U.S. patent application number 11/072057 was filed with the patent office on 2006-09-21 for panel system and method.
Invention is credited to David J. Klimek.
Application Number | 20060207201 11/072057 |
Document ID | / |
Family ID | 37008846 |
Filed Date | 2006-09-21 |
United States Patent
Application |
20060207201 |
Kind Code |
A1 |
Klimek; David J. |
September 21, 2006 |
Panel system and method
Abstract
Some embodiments of the present invention include a panel system
for mounting on a structure with a plurality of fasteners. In some
embodiments, the panel system includes a first panel having an
outwardly extending flange configured to receive a plurality of
fasteners for coupling the first panel to the structure and a
second panel couplable with the first panel and having a first end
and a second end and a front face extending therebetween. The first
end of the second panel can include a leg extending outwardly in
direction substantially parallel to the front face. In some
embodiments, when the second panel is coupled to the first panel,
the leg extends across the flange and substantially covers the
flange and at least one of the plurality of fasteners located in
the flange.
Inventors: |
Klimek; David J.; (Mosinee,
WI) |
Correspondence
Address: |
MICHAEL BEST & FRIEDRICH, LLP
100 E WISCONSIN AVENUE
MILWAUKEE
WI
53202
US
|
Family ID: |
37008846 |
Appl. No.: |
11/072057 |
Filed: |
March 4, 2005 |
Current U.S.
Class: |
52/239 |
Current CPC
Class: |
A47F 5/0846
20130101 |
Class at
Publication: |
052/239 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1. A panel system for mounting on a structure, the panel system
comprising: a first panel having an outwardly extending flange
configured to receive a plurality of fasteners for coupling the
first panel to the structure; and a second panel couplable with the
first panel and having a first end and a second end and a front
face extending therebetween, the first end including a leg
extending outwardly in direction substantially parallel to the
front face; wherein, when the second panel is coupled to the first
panel, the leg extends across the flange and substantially covers
the flange and at least one of the plurality of fasteners located
in the flange.
2. The panel system of claim 1, wherein the first panel includes a
front face, and wherein, when the second panel is coupled to the
first panel, the front face of the first panel and the front face
of the second panel are substantially aligned along an imaginary
plane.
3. The panel system of claim 1, further comprising a second leg
extending outwardly from the first end of the second panel in a
direction substantially parallel to the first leg.
4. The panel system of claim 3, wherein, when the second panel is
coupled to the first panel, the second leg engages the flange to
orient the second panel with respect to the first panel.
5. The panel system of claim 3, wherein the first leg extends
outwardly a first distance from the first end of the second panel
and the second leg extends outwardly a second distance from the
first end of the second panel, the first distance being greater
than the second distance.
6. The panel system of claim 3, wherein together the first and
second legs define a recess therebetween, and wherein, when the
second panel is coupled to the first panel, the flange extends into
the recess.
7. The panel system of claim 3, wherein the first panel includes a
front face, wherein the flange includes a shoulder extending along
the flange in a direction substantially perpendicular to the front
face of the first panel, and wherein, when the second panel is
coupled to the first panel, the second leg is engageable with the
shoulder to orient the second panel relative to the first
panel.
8. The panel system of claim 1, wherein the first panel includes a
first face plate, a second face plate, and a mounting flange
extending therebetween for receiving fasteners to secure the first
panel to the structure.
9. The panel system of claim 8, wherein together the first panel,
the second panel, and the mounting flange define a channel for
receiving a support.
10. The panel system of claim 9, wherein the support is moveable
along the channel between a plurality of positions relative to the
mounting flange.
11. The panel system of claim 9, wherein one of the first face
plate and the second face plate includes an outwardly extending
lip, the lip extending across the mounting flange for securing the
support in the channel.
12. The panel system of claim 1, wherein one of the first panel and
the second panel includes an outwardly extending lip, wherein, when
the second panel is coupled to the first panel, the lip extends
outwardly from the one of the first panel and the second panel
across at least a portion of the leg, and wherein the lip and the
leg define a channel for receiving a support.
13. The panel system of claim 12, wherein the support is moveable
along the channel between a plurality of positions relative to the
mounting flange.
14. The panel system of claim 12, wherein an other of the first
panel and the second panel includes a second lip, wherein, when the
second panel is coupled to the first panel, the second lip extends
outwardly from the other of the first panel and the second panel
across at least a second portion of the leg to secure the support
in the channel.
