Wall Surround System with Tile Inlays

Abstract

Provided is a wall surround system for use in a room having at least one existing wall. The system includes at least one wall surround panel configured to be installed along the existing wall, the wall surround panel defining at least one recessed portion. The system also includes at least one tile inlay configured to be received within the recessed portion. The system can be a remodeling system for remodeling a bathroom or kitchen in a residential or commercial building. Also provided are methods for remodeling a room having at least one existing wall. The method includes providing at least one wall surround panel that defines at least one recessed portion and at least one tile inlay, securing the wall surround panel to the wall, and securing the tile inlay in a respective recessed portion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/495,250, filed Jun. 9, 2011, entitled “Wall Surround System with Tile Inlays,” which application is incorporated herein by reference.

FIELD OF THE INVENTION

Provided are systems and methods for remodeling a bathroom or kitchen using one or more wall surround panels with recessed portions for receiving one or more tile inlays.

BACKGROUND OF THE INVENTION

There is often significant cost and inconvenience associated with remodeling a bathroom or kitchen. Many home owners, building owners and/or business owners would like to achieve an updated look, without the significant expense and inconvenience associated with a typical remodel.

Various systems are available that provide for a relatively inexpensive remodel with quick installation. Many of these systems include wall surround panels designed to cover existing walls or existing wall coverings.

However, when using these systems, the remodeler must simply select one of a limited number of wall surround panel designs manufactured and provided by the seller. There is little or no opportunity to further customize the look to fit with the decor of the surrounding areas or the remodeler's unique taste.

Thus, there is a need in the art for an inexpensive, easy to install, aesthetically pleasing and customizable system for remodeling a bathroom, kitchen or other room.

SUMMARY

In accordance with the purposes of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a wall surround system for use in a room having at least one existing wall. The system can include at least one wall surround panel configured to be installed along the existing wall, the wall surround panel defining at least one recessed portion. The system can also include at least one tile inlay configured to be received within the recessed portion. The system can be a remodeling system for remodeling a bathroom or kitchen in a residential or commercial building.

Also provided are methods for remodeling a room having at least one existing wall. The method includes providing at least one wall surround panel that defines at least one recessed portion and at least one tile inlay. The method also includes securing the wall surround panel to the wall, and securing the tile inlay in a respective recessed portion. The method can also include removing a portion of the wall that corresponds to a position of the recessed portion when the wall surround panel is installed along the wall. Securing the wall surround panel to the wall can then comprise positioning the wall surround panel such that the recessed portion extends into the removed portion of the wall.

Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and together with the description serve to explain the principles of the invention.

FIG. 1 illustrates an exemplary wall surround system installed around a bathtub, according to one embodiment.

FIG. 2A is an exploded view of three wall surround panels of a wall surround system, the wall surround panels having decorative trim, according to another embodiment.

FIG. 2B is an exploded view of three wall surround panels of a wall surround system, the wall surround panels having no decorative trim, according to another embodiment.

FIG. 3A is a front plan view of an exemplary wall surround panel, according to one embodiment.

FIG. 3B is a cross-sectional view of the wall surround panel of FIG. 3A, taken along line A-A of FIG. 3A.

FIG. 3C is a detailed cross-sectional view of section B of FIG. 3B.

FIG. 3D is a side elevational view of the wall surround panel of FIG. 3A.

FIG. 4 is a perspective view of the wall surround panel of FIG. 3A.

FIG. 5 is a front plan view of an exemplary wall surround panel, according to another embodiment.

FIG. 6 is a perspective view of the wall surround panel of FIG. 5.

FIG. 7A is a front partial view of an exemplary wall surround panel having decorative trim, according to one embodiment.

FIG. 7B is a rear partial view of the wall surround panel of FIG. 7A.

FIG. 7C is a perspective partial view of the wall surround panel of FIG. 7A.

FIG. 7D is a front partial view of the wall surround panel of FIG. 7A, with a tile inlay positioned in the recessed portion of the wall surround panel.

FIG. 8 illustrates an installed wall surround system in a bathroom having a bathtub, the wall surround system including bathtub wall surround panels and wainscot panels, according to one embodiment.

FIG. 9 illustrates an installed wall surround system in a bathroom having a corner shower, according to yet another embodiment.

FIG. 10 illustrates materials applied to a tile inlay in order to install the tile inlay in an exemplary wall surround system, according to one embodiment.

DETAILED DESCRIPTION

The present invention may be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “wall surround panel” or a “tile inlay” can include two or more such wall surround panels or tile inlays, unless the context indicates otherwise.

