PANEL MOUNT SYSTEM AND METHOD

Abstract

A system and method for securing a panel to a wall. The panel mount system includes a backing strip comprising a mounting plate with a front face for contact with the panel, an opposed rear face, and a plate opening extending therebetween. The mounting plate includes a rim extension extending from the front face around the plate opening for extension through the panel. The rim extension has an internal coupling component, and is further dimensioned to receive a body of a screw therethrough. The screw comprises a head, and the body extends from the head for securement to the wall. The body has an external coupling component configured to releasably couple with the internal coupling component of the rim extension when the body of the screw extends through the rim extension.

Claims

1. A panel mount system for securing a panel to a wall, the panel mount system comprising: a backing strip comprising: a mounting plate with a front face for contact with the panel, an opposed rear face, and a plate opening extending between the front face and the rear face; and a rim extension extending from the front face around the plate opening for extension through the panel, the rim extension comprising an internal coupling component, and further dimensioned to receive a body of a screw through the rim extension; and the screw comprising: a head; and the body extending from the head for securement to the wall, the body having an external coupling component configured to releasably couple with the internal coupling component of the rim extension when the body of the screw extends through the rim extension.

2. The panel mount system of claim 1, wherein the external coupling component of the body of the screw and the internal coupling component of the rim extension collectively form a snap-fit mechanism.

3. The panel mount system of claim 2, wherein the external coupling component of the body of the screw is a groove, and the internal coupling component of the rim extension is a ridge dimensioned to fit within the groove of the screw.

4. The mounting system of claim 1, wherein the external coupling component of the body of the screw is positioned proximate the head of the screw.

5. The mounting system of claim 4, wherein a height of the rim extension corresponds with a width of the panel.

6. The mounting system of claim 5, wherein the head of the screw further comprises an outwardly extending washer, the washer having a diameter that is larger than a diameter of the rim extension; wherein in use, the panel is positioned between the washer and the front face of the backing strip.

7. The mounting system of claim 6, wherein the washer is rotatably secured to the head of the screw.

8. The mounting system of claim 7, wherein the body of the screw further comprises a flange extending from the body, the flange positioned to hold the washer in positioned relative to the head of the screw and dimensioned to fit through the rim extension.

9. The mounting system of claim 8, wherein the flange is positioned to align with the mounting plate in use.

10. The mounting system of claim 1, wherein the backing strip further comprises: one or more spacer plates extending from the mounting plate, a frangible section separating the mounting plate and the one or more spacer plates from each other.

11. The mounting system of claim 10, wherein the frangible section comprises one or more apertures.

12. The mounting system of claim 10, wherein the backing strip is plastic.

13. The mounting system of claim 10, wherein the backing strip further comprises another mounting plate with another plate opening and another rim extension extending from around the other plate opening for extension through the panel.

14. The mounting system of claim 1, further comprising an insert nut having: external threads to secure the insert nut to a frame component of the wall; and internal threads to securely receive the body of the screw through the insert nut.

15. The mounting system of claim 1, further comprising the panel having a panel opening dimensioned to tightly receive the rim extension through the panel opening.

16. A method of mounting a panel to a wall, the method comprising: coupling a backing strip to a back side of the panel, the coupling comprising fitting a rim extension surrounding a plate opening in the backing strip through a panel opening in the panel, the rim extension having an internal coupling component; inserting a body of a screw, from an opposed front side of the panel, through the rim extension, plate opening, and the panel opening, the body of the screw having an external coupling component; releasably coupling the external coupling component of the screw with the internal coupling component of the rim extension to hold the panel between the backing strip and the screw; and securing the body of the screw to the wall, thereby securing the panel to the wall.

17. The method of claim 16, wherein the releasably coupling comprises snap-fitting the external coupling component of the screw with the internal coupling component of the rim extension.

18. The method of claim 16, wherein the screw further comprises a head with a washer extending from the head, the washer having a greater diameter than a diameter of the rim extension, and wherein the inserting of the body of the screw through the rim extension comprises inserting the body of the screw until the washer comes into contact with the rim extension.

19. The method of claim 16, wherein the securing of the body of the screw into the wall comprises rotating the screw to thread the body of the screw into the wall.

20. The method of claim 19, wherein the securing of the body of the screw into the wall further comprises securing an insert nut into the wall, and rotating the screw to thread the body of the screw into the insert nut in the wall.

