SOLID SURFACE MATERIAL AND PLASTER BOARD COMBINATION AND MEANS FOR MOUNTING
A combination material comprising a surface material and a backing such as plasterboard is adjoined to a connector that allows adjoinment with another connector affixed onto a frame. The combination material comprises overlapping regions, allowing stacking and the connection means allows adjustment of the combination material for perfect fit. A linear frame element provides an efficient means for connecting the combination material to a frame.
This invention claims the benefit of the provisional application entitled “SOLID SURFACE MATERIAL AND PLASTER BOARD COMBINATION AND MEANS FOR MOUNTING”, filed Oct. 2, 2007 and accorded Application No. 60/976,982.
BACKGROUND OF THE INVENTION1. Field of Invention
The present invention relates to a combination material comprising a means for mounting.
2. Background of the Invention
An efficient means for the construction of walls and other interior surfaces could provide many benefits. Ideally, materials for forming walls would incorporate a means for adapting the surfacing to pre-existing surfaces or frames. For example, an ideal surface material would be readily adjoined to a metal frame and comprise areas where additional surfaces can overlap. This stacking of surfaces provides that the surfaces are adjoined strongly. Further, adapting the surface composition may result in a surface mounting means that can incorporate several materials in a seamless manner. There is a present need for a device that can reduce labor, time, and cost in the construction of walls and other surfaces according to the above specifications.
SUMMARY OF THE INVENTIONThe present invention is, in one or more embodiments, a composite wall system comprising at least one first frame element adapted to join onto an existing frame; said first frame element(s) adapted to mate with at least one second frame element joined with a composite panel; and said composite panel comprising a solid surface material adhered onto a board panel; said composite panel optionally having at least one edge adapted to overlap with any additional composite panel(s); said first frame element(s) and said second frame element(s) adapted to allow for translational adjustment such that said composite panel may be adjusted for fitting. The present invention is also a method of installing the composite wall system of claim 1 comprising installing the first frame element(s) onto the existing frame; mating a first composite panel having said second frame element(s) with the first frame element(s); adjusting the mate to allow for a perfect fit of the composite wall material; optionally mating said additional composite panel(s) having additional second frame element(s) with said first frame element(s) and adjusting the mate of any composite panels to allow for a perfect fit of all composite wall materials; repeating until all composite panels are installed and adjusted for perfect fit; and optionally permanently joining any board element(s) onto the existing frame, thereby locking the composite panel(s) into place. Finally, the present invention is a linear frame element for mating comprising a flat panel having an angled extrusion, said angled extrusion adapted to squeeze a second angled extrusion on a second flat panel of a second linear frame element, said squeezing occurring by the force of the angled extrusion onto the second angled extrusion and the force of the flat panel onto the second angled extrusion, and the force of the second angled extrusion onto the angled extrusion and the force of the second flat panel onto the angled extrusion.
The present invention can best be understood in connection with the accompanying drawings. It is noted that the invention is not limited to the precise embodiments shown in drawings, in which:
50 Joined Connectors (Male and Female); 60 First Frame Element; 70 Second Frame Element; 80 Linear Frame Elements (First and Second); 90 Studs or other Architectural Mount Point; 100 Frame or other Architectural Feature; 102 Female Connector; 104 Male Connector; 106 Plasterboard; 108 Solid Surface Material; 109 Optional Beveled Edge; 120 Group 1—Screw, Bolt, or other Joining Means; 122 Group 2—Screw, Bolt, or other Joining Means; 130 Embedded Nut; 140 Adhesive and/or Insulating Material; 200 Overlapping Edge of Board Material; 202 Overlapping Edge of Solid Surface Material; 300 Force Point; and 302 Additional Force Point.
DETAILED DESCRIPTION OF THE INVENTIONTurning to the drawings,
Attached to the board is a solid surface material—such as acrylic polymer, plastic, CORIAN, or other material including especially those materials with minimal porosity—which comprises the outer surface. In some preferred embodiments, the solid surface material is comprised of compounds adapted to allow the diffuse transfer of light, such as to form ambient lighting for an environment. In a highly preferred embodiment, 108 is a solid surface-material comprising an acrylic polymer.
Normally, plasterboard is spackled. Utilization of an adhered or disposed solid surface material obviates the need for spackling. To the combination of 106 and 108, is a connector 104 (shown as a male connector, but optionally female or “neuter”). In another embodiment, the connector may be a female adaptor. Suitable adaptors are well know in the art and include: brackets, push button handle sections, angle adaptors, bolt and socket arrangements, magnetic attachments, sock and ball attachments, and any other device in which an extrusion can be placed in a cavity such that the cavity adheres, cradles, supports, or encloses the extrusion. The adaptors need not be female/male counterparts but can be “neuter” as in a magnet-to-magnet coupling. In a preferred embodiment, the adaptors are further adapted to allow translational adjustment of the connection. For example, a female to male coupling would be ideal if after the coupling is made, the female or male adaptor, while remaining disposed in, on, or around its counterpart, can be moved in a direction. Such a feature allows the material on which the adaptor is affixed to be adjusted to allow for better fitting of the material. A ball and socket joint may allow such translation adjustment or any other device which allows, by friction or otherwise, the adjustment of the fitting. The joint may be in combination with another adaptor, such as a linear adaptor, or the ball and socket joint or other joint may be linearly extended itself. The adaptor 102 (shown as female but optionally male or neuter) is disposed on a frame or other architectural feature 100. Element 50 shows the female to male coupling. The coupling need not be made by a female to male attachment, but may be made by linear (extended) elements.
