PANEL WITH DEFINED FASTENER LOCATION

Abstract

The disclosed subject matter pertains to an artificial panel comprising a spaced apart first wall and second wall. Each of the walls has an inside surface and an outside surface, and at least one fastener location configured at an outside surface of the at least one of the first wall and second wall of the panel. The fastener location is configured for receiving therethrough a fastener and wherein one or more ribs extend between the first wall and the second wall, along at least a portion of the panel, the fastener location being indicative of the location thereof.

Claims

1. A door system, comprising: a main body configured with a first face, a second face, a first edge rail-mount, a second edge rail-mount, a hinge stile, and a locking stile; a first rail and a second rail configured for interchangeably articulating to the first edge rail-mount and the second edge rail-mount; and at least one cladding panel configured for attaching over at least a portion of the first face of the main body, at either an upright orientation of the main body or a bottom-up orientation of the main body; wherein same components of the door system serve for both a left side door and a right side door.

2. The door system of claim 1, wherein at least the main body and the at least one cladding panel are made of molded material.

3. The door system of claim 1, wherein the at least one cladding panel is readily replaceable.

4. The door system of claim 1, wherein the first edge rail-mount and the second edge rail-mount are substantially identical.

5. The door system of claim 1, wherein the first rail and the second rail are substantially identical, interchangeable, and configured for top/bottom mount.

6. The door system of claim 1, wherein the main body is configured with symmetrically disposed apertures serving as windows or venting ports.

7. The door system of claim 6, wherein the at least one cladding panel conceals one or more of the apertures.

8. A corner coupler for securing two wall members, the corner coupler comprising: a generally omega-shaped member including: an inter-wall gap support; and a first wall support arm and a second wall support arm extending from the inter-wall gap support, the first wall support arm and the second wall support arm disposed at an angle of at least 90 with respect to the inter-wall gap support; wherein the first wall support arm has a free end configured with a first wall gripping edge; and wherein the second wall support arm has a free end configured with a second wall gripping edge.

9. The corner coupler of claim 8, wherein, when mounted at a corner of the two wall members of a structure, the inter-wall gap support of the corner coupler is configured for extending between facing edges of the two wall members, the first wall support arm and the second wall support arm being configured for bearing against respective portions of a first one of the two wall members and a second one of the two wall members, and the first wall gripping edge and the second wall gripping edge are configured for arresting within a groove extending at the first wall member and the second wall member, respectively.

10. The corner coupler of claim 9, wherein the first wall support arm and the second wall support arm are disposed at an angle greater than a nominal angular value thereof, so as to generate an engaging force bearing within the groove at the respective two wall members.

11. The corner coupler of claim 8, wherein the first and second wall support arms bear flush against the two wall members.

12. The corner coupler of claim 8, wherein the a generally omega-shaped member is made of metal sheet material or elastic sheet material.

13. The corner coupler of claim 8, wherein at least the first and second wall support arms are elastic.

14. The corner coupler of claim 8, being symmetric about a longitudinal axis thereof, or asymmetric as to conform to different shapes of the two wall members.

15. The corner coupler of claim 14, wherein the corner coupler is asymmetric, and having at least one of the following features: (i) a length of the first wall support arm is different from a length of the second wall support arm; (ii) a length of the first wall gripping edge is different from a length of the second wall gripping edge; or (iii) an angle of the first wall gripping edge with respect to the first wall support arm is different from an angle of the second wall gripping edge with respect to the second wall support arm.

16. The corner coupler of claim 8, wherein the inter-wall gap support includes a radial extent that is adjustable so as to span an entire gap between the two wall members or a portion thereof.

17. The corner coupler of claim 8, wherein the first wall support arm and the second wall support arm are spaced apart at 90, and wherein the inter-wall gap support has a central axis disposed at 135 with respect to the first and second wall support arms.

18. The corner coupler of claim 8, wherein the first wall gripping edge and the second wall gripping edge are disposed at a 90 with respect to the first and second wall support arms.

19. The corner coupler of claim 8, wherein at least one of the first wall gripping edge or second wall gripping edge extends from an edge of the first and second wall support arms, respectively, with an intermediate indent bulging inwards in direction of a space between the first and second support arms.

