Panel mounting system

Abstract

A zero-lift, snap fit mounting system includes clips that snap fit into rails. Panels are carried on the clips with the rail carried by a mounting surface. Different lengths of each component are disclosed. One rail configuration provides a base having features that make the rail flexible enough to receive the clips in a snap fit connection. Another feature of the rail is a shelf that supports the weight of the clip and panel being mounted to the rail. The system also can have the latching projections of the rails and clips configured for easier installation than removal.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional Patent Application No. 63 / 753,729 filed Feb. 4, 2025; the disclosures of which are incorporated herein by reference.BACKGROUND OF THE DISCLOSURE1. Technical Field

[0002] The disclosure generally relates to hangers that mount panels to walls and ceilings. More particularly, the disclosure relates to zero-lift, snap-fit systems that allow panels to be mounted in any order and without a lateral shift or lift requirement such that a panel can be mounted into and removed from a space surrounded by other panels.2. Background Information

[0003] A variety of zero-lift, snap fit mounting systems are known in the art. Despite the benefits provided by the existing systems, those in the industry desire systems with improved features and benefits.SUMMARY OF THE DISCLOSURE

[0004] The disclosure provides a panel mounting system that includes clips that snap fit into rails. Different lengths of each component are disclosed.

[0005] The disclosure provides in one exemplary embodiment a rail configuration that provides a base having features that make the rail flexible enough to receive the clips in a snap fit connection.

[0006] The disclosure provides in one exemplary embodiment a rail configuration having a shelf that supports the weight of the clip and panel being mounted to the rail.

[0007] The disclosure provides an exemplary embodiment wherein the latching projections of the rails and clips are configured for easier installation than removal.

[0008] The disclosure provides a rail and clip system that has offset fasteners.

[0009] The preceding non-limiting aspects of the disclosure, as well as others, are more particularly described below. A more complete understanding of the devices, assemblies, and methods can be obtained by reference to the accompanying drawings, which are not intended to indicate relative size and dimensions of the assemblies. In those drawings and the description below, like numeric designations refer to components of like function. Specific terms used in that description are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 is an end view of an exemplary embodiment of the panel mounting system mounting a panel to a wall.

[0011] FIG. 2 is a front elevation view of one version of a light duty clip.

[0012] FIG. 3 is an end view of FIG. 2.

[0013] FIG. 4 is a front elevation view of another version of a light duty clip.

[0014] FIG. 5 is an end view of FIG. 4.

[0015] FIG. 6 is a front elevation view of another version of a light duty clip.

[0016] FIG. 7 is an end view of FIG. 6.

[0017] FIG. 8 is a front elevation view of one version of a rail.

[0018] FIG. 9 is an end view of FIG. 8.

[0019] FIG. 10 is a front elevation view of another version of a rail.

[0020] FIG. 11 is an end view of FIG. 10.DETAILED DESCRIPTION OF THE DISCLOSURE

[0021] This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as “horizontal,”“vertical,”“up,”“down,”“top” and “bottom” as well as derivatives thereof (e.g., “horizontally,”“downwardly,”“upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,”“longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “joined,”“connected,” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.

[0022] The panel mounting system of the disclosure is used to mount decorative panels to walls and / or ceilings in a zero-lift, snap-fit configuration. This mounting configuration allows a structure such as a panel to be mounted into and removed from a position that is surrounded by other panels. An exemplary embodiment of the panel mounting system of the disclosure is indicated generally by the number 10 in FIG. 1 wherein mounting system 10 is shown mounting a panel 12 to a mounting structure 14 having a mounting surface in the form of the outer surface of a vertical wall 14. System 10 also can be used to mount panel 12 to a horizontal ceiling 14 surface or another angled surface. This exemplary embodiment of the zero-lift mounting system 10 can be used to install a wide variety of panels. System 10 is a snap-fit-type system of a first mounting component 20 which is also referred to herein as a clip 20 and a second mounting component 22 referred to herein as a rail 22, designed to allow for ⅜″ projection, or tight to ceilings with no lift off. Although clips 20 and rails 22 can be fabricated from a variety of materials such as metals and polymers, the exemplary configuration 10 is made from 6063-T6 aluminum and is designed to be extruded. The aluminum snap fit system is very durable and has a higher weight capacity than some existing polymer systems. System 10 provides a zero-lift design having a minimum ⅜″ projection on walls, ceilings, and other objects. Additional larger projection heights can be provided in other embodiments. Although FIG. 1 depicts clip 20 secured to panels and rail 22 secured to wall 14, the configurations can be reversed with clip 20 secured to wall 14 and rail 22 secured to panel 12 with appropriate length adjustments.

[0023] Each embodiment of system 10 is provided in a variety of versions with the lengths of the components being customizable. The drawings depict two exemplary configurations that include a light duty version and a heavy duty version. The light duty versions have short clips that snap into long rails. The heavy duty versions have long clips and long rails. In the exemplary embodiment depicted in the drawings, the light duty version is sold with clips 20 having a two inch length, and rails 22 in seventy-two inch or one hundred and forty-four inch lengths. The heavy duty version is sold with clips 20 being as long as rails 22 or in lengths such as half of the length of rails 22. This allows for the highest weight capacity and also aids in alignment. Again, these are exemplary and different length combinations are possible and fall under the scope of this disclosure.

