MODULAR WALL PANEL WITH INTERCHANGEABLE ENHANCEMENT BOARDS

Abstract

A modular wall panel including a backer board and a plurality of front boards arranged in a plurality of rows. At least one row of the plurality of rows includes two or more horizontally-adjacent front boards permanently affixed to the backer board. The two or more horizontally-adjacent front boards collectively spanning an entire width of the modular wall panel. At least one row of the plurality of rows includes an enhancement area without a permanently-affixed front board. The enhancement area is horizontally adjacent to a front board that is permanently affixed to the backer board. The modular wall panel further includes a removable enhancement board configured to be reversibly affixed to the backer board to fill the enhancement area.

Description

BACKGROUND

In some cases, an interior or exterior wall may be decorated with a plurality of panels to provide a desired aesthetic appearance. Typically, such panels are permanently installed on the wall such that the aesthetic appearance of the paneled wall does not change. In order to change the aesthetic appearance of the wall, the panels would have to be completely removed and different panels would have to be installed on the wall in place of the old panels. Such a process of removing and installing panels on a wall in order to change an aesthetic appearance of the wall may be labor intensive and costly.

SUMMARY

Accordingly, a modular wall panel including removable enhancement boards is disclosed. In one example, the modular wall panel includes a backer board and a plurality of front boards arranged in a plurality of rows. At least one row of the plurality of rows includes two or more horizontally-adjacent front boards permanently affixed to the backer board. The two or more horizontally-adjacent front boards collectively span an entire width of the modular wall panel. At least one row of the plurality of rows includes an enhancement area without a permanently-affixed front board. The enhancement area is horizontally adjacent to a front board that is permanently affixed to the backer board. The modular wall panel further includes a removable enhancement board configured to be reversibly affixed to the backer board to fill the enhancement area.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a plurality of example modular wall panels including enhancement areas that are not filled with removable enhancement boards.

FIG. 1B shows the plurality of modular wall panels of FIG. 1A with removable enhancement boards removably affixed to the plurality of modular wall panels to fill the enhancement areas.

FIG. 1C shows the plurality of modular wall panels of FIGS. 1A and 1B with different removable enhancement boards removably affixed to the plurality of modular wall panels than the removable enhancement boards shown in FIG. 1B.

FIGS. 2-7 show an example process of constructing a modular wall panel.

FIG. 8 shows a plurality of modular wall panels having different enhancement areas.

FIG. 9 shows an example modular wall panel where a row is horizontally offset relative to a backer board.

FIG. 10 shows an example modular wall panel where a row is vertically offset relative to a backer board.

FIG. 11 shows an example edge-joined modular wall panel.

FIG. 12 shows another example edge-joined modular wall panel.

FIG. 13 shows an example package including a plurality of modular wall panels and corresponding enhancement boards.

FIG. 14 shows an example package including a plurality of modular wall panels without corresponding enhancement boards.

FIG. 15 shows an example package including a plurality of enhancement boards without corresponding modular wall panels.

FIGS. 16-19 show an example process of paneling a wall with a plurality of modular wall panels.

FIG. 20 shows an example fence from which boards may be reclaimed to construct a modular wall panel.

FIG. 21 shows an example wood pallet from which boards may be reclaimed to construct a modular wall panel.

FIG. 22 shows an example method for constructing a modular wall panel.

DETAILED DESCRIPTION

The present description is directed to a modular wall panel including one or more removable enhancement boards that are removably affixable to one or more corresponding enhancement areas of the modular wall panel. The removable enhancement board(s) differ in appearance from other boards of the modular panel such that the removable enhancement board(s) form an aesthetic design. Moreover, the removable enhancement boards are configured to be removably affixable to the modular wall panel, such that different removable enhancement boards having different aesthetic qualities can be interchangeably affixed to the modular wall panel. Accordingly, the aesthetic design of the modular wall panel can be changed as desired in a quick and easy manner relative to other more permanent wall panel configurations.

