Mounting system for architectural panels

Abstract

The invention concerns a mounting system to support free-form architectural panels, in particular molded panels made from fiber composite materials such as concrete, resin, and gypsum. The mounting system comprises a socket which can be securely embedded in the panel during casting. The mounting system further comprises a ball joint which is clamped into the socket and allows for attachment of the panel to support structure.

Claims

1. A mounting system for connecting a panel to a support structure, the mounting system comprising: a plate assembly including: a plate configured to be embedded within the panel and including a plurality of holes extending through the plate and radially spaced from a center of the plate; and a socket extending orthogonally from the plate and configured to extend from one side of the panel, the socket having a semi-spherical interior surface; a ball assembly including a spherical ball nested in the semi-spherical interior surface of the socket and a shaft extending from the spherical ball, wherein the spherical ball is encapsulated by at least one of a resilient plastic sleeve and a coating thereby self-lubricating the socket; and an attachment structure for fixedly attaching the shaft of the ball assembly to the support structure so the panel may rotate relative to the support structure in any direction but cannot translate relative to the support structure.

2. The mounting system of claim 1, wherein the plate has a uniform thickness in a region extending radially from the socket and surrounding the holes.

3. The mounting system of claim 1, wherein the plate is between approximately one eighth to approximately one half of an inch thick and between approximately three inches to approximately eight inches in diameter.

4. The mounting system of claim 1, wherein the plurality of holes are radially elongated slots.

5. The mounting system of claim 1, the plate assembly further comprising a shock absorber configured to mitigate dynamic loading between the spherical ball and the socket.

6. The mounting system of claim 5, wherein the shock absorber is a rubber component positioned in the socket.

7. A mounting system for connecting a non-planar architectural panel to a support structure, the mounting system comprising: a plate assembly including: a flat, circular plate configured to be embedded within the panel and including a plurality of holes extending through the plate and radially spaced from a center of the plate; and a socket extending orthogonally from the plate and configured to extend from one side of the panel, the socket having a semi-spherical interior surface and a cylindrical, externally threaded outer surface; a ball assembly including a spherical ball nested in the socket of the plate assembly and a threaded bolt extending from the spherical ball, wherein the spherical ball is encapsulated by at least one of a resilient plastic sleeve or a coating thereby self-lubricating the socket; a locking collar having an internally threaded inner surface configured to engage the externally threaded outer surface of the socket to trap the spherical ball against the socket; and an attachment structure for fixedly attaching the threaded bolt of the ball assembly to the support structure so the panel may rotate relative to the support structure in any direction but is fixed in translation relative to the support structure, the attachment structure including: an L-shaped bracket having a first leg with a first slot and a second leg with a second slot, the first and second legs extending orthogonally relative to one another, fasteners for fixing the threaded bolt of the ball assembly in the first slot of the first leg of the bracket, and fasteners for attaching the second leg of the bracket to the support structure.

8. A mounting system for connecting a panel to a support structure, the mounting system comprising: a plate assembly including: a plate configured to be embedded within the panel; and a socket extending orthogonally from the plate and configured to extend from one side of the panel, the socket having a semi-spherical interior surface; a ball assembly including a spherical ball nested in the semi-spherical interior surface of the socket and a shaft extending from the spherical ball, wherein the spherical ball is encapsulated by at least one of a resilient plastic sleeve and a coating thereby self-lubricating the socket; a locking collar having a semi-spherical interior surface, the locking collar being configured to engage the socket so that the semi-spherical interior surface of the socket and the semi-spherical interior surface of the locking collar opposingly cradle the spherical ball to trap the spherical ball against the socket; and an attachment structure for fixedly attaching the shaft of the ball assembly to the support structure so the panel may rotate relative to the support structure in any direction but cannot translate relative to the support structure.

9. The mounting system of claim 8, wherein the plate has a uniform thickness in a region extending radially from the socket and surrounding the holes.

10. The mounting system of claim 8, wherein the plate is between approximately one eighth to approximately one half of an inch thick and between approximately three inches to approximately eight inches in diameter.

11. The mounting system of claim 8, wherein the plurality of holes are radially elongated slots.

12. The mounting system of claim 8, the plate assembly further comprising a shock absorber configured to mitigate dynamic loading between the spherical ball and the socket.

13. The mounting system of claim 12, wherein the shock absorber is a rubber component positioned in the socket.

14. A mounting system for connecting a panel to a support structure, the mounting system comprising: a plate assembly including: a plate configured to be embedded within the panel and including a plurality of holes extending through the plate, having an annular width and radially spaced from a center of the plate; and a socket extending orthogonally from the plate and configured to extend from one side of the panel, the socket having a semi-spherical interior surface; a ball assembly including a spherical ball nested in the semi-spherical interior surface of the socket and a shaft extending from the spherical ball; an attachment structure for fixedly attaching the shaft of the ball assembly to the support structure so the panel may rotate relative to the support structure in any direction but cannot translate relative to the support structure; and a rubber shock absorber positioned in the socket and configured to mitigate dynamic loading between the spherical ball and the socket.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a mounting system constructed in accordance with an embodiment of the invention schematically in longitudinal section.

