair of shallow sockets 198 each of which is provided with an octagonal opening which is sized to receive the octagonal bosses 142 which are provided on the comer connectors of the adjacent panels as described previously. Once the straight connector 190 has been positioned, a pair of screws 194 are inserted through openings provided in the opposing ends of the connector 190,
which screws are threaded downwardly into the threaded central portions of the octagonal bosses 142 thereby to secure the straight connector firmly in place. The upper and lower surfaces of the connector 190 are provided with ribs to add strength so that the connector may resist twisting or bending due to panel movement. The connector is provided with slots or cut-outs 196 which serve to allow the connector to fit around the glides (not shown) provided on the bottom edges of pre-joined panels. These slots or cut-outs 196 lead into the respective sockets 198 of octagon shape. Other features include a downwardly extending lug 200 disposed at each of the opposing ends of the connector. These lugs 200 are designed to fit into the rectangular 146 apertures provided in the comer connectors adjacent the octagonal bosses 142 thereon. When fitted together these lugs 200 assist in supporting the connector 190 by preventing bending or twisting thereof relative to the comer connector 110. To further enhance this capability, the connectors are also provided with a pair of relatively short lugs 202, each being located in spaced relation to the associated primary lug 200 on the opposite side of the octagonal socket 198 referred to above. These short lugs 202 are shaped to cooperate and to enter into the previously referred to additional notches 156 which are provided on each comer connector 110 intermediate the two bosses 142 with these elements again helping to prevent rotation of the panel-to- panel straight connectors relative to the comer connectors.
The panel-to-panel perpendicular connectors 206 will now be described with reference to Figs. 11,15, Figs. 24-27 and Figs. 28-31. The function of the panel-to-panel perpendicular connector is best illustrated in Figs. 24-27. In this form of perpendicular connector 206, the connector is again provided with a somewhat elongated body, the opposing end portions of the body having a pair of shallow downwardly extending sockets 208 having octagonal recesses therein designed to snugly receive therein the octagonal bosses 142 of the respective comer connectors of panels 100 which are arranged at right angles to one
another. The opposing end portions of the connector are joined together via a somewhat raised or arched intermediate section 210 which provides sufficient clearance as to allow the connector to bridge or extend over the marginal edge 212 of the panel which is extending at right angles to the connector. As with the straight connector, the opposing end portions of the perpendicular connector 206 are provided with openings 214 for receiving a pair of screws 215 which extend into the bosses as previously described thereby to hold the panel-to-panel perpendicular connector firmly in place.
It should be noted that the perpendicular connector is used both at the top and the bottom of the panel to provide a firm attachment. Additionally, as illustrated in Fig. 26, the perpendicular connector 206 allows panels to be connected at right angles to one another at any point along the panel. Hence, as shown in Fig. 26, a self-tapping screw 216 passes downwardly through an additional hole 218 provided outwardly of the previously mentioned opening 214 for receiving the primary attachment screw, this self-tapping screw being threaded downwardly into the marginal frame member 108 at the selected location, with the other end of the perpendicular connector 206 being fixed to the boss 142 on the comer connector 110 of the next adjacent panel and secured by means of the primary screw 215. The perpendicular connector also has a series of outwardly projecting bevelled pairs of straight ledges 228 effectively surrounding the respective sockets 208, the pairs of ledges 228 being at right angles to one another and being spaced to provide for a snap-fit engagement of the ledges with and between the distal edge enlargements 119 of the secondary flanges of the comer connectors 110. The tight snap-fit engagement provided by these ledges 228 secures the perpendicular connectors 206 in place and further resists rotation of the connector about its associated boss when in use. This compensates for the absence of lugs (e.g. lugs 200) on the perpendicular connectors.
Referring to Figs. 28-31, various stiffening ribs are provided on connector 206 to provide the necessary strength and rigidity. A slot or cut-out portion 222 leads into each of the sockets 208 thus allowing the connector 206 to readily be placed around the glides (not shown) typically provided at the bottom of the panel assembly. The opposing end portions of the perpendicular connector are provided with the pair of smaller holes 218 to receive the self- tapping screws in the manner illustrated in Fig. 26 so that the connector 206' may be secured to an adjacent panel at any point along that panel as described above.