FIG. 1A shows a plurality of example modular wall panels 100 with enhancement areas that are not filled with removable enhancement boards. Each of the plurality of modular wall panels 100 includes a backer board 102. The backer board 102 may include any suitable material. As one example, the backer board includes wood material, such as plank lumber or engineered wood (e.g., plywood, medium density fiberboard (MDF), particle board, oriented strand board (OSB), and other composite wood). In other examples, the backer board 102 may comprise other materials, such as metal, plastic, paper, vinyl, and cork. The backer board 102 may have any suitable size/dimensions. In one particular example, the backer board 102 is 4.75 mm thick×195 mm tall×1180 mm wide. In some embodiments, the backer board 102 may be untreated. In other embodiments, the backer board 102 may be treated (e.g., stained, painted, or varnished). In one example, the backer board 102 is painted black.

A plurality of front boards 104 are arranged in a plurality of rows 106 on the backer board 102. At least one row of the plurality of rows 106 includes two or more horizontally-adjacent front boards 104 permanently affixed to the backer board 102. The two or more horizontally-adjacent front boards 104 collectively span an entire width (W) of the backer board 102. At least one row of the plurality of rows includes an enhancement area 108 without a permanently-affixed front board. The enhancement area 108 is horizontally adjacent to a front board 104 that is permanently affixed to the backer board 102. In some examples, an enhancement area may be positioned in between two horizontally aligned front boards permanently affixed to the backer board. In other examples, an enhancement area may be positioned on an end of a row and adjacent to a front board that is permanently affixed to the backer board. In some examples, the plurality of modular wall panels 100 may be coupled together such that no enhancement areas are positioned in adjacent rows of the plurality of modular wall panels.

The rows 106 of each of the modular wall panels 100 may have any suitable size/dimensions. In some embodiments, the plurality of rows of a modular wall panel may include rows having different row heights. In one particular example, a first row of a modular wall panel is 120.65 mm tall and a second row is 76.2 mm tall. In some such embodiments, the different row heights may be consistent across the plurality of modular wall panels. In the illustrated example, each modular wall panel includes two rows including an upper row having a greater height (H1) and a lower row having a lesser height (H2). Note that in some examples different modular panels could be installed on a wall such that the row having the lesser height (H2) is positioned on top of the row having the greater height (H1) to change the visual aesthetic of a paneled wall. In other embodiments, the plurality of rows of a modular wall panel may be a same height. Further, that same row height may be consistent across a plurality of modular wall panels. Further still, it is to be understood that the modular wall panels could be rotated 90 degrees for a vertical installation and/or the modular wall panels could be made with another shape, including a square shape or a shape with a larger height than width. Similarly, the size/orientation of the constituent boards may be varied, e.g., to include many narrow rows as opposed to the two relatively wide rows illustrated in the example embodiment. A modular wall panel may include any suitable number of rows including two, three, or more rows. In some embodiments, the number of rows per modular wall panel may be consistent for a plurality of modular wall panels. In the illustrated example, each modular wall panel includes two rows. In other embodiments, the number of rows per modular panel may vary from panel to panel. As one example, different modular wall panels may vertically alternate between having two rows and three rows.

In some examples, at least a portion of a row of the plurality of rows may include a front board having a height that is equal to the row height of the row. In some other examples, for example as shown at 109 of FIG. 1A, at least a portion of a row of the plurality of rows may include two lesser-height front boards vertically stacked with a combined height equal to a row height of the row. In one particular example, a 50.8 mm tall front board may be vertically stacked with a 69.85 mm tall front board to combine for a row height of 120.65 mm. For example, two lesser-height boards may be vertically stacked in a row in order to use up smaller boards and reduce waste when fabricating the modular wall panels. In some embodiments, no front board may have a width that is less than 304 mm, such that the front boards 104 may be structurally sound and properly permanently affixed to the backer board 102. In some embodiments, the plurality of front boards 104 may have uniform thickness. In one example, each of the plurality of front boards 104 is 4-5 mm thick with a tolerance of +/−1-2 mm. In other embodiments, different front boards may have different thicknesses. The plurality of front boards may have any suitable size/dimensions.