15. The panel system of claim 1, wherein the flange defines a
groove configured to receive the plurality of fasteners and to
orient the plurality of fasteners along the flange, and wherein,
when the second panel is coupled to the first panel, the leg
extends across the groove substantially covering the groove.
16. The panel system of claim 15, wherein, when at least one
fastener is located in the groove, the at least one fastener is
substantially recessed in the groove with respect to a forward
surface of the flange.
17. A panel system for mounting on a structure, the panel system
comprising: a first panel including a front face and an outwardly
extending flange, the flange being configured to be secured to the
structure with a plurality of fasteners and having a shoulder
extending along the flange in a direction substantially
perpendicular to the front face; and a second panel having a first
end and a second end and a front face extending therebetween, the
first end including a forward leg extending outwardly in a
direction substantially parallel to the front face and a rearward
leg extending outwardly in a direction substantially parallel to
the forward leg, together the forward leg and the rearward leg
defining a recess, the flange being engageable in the recess to
couple the first and second panels, the rearward leg being
engageable with the shoulder to orient the second panel with
respect to the first panel.
18. The panel system of claim 17, wherein the rearward leg extends
outwardly a first distance from the first end of the second panel
and the forward leg extends outwardly a second distance from the
first end of the second panel, the second distance being different
than the first distance.
19. The panel system of claim 17, wherein the second panel defines
a mounting flange extending across the front face, the mounting
flange being configured to be secured to the structure with
fasteners.
20. The panel system of claim 19, wherein the mounting flange at
least partially defines a channel for receiving a support, the
support being moveable along the channel between a plurality of
positions relative to the mounting flange.
21. The panel system of claim 20, wherein the front face of the
second panel includes an outwardly extending lip, and wherein, when
the second panel is coupled to the first panel, the lip extends
across at least a portion of the forward leg to secure the support
in the channel.
22. The panel system of claim 17, wherein one of the first panel
and the second panel includes an outwardly extending lip, and
wherein, when the second panel is coupled to the first panel, the
lip extends across at least a portion of the forward leg.
23. The panel system of claim 22, wherein the lip and the forward
leg define a channel for receiving a support, and wherein the
support is moveable along the channel between a plurality of
positions relative to the forward leg.
24. The panel system of claim 23, wherein an other of the first
panel and the second panel includes a second lip, wherein, when the
second panel is coupled to the first panel, the second lip extends
outwardly from the other of the first panel and the second panel
across at least a second portion of the forward leg to secure the
support in the channel.
25. The panel system of claim 17, wherein the flange includes a
groove for locating the plurality of fasteners along the
recess.
26. The panel system of claim 25, wherein, when at least one
fastener is located in the groove, the at least one fastener is
substantially recessed with respect to a forward surface of the
flange.
27. The panel system of claim 17, wherein, when the flange is
engaged in the recess, the forward leg extends across the flange in
a direction substantially parallel to the front face of the second
panel substantially covering the flange and the plurality of
fasteners.
28. The panel system of claim 17, wherein the second end of the
second panel includes an outwardly extending flange configured to
be secured to the structure with a second plurality of fasteners,
and further comprising a third panel couplable with the second
panel and having an outwardly extending leg, the leg of the third
panel being engageable with the flange of the second panel to
secure the third panel to the second panel.
29. A method of assembling a panel system for a structure, the
panel system including a first panel and a second panel, the first
panel having a front face and an outwardly extending flange, the
second panel having a first end, a second end, and a front face
extending therebetween, the first end including a leg extending
outwardly in direction substantially parallel to the front face,
the method comprising: inserting a fastener through the flange and
into the structure to secure the first panel to the structure;
positioning the second panel adjacent to the first panel and
aligning the front face of the first panel with the front face of
the second panel; and moving the leg across the flange and the
fastener and substantially covering the flange and the fastener
with the forward leg.
30. The method of claim 29, wherein the first panel includes a
groove, and wherein the act of inserting a fastener through the
flange and into the structure to secure the first panel to the
structure includes the act of positioning the fastener along the
groove.
31. The method of claim 29, further comprising the act of inserting
a second fastener through the second panel and into the structure
to secure the second panel to the structure.
