Removable Wallboard System

Abstract

The present invention is a novel removable wallboard system. It includes a plurality of receiver strips [1] which are attached to framing members [8] of a structure to be paneled. Each receiver strip has a receiving channel [4]. Wall panels 7 are placed snugly between the receiver strips [1]. Trim units [2] are elongated strips having insertion strips [10] which are designed to fit into and be retained by receiving channels [4] of the receiver strips [1]. Since the trim units [2] are designed to have a low profile, and they cover the seams between the wall panels [7], there is no need for further finishing or caulking. Therefore, these wall panels [7] may be removed and replaced with minimal effort or cleanup. The system also includes easily installable, removable and replaceable base molding [16], crown molding [19], and chair rail molding [29]. These may be designed to create chase ways [18, 74] allowing hidden routing of electrical, utility cables, pipes and hoses. Since the system may interactively be constructed and removed, it is useful in business settings in which offices are constantly adjusted.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part of U.S. Provisional Patent Application 60/995,678 “Removable Wallboard System” by the same inventors as this application. It therefore, claims priority from the filing date of this earlier-filed Provisional Patent Application being the Sep. 26, 2008.

FEDERAL SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a removable wallboard system for homes and businesses.

2. Discussion of Prior Art

Present drywall installing, hanging and finishing methods do not provide accessibility behind the wall, are time-consuming and labor-intensive and therefore expensive.

Drywall is installed as follows: A sheet of drywall is held up against a previously framed wall. The edges are normally nailed with drywall nails temporarily securing the sheet to the framed wall. The middle of the sheet then has drywall screws placed every 10 to 12 inches permanently securing the sheet in place.

Sequential sheets are butted up to each other and installed using the same method until all wall area is covered.

A thin coat of a spackle or joint compound is placed over every seam between the drywall sections and paper seam tape is pressed into the spackle to cover each seem and inside corner while corner bead is installed to cover each outside corner.

Then every nail and screw hole is filled with spackle. This first coat of spackle is left to dry completely for at least 24 hours. Once the first coat of spackle is dry all said spackled surfaces must be sanded smooth. All said wall surfaces must then be cleaned of all dust and dirt.

A second coat of spackle is then applied over all said nail holes, screw holes and seams. This second coat is then left to dry for at least 24 hours. Once this second coat is dry all said nail holes, screw holes and seams are again sanded smooth. All said wall surfaces must again be cleaned of all dust and dirt.

Now, a third coat of spackle must be applied to all said nail holes, screw holes and seams. This third coat of spackle on said walls must again be left to dry completely for at least 24 hours. After completely drying, this third coat of spackle must again be sanded smooth. Now all surfaces of said wall must be thoroughly inspected, cleaned and prepared for paint. Before paint can be applied to the walls, you must install all necessary wood trim (i.e. base molding, crown molding, chair rail, window casing, window sill and door casing) to all necessary locations on said walls.

After all necessary trim is installed the walls are finally ready for paint. After three coats of paint are complete and dry all said walls must be inspected again. At this point all imperfections on said wall must be repaired. The imperfections on said walls are filled and feathered with the same spackle. This coat of spackle is again left for at least 24 hours to dry. After the spackle is completely dry all said repairs must be sanded smooth. All dirt and dust on said walls must be cleaned completely. Now all said repaired imperfections are painted trying to blend the paint as best as possible. This procedure repeats until the desired finish is achieved.

Once finished this system provides permanently fixed and secured wall panels. Electrical, mechanical and structural features behind the wall panels are difficult to locate. Once located these are difficult to access. Damaged panels results in replacement and wasted time.

There are existing inventions for construction assemblies to hang specialized wall panels. The wall panels are designed as a specific part of the assembly and will work only with said assembly. U.S. Pat. Nos. 5,715,638 and 6,918,212 describe such fabric wall panel systems. These systems are designed to handle specialized fabric with synthetic backing wall panels. These systems provide limited use. All panels are just 8 feet tall and they come in only one finish and only one color, are difficult to install and are expensive to construct.

Other patents have been issued for designs for supporting wall panels. These systems are designed to finish exterior walls and need specialized use of weatherproofing and caulk. These systems can be extruded aluminum, other metal components or PVC. The panels are attached to building walls using various types of mounting devices.