In some embodiments, each of the plurality of rows 106 is aligned with the backer board 102. In some examples, the edges of the front boards may be exactly even with an edge of the backer board 102. In some examples, the plurality of rows collectively have a combined row height equal to the backer board height, and each row has a row width equal to the backer board width. In other embodiments, the front boards may be sized to overhang one or more edges of the backer board. In one particular example, the backer board is 195 mm tall×1180 mm wide and the plurality of rows are collectively 196.85 mm tall×1181.1 mm wide. The plurality of rows of the modular wall panel may collectively form any suitable size/dimensions.

The plurality of front boards 104 may be any suitable type of wood or other material. In some embodiments, the plurality of front boards 104 may be new wood. In other embodiments, the plurality of front boards 104 may be reclaimed wood. For example, the front boards may be reclaimed from disassembled fencing and/or pallets. In some embodiments, the reclaimed wood may be processed such that the plurality of front boards have a relatively uniform appearance/dimensions. In some examples, different faces of the front boards may be textured with a circle saw or wire brush to provide a consistent, distressed appearance. In some examples, the reclaimed wood may be cut to suitable dimensions, such that the front boards have clean, consistent edges. In some examples, the reclaimed wood may be cut to remove defects and see-through voids (e.g., large holes, major splits, major knots). In some embodiments, the plurality of front boards 104 may be uncoated (e.g., raw wood). In other embodiments, the plurality of front boards 104 may be coated (e.g., stained, painted, varnished, or clear coated (e.g., with satin polyurethane)).

The plurality of front boards 104 may be permanently affixed to the backer board 102 in any suitable manner. In some embodiments, the plurality of front boards 104 are permanently affixed to the backer board 102 with glue or another adhesive. Additionally or alternatively, the plurality of front boards 104 may be permanently affixed to the backer board 102 with one or both of nails and staples. For example, nails or staples may be inserted from a back side of the backer board 102, such that the nails or staples pass through the backer board 102 and into a back side of a front board 104 to affix the front board 104 to the backer board 102. In this way, the nails or staples are not visible on the front side of the modular wall panel 100. In yet other embodiments, the plurality of front boards 104 may be affixed to the backer board 102 with hook-and-loop or hook-and-pile fasteners, magnets, or another adhesion method.

An enhancement area 108 may have any suitable size (e.g., length, width) and any suitable position within a particular row 106. In some embodiments, different modular wall panels 100 may include differently sized and/or differently positioned enhancement areas 108. In other embodiments, different modular wall panels 100 may include enhancement areas having a same size and/or same position. As one example, the enhancement areas of different modular wall panels may be aligned to give the appearance of a vertical stripe in the paneled wall. As another example, the enhancement areas of different modular wall panels may be staggered to give the appearance of a horizontal or diagonal stripe. As yet another example, the enhancement areas of different modular wall panels may be arbitrarily staggered. In the illustrated example, the enhancement areas are either 306.4 mm (˜12 in), 408 mm (˜16 in), or 509.6 mm (˜20 in) long.

In FIG. 1B, the plurality of modular wall panels 100 is shown with a first plurality of removable enhancement boards 112 removably affixed to the backer boards 102 to fill the enhancement areas 108. The plurality of removable enhancement boards 112 may be removably affixable to the backer boards 102 in the enhancement areas 108 in any suitable manner. In some embodiments, each of the plurality of modular wall panels 100 may include a primary touch fastener 110 affixed to a frontside of the backer board 102 in the enhancement area 108. Further, each enhancement board 112 may include a complimentary touch fastener 114 (obstructed by the enhancement boards, but represented with dotted lines in FIG. 1B) affixed to a backside of the removable enhancement board 114. The primary touch fastener 110 and the complimentary touch fastener 114 are reversibly joinable such that the removable enhancement board 112 is reversibly affixable to the backer board 102 to fill the enhancement area 106. As one example, the primary touch fastener 110 and the complimentary touch fastener 114 may collectively constitute a hook-and-loop or hook-and-pile fastener. As another example, the primary touch fastener 110 and the complimentary touch fastener 114 may constitute complimentary magnetic fasteners. In some embodiments, the primary and complimentary touch fasteners may be located on interfacing edges of the front boards and/or the enhancement boards.

