NZ595746A - System for supporting modular components wherein the support has horizontal, vertical, and diagonal grooves connectable with projections on the components - Google Patents

Abstract

Disclosed is an arrangement of supported modular components such as wall panels and tiles. The arrangement includes a support (10) in the form of a backing sheet (11) which has a front connecting face (12), and a plurality of modular components having a rear connecting face. The front and rear connecting faces co-operate to hold the faces in connection to support the modular components on the support. Cooperation between the front and rear connecting faces comprises a plurality of grooves (14) formed in the front connecting face of the support and a plurality of projections formed in the rear connecting face of the modular components. The projections of the modular components are received within the grooves of the support. A first plurality of the grooves extend parallel to each other and horizontally (15), a second plurality of the grooves extend parallel to each other and vertically (16) and a third plurality of the grooves extend parallel to each other and diagonally. The third plurality of the grooves intersects the first and second plurality of grooves.

Description

Patent Form No. 5 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION TITLE: SYSTEM FOR SUPPORTING MODULAR COMPONENTS I, David Bekesi of 6 Drew Street, East Keilor, Victoria, 3033, Australia, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: ■iooact 2 SYSTEM FOR SUPPORTING MODULAR COMPONENTS FIELD OF THE INVENTION The invention relates generally to assembly systems and in particular to a system for supporting modular components. The invention is applicable for supporting modular components used in the building industry such as wall panels and tiles, mouldings including corner mouldings and cornices, skirting boards, door jambs, fascias and so on. It will be convenient to hereinafter describe the invention in relation to exemplary applications of that kind, although it is to be appreciated that the invention is not limited to those applications.

BACKGROUND OF THE INVENTION The modular components referred to above are usually secured to a building structure using fasteners such as nails and/or screws (plaster screws for example) and/or by using adhesives. This effectively secures the components permanently to the building structure, with the result that the components are not readily removable. This can be a disadvantage if any of the components are damaged and need to be replaced, or if the building is to be substantially renovated requiring removal and replacement of certain of the modular components.

It is therefore desirable to provide a system for supporting modular components which facilitates the mounting and support of the components and facilitates any subsequent removal or repositioning of the components.

SUMMARY OF THE INVENTION The present invention provides in one aspect an arrangement of supported modular components including: a support in the form of a backing sheet which has a front connecting face; a plurality of modular components having a rear connecting face; the front and rear connecting faces co-operating to hold said faces in connection to support the modular components on the support, cooperation between the front and rear connecting faces comprising a plurality of grooves formed in the front connecting face of the support and a plurality of projections formed in the rear connecting face of the modular components, the projections of the modular 3 components being received within the grooves of the support, a first plurality of the grooves being formed in the front face of the support to extend parallel to each other and horizontally, a second plurality of the grooves being formed in the front face of the support to extend parallel to each other and vertically and a third plurality of the grooves being formed in the front face of the support to extend parallel to each other and diagonally, whereby the third plurality of the grooves intersects the first and second plurality of grooves.

The present invention provides in another aspect a modular component for use in the above system.

The present invention provides in yet another aspect a support means for use in the above system.

The backing sheet has a front face to which modular components can be connected and can have a rear face which can be secured in abutting or other relation to a surface of a building structure. Adhesive and/or other fasteners may be used to secure the backing sheet to that surface. It is also envisaged that the support can be a free-standing and self-supporting structure or a structure at least partly supported by the building structure. A connecting face can be provided on the rear face of the support as well as the front face.

The grooves of the backing sheet can have an elongate groove opening in the connecting face, elongate side walls extending inwardly from each edge of the groove opening and an elongate base wall adjoining the side walls at the base of the groove. The width of the groove at the groove opening can be less than the width further within the groove. The groove side walls can for example diverge progressively with respect to each other from the groove opening so that the width of the groove increases progressively into the groove from the groove opening towards the base wall. The groove side walls preferably diverge at an angle relative to each other with the divergence angle being measured between intersecting planes parallel to and extending from each of the groove side walls.