32. The method of claim 29, wherein the first end of the second
panel includes a second leg extending outwardly from the first end
in a direction substantially parallel to the first leg, wherein the
flange includes a shoulder extending along the flange in a
direction substantially perpendicular to the front face of the
first panel, and wherein the act of aligning the front face of the
first panel with the front face of the second panel includes the
act of engaging the shoulder with the second leg to orient the
second panel with respect to the first panel.
Description
BACKGROUND OF THE INVENTION
[0001] Panel systems, such as those often used in workshops and
store displays, typically include one or more interlocking panels.
The interlocking panels are typically secured to a building
structure to provide a location for displaying or storing items,
such as store merchandise, tools, storage containers, and the
like.
SUMMARY OF THE INVENTION
[0002] Some embodiments of the present invention provide a panel
system for mounting on a structure with a plurality of fasteners,
wherein the panel system comprises a first panel having an
outwardly extending flange configured to receive a plurality of
fasteners for coupling the first panel to the structure; and a
second panel couplable with the first panel and having a first end
and a second end and a front face extending therebetween, the first
end including a leg extending outwardly in direction substantially
parallel to the front face; wherein, when the second panel is
coupled to the first panel, the leg extends across the flange and
substantially covers the flange and at least one of the plurality
of fasteners located in the flange.
[0003] In some embodiments, a panel system for mounting on a
structure with a plurality of fasteners is provided and comprises a
first panel including a front face and an outwardly extending
flange, the flange being configured to be secured to the structure
with a plurality of fasteners and having a shoulder extending along
the flange in a direction substantially perpendicular to the front
face; and a second panel having a first end and a second end and a
front face extending therebetween, the first end including a
forward leg extending outwardly in a direction substantially
parallel to the front face and a rearward leg extending outwardly
in a direction substantially parallel to the forward leg, together
the forward leg and the rearward leg defining a recess, the flange
being engageable in the recess to couple the first and second
panels, the rearward leg being engageable with the shoulder to
orient the second panel with respect to the first panel.
[0004] One embodiment of the present invention provides a method of
assembling a panel system structure, wherein the panel system
includes a first panel and a second panel, the first panel having a
front face and an outwardly extending flange, the second panel
having a first end, a second end, and a front face extending
therebetween, the first end including a leg extending outwardly in
direction substantially parallel to the front face, and wherein the
method comprises inserting a fastener through the flange and into
the structure to secure the first panel to the structure;
positioning the second panel adjacent to the first panel and
aligning the front face of the first panel with the front face of
the second panel; and moving the forward leg across the flange and
the fastener and substantially covering the fastener and the flange
with the forward leg.
[0005] Further aspects of the present invention, together with the
organization and operation thereof, will become apparent from the
following detailed description of the invention when taken in
conjunction with the accompanying drawings, wherein like elements
have like numerals throughout the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of panel system according to an
embodiment of the present invention.
[0007] FIG. 2 is an enlarged perspective view of a portion of the
panel system shown in FIG. 1.
[0008] FIG. 3 is an exploded perspective view of a portion of the
panel system shown in FIG. 1.
[0009] FIG. 4 is a side view of one panel of the panel system shown
in FIG. 1.
[0010] FIG. 5 is an enlarged end view of a portion of one panel of
the panel system shown in FIG. 1.
[0011] Before the various embodiments of the present invention are
explained in detail, it is to be understood that the invention is
not limited in its application to the details of construction and
the arrangements of components set forth in the following
description or illustrated in the drawings. The invention is
capable of other embodiments and of being practiced or of being
carried out in various ways. Also, it is to be understood that
phraseology and terminology used herein with reference to system or
element orientation (such as, for example, terms like "front",
"back", "up", "down", "top", "bottom", and the like) are only used
to simplify description of the present invention, and do not alone
indicate or imply that the system or element referred to must have
a particular orientation. The panel system referred to in the
present invention can be installed and operated in any orientation
desired. In addition, terms such as "first", "second", and "third"
are used herein and in the appended claims for purposes of
description and are not intended to indicate or imply relative
importance or significance.
DETAILED DESCRIPTION
[0012] FIGS. 1-5 illustrate a wall covering or panel system 10
mountable on a structure 12, such as temporary or permanent walls,
dividing walls, ceilings, structural walls, store displays, and the
like. In the illustrated embodiment of FIGS. 1 and 2, the structure
12 includes a wall 16 and a number of structural supports 18 spaced
along the wall 16. As used herein and in the appended claims, the
term "structure" includes any structural element to which the panel
system 10 can be mounted, and includes without limitation walls,
floors, ceilings, joists, sub-joists, studs, I-beams or beams
having other shapes, struts, rafters, headers, girders, trusses,
and the like.