The plurality of removable enhancement boards 112 may include any suitable type of material. In some embodiments, the plurality of removable enhancement boards 112 may be made from wood. In some embodiments, the removable enhancement boards 112 may be made from the same material as the plurality of front boards 104. In some such embodiments where the removable enhancement boards 112 are made from reclaimed wood, the reclaimed wood may be processed in the same manner as the front boards (e.g., textured with a circle saw or wire brush, cut to suitable dimensions and/or to remove defects and see-through voids). In some embodiments, the plurality of removable enhancement boards 112 may have a different coat or finish than the plurality of front boards 104, such that the removable enhancement boards 112 are visually distinct from the front boards 104. For example, the front boards 104 may be clear coated and the removable enhancement boards may be painted one or more different colors. In some embodiments, each of the plurality of front boards 104 may be unpainted and the plurality of removable enhancement boards 112 may be painted or coated differently. In some embodiments, the plurality of removable enhancement boards 112 may include other materials, such as metal, mirrors, tile, wallpaper, cloth, leather, plastic, vinyl, ceramic, cork, and other non-wood materials.

In some embodiments, the removable enhancement boards 112 may have a same thickness as a thickness of the front boards 104. In other embodiments, the removable enhancement boards 112 may have a different thickness than a thickness of the front boards 104. For example, the removable enhancement boards 112 may be thicker than the front boards 104 such that the enhancement boards 112 protrude outward from the modular wall panels 100.

In some embodiments, all of the removable enhancement boards 112 may be coated or finished in the same manner (e.g., painted the same color). In other embodiments, different removable enhancement boards 112 may be coated differently (e.g., painted different colors). In some embodiments, each removable enhancement board 112 may be painted (or coated) differently on opposite sides, such that the removable enhancement board 112 may be reversed/flipped over to change an appearance of the removable enhancement board 112.

In some embodiments, different pluralities of removable enhancement boards having different visual characteristics (e.g., different colors, textures, patterns, materials) may be interchangeably installed in the enhancement areas 108 to change the appearance of the plurality of modular wall panels of the paneled wall. In FIG. 1C, the plurality of modular wall panels 100 is shown with a second plurality of removable enhancement boards 116 removably affixed to the backer boards 102 to fill the enhancement areas 108. The second plurality of removable enhancement boards 116 has a different aesthetic appearance than the first plurality of removable enhancement boards 112. For example, the second plurality of removable enhancement boards 116 may be painted a different color than the first plurality of removable enhancement boards 112. Any suitable enhancement boards having different visual characteristics may be removably installed in the plurality of modular wall panels to interchangeably fill the plurality of enhancement areas of the paneled wall.

Different sets of removable enhancement boards may correspond to any suitable theme, such as seasons, holidays, events, sports teams, schools, etc. As one example, a set of “winter” themed enhancement boards may be installed on a paneled wall during winter months, a set of “spring” themed enhancement boards may be installed on the paneled wall during spring months, a “summer” themed set of enhancement boards may be installed on the paneled wall during the summer months, and a set of “fall” themed enhancement boards may be installed on the paneled wall during fall months.

The plurality of modular wall panels 100 may be affixed to a wall in any suitable manner. In some embodiments, each modular wall panel 100 may include one or more touch fasteners affixed to a backside of the backer board 102 such that the backer board 102 is reversibly affixable to the wall when the wall includes one or more complimentary touch fasteners.

FIGS. 2-7 show an example process of constructing a modular wall panel 200. In FIG. 2, a backer board 102 is shown without any front boards permanently affixed to the backer board 102. In FIG. 3, a first front board 104A is permanently affixed to the backer board 102, such that the first front board 104A is aligned with an upper left corner of the backer board 102. In particular, the first front board 104A is aligned with a left edge and a top edge of the backer board 102. As noted above, embodiments in which the overall dimensions of the front boards exceeds the dimensions of the backer board, the first board (and all subsequent boards) may be installed with the proper overhang. Similarly, as discussed below with respect to FIGS. 9 and 10, when the panels are configured with lap joint connections, some (e.g., top boards and/or right boards) may be installed with the appropriate overhang, while opposite boards (e.g., bottom boards and/or left boards) may be installed with a corresponding underhang. This type of offsetting may also be applied in the steps discussed below with respect to FIGS. 4-7.