The cross-section of the grooves lateral to the longitudinal axis of the grooves can be in the form of a trapezium. Alternatively, the corners of the groove where the side wall 4 adjoins the base wall may have a radius of curvature so that the lateral cross-section may be more "tear drop" in form.

Each projection can be in the form of an elongate rib extending from the rear connecting face of the modular component and each rib can be arranged to be accommodated within a groove of the backing sheet. Each rib can have elongate side walls extending outwardly from the connecting face and an elongate end wall adjoining the side walls at the tip of the rib. The width of the rib adjacent to or at the end wall is preferably greater than the width of the rib immediately adjacent the connecting face from which the rib extends. The rib side walls can diverge progressively from the connecting face so that the width of the rib increases progressively from the connecting face. The rib side walls preferably diverge at an angle relative to each other, with the divergence angle being measured between intersecting planes parallel to and extending from each of the rib side walls.

The material in which the groove is provided and/or the material of the rib is preferably resilient to facilitate the insertion of the rib into the co-operating groove. The support and/or the modular components may for example be made from a resilient plastic material.

The corners of the ribs where the side walls adjoin the end wall can have a radius of curvature so that the cross section of the rib lateral to the longitudinal axis of the rib may be "tear drop" in form. The rib is preferably wider and is larger in dimension than the width of the groove opening of the female interlocking connector. The "rounded" edges of the end wall of the rib can facilitate the insertion into the groove.

Because of the widening of the rib away from the connecting face and the widening of the groove away from the groove opening, the rib will tend to "lock" into the groove when inserted therein. In the preferred form where the groove side walls and rib side walls progressively diverge, the rib tends to be "pulled" into the groove as the rib passes through the groove opening and the edges of the groove opening press against the rib side walls.

A clearance is preferably provided between the groove base wall and the rib end wall when the rib is completely inserted into the groove. Because the rib end wall does not engage the groove base wall in this embodiment, the pulling "force" applied to the rib is constantly maintained ensuring that the rib is securely retained in the groove. The divergence angle of the rib side walls is preferably at least substantially identical to the divergence angle of the groove side walls so that the rib side walls and groove side walls are in substantially abutting relation when the rib is fully inserted in the groove. This further ensures a secure connection between the rib and the groove.

BRIEF DESCRIPTION OF THE DRAWINGS In order to assist in arriving at an understanding of the present invention, examples of the of the invention are illustrated in the attached drawings. As the drawings illustrate examples only, their particularity is not to be understood as superseding the generality of the preceding description.

In the drawings: Fig. 1 is a plan view of a support in the form of a backing sheet according to the present invention; Fig. 2 illustrates lateral cross-sectional views of an edging strip and connection arrangement according to the present invention; Fig. 3 is a plan view of a modular component in the form of a panel according to the present invention; Fig. 4 is a rear view of the panel of Fig. 3; Fig. 5 is a cross-sectional view through section 5-5 of the panel of Fig. 3; Fig. 6 is a cross-sectional view through section 6-6 of the panel of Fig. 3; Fig. 7 is a lateral cross-sectional view of a rib according to the present invention; Fig. 8 is a plan view of a further modular component in the form of a panel according 6 to the present invention; Fig. 9 is a rear view of the panel of Fig. 8; Fig. 10 is a cross-sectional view through section 10-10 of the panel of Fig 8; Fig. 11 is a cross-sectional view through section 11-11 of the panel of Fig. 8; Fig. 12 is a lateral cross-sectional view of a female interlocking arrangement in the form of an interlocking groove according to the present invention; Fig. 13 is a plan view of a modular component in the form of a male/female corner panel according to the present invention; Fig. 14 is a rear view of the panel of Fig. 13; Fig. 15 is a cross-sectional view through section 15-15 of the panel of Fig. 13; Fig. 16 is a cross-sectional view through section 16-16 of the panel of Fig. 13; Fig. 17 is a plan view of a modular component in the form of a half male/female panel according to the present invention; Fig. 18 is a rear view of the panel of Fig. 17; Fig. 19 is a cross-sectional view through section 19-19 of the panel of Fig. 17; and Fig. 20 is a cross-sectional view through section 20-20 of the panel of Fig. 17.

