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.

We claim: 
     
         1 . A melt-bondable panel mounting bracket for mounting objects, including decorative architectural resin-based panels, to a support structure, the bracket comprising:
 a body;   one or more bonding protrusions integrated with the body, the one or more bonding protrusions extending from the body a first distance in a first 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 the first direction, 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 ways 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 , wherein the connection member comprises a female receptacle. 
     
     
         6 . 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. 
     
     
         7 . The bracket as recited in  claim 1 , further comprising an attachment interface configured to be coupled to a rotation tool. 
     
     
         8 . The bracket as recited in  claim 7 , wherein the attachment interface comprises a hex-nut shaped extension coupled to the body. 
     
     
         9 . The bracket as recited in  claim 1 , wherein the alignment stem comprising a cylindrically shaped column. 
     
     
         10 . A melt-bondable panel mounting bracket for mounting a decorative architectural resin-based panel to a support structure in a manner that at least partially conceals mounting hardware from a facing view of the architectural resin-based panel, the bracket comprising:
 a body;   a plurality of bonding protrusions integrated with the body, the plurality of bonding protrusions extending from the body a first distance in a first direction generally away from the body, each of the plurality bonding protrusions having an arcuate shape;   one or more flow ways separating the plurality of bonding protrusions from each other;   one or more ridges extending along the plurality of bonding protrusions, the one or more ridges being generally transverse to the plurality of bonding protrusions;   one or more bonding recesses extending generally transversely into the plurality bonding protrusions, the one or more bonding recesses separating the one or more ridges from each other; and   an alignment stem integrated with the body, the alignment stem extending from the body a second distance in the first direction, the second distance being greater than the first distance.   
     
     
         11 . The bracket as recited in  claim 10 , wherein the alignment stem is located approximately in alignment with a center axis of the body. 
     
     
         12 . The bracket as recited in  claim 11 , wherein the alignment stem is spaced away from the plurality of bonding protrusions. 
     
     
         13 . The bracket as recited in  claim 10 , wherein an outer surface of each of the plurality of bonding protrusions has a convex, partially cylindrical shape. 
     
     
         14 . The bracket as recited in  claim 13 , wherein the plurality of bonding protrusions are approximately concentric with the body. 
     
     
         15 . The bracket as recited in  claim 13 , wherein the alignment stem is approximately concentric with the bonding protrusions. 
     
     
         16 . The bracket as recited in  claim 13 , wherein the one or more ridges are located on or form the outer surfaces of plurality of bonding protrusions. 
     
     
         17 . The bracket as recited in  claim 10 , further comprising a channel at least partially surrounding the plurality of bonding protrusions. 
     
     
         18 . The bracket as recited in  claim 10 , wherein the alignment stem is approximately cylindrical. 
     
     
         19 . The bracket as recited in  claim 10 , further comprising a hole passing through the body and through the alignment stem. 
     
     
         20 . An architectural decorative resin-based panel system having a visible outside surface that is free of mounting hardware, the system comprising:
 a decorative resin-based architectural panel including the visible outside surface, an opposing mounting surface, and a thickness extending therebetween;   one or more melt-bondable panel mounting brackets, each of the one or more melt-bondable panel mounting brackets comprising:
 a body including one or more bonding protrusions integrated with the body and extending therefrom to a first distance in a first direction; 
 one or more ridges separated by one or more recesses, the one or more ridges extending outwardly from the one or more bonding protrusions; and 
 an alignment stem integrated with the body and extending therefrom to a second distance in the first direction; 
   wherein the one or more bonding protrusions are secured within the decorative resin-based architectural panel, the one or more bonding protrusions extending into and past the mounting surface of the decorative resin-based architectural panel in a manner that resin of the decorative resin-based architectural panel at least partially surrounds the one or more bonding protrusions and extends into the one or more bonding recesses, thereby securing the one or more bonding protrusions within the decorative resin-based architectural panel; and   wherein the visible outside surface of the decorative resin-based architectural panel is free of any portion of the one or more melt-bondable panel mounting brackets.