In FIG. 4, a second front board 104B is permanently affixed to the backer board 102, such that the second front board 104B is aligned with an upper right corner of the backer board 102. In particular, the second front board 104B is aligned with a right edge and a top edge of the backer board 102. The second front board 104B is spaced apart from the first front board 104A to create an enhancement area 108 in between the first front board 104A and the second front board 104B. A spacer board corresponding to the size of the desired enhancement area may be temporarily set in the desired enhancement area while the second board is affixed. The first and second front boards 104A and 104B and the enhancement area 108 collectively form a top row of the modular wall panel 200. In other embodiments, more or fewer front boards and/or enhancement areas may constitute a row.

In FIG. 5, a third front board 104C is permanently affixed to the backer board 102, such that the third front board 104C is aligned with a lower left corner of the backer board 102. In particular, the first front board 104C is aligned with a left edge and a bottom edge of the backer board 102. In FIG. 6, a fourth front board 104D is permanently affixed to the backer board 102, such that the fourth front board 104D is aligned with a lower right corner of the backer board 102. In particular, the fourth front board 104D is aligned with a right edge and a bottom edge of the backer board 102. The third and fourth front boards 104C and 104D collectively form a bottom row of the modular wall panel 200. Again, more or fewer front boards may constitute a row in other embodiments. In the illustrated example, the bottom row has a height that is less than a height of the top row.

In FIG. 7, a primary touch fastener 110 is permanently affixed to the backer board 102 in the enhancement area 108. The primary touch fastener 110 is configured to interface with a complimentary touch fastener affixed to an enhancement board to removable affix the enhancement board to the backer board 102 such that the enhancement board removably fills the enhancement area 108.

Different modular wall panels with differently sized and positioned enhancement areas may be constructed in the same manner as the modular wall panel 200 shown in FIGS. 2-7. FIG. 8 shows a plurality of different modular wall panels 800 having differently sized and positioned enhancement areas. The plurality of different modular wall panels 800 may be used to panel a wall. The paneled wall may have an aesthetic design that is created based on 1) the layout of the individual wall panels; and 2) the position and size of enhancement boards that are removably affixed to the modular wall panels to fill the enhancement areas.

In some embodiments, rows of a modular wall panel may be offset from edges of a backer board such that adjacent modular wall panels fit together via a lap joint. FIG. 9 shows an example modular wall panel 900 where a row 902 is horizontally offset relative a backer board 904 such that a front board 906 in the row 902 horizontally overlaps a backer board of a horizontally-neighboring modular wall panel (not shown) on a right side of the modular wall panel 900. In such a configuration, a front board and/or removable enhancement board of an opposite horizontally-neighboring wall panel (not shown) may overlap the left side of the backer board 904 of the modular wall panel 900.

FIG. 10 shows an example modular wall panel 1000 where a row 1002 is vertically offset relative a backer board 1004 of the modular wall panel 1000 such that a front board 1006 in the row 1002 vertically overlaps a backer board of a vertically-neighboring modular wall panel (not shown) positioned above the modular wall panel 1000. In such a configuration, a front board and/or removable enhancement board of a vertically-neighboring wall panel (not shown) positioned below the modular wall panel 1000 may overlap the backer board 1004 of the modular wall panel 1000. In some embodiments, the front boards may be offset both horizontally and vertically.

In some embodiments, a modular wall panel may be constructed without a backer board. FIG. 11 shows an example modular wall panel 1100 where a backer board is omitted, and instead each of a plurality of front boards is edge-joined to other neighboring front boards to construct the modular wall panel 1100. As one example, edges of a front board 1102 are glued to neighboring edges of neighboring front boards. As other examples, neighboring front boards may be biscuit joined, butterfly joined, or bracketed together. The front boards that are affixed to one another to form the modular wall panel 1100 may be collectively mounted directly on a wall 1104 via touch fasteners or some other form of fasteners or adhesive. Furthermore, primary touch fastener 1106, which is configured to removably affix a removable enhancement board to the modular wall panel 1100, is affixed directly to the wall 1104 on which the modular wall panel 1100 is mounted. The primary touch fastener 1106 is mounted such that the primary touch fastener 1106 aligns with an enhancement area 1108 of the modular wall panel 1100.