DETAILED DESCRIPTION OF THE DRAWINGS An arrangement for supporting a modular component or components is illustrated in the accompanying figures. In one example form of the arrangement, a support 10 is provided in the form of a backing sheet 11 secured to a vertically extending wall surface of a building structure (not shown). The backing sheet 11 has a front 7 connecting face 12 which includes a female interlocking arrangement 13 comprising a plurality of grooves 14 provided in the front connecting face 12.

The plurality of grooves 14 comprises a plurality of parallel grooves 15 extending horizontally across the connecting face 12, a further plurality of parallel grooves 16 extending vertically in parallel relation across the connecting face 12 and at least one further set of grooves 17 extending at an angle to the horizontal grooves 15 in parallel relation across the connecting face 12. The backing sheet 11 can therefore provide a "grid" of grooves 15 to 17 to which interlocking connectors in the form of ribs can interlock.

Figure 3 illustrates a modular component 20 which is arranged for connection to the backing sheet 11 of Figure 1. Figures 4, 5 and 6 show a rear view and cross-sectional views of the modular component 20. The modular component 20 will be described in the example form of a square wall panel 10 or tile. However, as previously noted, the modular component is not restricted to this form and may include other modular components to be supported.

The modular component 20 has a rear connecting face 21 that includes a plurality of elongate ribs 22 that extend away from the connecting face 21. The ribs 22 can extend from the rear face 21 in parallel relationship across the face 21.

As illustrated, the modular component 20 has a square peripheral shape and the ribs extend parallel to one set of side edges of the component 20.

The ribs 22 are arranged for insertion into any of the grooves 15 to 17 of the backing sheet 11. Thus, the ribs 22 are spaced apart to the same distance as the sets of grooves 15 to 17, so that the modular component 20 could be inserted with the ribs located within the grooves 15, whereby the component 20 is "square" with the backing sheet 11, or the ribs 22 could be located within the grooves 16 and also be located square, but at 90° to the alignment if the ribs 22 are located within the grooves 15.

The ribs 22 could alternatively be located within the grooves 17, so that the modular component 20 would be located "diagonal" to the backing sheet 11. 8 It will be appreciated that an arrangement of the present invention could include a plurality of wall panels fixed to a single backing sheet, so that patterns can be formed by the wall panels, or so that the installation can proceed on the basis of fastening or supporting the backing sheet to a wall structure and then placing the wall panels on the backing sheet as required. The use of smaller wall panels relative to the size of the backing sheet can make installation of the wall surface less complex than if a single and large wall panel was to be attached to the backing sheet.

The panels 20 can for example be supported in a "chess board" pattern on the backing sheet 11 with each of the four edges 25 of the panel (see figures 3 and 4) engaging the complete edge of an adjacent panel 20. The panels 20 can alternatively be supported in a "brick wall" pattern with each horizontal row of panels 20 being staggered approximately half a panel width relative to an adjacent row of panels 20. These are just two of the possible assembly patterns that can be formed by the panels 20. It is also to be appreciated that the panel 20 is not limited to quadrilateral shapes and that other shapes are envisaged, for example triangular or octagonal.

To securely support the wall panels 20 in an assembled condition on the backing sheet 11, an interlocking arrangement can also be provided on the peripheral edges 25 of each of the panels 20. The interlocking arrangement can be in the form of a male and/or female interlocking arrangement although other arrangements are possible.

