Wall panel system
A wall panel system comprises an array of panels that provide a prefinished wall surface. The panels may be of the same or different sizes and include grooves or reveals supporting inserts that cooperate to provide rectangular faux panels or other wall panel designs. A trim system for mounting the panels to a support wall includes elongated trim strips for completing panel edges and corners.
This invention relates to wall systems and, more particularly, to a wall panel system comprising an array of panels that cooperatively provide a finished wall surface.
Systems are known for assembling arrays of individual wall panels to produce a finished wall surface. U.S. Pat. Nos. 3,838,546, 4,783,941 and 4,854,095 each illustrate examples of such systems. Similar systems are also disclosed in assignee's prior U.S. Pat. Nos. 5,417,020 and 5,694,727 wherein panels or tiles of relatively small size, e.g., one or several feet on edge, are provided in an upscale more costly wall system. Typically, a frame or grid is initially installed and the individual panels are then mounted on the frame or grid in such systems. In some instances, clips are provided to secure and position the panels on the grid structure.
Such systems tend to be relatively complex and require a number of different structural elements which must be assembled by skilled installers. The systems do not readily lend themselves to alternative assembly techniques which may provide different overall appearances in accordance with designer aesthetic preferences. Similarly, the systems do not tend to easily accommodate unique support wall configurations.
Frequently, such systems are so-called progressive systems in that assembly and disassembly of the wall system must be sequential beginning with an edge or periphery panel. That is, in order to remove an intermediate panel, neighboring panels must first be removed beginning at an extremity of the wall panel system. This is a time consuming process, and it is especially disadvantageous in wall panel systems having locations of high wear or incidence of damage since frequently worn or damaged panels are not individually and easily replaced. For example, panel installations in public buildings, a hallway, door adjacent locations or the like tend to require frequent replacement of individual panels.
SUMMARY OF THE INVENTIONThe invention provides an improved panel system which offers flexibility of configuration and enables combinations of panels of various area sizes. The panels are rectangular which includes square for purposes herein.
The panels may be scored vertically and horizontally in square, rectangular or linear patterns. The panels are mechanically fastened to the wall through the horizontal reveals.
The wall panel system may include repeating sequences of panels of different area sizes which cooperate to provide a prefinished wall surface. The panels are typically formed of a high-pressure laminate on a wood fiber substrate. The laminate may be provided with a wood grain or colored front or exposed surface.
The panels may be sized for floor-to-ceiling, wainscot or column-wrap installations. Accordingly, full wall panels may be 4′ or 5′ wide by 8′ or 10′ tall, wainscot may be 4′ by 4′, 8′ by 4′ or 10′ by 4′ and column-wrap panels may be 2′ by 8′ or 2′ by 10′. As described below, panels of different sizes may be combined to provide a finished wall surface. The panels include reveals and reveal inserts that may be arranged to provide a repeating uniform pattern from panel-to-panel or a combined panel comprehensive pattern.
As indicated, the prefinished wall surface may be provided with a repeating design characterized by a plurality of smaller faux panel surfaces. For example, a 4′×4′ panel may be provided with horizontal and vertical grooves fitted with reveal inserts that cooperate to provide the prefinished wall surface with the appearance of an array of four 2′ by 2′ square faux panels. In this manner, the panels provide the appearance of smaller, individually installed panels or tiles, and the advantages of large panel installation.
In another arrangement, the prefinished wall surface may be provided with an overall integrated design appearance wherein adjacent panels provide different portions of a comprehensive design pattern extending over a plurality of panels. For example, a repeating array of three adjacent panels may include an aligned pair of horizontally extending reveal inserts extending along the surfaces of all three panels and intersecting vertical reveal inserts in only one or more of the panels. Of course, the pattern of reveal inserts may be identical in all three panels.
The panel system is directly fastened to a support wall, as by fasteners within the grooves, and covered by the reveal inserts. In addition, a trim system cooperates in the panel mounting.
The trim system complements the appearance of both the faux panel designs and the integrated plural panel designs. To that end, the trim system includes elongate trim strips or elements characterized by substantially planar flat trim walls. The trim wall engages substantially the entire area of the associated panel edge to provide effective protection against panel edge impacts that might otherwise tend to delaminate the panel.
The flat trim wall extends slightly beyond the surface of the panel to a flat trim surface that is substantially parallel with the panel wall surface. The trim system forms a dimensional outline of the panel disposed in a plane different from that of the panel surface.
In addition to providing a finished trim appearance that is aesthetically pleasing, the trim system is also efficient in that the strips thereof may be used for multiple purposes. For example, the vertical trim strips may also be used as inside corner trim strips as described below.