20. The corner coupler of claim 8, wherein the first wall support arm and the second wall support arm are disposed at an obtuse angle with respect to the inter-wall gap support.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

[0073] FIG. 1 illustrates a structure constructed with side walls composed of panels according to a first aspect of the present disclosure, the structure further configured with a modular, interchangeable door system according to a second aspect of the present disclosure;

[0074] FIG. 2A is a horizontal planer section along plane I in FIG. 1;

[0075] FIG. 2B is a vertical planer section along plane II in FIG. 1;

[0076] FIG. 3A is an enlarged view of the portion marked III in FIG. 2B;

[0077] FIG. 3B is a view of the portion illustrated in FIG. 3A from the outside thereof;

[0078] FIG. 4A is a schematic section through a panel according to the first aspect of the present disclosure, the panel illustrating different fastener locations;

[0079] FIG. 4B illustrates the panel of FIG. 4A, with fasteners secured at the different fastener locations;

[0080] FIGS. 4C and 4D illustrate a schematic section through a panel according to another example of the disclosed subject matter, illustrating yet another fastener location in FIG. 4C, with FIG. 4D illustrating a fastener secured at the fastener location;

[0081] FIG. 5A is a perspective front view of a front wall of a cabin, configured with two doors according to a second aspect of the present disclosure;

[0082] FIG. 5B is a perspective rear (inside) view of FIG. 5A;

[0083] FIG. 6A is a vertical section through an assembled door, taken along line V-V in FIG. 5A;

[0084] FIG. 6B is a horizontal section through an assembled door, taken along line VI-VI in FIG. 5A;

[0085] FIG. 7A is an exploded front perspective view of a right door seen in FIG. 5A;

[0086] FIG. 7B is a rear view of FIG. 7A;

[0087] FIG. 8 is an exploded perspective front view of the door's main body and the cladding panel at a right wing door configuration;

[0088] FIG. 9 is an exploded perspective front view of the door's main body and the cladding panel at a left wing door configuration;

[0089] FIG. 10 is an enlarged view of the portion marked X in FIG. 2A, illustrating a corner of the structure configured with a corner coupler according to a third aspect of the disclosure;

[0090] FIG. 11 is an enlarged top view of the portion marked XI in FIG. 10;

[0091] FIG. 12 is a perspective view of the corner coupler seen in FIG. 11; and

[0092] FIG. 13 is a top view illustrating a modification of the corner coupler articulated to wall members.

DETAILED DESCRIPTION OF EMBODIMENTS

[0093] Attention is first directed to FIGS. 1 and 2 of the drawings, illustrating a cabin generally designated 20, comprising walls 25 (front, rear and side walls), all made of horizontally disposed panels, said panels generally designated 30. The cabin further comprises a front door composed of a right wing door 40R and a left wing door 40L, roof 48, a floor 50 and other elements not seen in FIG. 1

[0094] As mentioned, and as can best be seen in FIGS. 3A and 3B, the panels 30 are horizontally disposed. The panels 30 are made of molded or extruded material, such as plastic materials, WPC (Wood Plastic Composite), etc., with a variety of additives possibly added thereto, e.g. color, UV repellent, etc. Each panel 30 comprises a first (inside surface) wall 60 and a parallely disposed, spaced apart, second (outside surface) wall 62. Each of the panels 30 is formed at its inside face 60, with a plurality of fastener locations designated 68, for receiving a fastener therethrough (FIG. 4B) and securing the panel 30 to a support member such as a beam (mullion/muntin) 70, or for mounting to the panel an article, such a shelf, picture and the like (not shown). FIGS. 4A and 4B make particular reference to different examples of fastener locations.

[0095] It is further seen that the horizontally disposed panels 30 are configured with male-female engaging elongate edges 74 and 76, respectively (best seen in FIG. 4A).

[0096] The panels 30 have a smooth, flat inside surface 60, whilst the outside surface 62 is formed with a longitudinally extending groove 78 (FIGS. 3B and 4A) imparting a single panel 30 with the appearance of several panels articulated to one another. Likewise, the male-female engaging elongate edges 74 and 76, respectively provide tight and water resistant attaching of neighboring panels 30, yet with an eye pleasing gap (nonfunctional), and extending at a fixed vertical distance, with some overlapping between mating edges of neighboring panels.

[0097] Different aesthetic features can be imparted to the panels, such colors and patterns and likewise, the panels can be or comprise translucent (see through or light-passing) portions. Also, the panels 30 can comprise venting grids 80, widows 82 (fixed or openable).

[0098] Turning now to FIGS. 4A and 4B particular examples of fastener locations are illustrated and exemplified. In the present examples the illustrated fastener is a self-screw 94 (e.g. self-tapping screw), though it is appreciated that other types of fasteners can be used, such as other types of screws and blind rivets.