21. The method of claim 16, further comprising cutting the panel opening in the panel.

22. The method of claim 16, wherein the backing strip comprises a mounting plate from which the rim extension extends, the backing strip further comprising one or more spacer plates extending from the mounting plate, the method further comprising: adjusting a length of the backing strip by removing at least one of the one or more spacer plates from the mounting plate.

23. The method of claim 22, wherein the backing strip further comprises a frangible section separating the mounting plate and the one or more spacer plates from each other, wherein removing the at least one of the one or more spacer plates from the mounting plate comprises manually breaking off the at least one of the one or more spacer plates from the mounting plate at the corresponding frangible section.

24. The method of claim 16, further comprising: coupling another rim extension surrounding another plate opening in the backing strip through another panel opening in the panel; inserting another screw, from the front side of the panel, through the other rim extension, the other plate opening, and the other panel opening, the body of the other screw having another external coupling component; releasably coupling the other screw with the other rim extension; and securing the other screw to the wall.

25. A kit for assembling a panel mount system for securing a panel to a wall, the kit comprising: a backing strip comprising: a mounting plate with a front face for contact with the panel, an opposed rear face, and a plate opening extending between the front face and the rear face; and a rim extension extending from the front face around the plate opening for extension through the panel, the rim extension comprising an internal coupling component, and further dimensioned to receive a body of a screw through the rim extension; and the screw comprising: a head; and the body extending from the head for securement to the wall, the body having an external coupling component configured to releasably couple with the internal coupling component of the rim extension when the body of the screw extends through the rim extension.

26. The kit of claim 25, further comprising an insert nut having: external threads to secure the insert nut to a frame component of the wall; and internal threads to securely receive the body of the screw through the insert nut.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments, and in which:

[0032] FIG. 1 is a front-right perspective, exploded, and partial view of a panel mount system in accordance with an example embodiment.

[0033] FIG. 2 is a cross-sectional view of the panel mount system of FIG. 1 along line A-A.

[0034] FIG. 3 is a perspective cross-sectional view of the panel mount system of FIG. 2 with a panel and a frame component of a wall.

[0035] FIG. 4 is a cross-sectional view of the panel mount system of FIG. 3 coupled to the panel and the frame component of the wall.

[0036] FIG. 5 is a rear perspective view of a backing strip in isolation.

[0037] FIG. 6 is a rear perspective view of the backing strip of FIG. 5 separated into two sections.

[0038] FIG. 7 is a rear perspective view of two of the backing strips of FIG. 6 positioned on a panel.

[0039] FIG. 8 is a front-left perspective view of multiple panel mount systems of FIG. 4 coupled to the panel and the frame components of the wall.

[0040] FIG. 9 is a rear view of the panel mount system of FIG. 8.

[0041] FIG. 10 is a cross-sectional view of FIG. 9 along line B-B.

[0042] FIG. 11 is an enlarged view of portion C of FIG. 10.

[0043] FIG. 12 is a flow diagram for a method of mounting a panel onto a wall, in accordance with an example embodiment.

[0044] Reference will be made below in detail to exemplary embodiments which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts.

DETAILED DESCRIPTION

[0045] FIGS. 1 to 11 illustrate an example embodiment of a panel mount system 10 for mounting a panel 100 to a frame components 102 of a wall. As best seen in FIGS. 8 to 11, the frame components 102 include top and bottom rails 104 and studs 106 extending therebetween. The panel 100 may include a front side 110 and an opposed back side 112.

[0046] Turning first to FIGS. 1 to 7, the panel mount system 10 generally includes a backing strip 12 and a screw 14. In some examples, such as the one depicted, the panel mount system 10 may further include an insert nut 16.

[0047] The backing strip 12 comprises a mounting plate 18a with a front face 20 for contact with the front or back side 110, 112 of the panel 100, an opposed rear face 22, and a plate opening 24 extending between the front face 20 and the rear face 22. In the depicted embodiment, the plate opening 24 is circular. However, in other examples, the plate opening 24 may have a different shape, such as oval or rectangular. The backing strip 12 further has a rim extension 26 extending from the front face 20 around the plate opening 24. Since the plate opening 24 in the depicted embodiment is circular, the rim extension 26 is, correspondingly, generally cylindrical. The rim extension 26 is configured to extend through the panel 100. To that end, the panel 100 may have a panel opening 108 dimensioned to receive the rim extension 26 therethrough, and the height of the rim extension 26 may correspond with the width of the panel 100, such that the rim extension 26 does not extend past the panel 100 in use. As will be further described below, the rim extension 26 is dimensioned to receive a body 36 of the screw 14 therethrough and comprises an internal coupling component 28.

