Note: Descriptions are shown in the official language in which they were submitted.
CA 02445476 2003-10-17
PANEL FITMENT SYSTEM
FIELD OF THE INVENTION
This invention relates to a panel fitment or interlock system for interlocking
panels or sheet material into a covering for a wall. The system finds
particular use in
the renovation of elevator cabs when it is desired to cover existing wall
surfaces during
refurbishment of older cabs.
BACKGROUND OF THE INVENTION
When retrofitting or refurbishing elevator cabs it is not possible, in most
instances, to place new panels of wall covering material within the cab as a
single
sheet, capable of covering an entire wall. It is not possible to move an
entire wall-
covering sheet through the elevator doors and hence it is necessary to effect
the
covering by means of a plurality of sheets cut to fit the wall to be covered,
which
sheets must be joined along abutting edges. The panels will not exhibit much
flexibility
and they will have a substantial weight which must be borne by whatever
fastening
system is available. Different fastening systems have been proposed, including
those
found in PCT publication WO01/43607 and US Patent No. 6,101,778. These systems
exhibit drawbacks in production and utilization making them undesirable for
efficient
and economical retrofitting of elevator cabs.
SUMMARY OF THE INVENTION
The system of the present invention overcomes the problems of the prior art by
utilizing an interlock or fitment member that is preferably extruded from
aluminum,
with a rather simple cross-section, the member fitting with corresponding
recesses or
cut-outs in the panels to be applied to a supporting surface, such as the wall
of an
elevator cab. The member has a generally T-shape with a pair of first or
rearmost
flanges extending laterally from a central web portion, the web portion being
perpendicular to the rearmost flanges. A second set of flanges extend
laterally from
the central web and are spaced from the rearmost flanges. The interlock member
strengthens the joint between the panels by having one of the second flanges
being
received in a kerf cut in an adjacent edge of the panel. Optionally, one of
the rearmost
flanges can be fastened to the panel as by adhesive or removable fasteners
such as a
plurality of screws. Each rearmost flange of the member fits into a cut-out
rabbet
1
CA 02445476 2007-02-12
portion of the rear face of the panel.
In another embodiment of the invention the fitment member is utilized with
thin
aluminum panels preferably carrying a decorative covering thereon. The
connection
between the fitment member and each panel is accomplished by way of an H-
shaped
extruded spacer. Two parallel legs of the spacer define a kerf that has a
tight fit with
the second flanges of the fitment member. The other two parallel legs of the
spacer
have through holes therein to receive appropriate fasteners to fix the spacer
to the
rearmost flange of the fitment member and to the panel itself, respectively.
For
additional strength, if needed, a plurality of channel members can be adhered
or
fastened to the rear surface of the panel extending normal to and between the
fitment
members. This embodiment of the invention will be lighter in weight than the
first
embodiment of the invention which utilizes solid core panels.
Generally speaking therefore the present invention may be considered as
providing a panelling system for covering a substrate with a plurality of
panels, the
system comprising at least two panels adapted for fitment together along
adjacent
edges thereof and a fitment member adapted for connection to the at least two
panels;
each panel having a panel body, an outer surface, an inner surface and a
plurality of
edges, a kerf extending into the panel body between the inner and the outer
surfaces
from at least one of the panel edges, and a rabbet portion extending into the
panel
body at the inner surface from the at least one panel edge; and the fitment
member
including a central web portion, a pair of first flanges extending laterally
from the web
portion and adapted for a tight fit in a respective panel kerf, and a pair of
second
flanges extending from one end of the web portion and adapted for a flush fit
in a
respective rabbet portion of a panel, one of the second flanges of each
fitment member
including means for securing that fitment member to the panel associated
therewith
and the other of the second flanges including means for securing the fitment
member
to the substrate to be covered, whereby with the at least two panels engaging
the
fitment member along the respective at least one panel edges, the panels will
be
spaced from each other by the thickness of the fitment member web portion and
the
panels will be interconnected by way of the first and second flanges engaging
the
respective kerfs and rabbet portions.