Ranges may be expressed herein as from “approximately” one particular value, and/or to “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “approximately,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

Reference will now be made in detail to the various embodiments, examples of which are illustrated in the accompanying drawings.

According to various embodiments, a wall surround system is provided for use in a room having at least one existing wall. For example, but not meant to be limiting, the wall surround system can be used in a bathroom or kitchen. If used in a bathroom, for instance, the wall surround system can be used on walls that surround a bathtub or shower, and/or on walls that do not surround a bathtub or shower. In a kitchen, exemplary wall surround systems could be used on portions of walls that form a backsplash between lower and upper cabinets.

According to one embodiment, the wall surround system has at least one wall surround panel configured to be installed along the at least one existing wall in the room. More specifically, the at least one wall surround panel is configured to cover at least a portion of the existing wall. Each wall surround panel has a face surface and at least one edge. Each wall surround panel can also define at least one recessed portion in the face surface. According to various embodiments, the wall surround panels are designed to be aesthetically pleasing, and may consist of one or more designs created by indentations, protrusions, surface textures, and/or color. The system can also comprise at least one tile inlay configured to be received within the at least one recessed portion.

For example, with reference to FIG. 1, a wall surround system 100 can be provided for use within a bathroom to cover the walls of the bathtub enclosure. The at least one wall surround panel can comprise any number of wall surround panels necessary to cover the desired surfaces. For example, for a bathroom having a recessed portion containing a bathtub 106, as shown in FIG. 1, the at least one wall surround panel can include a first panel 122, which is designed to cover the long wall located at the back of the recessed portion (the wall that traditionally includes the soap dish), a second panel 124 designed to cover the wall located at the front end of the bathtub that includes plumbing such as a faucet and/or a shower head (not shown), and a third panel 126 designed to cover the wall located at the back end of the bathtub. Each wall surround panel can have a face surface and at least one edge, such as the face surface 111 of the first panel 122 and the upper edge 112. A plurality of recessed portions are defined in the face surfaces of the respective wall surround panels. As can be seen, a tile inlay 132 is received within each recessed portion. These wall surround panels can also be seen in FIG. 2A, wherein each wall surround panel (122A, 124A, 126A) has a decorative trim 116 that extends along at least one edge of each respective wall surround panel. Optionally, as shown in FIG. 2B, each wall surround panel (122B, 124B, 126B) can be provided with undecorated edges. In the case of a decorative trim edge, the decorative trim can be a bull nosed edge, an edge with a crown molding appearance, or other decorative edge.

According to further embodiments, each wall surround panel can define at least one linear indentation extending along at least a portion of the face surface of the wall surround panel. For example, with reference to FIG. 3A, a wall surround panel 110 is shown that has a plurality of linear indentations. The linear indentations can include a plurality of first indentations 113 that are spaced from each other, and a plurality of second indentations 114 that are spaced from each other. The first indentations can be substantially perpendicular to each other, and the second indentations can be substantially perpendicular to each other. Each first indentation can extend substantially perpendicularly to at least one of the second indentations. Thus, as can be seen in FIG. 3A, the indentations can form a grid of vertical and horizontal indentations (when installed on a wall). In a further embodiment, a recessed portion 130 can be defined in the face area at an intersection of a first indentation 113 and a second indentation 114. A tile inlay 132 can then be secured in each recessed portion 130, as discussed further below.

According to one embodiment, the each indentation can have a width w_i of approximately ⅛ inch, and a depth of approximately 1/16 inch to approximately ¼ inch. Because the wall surround panels are designed for aesthetic purposes, these dimensions do not need to be machined to tight tolerances, and need not be exact. Additionally, because the face surface of the wall surround panels can be textured, the edges of each indentation can also be textured or dimpled, such that the width of depth of the indentation is not uniform along its length. The indentations can be designed to have an appearance similar to that of a grout line, such as can be seen in FIG. 4.

According to a further embodiment, the first indentations can be spaced at approximately 12 inches from each other. The second indentations can also be spaced approximately 12 inches from each other. Thus, in one embodiment the portions of the wall surround panel can have an appearance of a standard 12-inch tile. In other embodiments, the indentations can be spaced from each other at other distances, such as, but not limited to 4 inches, 6 inches, 15 inches, 16 inches, 18 inches, or any other desired distance. The indentations can also be spaced in a non-uniform manner, such that an uneven grid or other pattern could be created.