[0048] The backing strip 12 may further have one or more additional spacer plates 18b secured to or extending from the mounting plate 18a. As best seen in FIGS. 5 and 6, the mounting plates 18a and spacer plates 18b may be formed or secured together in series to collectively form the backing strip 12. The illustrated embodiment also shows the mounting plates 18a and spacer plates 18b being the same size, i.e. having the same shape and same dimensions. In that manner, the mounting plates 18a and spacer plates 18b may also act as a positioning guide or ruler to assist the installer in providing easy alignment of the screws 14 on the panel 100. In other examples, the mounting plates 18a may have different shapes and/or dimensions than the spacer plates 18b. In yet further examples, the spacer plates 18b may each have different shapes and/or dimensions relative to the other spacer plates 18b.

[0049] In examples where the backing strip 12 comprises multiple plates 18a, 18b, the backing strip 12 may also have a frangible section 30 separating each plate 18a, 18b from one another. The frangible section 30 may be frangible based on its material and/or its shape. For example, the frangible section 30 made of frangible material, such as plastic or composite metal materials. To that end, the plate 18a, 18b and the frangible sections 30 may be made of the same material, such as plastic, or they made be formed from different materials. The frangible section 30 may additionally or alternatively be thinner than the adjacent plates 18a, 18b, scored, perforated, and/or comprise one or more apertures 32 extending therethrough.

[0050] In the embodiment depicted in FIG. 5, the backing strip 12 comprises a mounting plate 18a, followed by six spacer plates 18b, followed by another mounting plate 18a, followed by seven spacer plates 18b, which are followed by another mounting plate 18a. In other examples, a different sequence of mounting plates 18a and spacer plates 18b may be used. Since each plate is separated by a frangible section 30, the length of the backing strip 12 may be reduced in size as desired by breaking off one or more plates along one of the frangible sections 30 (see FIGS. 6 and 7).

[0051] Returning to FIGS. 1 and 2, the screw 14 includes a head 34 and the body 36 extending from the head 34 for securement to the frame components 102, such as the stud 106. In the depicted embodiment, the head 34 may further include an outwardly extending washer 38, where the washer 38 has a diameter that is larger than a diameter of the rim extension 26. In that manner, when the body 36 of the screw 14 is directed through the rim extension 26, the washer 38 can act as a stop when it comes into contact with the rim extension 26. When in use with the panel 100, the washer 38 can also act as a stop when it comes into contact with the panel 100. To that end, the panel 100 may be positioned between the washer 38 and the front face 20 of the backing strip 12 in use (see FIG. 4, for example).

[0052] The body 36 of the screw 14 comprises a threaded portion 40 and a coupling portion 42. The threaded portion 40 is generally positioned opposite the head 34 of the screw 14, and is threaded for securement to the stud 106. The coupling portion 42 may be positioned between the washer 38 and the threaded portion 40, and in some examples, may be positioned proximate or adjacent to the head 34 of the screw 14. Notably, the coupling portion 42 comprises an external coupling component 44 configured to releasably couple with the internal coupling component 28 of the rim extension 26 when the body 36 of the screw 14 extends through the rim extension 26.

[0053] The external coupling component 44 of the body 36 of the screw 14 and the internal coupling component 28 of the rim extension 26 may relasably couple together via one of a variety of means, including a friction fit, magnetic attraction, or they may collectively form a snap-fit mechanism. In the embodiment depicted in FIGS. 1 to 4, they form a snap-fit mechanism where the external coupling component 44 of the body 36 of the screw 14 is a groove 46, and the internal coupling component 28 of the rim extension 26 is a ridge 48 dimensioned to fit within the groove 46 of the screw 14. In other examples, the position of the groove 46 and the ridge 48 may be swapped.