The outside corner trim strips or elements similarly outline the panel edges while providing protection against side impacts. To that end, the outside corner trim strips also include planar trim walls engaging adjacent panel edges and terminating in trim surfaces that are parallel with the adjacent panel surface. The trim strips are provided with simple geometric configurations that are easily manufactured, as metallic extrusions.
In an alternative arrangement, the trim system may include an array edge trim strip having a channel shape. The edge of the panel array is received in the channel shape to present a trim surface of increased width. For example, the front surface of the edge trim may have a width substantially equal to that of the reveal insert. This may be used with faux panel surfaces to complete the appearance of an array of smaller panels.
In yet another arrangement, the trim system may include an outside corner trim strip or element having a central trim portion aligned with the intersection line of the corner and laterally extending trim portions overhanging and engaging the adjacent panel surfaces. The trim portions include separately mounted trim pieces that may be selected to match or contrast panel surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
In accordance with the invention, a wall panel system includes a plurality of rectangular panels consisting of rows or courses of horizontally aligned panels assembled and mounted to provide a finished wall surface. As required, the courses may be of indefinite length and panels may be stacked in columns to provide a desired height.
The panels may be provided with substantially any desired surface finish and appearance. For example, the exposed panel surface may be provided with a simulated wood grain, a single or multicolor, abstract or like surface. Similarly, the panels may be provided with a wood veneer, a metal finish, or a high pressure laminate construction including a medium density fiberboard core or a particle board core and a backer layer.
With particular reference to
A plurality of reveals or grooves 26 are provided in the front or exposed surfaces of the panels 12a and 12b. In this embodiment, the grooves 26 are arranged to intersect at right angles in a spaced pattern that divides the surface of each panel 12a into eight squares and the surface of each panel 12b into four squares, all squares being of the same size.
Reveal inserts 28 are mounted within the grooves 26 to further enhance the appearance of the surface. In this manner, the panels 12a, 12b cooperate to provide the prefinished wall surface 24 with a repeating pattern of relatively smaller square faux panels 30 that simulate the appearance of individual panels or tiles.
The wall panel system 10 is fastened directly to the support wall 16 by fasteners 32 mounted within the grooves 26 as shown in
Referring to
The vertical edge of the wall panel system 10 is mounted to the support wall 16 with a vertical edge trim strip 36 as shown in
The trim strip 36 has an L-shaped cross-section including a base 40 and a perpendicularly extending trim wall 42 of substantially flat or planar configuration. The trim wall 42 is in substantial contact with the adjacent edge of the panel 12a or 12b, and protects the edge against delamination. The trim wall 42 is relatively thin, 1/16″ to 3/16″ thick, and projects beyond the surface on the panels about 0.03″ to a trim surface 44 that is substantially parallel when the wall panel surface 24.
The trim strip 38 has an L-shaped cross-section including a base 46 and a perpendicularly extending trim wall 48. The trim wall 48 also extends about 0.03″ beyond the wall surface 24 to a trim surface 50 that is parallel with the wall surface 24. The trim wall 48 also has a substantially flat or planar configuration, but includes a laterally projecting tongue 52 sized to be received within a mating kerf or groove 54 in the horizontal edge of the panel 12b.
As best shown in
The details of the cross-section of the reveal insert 28 are shown in
Referring to
A vertical edge trim strip 36 is mounted to the wall 16b by securing the base 40 of the strip to the wall surface. A first side 42a of the trim wall 42 is positioned against the front or exposed surface of the panel 12′. A second panel 12″, which also may be a panel 12a or 12b, is then mounted to the surface of the wall 16b. The edge of the panel 12″ is tightly butted against a second side 42b of the trim wall 42.
The trim wall 42 extends beyond the front or exposed surface of the panel 12″ to dispose the trim surface 44 in parallel and spaced relationship with the front surface of the panel. It should be appreciated that the exposed portion of the trim wall 42 provides a similar trim appearance with respect to the front or exposed surface of the panel 12′.
Referring to
For purposes of illustration, panels 12′ and 12″ are also shown forming the outside corner 72. Accordingly, the edge of the panel 12′ abuts the trim wall 76 and the edge of the panel 12″ abuts the trim wall 78. Each of the trim walls 76, 78 extends slightly beyond the adjacent surface of the panel to form trim surfaces 84, 86. The trim surfaces 84, 86 are respectively spaced from and parallel with the adjacent surfaces of the panels 12′ and 12″.