In yet another embodiment, each recessed portion can be substantially square in shape, with approximately equal dimensions in width and height, and have a length dimension l as shown in FIG. 5. In one non-limiting example, the width and height of the recessed portion can be approximately 4 inches, to accommodate a standard tile as the tile inlay. However, it is contemplated that the recessed portion can be sized to accommodate any standard tile as a tile inlay. Likewise, each recessed portion can have a depth that is sized to accommodate a standard tile. Thus, in one exemplary embodiment, the depth d (see FIG. 3C) of the recessed portion can be approximately ½ inch. The depth can be any dimension necessary to receive a tile inlay such that a face surface of the tile inlay is substantially flush with the face surface of the wall surround panel.

As discussed above, and with reference to FIG. 3A for example, each recessed portion 130 can be positioned at an intersection of a first indentation 113 and second indentation 114. In the case of square-shaped recessed portions, they can be positioned at an angle a relative to the second indentation 114. In one non-limiting example, the recessed portion can be positioned at 45° from the second indentation, such that it appears as a diamond shape in the grid.

The at least one tile inlay is designed to add aesthetic appeal to the wall surround system. Thus, tile inlays can be any size, color and/or texture, and are selected based on the tastes and preferences of a customer. The at least one tile inlay, in one embodiment, is comprised of a material selected from the group consisting of stone, ceramic, glass, metal, and laminated plastic with a metal surface sheet (sold under the name DECOMETAL® by Formica Corporation). Optionally, the tile inlays can be manufactured of any material or method known in the art. Additionally, in a system in which a plurality of tile inlays are used, each tile inlay can be provided in a combination of materials. For example, some tile inlays can be glass and others can be stone, or some other combination. The tile inlays can be arranged in a uniform or random pattern within the recessed portions, or any pattern that a customer desires. According to a further embodiment, each tile inlay can have a size and shape that enables it to be received within a respective recessed portion. Thus, if the recessed portion is approximately 4 inches in height and width, and approximately ½ inch in depth, the tile inlay can be approximately 3⅞ inches in height and width, and approximately ¼ inch in depth.

With reference to FIGS. 3A-3D, and FIG. 5, the at least one wall surround panel (110 or 210, respectively) can be any height H and width W necessary to cover the desired area. The depth D of the one or more wall surround panels ranges from approximately ¼ inch to approximately 2 inches in depth, according to the dimensions of the wall to be covered. According to one embodiment, by way of example only, and with reference to FIG. 1, the width of the first panel 122 is the width of the soap dish wall of the bathtub enclosure; the height of the first panel 122 can be the distance from the top of the bathtub to the ceiling, or the distance from the top of the bathtub to any desired point along the wall. While FIGS. 3A-3D and FIG. 4 illustrate a wall surround panel 110 that can be used as a first panel 122 in the bathtub enclosure shown in FIG. 1, FIGS. 5 and 6 illustrate a wall surround panel 210 that can be used as a second panel 124 or third panel 126 in the bathtub enclosure shown in FIG. 1, in one example.

With reference to FIGS. 7A-7D, partial views of a wall surround panel 310 are shown, that illustrate a decorative trim 316 along the edge portion of the wall surround panel. These figures also illustrate some of the surface texturing that can be used with the exemplary wall surround panels described herein. In FIG. 7C, the contours of the decorative trim 316 can be seen, along with the recessed portion 130 configured to receive the tile inlay 132, which can be seen in FIG. 7D.

According to another embodiment, and with reference to FIG. 8, a wall surround system 400 is shown that includes wall surround panels secured to the existing walls in a bathtub enclosure, as well as additional wall surround panels secured to the non-bathtub walls 402 of the bathroom. The wall surround system 400 thus includes a first panel 422, second panel 424, and third panel (hidden due to the perspective), such as described with reference to FIG. 1, along with several wainscot panels 428 along the non-bathtub walls 402 of the bathroom. The wainscot panels can be any height as desired by the customer, though the general rule of thumb is that a wainscot panel should cover the lower third to half of the wall. The width of the one or more wainscot panels is determined by the width of the existing wall along which the wainscot panel is to be installed. As with the bathtub enclosure wall surround panels, the depth of the wainscot panels can be approximately ¼ inch to approximately 2 inches. As can be seen in FIG. 8, the wainscot panels and bathtub enclosure panels can have different designs and configurations. Whereas the bathtub enclosure panels have an overall design as seen in FIG. 1, for instance, with the recessed portions being diamond-shaped and arranged in a grid, the wainscot panels have only a single line of spaced recessed portions that are square. Additionally, the bathtub enclosure panels can have one tile inlay 432A type (i.e., color, design and/or material) in them, while the wainscot panels can have a different tile inlay 432B type. Thus, it can be seen that virtually any configuration of positioning and arrangement of recessed portions and wall surround panels is possible according to the various embodiments discussed herein.