[0054] The threaded portion 40, the coupling portion 42, the head 34, and the washer 38 may be formed or secured together as a unitary piece. In some examples, the washer 38 may be rotatably secured around the head 34 of the screw 14. In such cases, the body 36 of the screw 14 may further include a flange 50 extending from the body 36, the flange 50 being positioned along the body 36 to operatively hold the washer 38 in place around the head 34 of the screw 14. In the example depicted in FIGS. 1 to 4, the coupling portion 42 and the washer 38 may be formed or secured together as a component separate from the threaded portion 40 and the head 34. The coupling portion 42 and the washer 38 then being rotatably positioned around the head 34 of the screw 14. In such cases, the flange 50 is positioned to operatively hold the coupling portion 42 and the washer 38 in place around the head 34 of the screw 14 such that the external coupling component 44 is positioned between the flange 50 and the head 34 of the screw 14. The flange 50, in such examples, is also dimensioned to fit through the rim extension 26 and may be positioned to align with the mounting plate 18a when coupled thereto. When configured in the above manners, the head 34 and the body 36 of the screw 14 may be drilled into the stud 106 without rotating the washer 38 and/or the coupling portion 42.

[0055] While the threaded portion 40 of the screw 14 may be drilled directly into the frame components 102, including studs 106, the panel mount system 10 may optionally include the insert nut 16. As best seen in in FIGS. 1 to 4, the insert nut 16 may have external threads 52, for driving the insert nut 16 into, and holding the insert nut 16 to, one of the frame components 102, including stud 106. The insert nut 16 may also have internal threads 54 to securely receive the threaded portion 40 of the body 36 of the screw 14 therethrough.

[0056] When coupled together, as shown in FIG. 4 for example, the panel mount system 10 allows the panel 100 to be moved towards or away from the stud 106 by turning the screw 14. When two or more panel mount systems 10 are used with the same panel 100, each panel mount systems 10 allows the portion of the panel 100 immediately adjacent to it to be moved towards or away from the stud 106 by turning its screw 14. In that manner, the overall orientation of the panel 100 can be adjusted relative to the studs 106 to be plumb, straight and/or level (with the floor, for example), even when the underlying framing component 102 or stud 106 is not. Thus, the panel 100 can be levelled without using drywall compound or other conventional leveling methods.

[0057] FIG. 12 is a flow diagram for a method 1200 for securing a panel 100 to framing components 102, using the panel mount system 10 in accordance with example embodiments. In examples, other systems may be used to perform the method 1200, other than the panel mount system 10.

[0058] At step 1202, the method 1200 may include cutting a panel opening 108 in a panel 100. The panel opening 108 may be dimensioned to fit around (i.e. be larger than) the rim extension 26 of the backing strip 12, and is preferably dimensioned to correspond and snugly fit around the rim extension 26 of the backing strip 12. In the embodiment shown in FIG. 3, since the rim extension 26 is cylindrical, the panel opening 108 is correspondingly cylindrical. In examples, if the backing strip 12 to be used includes more than one mounting plate 18a, more than one panel opening 108 may be cut at corresponding positions in the panel 100.

[0059] If the backing strip 12 is made up of multiple plates, including multiple mounting plates 18 and/or multiple spacer plates 18b, at step 1204, the backing strip 12 may be reduced to a desired length, such as to correspond to a dimension of the panel 100. To that end, the backing strip 12 may be cut to the desired length with a cutting tool. Alternatively, if the plates of the backing strip 12 has frangible sections 30 (in an example, the frangible sections 30 may be perforated or scored), at step 1206, the backing strip 12 may be reduced in length by breaking the backing strip 12 along one of the frangible sections (see FIGS. 5 and 6 for example).

[0060] At step 1208, the method 1200 includes coupling the backing strip 12 to one side, either the front or back side 110, 112, of the panel 100. In examples, at step 1210, the coupling may include fitting the rim extension 26 into the panel opening 108. If the backing strip 12 comprises more than one mounting plate 18, the coupling may include fitting each rim extension 26 into its corresponding panel opening 108 (see FIG. 7, for example)

[0061] At step 1212, the body 36 of the screw 14 may be inserted through the rim extension 26 from the side opposite from where the backing strip 12 is coupled to the panel 100, such that a (preferably significant) portion of the body 36 of the screw 14 extends past the backing strip 12. If the screw 14 has a washer 38, at step 1214, the body 36 of the screw 14 may be inserted through the rim extension 26 until the washer 38 comes into contact with the rim extension 26 and/or the panel 100. In the embodiment depicted in FIGS. 3-4 and 7-9, the rim extensions 26 of backing strip 12 are inserted through the back side 110 of the panel 100, and the screws 14 are inserted through the front side 108 of the panel 100. In that manner, the panel 100 may be held in place between the backing strip 12 and the washer 38 of the screw 14.