[0099] Detail A in FIGS. 4A and 4B is directed to a fastener location designated 90, wherein a thickened wall portion 92 is provided at the inside surface of inside wall 60 of the panel 30, with a self-screw 94 threaded directly into the fastener location 90 and projecting into the internal space 96 of the panel. If desired, a noticeable mark can be applied on the surface of the panel (not shown, however such a mark can be a slight groove similar to that illustrated in connection with detail D discussed hereinafter, or an indentation (not shown), such a visible mark can serve for easy identifying the locations of the fastener location and for eye-pleasing equi-distant applying of fasteners.

[0100] Detail B in FIGS. 4A and 4B is directed to a fastener location designated 100 which is a narrow gap between two neighboring ribs 102A and 102B. the gap 100 can be a bore open at the inside surface of wall 60 of the panel, or it can be filled with a soft material, such as a resin and the like, for eye pleasing, i.e. such that unused fastener locations are not open bores seen at the inside of the panel. Screw is screwed and retained within the tight gap 100. It will be appreciated that the gap can be nonexistent such that the rib is substantially solid, made from the same material as the remainder of the panel.

[0101] Detail C in FIGS. 4A and 4B is directed to a fastener location designated 110 wherein a rib 112 is disposed parallely between inside wall 60 and outside wall 62, and where a self-screw 94 is threaded directly into the fastener location 110 and penetrates through both the wall 60 and the rib 112, projecting into the internal space 114 of the panel.

[0102] If desired, a noticeable mark can be applied on the surface of the panel (not shown), however such a mark can be a slight groove or notch similar to that illustrated in connection with detail D discussed hereinafter, or an indention (not shown). Such a visible mark can serve for easy identifying the locations of the fastener location and for eye-pleasing equi-distant applying of fasteners. It will be appreciated that the mark can also be an outwardly protruding element.

[0103] Detail D in FIGS. 4A and 4B is directed to a fastener location designated 120 in the form of a longitudinal groove 122 extending through the panel 30 between two parallel ribs 124A and 124B and with a groove or indention 126 formed at the inside face of inside wall 60, for identification and easy location of the fastener location 120, such that a self-screw 94 can easily be threaded into the fastener location 120.

[0104] FIGS. 4C and 4D illustrate another example of the fastener location designated 120 (same elements are designated using same numerals as in connection with the previous example, while elements having different configuration, are marked with following the numeral). Detail E in FIGS. 4C and 4D is directed to a fastener location designated 100 which is in the form of a solid conical rib extending between the two opposite walls 60 and 62. It will be appreciated that the central longitudinal axis of the rib, is perpendicular to the walls 60 and 62. As in the previous example, the outer face of the inner wall 60 comprises a groove or indention 126, for identification and easy location of the fastener location 100, such that a self-screw 94 can easily be threaded into the fastener location 100.

[0105] The fastener location in the form of a conical rib 100 is comprised in accordance with this example of a conical solid portion 121 and a narrower extension rib 123 connecting the conical portion to the inside surface of the outer wall 62, such that the fastening element, e.g. a screw as seen in FIG. 4D, extends substantially therethrough. It will be appreciated that the screw can be screwed into the conical portion 121 only. This structure allows having a solid fastening location for tight threading, while the outer wall 62 of the panel is not affected by sink marks, which might result from fastener locations having a broader rib portion connecting to the outer wall 62 of the panel 30. This maintains an eye-pleasing surface on the outer wall, without giving a hint to the presence of the rib and the screw threaded therethrough. In addition, such a configuration allows economy in the plastic material used for the panel. The screw in accordance with an example of the disclosed subject matter can at least partially outwardly extend (e.g. its threads) beyond outer surface of the rib, thus to a certain degree resembling the function of the masonry anchor. It will be appreciated that the conical portion of the rib can be provided with a bore, e.g. filled with a soft material.

[0106] As seen in any one of the details described hereinabove, the screw does not require a fastening bolt and yet it does not penetrate through an external face of the panel, however without deteriorating fastening/gripping force of the bolt to the panel. The screw screws into the rib and is maintained securely in its position without unintentional falling out, or causing any damage to the outer surface such as cracks which might appear due to the type of the material used which is often brittle when compared with other materials. In particular, with panels having relatively thin walls which might be needed due to weight considerations or material saving considerations, it will be a tendency of a composite material for example such as WPC to exhibit fragility/brittleness when screwed into. Provision of the fastening locations in accordance with the disclosed subject matter allows reducing and preventing such unintentional defects.