With particular reference to
The wall panel system 10 is then completed by application of horizontal trim strip 38 to the upper edge of the panel array and vertical trim strip 36 to the remaining vertical edge of the panel array. The reveal inserts 28 are adhesively mounted within the grooves 26 of the panels 12. The adhesive mounting of the inserts 28 is primarily intended to avoid tampering. Accordingly, the inserts may be removed without damage to the panels.
As noted above, the wall panel system 10 is non-progressive since a single panel may be removed without prior removal of a neighboring course panel. However, in some cases, it may be necessary to remove an upper course panel before removing a lower course panel. Even such limited disassembly of upper and lower course panels provides considerable time and cost savings as compared with the disassembly required in progressive systems.
Referring to
The trim strip 92 has a double-Y shaped cross section formed by a pair of trim walls 94 and 96 joined at a right angle intersection to form a common leg 98. The leg 98 extends toward the support wall 16 to a pair of perpendicularly disposed base mounting legs 100 and 102. The mounting legs 100 and 102 are secured to the support wall by fasteners 32.
In this embodiment, corner-forming panels 108 and 110, which may comprise panels 12a and 12b, have shaped edges 108a and 110a engaging the trim strip 92. More particularly, the rearward portions of the edges 108a and 110a are chamfered to accommodate the angular intersection of the connecting leg 98. The forward portions of the edges 108a and 110a are cut at right angles to the panel surface to assure a tight abutting relationship with the trim walls 94 and 96. It should be appreciated that the rearward portions of the edges 108a and 110a may be cut at any angle to clear the leg 98 and that such cuts need not be finish cuts.
Referring to
Referring to
The top edge of the panel 120 is secured to the support wall 122 by a modified horizontal edge trim strip 132. The trim strip 132 has a J-shape including a base mounting leg 134 extending along and fastened to the support wall 122. A laterally extending connecting wall 136 projects from the base mounting leg 134 to a trim face wall 138 which overlies a portion of the upper surface of the panel 120. The trim face wall 138 may have a vertical dimension corresponding with that of the reveal insert 112.
The panel 120 is shown in
Referring to
Referring to
Reveal inserts 158, such as inserts 28 or 112, are mounted within the grooves 156. In this manner, the panels 152 and 154 cooperate to provide the wall panel system 150 with a wall panel surface 160. As shown, the wall panel surface 160 is formed of four 2′ by 4′ rectangular faux panels and eight 2′ by 2′ square faux panels.
The wall panel system 150 may be provided with an indefinite length by repeating the selected panel sequence or three array pattern of wall panels 152 and 154. The vertical and horizontal edges of the panel array may be completed with trim strips 36, 38, 126, with or without a mated reveal insert, or 132.
Referring to
Each of the panels includes a first pair of lower horizontal grooves 168 containing inserts 170 located at a height of about 3′ from the panel bottom edges and vertically spaced apart about 2″. The panels also include a second pair of lower horizontal grooves and inserts, also at about a 2″ spacing, and positioned about 4″ above the first pair of lower horizontal grooves. The groove pattern is completed by an upper groove 168 and inserts 170 spaced about 8″ form the top edge of each panel.
The panels 164 and 166 cooperate to provide the wall panel system 162 with a wall panel surface 172. In this arrangement, the faux panels and multiple reveal inserts cooperate to provide the surface 172 with a plaid-like pattern characterized by groups of horizontal inserts and groups of vertical inserts forming a pattern of unevenly spaced repeated stripes crossing at right angles. The plaid-like pattern has a linear appearance as opposed to a geometric pattern of squares, rectangles or other closed simple shapes.
The three panel sequence or array may be repeated to provide the wall panel system 162 with an indefinite length. The vertical and horizontal edges of the panel array may be completed with trim strips 36, 38, 126, with or without a mated reveal insert, or 132.
Referring to
The mounting base 182 includes mounting legs 184 and 186 secured to the adjacent walls 16c and 16d by fasteners 32. The legs 184 and 186 are joined to a U-shape female mounting coupler 188 that is aligned with the intersection of the corner and opens outwardly to form a female mounting channel 190 that extends along the full length of corner 178. The interior surface of the mounting channel is provided with teeth or grooves 192.
The trim strip 180 includes a central corner portion 194 having a rearwardly projecting male mounting rib 196 and laterally projecting trim portions 198 and 200. The rib 196 has teeth or grooves 201 extending along its exterior surface.
The rib 196 is sized to be laterally inserted or pushed into the channel 190. The engaging teeth or grooves 192 and 198 form a mechanical interlock that secures the trim strip 180 to the mounting base 182.