Where the panels 20 are square or rectangular, the following types of interlocking arrangement provide examples of what can be provided. As shown in Figures 3 to 6, the panel 20 can have ribs 26 extending completely around its peripheral edge 25. The ribs 26 are projecting ribs. As shown in Figures 10 to 12, the panel 28 may alternatively have grooves 27 extending completely around its peripheral edge. Thus, the wall panels 20 can have ribs 26 or grooves 27 formed in their peripheral edges 25, or in alternative arrangements, the edges can include both ribs and grooves. Figure 13 illustrates an arrangement in relation to a wall panel 30, in which grooves 27 are formed along two adjacent edges 25, and ribs 26 are formed along the other of the two adjacent edges 25. It will be evident that the provision of ribs and grooves along 9 the peripheral edge of a wall panel can thus take various forms in addition to the forms illustrated and an alternative arrangement is illustrated in Figures 17 to 20, in which a wall panel 35 is illustrated having ribs 36 extending from opposite edges 25 and grooves 37 extending from the other pair of opposite edges.

As shown in Figures 13 to 16 the panel 30 can have a rib 26 extending along two of its peripheral edges 25 and a groove extending along the other of its peripheral edges 25 except at the four corners 31 of the panel 30 where only a groove 32 is provided.

The ribs can be of any suitable shape and in Figure 7, the rib 29 has a "tear drop" form for receipt within a groove of complementary shape. Such a groove 33 is illustrated in Figure 12.

It is generally necessary to use the different types of panels discussed above to enable the various panels to be assembled in a particular pattern. For example, in the "chess board" pattern described above, three types of panels can be used. The panels may be laid in a repeating sequence such that four panels 28 (Figure 8) are provided around each panel 20 (Figure 3), each panel 28 completely engaging one of the peripheral edges 25 of the central panel 20. Four further panels 30 or 35 (Figures 13 and 17) can be positioned adjacent each of the corners of the panel 20 to complete a nine panel sequence. This sequence may be continued to cover the required area of the backing sheet 11.

To assemble the panels 10 in a "brick wall" pattern, alternating panels 20 and 28 may be connected in a row to provide a continuous row of panels 10. Alternating panels 30 and 35 can also be employed. Each row of panels can have a continuous groove along top and/or bottom edges for connection to an adjacent upper or lower row of panels that have a continuous rib.

To connect adjacent rows together, a further alternative connector can be provided, as shown in the plurality of drawings of Figure 2. In Figure 2, elongate connection strips are illustrated. Figure 2a illustrates a connecting strip 40 having ribs 41 extending from opposite sides of the strip 40, each rib 41 being engageable within the edge grooves of any of the panels 28, 30 or 35. The connection strip 40 can have a "kidney-shaped" lateral cross-section. Other forms of connection strips may be used depending on the pattern of and the type of panels used. For example the connection strip 42 illustrated in Figure 2b can comprise a pair of inter-locking grooves 43 provided in opposite sides of the strip 42. An edge strip 47 is illustrated in Figure 2d and that strip can be provided to engage the peripheral edges 25 of a completed panel assembly. The edge strip 47 can for example have a right-angle triangle lateral cross-section with a rib 48 and a groove 49.

The interlocking strip 40 of Figure 2a has a further rib 44 extending 90° to the ribs 41. This enables the strip 40 to connect panels which are located side by side, as well as to the backing sheet 11. Thus, the rib 44 could be inserted into any one of the grooves 15 to 17 of the backing sheet 11, while the ribs 41 could be inserted into edge grooves formed in adjacent panels.

Likewise, the strip 45 of Figure 2c is a modified version of the strip 42 of Figure 2b, whereby the strip 45 includes grooves 43 in each of opposite side edges, and a rib 46 for engagement within grooves 15 to 17 of the backing sheet 11.