FIG. 9 illustrates a wall surround system 500 in a shower enclosure that is positioned in a corner of a bathroom. The system shows a first panel 522 positioned on one wall 502A and a second panel 524 positioned on an adjoining wall 502B. As can be seen, the panels can be cut to accommodate existing fixtures, such as a shower head 503, a shower handle 504, a seat 507, a soap dish/bottle holder 508, and grab bars 509. As can be seen in this exemplary system, each wall surround panel 522, 524 includes a decorative trim along the respective top edges of the panels.

Thus, according to the various embodiments described herein, wall surround panels can be provided that can be installed along a wall surrounding a bathtub or shower, as well as wall surround panels that are configured to be installed along a non-bathtub or non-shower wall. While reference has been made to the one or more wall surround panels necessary to fit the specific bathroom layouts shown in FIGS. 1, 8 and 9, any number and combination of wall surround panels falls within the scope of the inventive concept.

The systems described herein can also include means for securing the at least one tile inlay in a respective recessed portion. Such a means can be any adhesive known in the art, such as double-sided tape, a silicone-based adhesive, or other known adhesives. In a further embodiment, the one or more adhesive used to secure the tile inlay in the recessed portion can be any adhesive that can stand up to the moist environment of bathrooms, including bathtub or shower enclosures.

According to one embodiment, the wall surround panels are comprised primarily of acrylic. According to other embodiments, the one or more wall surround panels are comprised of any thermoplastic material or combination of thermoplastic materials.

According to one embodiment, the one or more wall surround panels are manufactured by heating a sheet of raw material to approximately 330 degrees in a thermoforming oven for approximately two and a half minutes. The heated sheet is then placed over a male mold and vacuum formed to the shape of the mold. The formed wall surround panel is cooled for approximately 45 seconds. The wall surround panel is then removed from the mold and trimmed.

Provided herein are methods of remodeling a room having at least one wall, such as a bathroom or kitchen. The method in one aspect comprises providing at least one wall surround panel, such as those described herein, and providing a tile inlay. The method can comprise, before installing the at least one wall surround panel, ensuring that the existing wall is in clean and good condition. The existing wall can be cleaned using chemicals including, but not limited to, acetone and denatured alcohol. If the existing surface is not in satisfactory condition, it can be repaired as understood in the art. For example, if the existing surface is not flat, portions of the wall can be built-out using any American Society for Testing (ASTM) approved board including, but not limited to, fiber cement, fiber mat reinforced cement, glass mat gypsum backers, or fiber-reinforced gypsum backers, such as those known in the art.

The installer must then determine where the recessed portions of the wall surround panels will be located with respect to the existing wall or wall covering. The method can then comprise removing a portion of the at least one wall that corresponds to the position of the at least one recessed portion when the wall surround panel is installed against the respective wall. Thus, in one example, the installer can cut the existing wall or wall covering in those locations such that the existing wall or wall covering will accommodate the one or more recessed portions of the wall surround panels. Alternatively, the installer can build-out the existing wall in a manner that accounts for the location of the recessed portions of the wall surround panels.

The at least one wall surround panel can be trimmed to ensure an exact fit on the desired surface. This includes trimming to account for the height, width and depth of the wall to be covered. It may further include trimming or cutting the wall surround panels to account for windows, hardware (faucets, shower heads, etc.) and other accessories, including soap dishes and shelves. The installer must further account for the location of grout line simulating indentations, decorative trim and other pattern features to ensure an aesthetically pleasing result.

According to one embodiment, the method further comprises securing the at least one wall surround panel to the at least one wall. This can comprise, in one example, adhering the at least one wall surround panel to the at least one wall. Thus, in one non-limiting example, to install the one or more wall surround panels, the installer applies silicone primer to the existing wall or wall covering. The installer then applies double-sided tape, such as butyl tape, over the primed areas of the existing wall or wall covering, as known in the art. The installer removes the paper from the tape and applies a thick bead of silicone in the areas surrounding the tape. The wall surround panel is then placed against the existing wall and/or wall covering and pressed to ensure that the panel has made complete contact with the adhesive. According to another embodiment, the installer further applies a silicone primer to the back of the wall surround panel before adhering the wall surround panel to the existing wall or wall covering.

According to one embodiment, once each of the wall surround panels is adhered to the existing wall and/or wall covering, the joints between two or more wall surround panels are sealed by applying silicone to each joint. The plumbing access holes are also sealed using silicone. In one example, the room in which the wall surround panels are installed can have a first wall and a second adjoining wall, such that a first wall surround panel can be secured to the first wall, and a second wall surround panel can be secured to the second wall such that the first and second panels abut at a corner joint. The joint can then be sealed, such as with silicone.