[0024] Views of exemplary clip 20 embodiments are shown in FIGS. 2-7 with the profiles of the embodiments being the same. The profiles are seen in FIGS. 3, 5, and 7. The lengths are different in the different configurations. Clip 20 includes a base 30 and two arms 32 that project from the ends of base 30. In the exemplary embodiment, each arm 32 projects perpendicular to base 30. In other embodiments, arms 32 project at a different angle such as an angle from 90 degrees to 45 degrees (inwardly or outwardly with respect to base 30). Each arm 32 has an angled latching projection 34 that projects outwardly from arm 32. Latching projections project outwardly away from each with respect to the body of clip 20. In FIGS. 2 and 4, clip 20 is arranged vertically and the outward projection directions are vertically up and vertically down. As noted above, the directional terms are used to describe the arrangement depicted in the drawings. When clip is on a ceiling and arranged horizontally, the outward projection directions are horizontal. Each latching projection 34 has a flat rail side 36 and a flat panel side 38 that meet at a peak with rail side 36 having a more gentle slope than panel side 38. The more gentle slope of rail side 36 makes it easier to install panel 12 than to remove panel 14. Base 30 and arms 32 cooperate to have some flexibility that help clip 20 snap fit into rail 22.

[0025] Base 30 of clip 20 has a raised middle portion 40 and two end portions 42 from which arms 32 project. Raised middle base portion 40 increases the rigidity of clip 20 when provided in longer lengths. In the exemplary configuration, middle portion and end portions 42 are parallel to panel 12 and arms 32 project substantially perpendicular to panel 12. Middle base portion 40 is spaced from the inner surface of panel 12 with the outer surfaces of end portions 42 being flat and configured to engage panel 12. End portions 42 define offset fastener openings 44 for the fasteners 46 that connect panel 12 to clip 20.

[0026] Two embodiments of rail 22 are depicted in FIGS. 8-11 with the second version being twice the length of the first version. Both embodiments have the same profile depicted in FIGS. 9 and 11. Rail 22 includes a base 50 with feet 52 projecting outwardly from opposite ends of base 50. In the exemplary embodiment, each foot 52 projects substantially perpendicular to base 50. In other embodiments, each foot 52 projects at a different angle such as an angle from 90 degrees to 45 degrees (either inwardly or outwardly) to complement the angle of arms 32 on clip 20. Each foot 52 has an angled latching projection 54 that projects outwardly from foot 52 and inwardly with respect to the body of rail 22 toward the other latching projection 54. As such, to receive latching projections 34 from clip 20, latching projections 54 on feet 52 move apart when clip 20 is pressed into rail 22. The structure of base 50 helps this movement. Each latching projection 54 has a flat clip side 56 and a flat wall side 58 that meet at a peak with clip side 56 having a more gentle slope than wall side 58. The more gentle slope of clip side 56 makes it easier to install panel 12 than to remove panel 14.

[0027] Base 50 includes a middle portion 60 having a rear surface that lays flat against the surface of 14. Middle portion 60 defines fastener openings 62 that receive fasteners 64 that secure base 50 to wall 14. Fastener openings 62 are centered with respect to rail 22 while fastener openings 44 are offset from the center of clip 20 so that the fasteners do not interfere with each other as can be seen in FIG. 1.

[0028] Base legs 70 project from each outer end of middle portion 60. Each base leg 70 is offset outwardly (away from surface of 14) from the rear surface of middle portion 60 such that there is space between the wall surface and the rear surface of each base leg 70 when rail 22 is mounted to wall 14 as shown in FIG. 1. Each base leg 70 is thus cantilevered from middle portion 60. The cantilever configuration helps feet 52 flex open to receive arms 32. In the exemplary embodiment, each base leg 70 is spaced from and extends substantially parallel to the surface of wall 14 to which rail is mounted. Each base leg 70 is thus substantially parallel to middle portion 60 of base 50. Each base leg 70 has an end portion 72 from which leg 52 projects. To further help legs 52 flex open, each end portion 72 defines at least one area of reduced thickness 74. In the exemplary embodiment, two spaced areas of reduced thickness are defined by base 50 to help legs 52 move. Each area of reduced thickness has a base thickness of a third to two-thirds of the base thickness at that location.

[0029] A shelf 80 projects forwardly from each base leg 70. Each shelf 80 is located and sized to receive the end of an arm 32 when clip 20 is engaged with rail 22 as shown in FIG. 1. With reference to FIG. 1, the upper arm 32 of clip 20 is shown resting on shelf 80. This configuration helps rail 22 support the weight of panel 12. The lower arm 32 can be spaced from lower leg 52 as shown in FIG. 1 or, more typically, engages lower foot 52 to distribute the weight of panel 12.

[0030] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the above description and attached illustrations are examples and the invention is not limited to the exact details shown or described. Throughout the description and claims of this specification the words “comprise” and “include” as well as variations of those words, such as “comprises,”“includes,”“comprising,” and “including” are not intended to exclude additives, components, integers, or steps. Up, down, left, right, top, and bottom are in reference to the orientation of the drawings.