[0062] At step 1216, as or after the body 36 of the screw 14 is inserted through the rim extension 26, the external coupling component 44 of the screw 14 is coupled with the internal coupling component 28 of the rim extension 26. Depending on the structure of the external coupling component 44 and the internal coupling component 28, the external coupling component 44 and the internal coupling component 28 may be pressed together in a friction fit, via magnetic attraction, or they may be snap-fitted together (at step 1218). The coupling between the external coupling component 44 and the internal coupling component 28 may be permanent or releasable.

[0063] If another panel mount system 10 is to be coupled to the panel 100, the method 1200 may return to step 1202 or 1204 as necessary.

[0064] At step 1220, the panel 100 may be secured to the framing component 102, such as the stud 106, by securing the body 36 of the screw 14 to the framing component 102. If the body 36 of the screw 14 is relatively smooth, the body 36 (that extends past the backing strip 12) may be hammered into the framing component 102. If the screw 14 has a threaded portion 40, the threaded portion 40 (that extends past the backing strip 12) may be rotated/driven into the wall. In examples, the body 36 of the screw 14 may be secured directly into one of the frame components of the wall (such as the top or bottom rail 104 or a stud 106).

[0065] In other examples, the method 1200 may include, at step 1222, securing an insert nut 16 into the top or bottom rail 104 or the stud 106 (see FIG. 3, for example). Securing the insert nut 16 into the top or bottom rail 104 or the stud 106 may first include drilling a hole in the corresponding frame component 102 in order to receive the insert nut 16. After the insert nut is positioned within the framing component 102, at step 1224, the threaded portion 40 (that extends past the backing strip 12) may be rotated/driven into the insert nut 16, thereby securing the screw 14, and the panel 100, to the framing component 102. When coupled together in this manner, at step 1226, the distance of the panel 100 to the stud 106 may be adjusted by turning the screw 14 clockwise or counter clockwise as applicable.

[0066] If multiple panel mount systems 10 were coupled to the panel 100, at step 1220, the panel 100 may be secured to the framing component 102 by securing each of the bodies 36 of the screws 14 to the framing component 102 using one of the manners described above. As described above, each panel mount systems 10 allows the portion of the panel 100 immediately adjacent to it to be moved towards or away from the stud 106 by turning its screw 14 independently of the other panel mount systems 10. In other words, at step 1226, each panel mount system 10 may be used to independently adjust the distance of its portion of the panel 100 relative to the stud 106 by turning each screw 14 clockwise or counter clockwise. In that manner, the overall orientation of the panel 100 can be adjusted relative to the studs 106 to be plumb, straight and/or level (with the floor, for example), even when the underlying framing component 102 or stud 106 is not plumb, straight and/or level. Thus, the panel 100 can be levelled without using drywall compound or other conventional leveling methods.

[0067] While some of the above examples have been described as occurring in a particular order, it will be appreciated to persons skilled in the art that some of the steps or processes may be performed in a different order provided that the result of the changed order of any given step will not prevent or impair the occurrence of subsequent steps. Furthermore, some of the steps described above may be removed or combined in other embodiments, and some of the steps described above may be separated into a number of sub-steps in other embodiments. Even further, some or all of the steps may be repeated, as necessary. Elements described as methods or steps similarly apply to systems or subcomponents, and vice-versa.

[0068] Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various embodiments presented above are merely examples and are in no way meant to limit the scope of the examples. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art having the benefit of the examples, such variations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover and embrace all suitable changes in technology.

[0069] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

NUMERICAL DESIGNATIONS

[0070] 10 panel mount system [0071] 12 backing strip [0072] 14 screw [0073] 16 insert nut [0074] 18a mounting plate [0075] 18b spacer plate [0076] 20 front face (plate) [0077] 22 rear face (plate) [0078] 24 plate opening [0079] 26 rim extension [0080] 28 internal coupling component [0081] 30 frangible section [0082] 32 aperture (frangible) [0083] 34 head (screw) [0084] 36 body (screw) [0085] 38 washer [0086] 40 threaded portion (screw body) [0087] 42 coupling portion (screw body) [0088] 44 external coupling component [0089] 46 groove [0090] 48 ridge [0091] 50 flange [0092] 52 external threads (insert nut) [0093] 54 internal threads (insert nut) [0094] 100 panel [0095] 102 framing component [0096] 104 top and bottom rails [0097] 106 stud [0098] 108 panel opening [0099] 110 front side (panel) [0100] 112 back side (panel)