[0107] It is appreciated that the provision of air voids in the panel improved its thermal and noise isolation properties, and further, that the provision of support ribs improved rigidity of the panels.

[0108] Attention is now directed to FIGS. 5 to 9 directed to a second aspect of the present disclosure, concerned with a modular door.

[0109] The cabin 20 is configured at its front wall with a right door 40R and a left door 40L (also seen in FIG. 1). As will become apparent hereinafter, the two doors 40R and 40L are composed of same components, rendering the system modularity, simplicity and cost effective.

[0110] Each of the door systems comprises a main body 200 made of molded plastic or WPC material and configured with an outside face 204, an inside face 208 bounded between a first (top) edge rail-mount 210 and a second (bottom) edge rail-mount 212, a hinge stile 216 and a locking stile 218.

[0111] Snapingly articulated within the first (top) edge rail-mount 210 there is received a first (top) rail 222 and likewise, a second (bottom) rail 224 is snapingly articulated within the first (top) edge rail-mount 210. Each of the first rail 222 and the second rail 224 is fitted with a projecting hinge portion 226 (best seen in FIG. 7A) and configured for rotatably receiving within a door bushing 228 of the door jamb 230.

[0112] According to a particular configuration, the first (top) rail 222 and the second (bottom) rail 224 are identical and are configured for interchangingly articulating within either the respective first (top) edge rail-mount 210 and the second (bottom) edge rail-mount 212. However, in such a configuration the projecting hinge portion is configurable for respective projecting upwards or downwards such that after mounting on the respective top or bottom edge it projects from the door. This can be obtained by a fixed hinge projection extending at both sides of the rail, or for example by a hinge projection displaceably mounted between a top projection configuration and a bottom projecting configuration, respectively.

[0113] As seen in the figures, the main body 200 is configured with a central portion 234 in the form of solid sheet panel symmetrically extending between the hinge stile 216 and the locking stile 218 and between two venting grid portions 236A and 236B and further, two window portions 238A and 238B. The central solid portion 234 is configured at its front face 204 with a plurality of reinforcing ribs 242 (longitudinal in the present example) projecting from the surface of the front surface. The back, inside face 208, is substantially flat though texturized with longitudinal grooves 246 so as to impart the central portion with a mating panel-like appearance.

[0114] The central portion 234 and the venting grid portions 236A and 236B are configured with a plurality of openings 250 and the front surface of the central portion 234 and the venting grid portions 236A and 236B are configured with a plurality of snap locations 254.

[0115] A cladding panel 260 is configured with a flat outside panel portion 262 (designed with a grid pattern for imparting a mating-like panel appearance), a translucent window portion 264 conforming as far as shape and size with the venting grid portions 236A and 236B, and a venting portion 266 conforming as far as shape and size with the window portion 238A and 238B. In the particular example the window portion 264 is an opening in the cladding panel, though according to a different example (not shown) the venting portion can be a grid-like portion.

[0116] An inside face of the panel portion 265 is configured with a plurality of coupling bolts 270 sized and spaced apart in register with the plurality of openings 250 configured at the main body 200, and a plurality of snapping members 274 extending in register with the plurality of snap locations 254 configured at the main body 200.

[0117] The cladding panel is mounted and secured to the outside face 204 of the main body 200 by snap articulation of the snapping members 274 of the cladding panel 260 to the snap locations 274 of the main body 200, and further by screws extending from the inside face 208 of the main body 200, through openings 250 and coupled to the bolts 270 of the cladding panel 260.

[0118] It is seen that the cladding panel can be articulated to the outside face 204 of the main body 200 at either an upright position (right side door configuration) or a bottoms up position of the main body 200 upon rotating at 180 in the plane of the door (arrowed line 213 in FIG. 9; left side door configuration), wherein the cladding panel 260 remains at an upright position as indicated by arrow 215, i.e. its orientation does not change while assembling a door at either orientation thereof.

[0119] In both a right side door orientation (FIG. 8) and a left side door orientation (FIG. 9) the cladding panel 260 covers (covers so as to conceal and render same nonfunctional) the respective bottom venting grid portion 236A and the respective, whilst the respective top venting grid portions 236B and the respective top window portion 238B remain functional, i.e. the top venting grid portion 236B of the main body extends in register with the window portion 264 of the cladding panel 260 and the top window portion 238B of the main body 200 extends in register with the translucent window portion 264 of the cladding panel 260.