Panel-to-post connectors 230, as well as comer post configurations 232, are illustrated in Figs. 12, 16 and 32-40. Before describing this particular form of connector it seems advisable to describe the post 232 per se. The post comprises a hollow extrusion which is symmetrical about mutually transverse axes. The central core of the post is of square cross-section having a double wall construction with the inner wall 234 being connected to the outer wall 236 via diagonally disposed webs. The four comers of the post are defined by respective square cross-section tubular elements 238, each disposed outboard of its associated comer of the rectangular core via a short diagonally arranged web portion 240. Each tubular element 238 is provided with a pair of sloping shoulder-like profiles 242 which are dimensioned, shaped and spaced apart from one another so as to correspond with the profiles formed at the distal ends of the secondary flanges 118 of the peripheral frame members 108 thereby to permit various forms of connectors and trim strips to be snap-fitted thereonto.
Disposed between and spaced from the tubular elements 238 at the four comers of the post are spaced pairs of outwardly projecting somewhat L-shaped elements 244 directed toward each other and forming respective re-entrant channels 246 extending along each of the four sides of the comer post 232. These re-entrant channels 246 are provided (adjacent opposing sides of the mouth of the channel), with inwardly directed semi-circular grooves 248 within
these re-entrant channels being dimensioned and configured to receive the head portion of a panel-to-post connector to be described hereinafter. As will be seen hereinafter, these semi-circular grooves 248 cooperate with correspondingly shaped ribs formed on the head of the connector to assist in preventing the head of the connector from twisting out of the channel in the post during use.
The panel-to-post connector 230 per se is illustrated in several drawings, especially Figs. 34-36. The panel-to-post connector 230 includes a body portion having, adjacent one end thereof, a downwardly extending socket 250 of octagonal configuration for receiving the octagonal boss 142 of the panel comer connector. A slot or cut-out 252 in the side of the connector leads into this octagonal socket and allows the connector to be installed at the bottom of a panel by fitting around the panel glide although of course it will be realized that this same form of connector is quite suitable for use at the top of a panel as well. A rib pattern 254 is provided around this slot to create an elevated surface so that the nut on the glide (not shown) may be seen from the bottom of the panel as it is being tightened up against this connector. The top surface of the connector is also provided with a supporting rib 256 which strengthens the connector and helps to prevent it from twisting and bending in any way which would compromise its connection with the comer connector 110. The opposing end of the panel-to-post connector 230 is provided with the previously mentioned generally T-shaped head 258 which is designed to fit into the previously described channels 246 provided along each of the four sides of the post. On opposing sides of the neck of the T-head are provided the aforementioned shallow ribs 260 which mate with the shallow grooves 248 provided adjacent the mouth of the channel to secure the head 258 of the panel- to-post connector 230 in position and to aid in preventing it from accidentally twisting out of position once seated in the post channel.
With reference to Fig. 36, it will also be noted that the lower surface of
the connector 230 is provided at its one end distant from the head, with a downwardly depending lug 265 dimensioned and arranged to fit downwardly into the previously described aperture 146 in the comer connector to provide additional support for the connection between the comer connector 110 and the panel-to-post connector. An additional short lug 262 is positioned on the opposite side of the octagonal socket which fits into the notch 156 of the panel comer connector, again to provide additional stability.
The manner of installing the panel-to-post connector 230 is illustrated in Figs. 32, 33 and 37. With reference to Fig. 32, the connector 230 is oriented as shown and the head 258 is inserted into the channel 246 in the side of the post 232 following which the connector is rotated 90° into the horizontal position and then lowered downwardly such that the octagonal boss 142 on the panel comer connector engages the octagonal socket 250 on the underside of the panel-to-post connector. Following this, a screw 264 is inserted as illustrated in Fig. 32 to secure the components together.
The assembly procedure is further illustrated in Fig. 37. In Fig. 37 a pair of panels 100 are to be effectively joined at right angles to one another by way of the vertical comer post. For this arrangement, four panel-to-post connectors 230 are required, two for each panel, one at the top and one at the bottom of same. Also illustrated in Fig. 37 are a pair of flat trim strips 270, one of which is illustrated in Fig. 41, such trim strips having spaced apart snap-in flanges 272 which come into snap-fitting engagement with the shoulder-like profiles 242 formed on the tubular comer elements 238 of the post. Also shown is a square top plate 274 which is provided with suitable means (not shown) for effecting engagement with the top of the post to provide an attractive appearance.