The outside corner is finished with wall panels 12′ and 12″, which may be provided by panels 12a or 12b. The adjacent corner edge of the panel 12′ is cut at an acute angle to fit against the mounting coupler 188. For purposes of illustration, the adjacent corner edge of the panel 12″ is not specially finished, but rather, extends at a right angle as formed during manufacture. In both cases, the trim portions 198 and 200 are provided with a sufficient lateral dimension to extend beyond the finished surface edges of the panels 12′ and 12″ so that no special finish edge cut is required. Also, the trim portions 198 and 200 are configured to tightly abut against the surface on the panels 12′ and 12″, and thereby provide a finished joint.
The trim portions 198 and 200 respectively include laterally disposed and vertically extending insert channels or trim slots 202 and 204. The trim slots 202 and 204 may have a lateral dimension of less than an inch, e.g., ⅝, as desired, and generally extend along substantially the entire lateral width of the trim portion. The vertical height of the trim slots 202 and 204 generally corresponds with that of the outside corner trim strip 180.
The trim slots 202 and 204 have flat bottoms provided by the trim portions 198 and 200. The trim slots 202 and 204 are bounded by overhangs 206 and 208 and, respectively associated, lips 210 and 212. The lips project from the trim portions 198 and 200, and have a slight reverse bend to provide a J-shape cross-section and overhang.
The trim slots 202 and 2Q4 have a thickness or depth equal to thickness of commercially available laminate materials such as FORMICA brand laminate, e.g., 0.030″ TO 0.060″. Laminate trim pieces 214 and 216 are mounted in the trim slots 202 and 204. The trim pieces 214 and 216 may be inserted longitudinally into the trim slots prior to-the mounting of the trim strip 180, or they may be laterally flexed and pushed into the trim slots.
The front or exposed surfaces of the trim pieces 214 and 216 are finished and may match or contrast the front or exposed surfaces of the panels 12′ and 12″. In most cases, the trim pieces 214 and 216 will match each other, but this is not necessary.
While the invention has been shown and described with respect to particular embodiments thereof, this is for the purpose of illustration rather than limitation, and other variations and modifications of the specific embodiments herein shown and described will be apparent to those skilled in the art all within the intended spirit and scope of the invention. Accordingly, the patent is not to be limited in scope and effect to the specific embodiments herein shown and described nor in any other way that is inconsistent with the extent to which the progress in the art has been advanced by the invention.
Claims
1. A kit for constructing a prefinished wall comprising a plurality of trim elements for mounting of rectangular panels in an array to a support wall to form said prefinished wall, said panels having horizontal edges, vertical edges and substantially planar surfaces extending between panel edges, said prefinished wall including at least one outside corner formed by angularly intersecting panels, said trim elements including horizontal trim elements for mounting in a horizontal direction along said horizontal panel edges, vertical trim elements for mounting in a vertical direction along said vertical panel edges and outside corner trim elements for mounting along vertical panel edges at said outside corner of said prefinished wall, each of said trim elements including a base to be secured to said support wall and a trim wall extending from said base along the adjacent panel edge, said trim wall having a planar configuration that is in substantial continuous contact with the entire area of said panel edge and projects beyond the adjacent panel surface to a trim surface that is parallel with said panel surface.
2. The kit of claim 1, wherein said vertical trim element has an L-shape cross-section, said prefinished wall includes at least one inside corner formed by abutting first and second panels separated by a corner mounted vertical trim element having opposed first and second vertical sides, said corner mounted trim element extending along an adjacent edge of said first abutting panel with said first vertical side in substantial contact with said panel edge and said second vertical side extending along the adjacent surface of said second abutting panel, said trim surface of said trim element being spaced from and parallel with said panel surface of said first abutting panel and extending perpendicularly along said panel surface of said second abutting panel whereby said inside corner provides a finished trim appearance similar to that provided by said trim elements extending along the horizontal and vertical edges of said panels.
3. The kit of claim 1, wherein said trim surface has a width equal to less than about 0.1 inch.
4. The kit of claim 1, wherein said trim surface has a width equal to from about 0.05 inch to about 0.125 inch.
5. The kit of claim 1, wherein said outside corner trim element comprises a elongate channel having an X shaped cross section formed by a pair of said trim walls joined at a right angle intersection, each of said trim walls extending from said intersection to form said base as a pair of mounting legs.
6. The kit of claim 1, wherein said outside corner trim element comprises an elongate channel having a double-Y shaped cross-section formed by a pair of said trim walls joined at a first right angle intersection to form a common leg extending from said intersection to a second right angle intersection formed by a pair of mounting legs projecting away from each other at right angles and parallel with said trim walls.