[0120] According to the disclosed arrangement, the door system disclosed hereinabove can be configured as either a right door configuration or a left door configuration, however using the same components, rendering the door system complete modularity.

[0121] It is appreciated that the door system can be configured with any one or both of the venting units and the window.

[0122] The door is further fitted with a locking system generally designated 280 comprising a lock, a lever and vertically displaceable locking latches (FIG. 7A).

[0123] It is also appreciated that while in the disclosure above the door system comprises a single cladding panel configured for articulation at a front face of the door (i.e. external face of a door), a cladding panel may also be applied at an inside face of the door and even more so, the cladding panel can be composed of several panel segments.

[0124] Further attention is now directed to FIGS. 10 to 13 of the drawings, directed to a third aspect of the present disclosure, concerned with a corner coupler configured for coupling two wall members.

[0125] As seen in FIGS. 2A and 2B, and better so in FIG. 10, the cabin 20 has wall members designated 25A (back wall of the cabin 20) and 25B (right side wall of the cabin 20) articulated at a corner of the cabin through a corner coupler generally designated 300.

[0126] As can be seen in the drawings, the corner coupler 300 is generally a symmetric -like shaped metal-sheet member, comprising a U-like shaped inter-wall gap support 304 from which extend a first wall support arm 308A and a second wall support arm 308B, both disposed at an angle of at least 90 with respect to the inter-wall gap support 304. The first wall support arm 308A is configured at a free end thereof with a first wall gripping edge 310A, and the second wall support arm 308B is configured at a free end thereof with a second wall gripping edge 310B.

[0127] Whilst in the present disclosure the interconnecting portion 312 of the inter-wall gap support 304 is straight and disposed at 90 with respect to its side members 314A and 314B (parallely disposed), an arched configuration can be formed as well, concave or convex with respect to a bisector X symmetrically extending between the first wall support arm 308A and the second wall support arm 308B.

[0128] The first wall support arm 308A and the second wall support arm 308B as well as the interconnecting portion 312 of the inter-wall gap support 304 are configured with a plurality of openings 320. The openings formed at the first wall support arm 308A and the second wall support arm 308B are configured for coupling the corner coupler 300 to the wall members 25A and 25B, respectively, through a plurality of screws 325. Openings 320 at the interconnecting portion 312 of the inter-wall gap support 304 serve for securing an external cap profile 330 (represented in FIG. 11 by dashed lines) concealing an outside of the gap 311 (referred to as an inter-wall gap).

[0129] The arrangement is such that when the corner coupler 300 is mounted at a corner between two wall members 25A and 25B of the cabin 20, the inter-wall gap support 304 extends between facing chamfered edges 332A and 332B of the wall members 25A and 25B, respectively, with said chamfered edges 332A and 332B bearing against the side members 314A and 314B of the inter-wall gap support 304, and the first wall support arm 308A and the second wall support arm 308B bear against respective portions of the first wall member 25A and the second wall member 25B, with the first wall gripping edge 310A and the second wall gripping edge 310B bearing within a groove 27A and 27B (best seen in FIG. 11) of the wall member 25A and the second wall member 25B, respectively.

[0130] It is seen that in FIG. 11 the first wall support arm 308A and the second wall support arm 308B are slightly spaced apart from the respective wall members 25A and 25B, wherein the extent of fastening the screws 325 governs elasticity thereof. However, in the example of FIG. 13 first wall support arms bear flush against the respective wall members, as will be explained hereinafter.

[0131] FIG. 13 illustrates a corner coupler 350 similar to corner coupler 300 disclosed in FIGS. 10 to 12, however with some differences. In the embodiment illustrated in FIG. 13, the side members of the 352A and 352B of the inter-wall gap support 354 extend the full depth of the inter-wall gap 356, such that interconnecting portion 358 extends in-line with the external edges of the chamfered edges 332A and 332B of the wall members 25A and 25B, respectively.

[0132] Furthermore, first wall support arm 360A and the second wall support arm 360B are configured for flush bearing against the respective wall members 25A and 25B and securing thereto by screws (not shown) through openings 320. It is seen that the first wall gripping edge 370A and the second wall gripping edge 370B extend at the free ends of the first wall support arm 360A and the second wall support arm 360B, however via an intermediate, inwardly curved portion 374 imparting the wall support arms resiliency for spring biasing into the respective grooves 27A and 27B of the wall members 25A and 25B.