[0013] The panel system 10 can have any shape desired, such as a
round shape, a rectangular, triangular, or other polygonal shape,
an irregular shape, and the like. By way of example only, the panel
system 10 of the illustrated embodiment has a generally rectangular
shape, and includes a number of panels 22.
[0014] With reference to the illustrated embodiment of FIGS. 1-5,
three panels 22a, 22b, 22c are shown by way of example only. Each
of the illustrated panels 22a, 22b, 22c can have a front face 24, a
rear face 26, sides 28, 30, upper ends 32, and lower ends 34 (with
reference to the orientation of the panels 22a, 22b, 22c shown in
FIGS. 1-5). Together, the front face 24, rear face 26, sides 28,
30, upper ends 32, and lower ends 34 of each panel 22a, 22b, 22c
can define an interior space 38.
[0015] While reference is made herein to embodiments in which the
panel system 10 includes three panels 22a, 22b, 22c, it should be
understood that in other embodiments one, two, four or more panels
22 can also or alternatively be used, depending upon one or more of
the intended use for the panel system 10, the space available for
the panel system 10, the desired orientation of the panel system
10, and/or the dimensions of the individual panels 22a, 22b,
22c.
[0016] Each of the illustrated panels 22a, 22b, 22c can include
couplers for engaging adjacent panels 22a, 22b, 22c. In the
illustrated embodiment, each panel 22a, 22b, 22c includes a first
coupler 42 and a second coupler 44 located on respective lower and
upper ends 34, 32. The first couplers 42 can include legs 46, 48,
which extend downwardly from the lower ends 34 of the panels 22a,
22b, 22c in a generally parallel direction. Together, the legs 46,
48 and the lower ends 34 define channels or recesses 50.
[0017] In the illustrated embodiment, the first or forward leg 46
of each panel 22a, 22b, 22c extends a first distance from the lower
end 34 of each panel 22a, 22b, 22c and the second or rearward leg
48 of each panel 22a, 22b, 22c extends a second, shorter distance
from the lower end 34 of each panel 22a, 22b, 22c. In other
embodiments, the legs 46, 48 can be similarly sized, or
alternatively, the second leg 48 can extend a greater distance from
the lower end 34 of each panel 22a, 22b, 22c than the first leg
46.
[0018] The second coupler 44 of each panel 22a, 22b, 22c can
include an outwardly extending mounting flange 52. In the
illustrated embodiment of FIGS. 3-5, upper ends 54 of the mounting
flanges 52 include shoulders 56, which extend along the mounting
flanges 52 in a direction substantially parallel to the upper end
32 of each of the panels 22a, 22b, 22c. The mounting flanges 52 can
also define grooves 60 which extend along a front surface of each
of the mounting flanges 52 in a direction substantially parallel to
the upper end 32 of each of the panels 22a, 22b, 22c. As explained
in greater detail below, the mounting flanges 52 are sized to
receive fasteners 72 for securing the panels 22a, 22b, 22c (and
therefore, the panel system 10) to a building structure 12. In
embodiments in which the mounting flanges 52 provide grooves 60,
the grooves 60 are configured to receive fasteners 72 so that the
fasteners 72 or portions of the fasteners 72 (e.g., the heads of
the fasteners 72) can be at least partially recessed within the
mounting flanges 52. In addition, and as explained below, in
embodiments having legs 46, 48, the legs 46 of adjacent panels 22a,
22b, 22c can be sized to extend across and substantially cover the
fasteners 72 or portions of the fasteners 72 (e.g., the heads of
the fasteners 72) located on the grooves 60.
[0019] As shown in the illustrated embodiment, each panel 22a, 22b,
22c can include first and second couplers 42, 44. However, in other
embodiments (not shown), one or more of the panels 22a, 22b, 22c
can have only one coupler. In these embodiments, panels 22 having
only one coupler can be arranged at opposite ends of the panel
system 10 so that each coupler is interconnected with another
coupler and so that the panel system 10 has a uniform outer
surface. For example, a lower-most panel 22a can include a single
upwardly extending coupler 44, which is engageable with one of the
couplers of an intermediate panel 22b. Alternatively or in
addition, an upper-most panel 22c can include a single downwardly
extending coupler 42, which is engageable with a second coupler of
the intermediate panel 22b.