The invention may also be considered as providing a fitment member for use in
a panelling system to interconnect at least two panels together along adjacent
edges
thereof, the fitment member comprising an elongated central web portion, a
pair of
2
CA 02445476 2007-02-12
first flanges extending laterally from the web portion intermediate the ends
thereof and
along the length thereof, and a pair of second flanges extending from one end
of the
web portion, each of the second flanges being sized for mating reception in a
corresponding rabbet portion formed in an inner surface of a panel along the
edge
thereof, one of the second flanges of each fitment member including means for
securing that fitment member to the panel associated therewith and the other
of the
second flanges including means for securing the fitment member to a substrate
to be
covered, whereby in use a connecting portion of each panel will be tightly
engaged
2a
CA 02445476 2003-10-17
by the first and second flanges on each side of the web portion such that the
panels
will be spaced apart by the thickness of the web portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail with reference to the
drawings
wherein:
Fig. 1 is a cross-sectional view of an interlock or fitment member in
accordance
with this invention;
Fig. 2 is a cross-sectional view showing one embodiment of the fitment member
in position between a pair of panels for fitting to a supporting surface; and
Fig. 3 is a cross-sectional view of a panel used with this interlock or
fitment
system illustrating the cut-outs that co-operate with the interlock member.
Fig. 4 is a view similar to Fig. 2 showing the use of a second embodiment of
the
fitment member of this invention.
Fig. 5 is a cross-sectional view of a panel member having a decorative cap in
accordance with this invention extending along one edge thereof.
Fig. 6 is an enlarged partial cross-sectional view of a fitment member of this
invention showing the arrangement of countersunk through holes for attachment
of the
fitment member to a panel and to a wall.
Fig. 7 is a cross-sectional view of another embodiment of the paneling system
of the invention utilizing the fitment member with a set of light-weight
panels.
Fig. 8 is a cross-sectional view of a spacer rTiember that is used with the
embodiment of Fig. 7.
Fig. 9 is a rear elevational view of a panel as used with the embodiment of
Fig.
7.
Fig. 10 is an enlarged partial cross-sectional view of a panel with a
strengthening
channel member connected thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fig. 1 shows in cross-section an interlock or fitment member 10 that is at the
heart of the present invention. The member 10 would typically be extruded from
aluminum to have the indicated cross-section and thus would be an integral
piece of
the desired length. It should be understood that the length of the member will
be
determined by the particular application with which it is to be utilized and
that each
3
CA 02445476 2003-10-17
member will likely be cut from an extrusion that is originally longer than the
required
length. While the member is preferably extruded from aluminum it could also be
extruded from a suitable plastics material, especially if the possibility of
fire is not
something that has to be considered in the particular application.
The member 10 is seen as including a central web portion 12 from which
extends a pair of first or rearmost flanges 14, giving the member a generally
T-shape.
A pair of second, shorter, flanges 16 extends laterally and oppositely from
the central
web portion 12, spaced from the rearmost flanges and generally parallel
thereto.
Preferably the outermost ends of the second flanges 16 are slightly tapered as
seen in
Fig. 1.
Fig. 3 illustrates in cross-section a panel 18 that would be used with the
interlock
or fitment member 10. The panel 18 will include a core 20, likely of a
particle board,
MDF (medium density fiberboard) or similar material, likely treated to be fire
retardant.
The panel will also likely include a thin decorative outer layer 22 of a
different material,
giving the panel when in place a particularly attractive appearance.
Usually, but not exclusively, a panel 18 will be positioned such that its
longest
edges are parallel to the floor of the elevator cab. The upper and lower edges
of the
panel will be cut so as to be provided with a recess or kerf 24 extending the
full length
of the panel edge. The kerf 24 is sized to receive a second flange 16 of a
fitment
member 10 in an interference fit therewith. Along the rear face of the panel
18
adjacent the edge containing the kerf 24 there is provided a rabbet or
rectangular cut-
out 26 sized to mate with one of the rearmost flanges 14 of the fitment
member. The
kerf and rabbet portion formed in this solid core panel may be considered as a
connecting portion for the panel
Turning now to Fig. 2 the manner in which the fitment member 10 is interlocked
with a pair of panels 18 is shown. The fitment member 10 is first of all
fitted with the
lowermost panel by sliding the lower second flange 16 into the kerf 24, the
rearmost
flange 14 being matingly received within the rabbet 26. Depending on the
weight of
the panels this interlocking fitment of the fitment member 10 with the
lowermost panel
might be sufficient to lock the panel and the member together. If additional
strength
at the joint is required then it would be possible to utilize a suitable
adhesive within the
kerf 24 and the rabbet 26 which, when set, will prevent the fitment member
from
parting company from the panel during assembly of an entire wall. Other
fastening
means, including screws, rivets, staples, etc. might be used in place of an
adhesive.
4
CA 02445476 2003-10-17
Once the fitment member has been secured to a lower panel, the panel with the
fitment member in place is brought into abutment with a supporting surface and
secured thereagainst, as by screws or other fastening means extending through
the
upper of the rearmost flanges (see Fig. 6). Once the lower panel is in
position an
upper panel 18 is brought into registry with the exposed upper portions of the
fitment
member, the kerf 24 in the lower edge of the upper panel mating with the upper
second flange 16 of the fitment member. Since the upper panel will be resting
on the
fitment member, as on the central web thereof, it is not essential that it be
specifically
adhered to the fitment member. Another fitment member will be applied to the
upper
edge of the upper panel and secured to the supporting surface, as was done
with the
first panel.
This assembly process continues until a desired height of panels is achieved.
The remaining fitment member is then "capped off" with a decorative topmost
panel
or left visible, depending on the desired decorative effect.
The fitment member shown in Fig. 1 has a flat free end to the central web.
This
is more clearly illustrated by the surface 30 as seen in Fig. 4. The web would
be the
same height as the distance from the rabbet 26 to the outer surface of the
panel such
that the end surface 30 of the central web would be flush with the panel
surface. The
flat free end could be finished so that it blends in with the decorative
surface of the
panels, giving the finished wall a continuous uninterrupted appearance.
Alternatively,
the end face could carry a finish which contrasts with the surface 22, giving
the
appearance of a decorative accent line between adjacent panels. The same
effect
could be obtained by providing the free end of the central web with an arcuate
or
ribbed end surface 28, as seen in Fig. 2. In this case the end surface 28
projects
slightly from the panel surfaces 22, giving the wall added detail and depth to
a surface
which would otherwise be completely flat.
As indicated above, the fitment member can be secured to a panel by the use
of threaded screws in addition to or in place of a suitable adhesive. Fig. 6
shows an
enlarged cross-section of the first flanges 14 of a fitment member, wherein it
is seen
that each of the flanges is provided with a countersunk through hole extending
therethrough. One of the flanges, the one to be mated with the lower panel of
Fig. 2,
has the countersunk hole 36 extending through the flange 14 from the back
surface,
so that a flat headed screw can be driven through the hole 36 into the panel
body, with
the screw head being flush with the back surface of the flange. The other
flange has
5
CA 02445476 2003-10-17
a countersunk hole 38 extending through the flange from the inner or front
surface of
the flange so that a flat headed screw can be driven through the hole 38 into
the
supporting wall to which the paneling system is to be attached. The holes 36
and 38
would be spaced apart along the length of the fitment member.
Also as indicated above it is possible to "cap off" the paneling system with a
decorative panel section custom fit to mate with the uppermost panel and to
fill in any
gap between the uppermost panel and a ceiling. It is also possible to "cap
off" an
uppermost, or any other panel, with a partial fitment member formed as a
decorative
cap member, as seen in Fig. 5. The cap member 32 has a single rearmost or
first
flange 14 for mating with a rabbet portion of a panel and a single second
flange 16
extending from the web portion 34 for fitment within a kerf 24 of a panel. In
this
embodiment of the fitment member the visible surface of the web portion 34
would
have an attractive appearance so that it will act as a finishing piece for the
paneling
system.
Figures 7 to 10 illustrate yet another embodiment of the present invention,
providing a attractive and light-weight paneling system based on the
principles of the
embodiments described above. With this system, shown by reference number 50,
an
extruded aluminum fitment member 52 having a central web portion and laterally
extending flanges as with the fitment member 10 described above is used to
interconnect a pair of decorative panels 70. In this case the panels 70 are
formed of
thin aluminum (preferably) sheet and in turn are covered with a sheet 72 of
decorative
material. To connect the fitment member 52 and a panel 70 together there is
provided
a spacer member 54 shown in greater detail in Fig. 8.
The spacer member 54 has a cross-section that can be described as being H-
shaped with one pair of parallel legs 57 extending in one direction from a
central web
portion 58 and a second pair of parallel legs 59 extending in an opposite
direction from
the central web portion 57. The legs 59 are thicker than the legs 57 and they
define
a kerf 56 therebetween, the kerf 56 being essentially the same size as a kerf
24 that
would be provided in a solid panel as described above. A plurality of holes 60
and 62
spaced apart along the length of the spacer extend through the legs 57.
With reference to Fig. 7 it will be seen that a spacer member 54 is secured to
a panel 70 along one edge thereof, as by way of a suitable adhesive and/or
suitable
fasteners extending through the panel and the through holes 60 in the spacer
member.
Preferably, the spacer member is affixed to the aluminum panel 70 before the
6
CA 02445476 2006-08-31
decorative covering 72 is applied to the outer surface of the panel. The
spacer
mernber 54 thus creates a connecting portion for a panel used in the present
invention
With reference again to Fig. 7 it will be seen that a spacer 54 fits with a
fitment
mernber on each side of the central web portion thereof, with the first
flanges of the
fitment member being received within a kerf of the corresponding spacer
member. The
spacer member is dimensioned so that one flat surface thereof will lie on the
upper
surface of the rearmost flange of the fitment member, ensuring a tight fit
between the
spacer member and the fitment member. As shown, the through holes 62 of each
spacer member will be aligned with corresponding through holes 64 in the
rearmost
flan(les of the fitment member for reception of suitable fasteners such as
machine
screws or "pop" rivets. An adhesive can be placed between the spacer member
and
the irearmost flange to enhance the attachment of the spacer member to the
fitment
meniber.
Fig. 9 illustrates the rear of a panel 70 having a fitment member extending
along
eachi of the upper and lower edges thereof, only the rear surface 76 of each
fitment
meniber being visible. The fitment member 52 and the spacers 54 provide
reasonable
lengthwise strength to the panel. In order to reduce or eliminate flex or
twisting of a
panel prior to assembly to a substrate a plurality of channel members 78 can
be affixed
to the rear of the panel either by a suitable adhesive or by suitable
fasteners such as
machine screws or "pop" rivets extending through the panel and the bight of
the
channel member on the center line 80. Preferably a channel member will be
affixed
to a panel adjacent each end thereof, with the channel members extending
normal to
the fitment members. Strengthening channel members 78 are a desirable feature
and
do not add much weight to a panel; they are not illustrated in Fig. 7.
The paneling system of Figs. 7 to 10 is applied to a substrate in the same
manner as the earlier described system. With reference to Fig. 7 a spacer
member 54
is first of all secured to a panel 70 and the covering 72 is applied thereto.
Then, a
fitment member is secured to the uppermost spacer member 54 of the lowermost
panel to be applied to a substrate, for example the spacer 54 shown to the
left of the
fitment member in Fig. 7. The panel with the fitment member extending along
the
upper edge thereof is placed against the substrate and suitable fasteners,
such as flat
headed screws are used to secure the fitment member to the substrate, by
passing
through the holes 64 in the upper, or right hand, rearmost flange of the
fitment
member. Then the next upper panel with a spacer member extending along the
7
CA 02445476 2003-10-17
lowermost edge of the panel 70 is lowered onto the fitment member along the
upper
edge of the lower panel so as to be interlocked therewith. Assembly continues
in a
vertical manner until an entire wall is created. Decorative caps can be
provided to
cover the uppermost fitment member or to fill in any gaps that might be left
between
the uppermost panel and a ceiling. Decorative angle strips can be positioned
at each
vertical end of a panel, if needed, to hide the end of the fitment member and
the side
edge of a channel member 78.
While the paneling system has been generally described with the fitment
members of the invention extending horizontally between vertically adjacent
panels it
is clear that they can also extend vertically between horizontally extending
panels. It
would likely be necessary in instances where the vertical and horizontal
fitment
members are use to trim one or both members at any corner where they meet to
ensure a clean appearance at such corners. It would also be possible to use
the
fitment members running at an angle to the vertical or the horizontal for a
different
visual effect, although the panels would have to be prepared appropriately to
accommodate an angled appearance.
The system of the present invention is inexpensive to manufacture and simple
to install. The ease of installation has the added bonus of reducing necessary
downtime associated with elevator maintenance.
While the fitment system of the present invention was developed in association
with elevator refurbishment it is clear that it could be used with original
manufacture
of elevator cabs and that it could also be used for any type of panel
installation where
the panels can be provided with edge kerfs and rabbets without seriously
affecting the
strength or other important properties of the panels.
8
