Modular panel assembly

Abstract

The modular panel assembly comprises a plurality of different design inserts that can be readily assembled into a panel using a plurality of structural members. The different kinds of design inserts and structural members have the same type of coupling mechanism so as to allow many different configurations based on insert members of many different appearances.

1 . A modular panel assembly comprising:
 a) a plurality of structural members for assembling to define a plurality of insert-receiving spaces, wherein the plurality of structural members comprise a plurality of structural couplers for each insert-receiving space in the plurality of insert-receiving spaces; and,   b) a plurality of design inserts of a plurality of different design insert kinds, wherein
 each design insert kind in the plurality of different design insert kinds has a distinct appearance, and 
 each design insert of the plurality of design inserts i) is receivable into a corresponding insert-receiving space in the plurality of insert-receiving spaces, ii) is of a corresponding design insert kind in the plurality of different design insert kinds, and, iii) comprises a configuration of design members to provide the distinct appearance of the corresponding design insert kind, the configuration of design members including a plurality of insert couplers for mating with the plurality of structural couplers to secure the design insert in the corresponding insert-receiving space; 
   
     such that when different design inserts are of different corresponding design insert kinds, the configurations of the different design members differ to provide the distinct appearances of the corresponding design insert kinds. 
   
   
       2 . The assembly as defined in  claim 1  wherein
 the plurality of design inserts comprises design inserts of different sizes; and,   the plurality of structural members comprises structural members of different sizes operable to form insert-receiving spaces of different sizes to accommodate the design inserts of different sizes.   
   
   
       3 . The assembly as defined in  claim 1  wherein i) the configuration of design members includes an external frame having a plurality of insert couplers, ii) each structural coupler in the plurality of structural couplers comprises a groove of a selected dimension, and iii) each insert coupler in the plurality of insert couplers comprises an edge of the external frame dimensioned to engage with the groove of the selected dimension. 
   
   
       4 . The assembly as defined in  claim 3  wherein, for each design insert of the plurality of design inserts, the configuration of design members defines an internal design area surrounded by the external frame and comprises an internal member extending into the internal design area. 
   
   
       5 . The assembly as defined in  claim 3  wherein the internal member is one of a curved member for dividing the internal design area into two openings, a straight member for dividing the internal design area into two openings, an extended member for completely covering the internal design area, and a lattice for dividing the internal design area into at least four openings. 
   
   
       6 . The assembly as defined in  claim 4  wherein when different design inserts have different corresponding design insert kinds, the internal members of the different design inserts differ to provide the distinct appearances of the corresponding design insert kinds. 
   
   
       7 . The assembly as defined in  claim 3  wherein each structural coupler in the plurality of structural couplers comprises a groove of a selected dimension, and each insert coupler in the plurality of insert couplers comprises an edge of the external frame dimensioned to engage with the groove of the selected dimension. 
   
   
       8 . The assembly as defined in  claim 7  wherein each design insert in the plurality of design inserts comprises a lip on each side of the edge to define a non-planar sealing surface for abutting a corresponding sealing surface along the groove of the plurality of structural members. 
   
   
       9 . The assembly as defined in  claim 3  wherein the plurality of structural members comprises
 a plurality of structural members for assembling to provide a structural frame having an internal perimeter, wherein the structural coupler of each external member comprises a groove of a selected dimension along at least one side thereof such that after assembly the structural frame comprises the groove along the internal perimeter; and,   at least one internal member for extending across the internal perimeter, wherein i) the structural coupler of the at least one internal member comprises a first groove of the selected dimension along a first side of the at least one internal member and a second groove of the selected dimension along a second side of the at least one internal member, the second side being opposite to the first side, and, ii) the at least one internal member comprises, at each end of the internal member, an end protrusion dimensioned to engage with the groove along the internal perimeter.   
   
   
       10 . The assembly as defined in  claim 1  wherein, i) each structural coupler in the plurality of structural couplers comprises a groove of a selected dimension, ii) for each design insert in the plurality of design inserts, the plurality of design members comprises at least one internal member and the plurality of insert couplers are a plurality of ends of the at least one internal member, iii) the plurality of ends have a combined thickness dimensioned to engage the groove of the selected dimension. 
   
   
       11 . The assembly as defined in  claim 10  wherein the at least one internal member comprises a plurality of overlapping design members. 
   
   
       12 . The assembly as defined in  claim 10  wherein each internal member in the configuration of design members is made of wood. 
   
   
       13 . The assembly as defined in  claim 10  wherein the plurality of structural members comprises
 a plurality of structural members for assembling to provide a structural frame having an internal perimeter, wherein the groove runs along at least one side thereof such that after assembly the structural frame comprises the groove along the internal perimeter; and,   at least one internal member for extending across the internal perimeter, wherein i) the structural coupler of the at least one internal member comprises a first groove of the selected dimension along a first side of the at least one internal member and a second groove of the selected dimension along a second side of the at least one internal member, the second side being opposite to the first side, and, ii) the at least one internal member comprises, at each end of the internal member, an end protrusion dimensioned to engage with the groove along the internal perimeter.   
   
   
       14 . A method of manufacturing a panel assembly comprising:
 a) manufacturing a plurality of structural members for assembling to define a plurality of insert-receiving spaces, wherein the plurality of structural members comprise a plurality of structural couplers for each insert-receiving space in the plurality of insert-receiving spaces; and,   b) manufacturing a plurality of design inserts of a plurality of different design insert kinds, wherein each design insert kind in the plurality of different design insert kinds has a distinct appearance, and each design insert of the plurality of design inserts i) is receivable into a corresponding insert-receiving space in the plurality of insert-receiving spaces, ii) is of a corresponding design insert kind in the plurality of different design insert kinds, iii) comprises a configuration of design members to provide the distinct appearance of the corresponding design insert kind, the configuration of design members including a plurality of insert couplers for mating with the plurality of structural couplers to secure the design insert in the corresponding insert-receiving space; and, iv) when different design inserts are of different corresponding design insert kinds, the configurations of the different design members differ to provide the distinct appearances of the corresponding design insert kinds.   
   
   
       15 . The method as defined in  claim 14  further comprising, assembling the panel assembly into a panel, by
 c) selecting a set of design inserts to be included in the panel from the plurality of design inserts of the plurality of different design insert kinds;   d) selecting from the plurality of structural members a set of structural members for assembling to define a plurality of insert-receiving spaces to accommodate the set of design inserts; and   e) assembling the set of structural members and the set of design inserts such that the set of structural members define a set of insert-receiving spaces containing the set of design inserts, and the plurality of ends of the configuration of design members for each design insert in the set of design mate with the plurality of grooves to secure the design insert in the corresponding insert-receiving space.