[0020] In other embodiments, one or more of the panels 22a, 22b,
22c can include three or more outwardly extending couplers. For
example, in some embodiments, third and fourth couplers can extend
laterally outwardly from one or both sides 28, 30 of one or more of
the panels 22a, 22b, 22c. In these embodiments, the third and
fourth couplers can be engageable with corresponding couplers on
adjacent panels to form an interconnected wall. Alternatively or in
addition, the third and fourth couplers can provide hangers for
supporting tools, shelves, and like elements on the panel system
10.
[0021] In the illustrated embodiment of FIGS. 1-5, each of the
panels 22a, 22b, 22c also includes a first face plate 64 and a
second face plate 66. As shown in FIGS. 2-4, the first and second
face plates 64, 66 extend between the sides 28, 30 of the panels
22a, 22b, 22c and define mounting flanges 68 extending
therebetween. As explained in greater detail below, the mounting
flanges 68 are sized to receive fasteners 72 for securing the
panels 22a, 22b, 22c (and therefore, the panel system 10) to the
structure 12. Lips 76, 78 extend outwardly from the first and
second face plates 64, 66 respectively and extend across at least a
portion of the mounting flanges 68. In the illustrated embodiment
of FIGS. 2-5, lips 80, 82 extend outwardly from the first and
second face plates 64, 66 across portions of the first and second
couplers 42, 44 of each of the panels 22a, 22b, 22c.
[0022] As shown in FIGS. 3 and 4, in some embodiments of the
present invention, the panels 22a, 22b, 22c can include one or more
interior supports 88 for reinforcing and supporting the panels 22a,
22b, 22c. In the illustrated embodiment of FIGS. 3-5, a number of
interior supports 88 extend through at least a portion of the
interior space 38 of each of the panels 22a, 22b, 22c and are
connected to interior sides of one or more of the front face 24,
the rear face 26, the upper end 32, and the lower end 34 of each of
the panels 22a, 22b, 22c. As also shown in the embodiment of FIGS.
3-5, the interior supports 88 can be located in a number of
locations throughout the interior spaces 38 and can be oriented in
a number of orientations.
[0023] For example, one or more interior supports 88 can extend
through the interior space 38 of one or more of the panels 22a,
22b, 22c between an interior side of the front face 24 and the
interior side of the rear face 26 and in a direction substantially
parallel to the upper end 32. Other interior supports 88 can extend
through the interior space 38 at an angle with respect to one or
both of the upper and lower ends 32, 34. In other embodiments, two
or more interior supports 88 can intersect and/or be
interconnected.
[0024] Each of the panels 22a, 22b, 22c can also include insulation
90. For example, in some embodiments, the interior space 38, and/or
portions of the interior space 38 can be at least partially filled
with sound-absorbing material and/or thermal insulation. In other
embodiments, at least a portion of the interior space 38 can define
vacuum cavities having little or no air. Such vacuum cavities can
prevent and/or reduce the transmission of sound and/or thermal
energy through the panel system 10.
[0025] The panel system 10 can be mounted in any orientation, such
as in a vertical orientation (i.e., with the upper and lower ends
32, 34 substantially perpendicular to a floor or a ceiling 92), a
horizontal orientation (i.e., with the upper and lower ends 32, 34
substantially parallel to a floor or a ceiling 92), or in any other
orientation desired (i.e., with the upper and lower ends 32, 34 at
an angle between about 90 degrees and about 0 degrees with respect
to a floor or a ceiling 92). The panel system 10 of the illustrated
embodiment of FIGS. 1-5 is oriented substantially horizontally,
with the upper and lower ends 32, 34 of the panels 22a, 22b, 22c
substantially perpendicular to the structural supports 18 and
substantially parallel to the floor 92. In alternate embodiments,
the panel system 10 can have other orientations with respect to the
building structure and its structural support(s) 18, typically
determined at least in part by space constraints, the orientation
of the structural support(s) 18, and/or the spacing between
structural supports 18.