For example, installation requires first installing a corner or terminal support, then a panel, then a center seam or “H” support with another panel and so on until another corner or terminal support is reached. If the panels are misaligned or a panel becomes damaged, the panels must be removed in sequence in the backward direction. An individual panel cannot be accessed out of sequence.

U.S. Pat. Nos. 3,380,210, 3,932,974, 4,184,297, 5107647 and Canadian Patent 1,066,472 are constructed of aluminum or other metal components and are used for store fronts, sunrooms, greenhouses and curtain walls. They all make specialized use of the mechanical strength of metals. They are not suited for drywall or for finishing interior walls. These systems do not produce the soft and warm finish necessary when finishing interior residential and office space. These systems also are expensive to construct.

U.S. Pat. No. 6,558,165 B1 discloses a system for holding wall panels and allowing removal of the panels. It should be noted that “receiver flanges 24” of the figures receives “outer cap 10”. It also shows in FIG. 1C that there is a gap between wall panel marked “wp” and “receiver flanges 24”. This gap is filled with calking marked “cc”. It becomes time consuming to calk, wait for it to dry, then sand the wall panels with this system.

Also, upon removal of the panel, the calking must be removed and reapplied upon assembly. The calking typically crumbles as it is removed; creating calking powder and a mess that is required to be cleaned.

Therefore, there is a current need for an easy to use, inexpensive to construct, clean, removable wall assembly.

OBJECTS OF THE INVENTION

Accordingly, it is an object of the present invention:

• • (a) to provide a less complicated wall system for constructing walls;
  • (b) to provide an easier to use wall installation system;
  • (c) to provide a quicker wall installation system;
  • (d) to provide a cleaner wall installation system;
  • (e) to provide a more economical wall installation system;
  • (f) to provide a wall system which eliminates the need for wall nails and screws to construct walls;
  • (g) to provide a wall system which eliminates the need for joint compound or spackle in constructing walls;
  • (h) to provide a wall system which eliminates the need for traditional joint tape and corner bead when constructing walls;
  • (i) to provide a system which minimizes sanding when constructing walls;
  • (j) to provide a wall system which allows easy removal of each wall panel;
  • (k) to provide a wall system which allows easy access to plumbing, HVAC, electric and structural components behind the wall panels;
  • (l) to provide to provide a wall system which allows easier wire, cable and utility installation after wall completion;
  • (m) to provide a wall system which allows for easy inspection and modification behind the walls;
  • (n) to provide a wall system which is moisture, mildew and mold resistant;
  • (o) to provide a wall system which reduces post installation maintenance;
  • (p) to provide a wall system which allows attachment of removable trim;
  • (q) to provide a wall system which allows easy storm proofing of homes and businesses;
  • (r) to provide a wall system which allows easy clean up and repair;
  • (s) to provide a wall system which allows a healthier indoor air environment;
  • (t) to provide a wall system which allows for quicker, cleaner and easier retail, office, restaurant and commercial wall modifications; and
  • (u) to provide a wall system which is reusable.

SUMMARY OF THE INVENTION

The present invention may be embodied as a removable wallboard system for holding a plurality of wall panels to a frame having a plurality of frame members, the system comprising:

• • a) at least one receiver strip 1 having
    • i. a base strip capable of being attached to said frame, and
    • ii. a receiving channel, and
  • b) a trim unit having
    • i. at least one insertion strip which are sized and shaped to fit inside of and be removably retained by the receiving channel, and
    • ii. a flat top sized and shaped to retain said wall panels between the flat top and the base strip of the receiver strip.

The present invention may also be embodied as a method of constructing removable walls on a frame having a plurality of frame members comprising the steps of:

• • a) attaching a receiver strip having a base strip capable of being attached to said frame and a receiving channel to at least one frame member,
  • b) providing a trim unit having at least one insertion strip which are sized and shaped to fit inside of, and be removably retained by the receiving channel, and a flat top,
  • c) providing wall panels and placing the wall panels between the receiver strips,
  • d) pressing the insertion strip of the trim units into the receiving channels of the receiver strips to removeably retain said panels between the trim unit and the receiver strip.