Finally, a strip connector 50 is illustrated in Figure 2e and such a connector can be used between adjacent panels when the panels have facing groove edges. For example, where a pair of panels 28 are placed adjacent to one another, so that grooved edges of each of the panels face each other, the strip 50 can be used to engage each of the facing grooves and so connect the adjacent panels together. The use of the strip 50 is illustrated in Figures 15 and 16, in which the groove 27 of the panel 30 includes the strip 50 fitted thereto. The strip 50 is not employed along the opposite side edge 25, given that that edge already includes a rib 26 extending therefrom.

Because the edges 25 of adjacent panels are secured together, it is possible to make the completed panel assembly watertight. Also, by making the backing sheet and panels in plastic, the costs for covering a wall surface could be significantly less than if conventional wooden panels or ceramic tiles were used. The time involved in installing the wall panel assembly could also be significantly less than with conventional methods used for wall coverings. 11 Because the panels would be readily removable and replaceable, the panels may incorporate photo or print holders or may have pictures photographically reproduced thereon. This would eliminate the need for conventional picture frames. The panels could also incorporate holographic images or be liquid filled to provide decorative wall surfaces.

The system is of course not limited to wall panels but may be used to readily secure different forms of modular components while facilitating the removal or replacement of these components.

Finally, it is to be appreciated that various modifications and/or additions may be made to the system without departing from the ambit of the present invention described herein.

Claims (12)

RECEIVED at IPONZ on 8 December 2011 12 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An arrangement of supported modular components including: a support in the form of a backing sheet which has a front connecting face; 5 a plurality of modular components having a rear connecting face; the front and rear connecting faces co-operating to hold said faces in connection to support the modular components on the support, cooperation between the front and rear connecting faces comprising a plurality of grooves formed in the front connecting face of the support and a plurality of projections 10 formed in the rear connecting face of the modular components, the projections of the modular components being received within the grooves of the support, a first plurality of the grooves being formed in the front face of the support to extend parallel to each other and horizontally, a second plurality of the grooves being formed in the front face of the support to extend parallel to each other and vertically and a third plurality of the grooves being formed in the 15 front face of the support to extend parallel to each other and diagonally, whereby the third plurality of the grooves intersects the first and second plurality of grooves.

2. An arrangement according to claim 1, wherein the projections of the modular components are in the form of a plurality of parallel, elongate ribs configured to be 20 accommodated within the grooves of the front connecting face of the support.

3. An arrangement according to claim 2, wherein each rib has a pair of elongate side walls extending outwardly from the connecting face and an elongate end wall adjoining the side walls at the tip of the rib. 25

4. An arrangement according to claim 3, wherein the width of each rib adjacent to or at the end wall is greater than the width of the rib immediately adjacent the connecting face from which the rib extends. 30

5. An arrangement according to claim 3 or 4, wherein each of the rib side walls diverge progressively from the connecting face so that the width of the rib increases progressively from the connecting face.

6. An arrangement according to claim 5, wherein the rib side walls diverge at a constant 35 angle relative to each other, the divergence angle being measured between intersecting planes parallel to and extending from each of the rib side walls. C:\pof\word\SPEC-NZ17878-11 .doc RECEIVED at IPONZ on 8 December 2011 13

7. An arrangement according to any one of claims 3 to 6, wherein the ribs have corners where the side walls adjoin the top wall and the corners of the ribs have a radius of curvature so that the cross section of the rib lateral to the longitudinal axis of the rib is "tear drop" in form. 5

8. An arrangement according to claim 7, wherein each rib has a maximum width dimension which and is larger in dimension than the width of the opening of the groove of the support. 10

9. An arrangement according to any one of claims 1 to 8, wherein the support is a freestanding and self-supporting structure or a structure at least partly supported by a building structure.

10. An arrangement according to any one of claims 1 to 9, edges of the modular 15 components being arranged so that adjacent modular components can interlocking with each other along respective edges.

11. An arrangement according to claim 10, wherein the edges include grooves or ribs for interlocking with edges having respective ribs or grooves. 20

12. An arrangement according to any one of claims 1 to 11, the modular components being wall panels. C:\pof\word\SPEC-NZ17878-11 .doc