[0026] One or more fasteners 72 can be employed to secure the
panels 22a, 22b, 22c (and therefore, the panel system 10) to a
building structure 12. In such cases, fasteners 72 can connect any
part, such as the front face 24, the rear face 26, either end 28,
30, the upper end 32, or the lower end 34 of any one of the panels
22a, 22b, 22c to the building structure 12, and can extend through
attachment holes 96 in the panels 22a, 22b, 22c for this purpose.
Any conventional fastener can be employed to secure the panels 22
as just described, such as screws, nails, rivets, pins, posts,
clips, clamps, inter-engaging elements, and combinations of such
fasteners.
[0027] In the illustrated embodiment of FIG. 3, fasteners 72 pass
through attachment holes 96 in mounting flange 52, 68 thereby
securing the panels 22a, 22b, 22c to the structural supports 18. In
some embodiments, the attachment holes 96 are preformed to simplify
installation of the panel system 10. In other embodiments, the
mounting flanges 52, 68 can include one or more grooves 100 for
locating the fasteners 72. In these embodiments, the grooves 100
can extend between the sides 28, 30 and can assist an installer in
selecting a location for drilling the attachment holes 96.
[0028] In some embodiments, the panels 22a, 22b, 22c are secured to
the structural supports 18 in two or more locations in order to
provide a more secure attachment to the structure 12 and/or to
distribute weight of the panel system 10 and the weight of items
supported by the panel system 10 along the structure 12. For
example, in the illustrated construction of FIG. 1, each panel 22a,
22b, 22c is secured to the structure 12 with fasteners 72 extending
through attachment holes 96 in the mounting flanges 52, 68 to
secure the panels 22 to four individual structural supports 18.
[0029] To mount the panel system 10 on a structure 12 according to
the present invention, an installer first selects a desired
mounting location for the panel system 10. If the desired mounting
location or intended use of the panel system 10 necessitates or
suggests the desirability of mounting the panel system 10 on a
structural support 18, the installer then locates one or more
structural supports 18 and orients the first panel 22a in the
desired location with respect to the structural support(s) 18
(i.e., with the upper and lower ends 32, 34 substantially
perpendicular to the structural support(s) 18 as shown in FIG. 1,
or alternatively, with the upper and lower ends 32, 34
substantially parallel to the structural support(s) 18).
[0030] After the installer selects an appropriate location and
orientation for the panel system 10, the installer secures the
first panel 22a to the structure 12 with one or more fasteners 72.
As mentioned above, in some embodiments, fasteners 72 can be
inserted into preformed attachment holes 96 located along the
mounting flanges 52, 68, or alternatively, the installer can drill
attachment holes 96 anywhere along one or both of the mounting
flanges 52, 68. In embodiments of the present invention having
grooves 100, the installer can use the grooves 100 to locate a
drill bit for drilling attachment holes 96.
[0031] As mentioned above, in some embodiments of the present
invention, such as the illustrated embodiment of FIGS. 3-5, the
panels 22a, 22b, 22c are secured to the structure 12 with fasteners
72 extending through mounting flange 52 and mounting flange 68. In
other embodiments, the panels 22a, 22b, 22c can be secured to the
structure 12 with fasteners 72 extending through only one of the
mounting flanges 52, 68. In still other embodiments, one or more
fasteners 72 can be inserted through another location (e.g., the
first face plate 64 and/or the second face plate 66) on the panels
22a, 22b, 22c to secure the panels 22a, 22b, 22c to the structure
12.
[0032] After the first panel 22a is secured to the structure 12,
the installer moves the second panel 22b toward the first panel
22a, aligning the first coupler 42 of the second panel with the
second coupler 44 of the first panel 22a. As shown in FIG. 3, the
installer then moves the first and second legs 46, 48 of the second
panel 22b into engagement with the mounting flange 52 of the first
panel 22a. In some embodiments of the present invention, the first
leg 46 of the second panel 22b extends across the groove 60a of the
first panel 22a, substantially covering any fasteners 72 located
along the mounting flange 52 to secure the first panel 22a to the
structure 12 and giving the panel system a "finished"
appearance.
[0033] As shown in FIG. 3, the first leg 46 of the second panel 22b
engages the upper end 32 of the first panel 22a and the second leg
48 of the second panel 22b engages the shoulder 56 of the second
panel 22b to maintain a predetermined spacing between the first and
second panels 22a, 22b. As also shown in FIG. 3, in some
embodiments, the engagement between the legs 46, 48 and the flange
52 orients the second panel 22b in a desired orientation with
respect to the first panel 22a (e.g., with the front face 24 of the
second panel 22b and the front face 24 of the first panel 22a
substantially aligned along an imaginary plane (not shown)) and the
structure 12.