7. The kit of claim 1, wherein a said outside corner trim element includes a central corner element aligned with said intersection and laterally extending trim portions, said trim portions extending over adjacent vertical panel edges and including separately mounted trim pieces selected to match or contrast said planar surfaces of said panels.
8. The kit of claim 1, wherein said outside corner trim element is an integrally formed metallic extrusion.
9. The kit of claim 1, wherein a plurality of intersecting grooves extend in said planar surfaces of said panels, and said kit further includes a plurality of reveal inserts mounted in said grooves.
10. A wall panel system comprising a plurality of rectangular panels adapted to be mounted in abutting relationship to a support wall in a planar array to form a finished wall, each panel having a generally planar surface extending between panel edges arranged along horizontally and vertically extending directions, each of said panels having a plurality of intersecting grooves extending in the panel surface intermediate said panel edges, and a plurality of reveal inserts mounted in said grooves to subdivide the panel surface into a plurality of smaller rectangular faux panels.
11. The wall panel system of claim 10, wherein said intersecting groove has a cross-section, adjacent panel edges each provide one-half of said groove cross-section and cooperate to form an edge groove corresponding in cross-section with said cross-section of said intersecting groove, and said reveal inserts are also mounted in said edge groove.
12. The wall panel system of claim 11, wherein said panel array includes an array edge formed by vertical panel edges and an inside corner formed by angularly intersecting panels, and identical elongate trim strips having trim walls for engaging panel edges form both a vertical trim for said vertical panel edges and an inside corner trim disposed between said angular and he intersecting panels.
13. The wall panel system of claim 11, wherein said intersecting grooves in each of said panels cooperate to form horizontally aligned grooves in an adjacent panels in said array of panels.
14. The wall panel system of claim 11, wherein said panels are of at least two different area sizes.
15. The wall panel system of claim 14, wherein said panels are of the same height and different widths.
16. The wall panel system of claim 15, wherein said panels of different sizes are arranged in a selected panel sequence and said panel sequence is repeated to form said panel array of said prefinished wall.
17. The wall panel system of claim 10, wherein mounting fasteners extend through said grooves to secure said panel to said support wall, said mounting fasteners being hidden from view by said reveal inserts.
18. The wall panel system of claim 17, wherein said panels are individually mounted to said support wall to provide a nonprogressive panel system wherein any panel may be removed without prior removal of an adjacent panel.
19. The wall panel system of claim 10, wherein said intersecting grooves in each of said panels cooperate to form a plaid-like pattern of unevenly spaced repeated grooves crossing at right angles whereby the pattern has an overall linear appearance.
20. The wall panel system of claim 19, wherein said panels are of at least two different area sizes.
21. The wall panel system of claim 20, wherein said panels are of the same height and different widths.
22. The wall panel system of claim 20, wherein said panels of different sizes are arranged in a selected panel sequence and said panel sequence is repeated to form said panel array of said prefinished wall.
23. In a wall panel system comprising a plurality of panels adapted to be mounted to a support wall to form a prefinished wall, each of said panels having a finished front surface extending between panel edges lying in vertical and horizontal orientations, said panels including adjacent vertical edges forming at least one outside corner at the adjacent edges of intersecting first and second panels, the improvement comprising an outside corner trim element mounted to said support wall along said corner, said trim element including a central corner element aligned with said intersection and laterally extending trim portions, said trim portions extending over said adjacent vertical edges and including separately mounted trim pieces that may be selected to match or contrast said finished front surfaces of said panels.
24. The wall system of claim 23, wherein said trim portions include insert channels for receiving said trim pieces.
25. The wall system of claim 24, wherein said insert channel has a height substantially equal to the height of said outside corner trim element, a width substantially equal to the lateral extent of said trim portion and a thickness substantially equal to the thickness of said trim piece.
26. The wall system of claim 25, wherein said insert channel is formed with a generally flat bottom and first and second opposed overhangs for receiving opposite vertical edges of said trim piece.
27. The wall system of claim 26, wherein said central corner element includes said first overhang adjacent each of said trim portions, and a lip projecting from said trim portion provides said second overhang adjacent a lateral extremity of said trim portion.
28. The wall system of claim 25, wherein said trim pieces are formed of a laminated plastic.
29. The wall system of claim 23, wherein said trim portions resiliently engage said panels.
30. The wall system of claim 23, wherein said trim portions cover and hide from view said vertical panel edges at said corner.
Type: Application
Filed: Aug 25, 2004
Publication Date: Apr 20, 2006
Inventors: Steven Bledsoe (San Clemente, CA), Michael Dobija (Laguna Beach, CA)
Application Number: 10/925,810
International Classification: E04B 1/00 (20060101);