Figs. 37, 39 and 41 illustrate, among other things, the H-connector 276 which is provided with opposing pairs 278, 280 of ramped shoulder defining formations extending outwardly from opposing faces of a central web and which
engage the shoulder-like profiles 242 formed on the tubular elements 238 at the four comers of the post 232 and which are also engageable with the enlarged formations formed on the distal edges of the secondary flanges 118 of the panel frame members 108. Hence, the H-connector thereby provides convenient panel- to-panel edge connections and panel-to-post connections thereby to supplement the action provided by the various panel-to-panel and panel-to-post connectors described above and also to aid in alignment of the panels and securement together during installation procedures.
It might also be pointed out here that other forms of post profiles or cross- sections are possible. Reference is had here to Figures 42 and 43 which illustrate some possible variations of posts (232' and 232").
A still further type of connector is known as a transition panel connector 286, this connector being illustrated in Figs. 13, 17 and Figs. 45A and 47A with the use of same being illustrated in Figs. 44-47 (including Figs. 45 A and 47A). The transition connector 286 of Fig. 13 comprises two body portions integrally formed at right angles to one another with one portion having an octagonal socket 288 formed thereon and with both portions also having an aperture 290 extending therethrough for receiving a screw. This transition connector 286 is very useful when joining panels together which are of unequal height. For example, as shown in Fig. 44, the lower height panel 100' is provided with a transition connector 286 at its one end with the socket 288 of the transition connector being mounted on the octagonal boss 142 of the panel comer connector and secured in place by a screw. Then, a self-tapping screw (not shown) is inserted through the aperture in the other section of the connector 286 and screwed into the central portion of the vertical frame member 108 of the next adjacent panel.
In Fig. 45A a modified transition connector 286' is provided with an octagonal socket 288' on both body portions, each portion having an aperture 290
for receiving a screw. Thus, comer connectors of equal height panels may be secured to one another as in Fig. 45 A via their respective bosses 142 which seat in the sockets 288' and are held in place by a pair of screws extending through apertures 290' into these bosses. Fig. 47A shows the same transition connector 286' with auxiliary apertures 292 at the distal end of the two body portions which receive self- tapping screws 294 which thread into a frame member 108 at the location determined by the respective heights of the adjacent panels.
Figures 44-46 illustrate the manner in which the several different types of connectors, namely the H-connectors 276, the panel-to-panel straight connectors 190, the panel-to-post connectors 230 and transition connectors 286 are utilized to effect securement of the several panels.
Figures 48 and 49 illustrate the manner in which the panels are joined horizontally by means of the H-connector 276. With reference to Fig. 49- 1 , the panels 100 are brought into general alignment and one panel is moved toward the other in the direction of the arrow. This panel is then angled slightly relative to the other panel (Fig. 49-2) to bring the H-connector 276 into partial engagement following which the panels are realigned with one another and pushed together (Fig. 49-3) to snap the H-connector into place in engagement with the vertical frame members 108 of the adjacent panels. The required panel-to-panel straight connectors 190 are then installed as described previously.
With reference to Fig. 50, which relates to the joining of panels vertically, firstly a plurality of H-connectors 276 are installed as shown (Fig.50-1). The side connector is then engaged first (Fig. 50-2) and then the panel is forced downwardly to engage the lower H-connectors 276 making use of a rubber mallet if necessary (Fig.50-3).
The several steps involved in the joining of panels together utilizing H- connectors 276, panel-to-panel straight connectors 190 and panel-to-post
connectors 230 are illustrated in Figs. 51-1 to Fig. 51-5. The relative positions of the panels 100 and post 232 and the locations of the several connectors 190, 230 and 276 are clearly shown in the illustrations and a further verbal description at this point is believed to be unnecessary. Following step 5, to continue adding panels, one starts again with step 1 and repeats the same sequence of steps.
Preferred embodiments of the invention have been described and illustrated by way of example. Those skilled in the art will realize that various modifications and changes may be made while still remaining within the spirit and scope of the invention. Hence the invention is not to be limited to the embodiments as described but, rather, the invention encompasses the full range of equivalencies as defined by the appended claims.