[0034] Once the second panel 22b is coupled to the first panel 22a,
fasteners 72 can be inserted through attachment holes 96 in one or
both of the mounting flanges 52, 68 of the second panel 22b to
secure the second panel 22b to the structure 12.
[0035] After the first and second panels 22a, 22b are coupled
together and are secured to the structure 12, the installer moves
the third panel 22c toward the second panel 22b, aligning the first
coupler 42 of the third panel 22c with the second coupler 44 of the
second panel 22b. As shown in FIG. 3, the installer then moves the
first and second legs 46, 48 of the third panel 22c into engagement
with the mounting flange 52 of the second panel 22b. In some
embodiments of the present invention, fasteners 72 can be inserted
through attachment holes 96 in one or both of the mounting flanges
52, 68 of the third panel 22c to secure the third panel 22c to the
structure 12. This process can be repeated as necessary to form a
panel system 10 having the desired number of panels 22.
[0036] After the panels 22a, 22b, 22c are coupled together and are
secured to the structure 12, trim pieces 106 can be secured to one
or both sides 28, 30 of the panels 22a, 22b, 22c to provide a
"finished" appearance and to substantially enclose the interior
spaces 38, hiding the interior supports 88 and/or the insulation
90. In some embodiments, trim pieces 106 can also or alternatively
be secured to the upper and lower ends 32, 34 or to the first and
second couplers 42, 44 of the panels 22a, 22b, 22c.
[0037] As shown in FIG. 2, in some embodiments, hooks, shelves,
brackets, and other supports 108 can be secured to the panel system
10. In some embodiments, the panels 22a, 22b, 22c define channels
110 between the mounting flanges 68 and the first and second face
plates 64, 66. In the illustrated embodiment of FIGS. 2-4, lips 76,
78 extend across at least a portion of the channels 110 to maintain
supports 108 in the channels 110 and to prevent the supports 108
from moving outwardly away from the front face 24 of the panels
22a, 22b, 22c. In these embodiments, the supports 108 can be
inserted into the channels 110, and in some cases, can be moved
along the length of the channels 110 to a desired location. For
example, as shown in FIG. 2, hooks and shelf brackets can be
inserted into the channels 110 of the panels 22a, 22b, 22c and can
be moved along the channels 110 to desired locations. To install
the supports, an operator can remove one of the trim pieces 106 and
can slide one or more supports 108 along the channel 110 toward a
desired location. The operator can then replace the trim piece 106
to maintain the support 108 in the channel 110.
[0038] In other embodiments, the supports 108 can be positioned
between two panels 22a, 22b or 22b, 22c. In these embodiments, two
panels (e.g., panels 22a, 22b) can define channels 112. For
example, in the illustrated embodiment of FIG. 2, the upper end 32
and the lip 82 of the first panel 22a together with the lower end
34, lip 80, and leg 46 of the second panel 22b define a channel
112. Alternatively or in addition, the upper end 32 and the 82 lip
of the second panel 22b together with the lower end 34, lip 80, and
leg 46 of the third panel 22c define a channel 112. In these
embodiments, the supports 108 can be inserted into the channels
112, and in some cases, can be moved along the length of the
channels 112 to a desired location. To install the supports, an
operator can remove one of the trim pieces 106 and can slide one or
more supports 108 along the channel 112 toward a desired location.
The operator can then replace the trim piece 106 to maintain the
support 108 in the channel 112.
[0039] In embodiments having channels 110 located between the first
and second face plates 64, 66 and having channels 112 located
between the panels 22a, 22b or 22b, 22c, the channels 110, 112 can
be similarly sized to receive similarly sized and similarly
configured supports 108, or alternatively, the channels 110, 112
can be differently sized to receive differently sized and/or
differently configured supports 108.
[0040] In other embodiments, supports 108 can be secured to other
portions of the panels 22a, 22b, 22c (and therefore, the panel
system 10), such as the first face plate 64 or the second face
plate 66, using conventional fasteners.
[0041] Various alternatives and embodiments are contemplated as
being within the scope of the following claims particularly
pointing out and distinctly claiming the subject matter regarded as
the invention.
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