BRIEF DESCRIPTION OF THE DRAWINGS

While the novel features of the invention are set forth with particularity in the appended claims, the invention, both as to organization and content, will be better understood and appreciated, along with other objects and features thereof, from the following detailed description taken in conjunction with the drawing, in which:

FIG. 1 is a perspective view of a room having walls that show walls partially installed using the system of the present invention.

FIG. 2 is an enlarged cross-sectional view of the major components of the removable wallboard system according to the present invention, before attachment of the trim unit.

FIG. 3 is an enlarged cross-sectional view of the major components of the removable wallboard system of FIG. 2, after attachment of the trim unit holding two wall panels in place.

FIG. 4 is an enlarged cross-sectional view of another embodiment of the major components of the removable wall system according to the present invention before attachment of the trim unit.

FIG. 5 is an enlarged cross-sectional view of the major components of the removable wall system of an embodiment according to the present invention intended to be used with thinner wall panels.

FIG. 6 shows a side view of one of the many types of base molding assemblies and a side view of one of the many types of crown molding assemblies.

FIG. 7 shows base molding of a removable wallboard system according to the present invention prior to attachment.

FIG. 8 shows an enlarged view of one embodiment of crown molding according to the present invention.

FIG. 9 shows another embodiment of base strip of the present invention used for metal stud framing.

FIG. 10 shows a construction assembly for one type of many chair rail moldings.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 is a perspective view of a section of a room having partially installed walls using the system of the present invention. A plurality of frame members 8 are installed using a traditional installation method.

Multiple receiver strips 1 are attached to support frame members 8 a specific distance apart. Wall panels 7 are positioned adjacent to a receiver strip 1 and held in place.

Trim units 2 are pressed into the receiver strips 1 such that they secure wall panels 7. Trim units 2 also act to cover the vertical seams.

Wall panel 7 is typically made of gypsum, commonly called drywall. Since this drywall is inexpensive and plentiful, this system is very cost effective. Other types of panels may also be used.

A receiver strip 1 is installed horizontally at floor height.

Base molding 16 is pressed into receiver strips 1.

Similarly, a receiver strip 1 is mounted horizontally at ceiling level. A crown molding 19 is pressed into receiver strip 1 near the ceiling.

FIG. 2 is an enlarged cross-sectional view of the major components of the removable wall system according to the present invention, before attachment of the trim unit.

The cross section of trim unit 2 is generally “T” shaped. It includes a flat top section 1 1 attached to at least one generally perpendicular insertion strip 10.

There is also a receiver strip 1 having an elongated base strip 3 having means to attach the elongated base strip 3 to a frame member 8. For example, a frame member 8 being formed by 2″×4″ or 2″×6″ lumber. Frame member 8 may also be formed with metal studs or any other framed wall assembly.

Attaching means 9 may include various fasteners, such as nails, screws and the like, attaching base strip 3 to frame member 8.

Here it can be seen that a pair of flanges 5 define a receiving channel 4. Each flange 5 has one or more securing ridges 6.

Similarly, insertion strips 10 of trim unit 2 have one or more securing notches 12 positioned and spaced to match the securing ridges 6. Wall panels 7 are shown here in position prior to being secured.

FIG. 3 is an enlarged cross-sectional view of the major components of the removable wallboard system of FIG. 2, after attachment of the trim unit 2 holding two wall panels 7 in place.

Here it can be seen that the plurality of securing ridges 6 fit into securing notches 12 to tightly hold trim unit 2 to receiver strip 1. In doing so, it clamps wall panels 7 between base strip 3 and flat top 11.

Since trim unit 2 is removeably attached to receiver strip 1, trim unit 2 may be removed to allow wall panel 7 to be removed, then reattached after wall panel 7 is replaced. It is also shown how flat top 11 covers the vertical seam between the wall panels 7 without the need of caulking or other process.

FIG. 4 is an enlarged cross sectional view of another embodiment of the major components of the removable wall system according to the present invention designed for use with metal framing.

Here metal frame base strip 13 is created to include a slot 20 running the length of metal frame base strip 13. Slot 20 of metal frame base strip 13 is designed to slide over and receive metal support frame 8.

FIG. 5 is an enlarged cross-sectional view of the major components of the removable wall system of an embodiment according to the present invention, intended to be used with thinner wall panels.

