Melt-bondable panel mounting brackets, systems, and methods

Abstract

Panel mounting components and systems for mounting objects, such as decorative architectural resin panels, can include a melt-bondable panel mounting bracket. Melt-bondable panel mounting brackets can include one or more bonding features configured to be pressed or rotated into a resin-based panel, thereby allowing additional components, such as a twist-lock mounting assembly, to be secured directly to a single side of a panel. Methods of securing melt-bondable panel mounting brackets to a resin panel can include rotating the melt-bondable panel mounting brackets at high speeds of rotation to cause a portion of the resin panel to melt and bond about the melt-bondable panel mounting brackets.

1 . A melt-bondable panel mounting bracket for mounting an object, such as a decorative architectural resin-based panel, to a support structure comprising:
 a body;   one or more bonding protrusions extending a first distance in a direction generally away from the body;   one or more ridges extending generally transversely from the one or more bonding protrusions; and   an alignment stem extending a second distance in a direction generally away from the body, the second distance being greater than the first distance.   
     
     
         2 . The bracket as recited in  claim 1 , further comprising:
 a bonding surface from which the one or more bonding protrusions extend; and   one or more recesses extending generally into the bonding surface.   
     
     
         3 . The bracket as recited in  claim 1 , further comprising one or more flow recesses extending generally transversely into the one or more bonding protrusions. 
     
     
         4 . The bracket as recited in  claim 1 , further comprising a connection member configured to connect the melt-bondable panel mounting bracket to an additional hardware component. 
     
     
         5 . The bracket as recited in  claim 4 , further comprising a slot extending into the connection member, wherein the slot is configured to be placed about a standoff or screw. 
     
     
         6 . The bracket as recited in  claim 1 , further comprising an attachment interface configured to be coupled to a rotation tool. 
     
     
         7 . The bracket as recited in  claim 5 , wherein the attachment interface comprises a hex-nut shaped extension coupled to the body. 
     
     
         8 . The bracket as recited in  claim 1 , wherein the alignment stem comprising a cylindrically shaped column. 
     
     
         9 . A system for securing a melt-bondable panel mounting bracket into a resin panel, comprising:
 a drill interface configured to couple a melt-bondable panel mounting bracket to a rotation tool;   a fender coupled to the drill interface; and   a stop guide configured to receive the melt-bondable panel mounting bracket therein;   wherein the stop guide prevents advancement of the melt-bondable panel mounting bracket and the fender relative to the stop guide after the melt-bondable panel mounting bracket has been advanced a predetermined distance into the resin panel.   
     
     
         10 . The system as recited in  claim 9 , further comprising a spring configured to bias the fender away from the stop guide. 
     
     
         11 . The system as recited in  claim 9 , wherein the drill interface comprises a bit having a first end configured to be received within a rotation tool, and a second end configured to receive an attachment interface of the melt-bondable panel mounting bracket. 
     
     
         12 . The system as recited in  claim 9 , wherein the stop guide is configured to be rotationally fixed. 
     
     
         13 . A method of mounting a panel to a support structure, comprising:
 drilling a guide hole at least partially through a resin panel;   inserting an alignment stem of a melt bondable mounting bracket into the guide hole;   rotating the melt-bondable panel mounting bracket at a high rate of rotation thereby causing resin of the resin panel to melt about one or more ridges of the melt-bondable panel mounting bracket and thereby creating a bond between the melt-bondable panel mounting bracket and the resin panel; and   advancing the melt-bondable panel mounting bracket into the resin panel.   
     
     
         14 . The method as recited in  claim 13 , further comprising securing a drill interface to the melt-bondable panel mounting bracket. 
     
     
         15 . The method as recited in  claim 14 , wherein securing a drill interface to the melt-bondable panel mounting bracket comprises securing a hex nut within a connection o member of the melt-bondable panel mounting bracket. 
     
     
         16 . The method as recited in  claim 13 , further comprising securing the melt-bondable panel mounting bracket to a support structure via a standoff. 
     
     
         17 . The method as recited in  claim 16 , further comprising positioning the standoff within a slot of the connection member of the melt-bondable panel mounting bracket. 
     
     
         18 . The method as recited in  claim 16 , further comprising:
 securing one of a locking pin and a housing to a support structure;   securing the other of the locking pin and the housing to the melt-bondable panel mounting bracket;   inserting the locking pin into the housing, wherein:
 the locking pin automatically rotates relative to the housing into a locked position; and 
 the housing prevents the locking pin from being removed from the housing. 
   
     
     
         19 . The method as recited in  claim 13 , further comprising rotating the melt-bondable panel mounting bracket at between about 1700 revolutions per minute and about 2200 revolutions per minute. 
     
     
         20 . The method as recited in  claim 13 , further comprising advancing the melt-bondable panel mounting bracket into the resin panel until a fender contacts a stop guide, thereby preventing further advancement of the melt-bondable panel mounting bracket into the resin panel.