Claims

1. A mounting system comprising:a first mounting component capable of being secured to a mounting structure;a second mounting component capable of being secured to an item to be mounted to the mounting structure; the first and second mounting structures selectively engaging each other in a snap-fit, zero-lift mounting configuration;one of the first and second mounting components having a base that includes a middle base portion with base legs projecting in opposite directions from the middle base portion; each of the base legs being cantilevered from the middle base portion;a foot projecting from an end portion of each of the base legs; each of the feet having a latching projection; andthe other of the first and second mounting components having a base and first and second arms projecting outward from the base; each of the first and second arms having a latching projection capable of engaging one of the latching projections of the one of the first and second mounting components.

2. The system of claim 1, wherein the base of the other of the first and second mounting components has a raised middle portion with two end portions projecting in opposite directions from the raised middle portion; the raised middle portion having a rear surface and each of the two end portions having a rear surface; the rear surface of the raised middle portion being offset in the outward direction of the arms from the rear surfaces of the end portions.

3. The system of claim 2, wherein the middle base portion defines at least one fastener opening and wherein each of the two end portions of the base of the other of the first and second mounting components defines at least one fastener opening.

4. The system of claim 1, wherein the latching projections of the feet project toward each other and the latching projections of the arms project away from each other.

5. The system of claim 1, wherein each of the latching projections includes a first side and a second side that are joined at a peak.

6. The system of claim 5, wherein each of the first and second sides are flat.

7. The system of claim 6, wherein one of the first and second sides of each latching projection is longer than the other of the first and second sides.

8. The system of claim 1, wherein the middle base portion has a rear surface and each of the base legs having a rear surface; each of the rear surfaces of the base legs being offset from the rear surface of the middle base portion.

9. The system of claim 1, wherein each of the end portions of the base legs includes a shelf spaced from the foot that projects from that end portion.

10. The system of claim 9, wherein each end portion defines a first area of reduced thickness at the location where the foot projects from the end portion.

11. The system of claim 10, wherein each end portion defines a second area of reduced thickness at the location where the shelf projects from the end portion.

12. The system of claim 11, wherein the second area of reduced thickness is spaced from the first area of reduced thickness.

13. A zero-lift, snap fit panel mounting system comprising:a rail capable of being secured to a mounting structure;a clip capable of being secured to a panel to be mounted to the mounting structure; the clip engaging the rail to secure the panel to the mounting structure;the rail having a rail base with first and second end portions;a foot projecting from each of the end portions of the rail base; each of the feet having a latching projection;each of the end portions of the base of the rail including a shelf spaced from the foot that projects from that end portion;the clip having a clip base and first and second arms projecting outward from the clip base; each of the first and second arms having a latching projection capable of engaging one of the latching projections of the feet; andone of the arms being supported by one of the shelves.

14. The system of claim 13, wherein the base of the rail includes a middle base portion with base legs projecting in opposite directions from the middle base portion; each of the base legs being cantilevered from the middle base portion.

15. The system of claim 14, wherein the middle base portion has a rear surface and each of the base legs having a rear surface; each of the rear surfaces of the base legs being offset from the rear surface of the middle base portion.

16. The system of claim 13, wherein each end portion defines a first area of reduced thickness at the location where the foot projects from the end portion; each end portion defines a second area of reduced thickness at the location where the shelf projects from the end portion; and the second area of reduced thickness being spaced from the first area of reduced thickness.

17. The system of claim 13, wherein each of the latching projections includes a first side and a second side that are joined at a peak; each of the first and second sides being flat; and one of the first and second sides of each latching projection is longer than the other of the first and second sides.

18. A zero-lift, snap fit panel mounting system comprising:a rail capable of being secured to a mounting structure;a clip capable of being secured to a panel to be mounted to the mounting structure;the rail having a rail base that includes a middle base portion with base legs projecting in opposite directions from the middle base portion; each of the base legs being cantilevered from the middle base portion;a foot projecting from an end portion of each of the base legs; each of the feet having a latching projection;each of the end portions of the rail base including a shelf spaced from the foot that projects from that end portion;each end portion defining a first area of reduced thickness at the location where the foot projects from the end portion; each end portion defines a second area of reduced thickness at the location where the shelf projects from the end portion; and the second area of reduced thickness being spaced from the first area of reduced thickness; andthe clip having a clip base and first and second arms projecting outward from the clip base; each of the first and second arms having a latching projection capable of engaging one of the latching projections of the feet.

19. The system of claim 18, wherein each of the latching projections includes a first side and a second side that are joined at a peak; each of the first and second sides being flat; and one of the first and second sides of each latching projection is longer than the other of the first and second sides.

20. The system of claim 18, wherein the clip base has a raised middle portion with two end portions projecting in opposite directions from the raised middle portion; the raised middle portion having a rear surface and each of the two end portions having a rear surface; the rear surface of the raised middle portion being offset in the outward direction of the arms from the rear surfaces of the end portions; the middle base portion defines at least one fastener opening and wherein each of the two end portions of the clip base defines at least one fastener opening.

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