Here two elongated spacers 14 hold the wall panels 7 away from base strip 3 such that wall panels are pressed securely against flat top 11 of trim unit 2. This allows securing of thinner wall panels 7 while allowing full sized insertion strips 10 for more secure attachment.

FIG. 6 illustrates an enlarged cross-sectional view of the top and bottom of a wall assembly according to one embodiment of the present invention.

The bottom of FIG. 6 and FIG. 7 show a molding receiver strip 15 attached to frame members 8 at floor height. Molding receiver strip 15 has receiving channels 4 defined by flanges 5, which receive the insertion strips 10 with their securing notches 12 of base molding 16. This secures base molding 16 to receiver strip 1 such that an upper edge 17 provides vertical support to wall panel 7.

Chase ways 18 are created between base molding 16 and molding receiver strip 15. These allow hoses, pipes, cabling and wires to run along through the walls. Since base molding 16 is easily removed and replaced, one can easily run and re-route wiring through the system of the present invention.

The top of FIG. 6 shows a receiver strip 1 installed at the top at ceiling height. Receiver strip 1 includes a receiving channel 4 defined by flanges 5. The flanges 5 include securing ridges 6.

Crown molding 19 includes at least one insertion strip 10 received by receiving channel 4. Crown molding 19 is shaped to receive wall panel 7 from below and also to support a ceiling panel 22.

An enlarged view of one embodiment of the crown molding is shown in FIG. 8.

FIG. 9 shows another embodiment of the base strip 13 of a receiver strip 1 according to the present invention used for metal stud framing.

FIG. 10 illustrates an enlarged cross-sectional view of one type of chair rail molding 29. A receiver strip 1 is secured in place horizontally at the desired height. Chair rail molding 29 having the same color and finish as trim unit 2 is attached to receiver strip 1. Chair rail molding 29 has insertion strips 10 which snap into the receiving channels 4 of the receiver strip 1. Chair rail molding 29 can support the center horizontal seam of drywall wall panels or act solely as decorative trim. Chase ways 18 are created when using chair rail molding 29 as a decorative trim.

FIG. 11 shows a cross sectional view of an outside corner piece as it would appear installed.

Here, several frame members 8 are shown. These are made of metal and have an open rectangular shape. An inner support 50 has an inner arm 52 and another inner arm 54 connected at an inner junction piece 56 shaped to fit around, and secure to an outside corner of at least one of the frame members 8. Inner support 50 also includes a pair of flanges 5 which define a receiving channel 4 facing outward from the inner junction piece 56.

Wall panels 7 are placed against the inner support 56 and are further secured by inner ridges 54.

Outer support 60 includes an outer arm 62 and another outer arm 64 connected at outer junction piece 66. An insertion tab 40 extends inwardly from outer junction piece 66.

The insertion tab 40 is pressed into and retained by receiving channel 4 to hold outer support 60 to inner support 50 thereby sandwiching and securing wall panels 7. Inner claws 58 and outer claws 68 press into and further secure wall boards 7 holding them in place.

Since insertion tab 40 may be removed from receiving channel 4, this is system in which wall panels 7 may easily be constructed and disassembled.

FIG. 12 shows a cross section of another embodiment of a base board piece 70 according to the present invention. In this view the baseboard is sideways with the upper side to the left and the lower side to the right.

Here flanges 5 create two receiving channels 4. These receiving channels are secured to insertion strips which extend from a receiver strip, such as receiver strip 15 that shown in FIG. 6.

A recess 72 receives the edge of wall panel 7. A chase way 74 is provided to allow wires, cables, pipes and tubes to run along the baseboard without being seen.

FIG. 13 shows an alternative embodiment of a crown molding constructed as a hollowed piece.

In this embodiment, crown molding 30 is formed with a hollow center 32 to save material and reduce weight. It includes an insertion tab 40 having securing notches 42.

Even though a crown molding piece was used here for illustrative purposes, it is understood that any of the larger pieces may be constructed with a hollow center to reduce cost of manufacture, and weight.

While specific embodiments of the invention have been illustrated and described herein, it is realized that modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit and scope of the invention.

Claims

1. A removable wallboard system 10 for holding a plurality of wall panels to a frame having a plurality of frame members, the system comprising:

a) at least one receiver strip having i. a base strip capable of being attached to said frame member, and ii. a receiving channel, and

b) a trim unit having i. at least one insertion strip 1 which are sized and shaped to fit inside of and be removably retained by the receiving channel, and ii. a flat top sized and shaped to retain said wall panels between the flat top and the base strip of the receiver strip.