(2) FIG. 2 is an end view of the mounting system.

(3) FIG. 3 is an exploded view of the mounting system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) FIG. 1 shows a composite panel P attached to a support structure S by a mounting system M constructed in accordance with an embodiment of the invention. A portion of the mounting system M is embedded within the panel and encapsulated by a bonding pad B of the same material as panel P. The mounting system may be used with any panel and any support structure.

(5) As best depicted in FIG. 3, an embodiment of the mounting system M broadly comprises a plate assembly 1; a ball assembly 2, a locking collar 3, and attachment structure 4.

(6) The plate assembly 1 attaches to the panel P and includes a plate 5 configured to be embedded within the panel and a socket 6 extending orthogonally from the plate and configured to extend out from one side of the panel.

(7) An embodiment of the plate 5 is formed of stainless steel or other metals or composites and is flat and circular. In one embodiment, the plate is approximately ⅛-½″ thick and 3-8″ in diameter. Slots or holes 7 may be formed in the plate to allow for the flow of materials used to form the panel to better distribute forces through the panel and its bonding pad.

(8) The socket 6 extends from one face of the plate 5 and has a semi-spherical interior surface 8 and a cylindrical, externally threaded outer surface 9. A rubber component 10 may be placed in the socket to provide shock absorption in case of dynamic loads and extra friction against panel rotation during panel installation.

(9) The ball assembly 2 includes a spherical ball 11 configured to nest in the socket 6 of the plate assembly and a threaded bolt 12 extending from the spherical ball. In one embodiment, the spherical ball is between 1-4″ in diameter. The spherical ball 11 may be encapsulated with a resilient plastic sleeve 13 or coating such that the joint between the ball and the socket is self-lubricated. The plastic sleeve 13 or coating also prevents bi-metallic reactions by isolating the components for embodiments where some of the components are made from stainless steel and other components made from other materials. For example, in some embodiments, the plate assembly 1 is made from stainless steel while the ball assembly 2 is made of less expensive grades of metal. Additionally, the resilient plastic sleeve can absorb some shock from dynamic loads.

(10) The locking collar 3 is internally threaded and configured to be threaded over the socket 6 to trap the spherical ball 11 in the socket 6. The locking collar 3 allows the ball to resist and transfer translational forces while still allowing it to rotate freely relative to the plate assembly. In preferred embodiments, the spherical ball 11 may rotate 90° in any direction relative to the socket 6 such that the panel P may be mounted to a rectilinear structure S regardless of the desired angle between the panel and the support structure. However, the mounting system and other embodiments thereof may have other degrees of rotation without departing from the scope of the invention.

(11) The attachment structure 4 attaches the ball assembly 2 to the support structure 5 such that the panel P may rotate relative to the support structure 5 in any direction but cannot translate relative to the support structure.

(12) An embodiment of the attachment structure 4 includes an L-shaped bracket 14 having a first serrated leg 15 with a first slot 16 and a second leg 17 with a second slot 18. The first and second legs extend orthogonally relative to one another. The attachment structure also includes fasteners (embodiments described below) for fixing the threaded bolt 12 of the ball assembly in the first slot of the first leg of the bracket and fasteners for attaching the second leg of the bracket to the support structure.

(13) In one embodiment, the threaded bolt 12 is inserted through the slot 16 in the first serrated leg 15 of the bracket 14 and is locked into vertical position via a serrated washer 19, isolation washer 20, and nut 21 on one side of the leg and a serrated washer 22, an isolation washer 23, and nut 24 on the opposite side of the leg. This permits vertical adjustment of the panel P relative to the support structure during installation. When the nuts 21, 24 are tightened, the panel P is fixed relative to the bracket 14. This is just one example of many possible fasteners that allow for vertical adjustment of the panel during installation and subsequently locking the ball assembly into place vertically such that the bracket can take loads once the correct position has been established.

(14) The second leg 17 of the bracket 14 is fixed to a slot 25 in the support structure S via a bolt 26 in conjunction with an isolation washer 27 and locking nut 28. This allows for horizontal adjustment of the bracket 14 and hence the panel relative to the support structure. This is also just one example of many possible fasteners that allow for panel movement horizontally and subsequently fixing the bracket into position.

(15) Another embodiment of the invention is a method of mounting a non-planar, architectural panel to a support structure. An embodiment of the method comprises: forming the panel from composite materials; partially embedding a plate assembly within the non-planar panel as it is formed so that a flat, circular plate of the plate assembly is embedded entirely within the panel and a socket of the plate assembly extends orthogonally out from one side of the panel, the socket having a semi-spherical interior surface and a cylindrical, externally threaded outer surface; inserting a spherical ball of a ball assembly in the semi-spherical interior surface of the socket; threading a locking collar over the externally threaded outer surface of the socket to trap the spherical ball in the socket but to allow the spherical ball to rotate relative to the socket; and attaching the ball assembly to the support structure so the panel may rotate relative to the support structure in any direction but cannot translate relative to the support structure.

(16) Although the invention has been described with reference to the particular embodiments, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention.