Thin flat panel construction apparatus and method

THIN FLAT PANEL CONSTRUCTION APPARATUS AND METHOD

The present invention relates to a thin flat panel construction apparatus and method for the provision of light modular knock-down structures designed to support a wide range of modern lightweight merchandising systems currently used in the retail industry but also suitable for many other diverse applications where support structures are required. Many merchandising systems are designed to hang on and/or be supported by standard shelving systems ¹⁰ found in the majority of retail outlets, but have not heretofore been provided as free standing units.

Prior Art constructions of free standing structures in the retail industry fall into the following categories:

(a) tubular metal structures (b) wire mesh and metal structures (c) pressed sheet metal and metal structures (d) timber structures with metal frames (e) timber structures without metal frames

Despite many advances and innovative developments in all 20 these traditional construction methods, many inherent disadvantages still remain rendering the structures unsuitable for the support of lightweight modular merchandising systems for the following reasons:1 . Bulky to pack and store ²⁵ 2. Heavy to carry

3. Visually 'heavy' and unattractive

4. Inefficient for short run

5. Inflexible in use

6. Incompatible for use with

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production modern lightweight

OPEN TO PUBLIC INSPECTION

UNDER

SECTION 26 AND RULE 23

JNL. No . H.kftr OF

893022 materials.

Referring to the latter, the use of clear acrylic material in the retail industry for merchandising systems has escalated in recent years due to the suitability of the material for the purpose and the introduction of new innovative modular designs offering major benefits to the retailer in terms of:

- improved product presentation more efficient space utilisation flexibility for seasonal changes compatibility with all shelving equipment increased sales space per square metre

The main thrust of the present invention is towards providing a construction system to support these new modular merchandising systems which is modular, light weight and flexible in use. Also the construction should be cheap and efficient to manufacture, ideally, on the same equipment used in the manufacture of the acrylic merchandising systems referred to.

Modern developments in the manufacture of strong lightweight thin flat panels in various materials and combinations of materials have provided the basis for the invention. Suitable materials include:

Alucobond sheet comprising wafer thin aluminium sheets laminated to a core of polyethylene plastic.

Fibreboard sheet comprising highly compressed timber and paper pulp.

Foamex rigid foamed PVC sheet and similar plastic sheets.

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Traditional plywood sheet, etc. etc.

All the foregoing and similar rigid flat panel materials are ideal for the creation of modular lightweight structures, which would be compatible with the merchandising systems referred to and also compatible with modern retail interior design requirements. However in terms of providing flat pack modular knock-down structures in these thin panel materials, it has been found that no satisfactory jointing system is available to connect and disconnect panels as required. While numerous jointing systems are available for thick flat panels of 12mm and over, none are available for the thin (5mm-10mm) panels which are required in this application. Furthermore the jointing systems designed for thick panels cannot be scaled down to fit 5mm to 10mm panels as these panels are too thin to accommodate them.

The present invention provides a construction for a display or merchandise support for use in merchandising, the construction comprising at least two thin panels of a lightweight material disengageably connected together by a connector means, said connector means including a connector having two portions, one of which is rigidly secured to the first panel and the other portion being disengageably connected to the second panel through an orifice provided in the second panel.

Advantageously, the first portion of the connector is in the form of a socket securable to a formation on the first panel and the second portion is in the form of a resilient clip extendable through the orifice and resiliently engageable across the thickness of the second panel.

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Preferably, the formation on the first panel comprises a tongue formed between two slots, and the socket is engageable over the tongue and is securable thereto by an interference fit, glue or any other suitable fixing means.

Conveniently, the socket includes a pair of flanges, one at each side thereof, with each flange extending beyond the slots forming the tongue on the first panel so as to strengthen the structure.

Alternatively, the formation on the first panel comprises a slot and the socket is engageable with the slot by suitable fixing means, such as by snap-fit. The first panel is advantageously provided with a cut out portion in its edge into which the socket nests to provide a smooth edge in the finished construction.

Preferably, the structure formed by the panels connected together is provided with means to support the particular merchandising apparatus, equipment or device.

Conveniently, a shelf is connected to at least one panel by the construction as described above and to a further panel by means of a formation provided in the shelf, the formation extending through an orifice in the further panel for robustly supporting the shelf.

Advantageously, a plug or similar element is inserted into the orifice to prevent unintentional disengagement of the clip portion from the second panel.

The invention also provides a method of assembling a construction from at least two flat thin panels for a display support or merchandise support for use in merchandising, the method comprising providing a formation on a first panel, securing a first portion of a connector device to the formation, providing an orifice in a second panel, passing a second portion of the connector through the orifice and disengageably connecting the second portion of the connector to the second panel.

The invention thus presents a solution to the problem of connecting thin flat panels together in a modular demountable structural system and furthermore provides connection means for the integrated support of known merchandising systems (e.g. gravity feed apparatus, display rack apparatus for flat or flat packed products such as disclosed in our co-pending Irish Patent Applications Nos. 1574/87, 3699/88 and 920685, the disclosures of which are incorporated herein by reference).

The structures thus created have major advantages over prior art structures in terms of modularity, light weight, strength, flexibility, visual attractiveness and compatibility with known modular merchandising systems and similar products. In addition, many other applications are envisaged for the use of this construction concept illustrated in the drawings accompanying this application but not confined only to these applications or this industry sector.

The present invention uses thin flat panels machined with various slots either in multiple form for standard construction systems or in specific locations to suit specials or contract constructions. The slots accommodate various connectors for jointing of the panels together and also for the connection of various merchandising systems $930223 directly to the structure.

The invention will hereinafter be more particularly described with reference to the accompanying drawings which show by way of example only, various embodiments of thin panel constructions according to the invention and a number of components used to produce such constructions.

In the drawings:

Figure 1 is a perspective view of a vertical panel connector clip used to produce constructions according to the invention, with the connector clip mounted on a vertical panel in a position to engage with an orifice on a second panel at right angles to the first panel;

Figure 1a is a section through the two connected panels and the components of the connection;

Figure 2 is an exploded view of the connector clip and the vertical panel on which it is secured;

Figure 3 is a cross-sectional view through the connector and panel;

Figure 4 is an exploded view of an alternative embodiment of a vertical panel connector clip and panel;

Figure 4a is a section through the connector clip of Figure 4, connected onto the panel;

Figure 5 is an exploded view of a horizontal panel connector;

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Figure 6 is a section through a back panel of a construction showing a hanger component engaged thereon;

Figure 6a is a section through the back panel of Figure 6 fitted with an alternative construction of hanger component;

Figure 7 is a perspective view of one embodiment of construction of a sloping shelf arrangement according to the invention illustrating the use of the hanger component;

Figure 7a is an exploded perspective view of a sloping shelf arrangement very similar to that of Figure 7;

Figure 8 is a perspective view of a second embodiment of construction according to the invention mounted on a static base;

Figure 8a is a front view of a portion of the second embodiment modified so as to have a mobile base;

Figure 9 is a perspective view of a third embodiment of construction in the form of a stackable units;

Figure 9a is a section through the assembled embodiment of Figure 9;

Figures 10a, 10b and 10c are a perspective view, a side view and front view of a further embodiment of construction in the form of a sloping shelf arrangement without a back panel;

Figure 11 is a cross-sectional view of a fifth embodiment of construction showing how various types of merchandising

S039223 shelves can be accommodated;

Figure 12a and 12b are a plan view and side view of a sixth embodiment of construction according to the invention;

Figure 13a and 13b are two perspective views of a seventh embodiment of construction in the form of a cube display unit, respectively showing a partially exploded and assembled view.

Figures 14a and 14b are plan and side views respectively of a mobile display unit accommodating differing embodiments of constructions according to the invention;

Figures 15a and 15b are plan and side views respectively of a unit for merchandising large items such as duvets, pillows and the like;

Figure 16 is a side view of a stepped display stand;

Figure 17 is a perspective view of a single or double sided greeting card or magazine stand;

Figure 18 is a partial sectional view of a single or double sided gravity-feed display unit; and

Figures 19 and 19a are perspective and side views respectively of a single or double sided construction having a sloping back.

In the drawings, three basic types of formations are provided on the panels used to produce the constructions, namely:

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Type A. twin slots on edges of panels to accommodate injection moulded edge connector clips generally located in back panels and similar (see Figures 1, 2 and 5 or 4);

Type B. short slots or holes generally located in side panels to accommodate connector clips referred to in A. above (see Figure 1); and

Type C. longitudinal slots, generally located in back panels, to accommodate extruded PVC hanger, or similar components, which in turn support the connection of various merchandising systems to the structure (see Figures 6 and 7).

The edge connector clips 10 referred to in A. above have a socket 11 and a resilient clip 13 and are manufactured from a tough material such as polycarbonate (see Figures 1 and 2). The socket 11 is hollow in configuration and is driven onto the tongue 15 between the twin slots 14 referred to above and is secured by interference fit friction and/or aided by gluing.

An alternative connector, shown in Figures 4 and 4a, has a socket 411 with a pair of resilient legs 412, the feet of each of which are formed with an inwardly facing tooth 413. The socket fits into a cut-out 415 in the panel edge and the teeth 413 engage in a slot 414 of the panel as a snap fit when the socket is pressed onto the panel.

The panels fitted with these connectors are offered up at right angles to panels with slots of type B, the resilient clips 13 of the connectors are pushed through the slots (see 19 in Figure 1) and knocked downwards into position thus securing the two panels at right angles to one another

S#3 0223 and forming the basis of the structure. A locking cap 20 (Figures 1 and 1a) is pushed into the aperture and prevents the connector from moving upwards in the slot into disconnect mode. The cap 20 has a pair of toothed flanges 201 which lock the cap behind the slot 19, and a locating pin 202. The cap 20 also serves the function of covering the connector 10 and slot 19 in the side panel.

This assembly process is repeated to achieve a three sided structure and so on to complete the required structural configuration.

Referring to Figure 6, the extruded PVC (or similar) profile 30 (Type C), with dog-leg configuration, is offered up to a longitudinal slot 31 in a back panel and rotated through 90° thus forming a hanger into which various merchandising system components can be connected. As shown in Figure 6a, an alternative arrangement has a shelf 63 component supported by a routed tongue engaged in the back panel slots. In that case, the shelf is supported at its forward edge to side panels, as shown in Figure 7, using the connector 10 or 50 shown in Figures 1 or 5. This completes the structure in its simplest form.

Numerous variations on this theme can achieve a multiplicity of structures e.g. single, double and multi sided displays illustrated in the drawings but not confined only to those concept ideas.

In Figure 5, the connector 50 is orientated at right angles to the connector 10 so as to support a horizontal display. This type of connector 50 is used in the arrangement shown in Figure 13a. Both connector 10 and connector 50 have an extension 60 which extends beyond the slots 14 of the panel

022j so as to strengthen the structure and make it more resistant to being broken off the tongue 15 between the slots 14.

Various modifications of the construction are shown in Figure 7a, although it will be appreciated that these are applicable, as appropriate, to the other described embodiments of the construction of the invention. For example, the apertures 719 in the end panel for receiving the connectors may be rectangular, circular or any other suitable shape, and the end cap may be shaped to compliment the apertures. In the Figure 7a embodiment, a tie panel 701 may be optionally provided.

In Figure 9, a H-cross section PVC or aluminium extrusion 90 is located between the two stackable structures. As shown in Figure 9a, the H-cross section extrusion receives the lower and upper rims respectively of the upper and lower structures of the stack.

The fifth embodiment of construction shown in Figure 11 has various examples of types of merchandising shelves arranged in accordance with the invention. In descending order these are:

1. a horizontal shelf with upstand for fragile products

2. horizontal shelf with downturn for products

3. back sloping and stepped shelf for slab chocolate bars and similar problematic products

4. sloping shelf with upstand for boxed products on gravity feed to the front of shelf.

Further embodiments of construction are shown in Figures 12 to 19. Exemplary uses for these various constructions

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are:

Figure 12a and 12b, a standing unit accessible from four sides, for magazines, cassettes and the like;

Figure 13a and 13b, a cube display structure for hardware and the like;

Figure 14a and 14b, a wheelable unit for displaying small goods and magazines, for example at a supermarket checkout area;

Figure 15a and 15b, a stand accessible from four sides and having large compartments for bulky items such as duvets, pillows and the like;

Figure 16, a stepped display, for example for small product display in a supermarket or pharmacy;

Figure 17, a single sided or double sided stand for greeting cards, magazines or the like;

Figure 18, a single or double sided display for boxes or other items supplied by gravity feed; and

Figure 19 and 19a, a single or double sided display with a sloping back, suitable for displaying articles such as footware.

Any of the constructions described may be fabricated from clear or tinted plastics material, or any other suitable lightweight material.

An illuminated sign box, as shown for example in Figure

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18, may be provided with any of the constructions described.

It will of course be understood that the invention is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the invention as defined in the appended claims.