2. The system of claim 1 wherein the insertion projection is one of the group consisting of insertion strip and an insertion tab.

3. The system of claim 1 wherein the base strip further comprises:

a slot capable of receiving flat metal frame members.

4. The system of claim 1 wherein the receiver strip is secured horizontally near the floor and further comprising:

a base molding having insertion strips 1 shaped and positioned to be received and secured in receiving channel of receiver strip, the base molding also having a recess for defining a chase way.

5. The system of claim 1 wherein the recess is formed within the base molding.

6. The system of claim 1 wherein the receiver strip is secured horizontally near the ceiling and further comprising:

a crown molding having insertion strips 1 shaped and positioned to be received and secured in receiving channel of receiver strip, the crown molding 19] also shaped to support a ceiling panel.

7. The system of claim 1 wherein the crown molding is constructed of a flexible extruded plastic material.

8. The system of claim 1 wherein said wall panels are drywall panels.

9. The system of claim 1 wherein said wall panels are gypsum board.

10. The system of claim 1 wherein said wall panels are constructed of a material which is paintable.

11. The system of claim 1 wherein said wall panels are removable and replaceable providing easy access behind them.

12. A removable wallboard system for holding a plurality of wall panels to at least one frame member having two surfaces which meet at a corner, the system comprising:

a) at least one inner support attached to said frame member corner having: i. a first inner arm attached to one surface of said frame member, ii. a second inner arm attached to said second surface of said frame member, iii. an inner junction piece connecting the first and second inner legs at an angle approximately the same as the angle of surfaces of the frame supports to which inner support is attached, the inner junction piece 56] also having a receiving channel projecting outward from the inner junction piece, and

b) at least one outer support having: i. a first outer arm, ii. a second outer arm, iii. an outer junction piece connecting the first and second outer arms, at approximately the same relative angle between the inner arms, the outer junction piece also having an insertion projection projecting inward from the outer junction piece, which is received and secured in the receiving channel thereby holding outer support to inner support sandwiching wall boards and securing them to said frame member.

13. The system of claim 12 wherein the insertion projection is one of the group consisting of insertion strip and an insertion tab.

14. A method of constructing removable walls on a frame having a plurality of frame members comprising the steps of:

a) attaching a receiver strip having a base strip capable of being attached to said frame members and a receiving channel, to at least one frame member,

b) providing a trim unit having at least one insertion strip which are sized and shaped to fit inside of, and be removably retained by the receiving channel,

c) providing wall panels and placing the wall panels between the receiver strips,

d) pressing the insertion strip 1 of the trim units into the receiving channels of the receiver strips to removeably retain said panels between the trim unit 2] and the receiver strip.

15. The method of constructing removable walls of claim 14 wherein the step of attaching to at least one frame member comprises the step of:

a) providing a receiver strip having a base strip with a slot 2 for receiving a metal frame member,

b) sliding the metal frame member into the slot of base strip to attach said receiver strip to said frame member.

16. The method of constructing removable walls of claim 14 wherein the step of providing wall panels comprises the step of providing drywall panels.

17. The method of constructing removable walls of claim 14 wherein the step of providing wall panels comprises the step of providing gypsum board.

18. The method of constructing removable walls of claim 14 further comprising the step of:

a) attaching a receiver strip horizontally at a floor level which would be under a wall panel,

b) providing a base molding having at least one insertion strip which is sized and shaped to fit inside of, and be removably retained by the receiving channel, the base molding also having and upper edge capable of supporting the wall panel and recesses for creating chase ways,

c) pressing the insertion strip of the base molding into the receiving channels of the receiver strips to removeably retain and support said wall panels on the upper edge of base molding.

19. The method of constructing removable walls of claim 14 further comprising the step of:

a) attaching a receiver strip horizontally at ceiling height,

b) providing a crown molding having at least one insertion strip which is sized and shaped to fit inside of, and be removably retained by the receiving channel, the crown molding also capable of supporting a ceiling panel,

c) pressing the insertion strip of the crown molding into the receiving channels of the receiver strips to removeably retain and support said ceiling panel.