The composite wall system has a first frame and second frame element or elements. These elements may be, but need not be, male/female or female/male mate-able elements. Alternatively, the elements may be any coupling system but preferably are mate-able and adjustable such that the element-to-element fitting may be adjusted to provide a better fit for the board element. Mating does not require a male and female element but can occur anytime an element, including linear elements, are disposed onto, interposed with, or interleaved with another element such as a second linear element in such a manner that friction, gravity, or other forces retain the elements together. Such other forces can include adhesive forces such as from a glue or joining forces such as from a bolt or screw. Additionally, the elements are, in a preferred embodiment, linear elements, meaning the element extends along an axis, such as, for example, a point on the far left portion of a frame to a point on the far right portion of a frame, thereby providing uniform, high-holding strength. The element systems are preferably metal, especially light-weight and high-strength metals. The board wall panel can be a number of compositions and in an exemplary embodiment is plasterboard, gypsum, or gypsum-composite since these are commonly used materials for installation of walls. The board wall panel is affixed onto a solid surface material.
Engagement between adjoining composite panels occurs via the overlapping edges, which may be beveled, on the complimentary solid surfaces. The exposed plasterboard or other material on the right side of the panel thus mounted can then be fixed to the metal studs (or other architectural feature) with a joining means, such as a screw, nail or adhesive, before the next panel is mounted, slid to adjoin the now fixed panel, and then again fixed to studs (or other architectural feature) on or of the frame. Non-metal studs may also be used, such as high-strength plastic studs or studs made of other high-strength materials sufficient to securely hold the composite wall panels into place. With particular reference to the elements in
The particular structure of linear elements 60 and 70 shown in
Again,
Bolts, screws, or other similar joining means 122 are shown joining the elements to the frame, as by connection to studs (not shown). Bolts, screws, other joining means 120 attach the other linear element to the board material. The bolts or screws need not extend into the solid surface material as shown in
In the foregoing description, certain terms and visual depictions are used to illustrate the preferred embodiment. However, no unnecessary limitations are to be construed by the terms used or illustrations depicted, beyond what is shown in the prior art, since the terms and illustrations are exemplary only, and are not meant to limit the scope of the present invention. It is further known that other modifications may be made to the present invention, without departing the scope of the invention, as noted in the appended claims.
Claims
1. A composite wall system comprising
- a) At least one first frame element adapted to join onto an existing frame; said first frame element(s) adapted to mate with at least one second frame element joined with a composite panel; and
- b) said composite panel comprising a surface material adhered onto a board panel; said composite panel optionally having at least one edge adapted to overlap with any additional composite panel(s); said first frame element(s) and said second frame element(s) adapted to allow for translational adjustment such that said composite panel may be adjusted for fitting.
2. The composite wall system of claim 1 in which said board panel comprises a core material surrounded by one or more layers of a layered material.
3. The composite wall system of claim 1 in which said first frame element(s) is a clippable female unit and said second frame element(s) is a clippable male unit.
4. The composite wall system of claim 1 in which said first element(s) and said second elements(s) are metal elements.
5. The composite wall system of claim 1 in which said board wall panel is plasterboard or gypsum.
6. The composite wall system of claim 1 in which said first element(s) and said second element(s) are linear elements.
7. The composite wall system of claim 1 in which the composite wall system comprises curves.
8. The composite wall system of claim 1 in which said composite wall system is adapted for placement at corners.
9. The composite wall system of claim 1 further comprising an intervening layer of material between the solid surface material and the board material.
10. The composite wall system of claim 9 in which said intervening layer of material is KEVLAR.
11. The composite wall system of claim 9 in which said intervening layer of material is adapted to prevent projectiles from puncturing or breaking the intervening layer.
12. The composite wall system of claim 9 in which said intervening layer of material is adapted to provide insulation.
13. A method of installing the composite wall system of claim 1 comprising
- a) installing the first frame element(s) onto the existing frame;
- b) mating a first composite panel having said second frame element(s) with the first frame element(s);
- c) adjusting the mate to allow for a perfect fit of the composite wall material;
- d) optionally mating said additional composite panel(s) having additional second frame element(s) with said first frame element(s) and adjusting the mate of any composite panels to allow for a perfect fit of all composite wall materials;
- e) repeating step d) until all composite panels are installed and adjusted for perfect fit; and
- d) optionally permanently joining any board element(s) onto the existing frame, thereby locking the composite panel(s) into place.
14. The method of claim 13 in which any overlapping edges that meet any other overlapping edges are sealed; thereby resulting in a seamless joining of composite wall materials.
15. The method of claim 13 in which the adjustment for perfect fit comprises aligning any overlapping edges on adjacent composite wall materials.
16. The method of claim 13 in which adjustment of fitting is performed once, after any and all first frame elements have been mated with their corresponding second frame elements, and prior to permanently joining any board elements.
17. A linear frame element for mating comprising a flat panel having an angled extrusion, said angled extrusion adapted to squeeze a second angled extrusion on a second flat panel of a second linear frame element, said squeezing occurring by the force of the angled extrusion onto the second angled extrusion and the force of the flat panel onto the second angled extrusion, and the force of the second angled extrusion onto the angled extrusion and the force of the second flat panel onto the angled extrusion.
18. The linear frame element of claim 17 in which said mate is also achieved by force of friction and/or gravity.
19. The linear frame element of claim 17 where the angle of extrusion is no more than 60 degrees between the flat panel and the angled extrusion.
Type: Application
Filed: Nov 8, 2007
Publication Date: Apr 2, 2009
Inventors: JOHN R. MANGIARDI (GREENWICH, CT), JEFFREY W. EVANS (MORICHES, NY), JOHN CHRISTOPHER WHITELAW (NEW YORK, NY)
Application Number: 11/937,136
International Classification: E04F 13/072 (20060101);