Once the one or more wall surround panels are installed, the one or more tile inlays are secured in the recessed portions of the one or more wall surround panels in any configuration desired by the customer. In one embodiment, the tile inlays can be secured in the recessed portions by adhering each tile inlay to a surface of a respective recessed area 130, such as shown in FIG. 10. According to one embodiment, each tile inlay is secured to the recessed portion by placing a strip of double-sided tape, such as butyl tape, at the center of the recessed portion; applying a sealant, such as thermal expansion sealant (TES), to the recessed portion, on either side of the tape; applying clear silicone to the perimeter of the recessed portion; and finally placing the tile in the recessed portion.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Other aspects of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. A wall surround system for use in a room having at least one existing wall, comprising:

at least one wall surround panel configured to be installed along the at least one existing wall, wherein each wall surround panel has a face surface and at least one edge, and wherein each wall surround panel defines at least one recessed portion in the face surface; and

at least one tile inlay configured to be received within the at least one recessed portion.

2. The wall surround system of claim 1, wherein each wall surround panel defines at least one linear indentation extending along at least a portion of the face surface of the wall surround panel.

3. The wall surround system of claim 2, wherein the at least one linear indentation comprises at least two linear indentations that extend substantially perpendicularly to each other.

4. The wall surround system of claim 2, wherein the at least one linear indentation comprises a plurality of first indentations spaced from each other and a plurality of second indentations spaced from each other, wherein each first indentation extends substantially perpendicularly to at least one of said second indentations.

5. The wall surround system of claim 4, wherein the first indentations are spaced approximately 12 inches from each other and wherein the second indentations are spaced approximately 12 inches from each other.

6. The wall surround system of claim 4, wherein the at least one recessed portion is defined at an intersection of a first indentation and a second indentation.

7. The wall surround system of claim 2, wherein the at least one indentation has a width of approximately ⅛ inch, and a depth of approximately 1/16 to ¼ inch.

8. The wall surround system of claim 1, wherein each recessed portion is substantially square in shape and has a width of approximately 4 inches, a height of approximately 4 inches, and a depth of approximately ½ inch.

9. The wall surround system of claim 1, wherein the at least one wall surround panel comprises a decorative trim along the at least one edge.

10. The wall surround system of claim 1, further comprising means for securing the at least one tile inlay in the at least one recessed portion.

11. The wall surround system of claim 10, wherein the means for securing comprises an adhesive.

12. The wall surround system of claim 1, wherein the at least one surround panel is acrylic.

13. The wall surround system of claim 1, wherein the room has at least one first wall surrounding a bathtub or shower and at least one second wall that does not surround a bathtub or shower, and wherein one or more of the at least one wall surround panels is configured to be installed along the at least one first wall.

14. The wall surround system of claim 13, wherein one or more of the at least one wall surround panels is configured to be installed along the at least one second wall.

15. The wall surround system of claim 1, wherein the at least one tile inlay is comprised of a material selected from the group consisting of stone, ceramic, glass, metal, and laminated plastic with a metal surface sheet.

16. A method of remodeling a room having at least one existing wall, comprising:

providing at least one wall surround panel, wherein each wall surround panel has a face surface and at least one edge, and wherein each wall surround panel defines at least one recessed portion in the face surface;

providing at least one tile inlay;

securing the at least one wall surround panel to the at least one wall; and

securing the at least one tile inlay in a respective recessed portion.

17. The method of claim 16, further comprising removing a portion of the at least one wall that corresponds to the position of the at least one recessed portion when the wall surround panel is installed along the at least one wall, wherein said step of removing occurs prior to the step of securing the at least one wall surround panel to the at least one wall, and wherein securing the at least one wall surround panel to the at least one wall comprises positioning the at least one wall surround panel such that the at least one recessed portion extends into the removed portion of the at least one wall.

18. The method of claim 16, wherein securing the at least one tile inlay comprises adhering the tile inlay to a surface of the recessed portion.

19. The method of claim 16, wherein securing the at least one wall surround panel to the at least one wall comprises adhering the at least one wall surround panel to the at least one wall.

20. The method of claim 16, wherein the room has a first wall and a second adjoining wall, and wherein the at least one wall surround panel comprises a first wall surround panel and a second wall surround panel, wherein securing the at least one wall surround panel to the at least one wall comprises securing the first wall surround panel to the first wall and securing the second wall surround panel to the second wall such that the first and second wall surround panels abut at a corner joint, the method further comprising sealing the joint between the first and second wall surround panels.