FIG. 12 shows another example modular wall panel 1200 where a backer board is omitted, and front boards are edge glued or fastened together similar to the modular wall panel 1100 shown in FIG. 11. In particular, edges of a front board 1202 are affixed to edges of neighboring front boards to form the modular wall panel 1200. The modular wall panel 1200 is mounted directly on a wall 1204 via touch fasteners or some other form of fasteners or adhesive. Additionally, in this embodiment, the modular wall panel 1200 includes a primary touch fastener 1206 that is positioned on exposed edges of the front boards 1202 that neighbor an enhancement area 1208. In this case, a removable enhancement board may include a complimentary touch fastener that is affixed to edges that interface with the edges of the front boards that neighbor the enhancement area 1208 of the modular wall panel 1200.

In some embodiments, front boards adjacent enhancement areas may be given a beveled edge, and enhancement boards may be given a corresponding beveled edge (e.g., the opening for the enhancement board is larger at the forward-facing surface(s) of the front boards than at the rearward-facing surface(s) of the front boards).

FIG. 13 shows an example package 1300 including a plurality of constructed modular wall panels (e.g., 6 modular wall panels) 1302 and a set of corresponding enhancement boards 1304 configured to be removably installed in the plurality of modular wall panels to fill enhancement areas of the plurality of modular wall panels. The plurality of modular wall panels 1304 may be packaged in this manner to sell as a kit for paneling a wall. In some examples, each kit will include panels that have differently-sized and/or differently-positioned enhancement areas. For example, the example kit illustrated in FIG. 13 includes one each of the six panels illustrated in FIG. 8. Furthermore, the kit includes one each of the six differently-sized enhancement boards sized to fit the corresponding enhancement areas of the panels included in the kit. In some embodiments, the package 1300 may include one or more additional sets of differently configured auxiliary enhancement boards that may be interchangeably affixed to the plurality of modular wall panels 1302 in place of the set of enhancement boards 1304.

FIG. 14 shows another example package 1400 including a plurality of constructed modular wall panels (e.g., 6 modular wall panels) 1402. In this example, the plurality of modular wall panels 1402 are packaged without corresponding enhancement boards. FIG. 15 shows another example package 1500 including a plurality of enhancement boards 1502 that are configured to be removably affixed to corresponding modular wall panels of a modular wall panel kit. In this case, the enhancement boards may be packaged and sold separately from the modular wall panels. For example, this package could be used for different sets of auxiliary enhancement boards. When sold separately, the packages of enhancement boards may include an enhancement board sized to fit each enhancement area included in a corresponding package of modular wall panels (e.g., the six enhancement boards 1502 in package 1500 are sized to fit the corresponding six enhancement areas of the modular wall panels 1402 in package 1400).

FIGS. 16-19 show an example process of paneling a wall with a plurality of modular wall panels. In FIG. 16 a wall 1600 to be paneled is shown without any modular wall panels affixed to the wall 1600. In FIG. 17, a plurality of touch fasteners 1700 are affixed to the wall 1600 (e.g., via adhesive exposed via removal of a protective tape). The plurality of touch fasteners 1700 are configured to affix modular wall panels to the wall 1600. The plurality of touch fasteners 1700 may be any suitable width, and may be spaced apart from one other by any suitable spacing. For example, the touch fasteners may be spaced apart from one another by 12 inches or 16 inches on center. In FIG. 1800, a first modular wall panel 1800 is affixed to the plurality of touch fasteners 1700 to affix the first modular wall panel 1800 on a left side of the wall 1600. A second modular wall panel 1802 is affixed to the plurality of touch fasteners 1700 to affix the second modular wall panel 1800 on a right side of the wall 1600. This process is repeated as desired. Any suitable number of modular wall panels may be installed together to provide any suitable sized panel to cover some or all of a wall. In some examples, a portion of one or more modular wall panels may be trimmed in order to fit within a certain dimension of a wall being paneled. When trimmed, the trimmed portion may be used to start the next row of panels. While touch fasteners are provided as an example mechanism for affixing modular wall panels to a wall, it is to be understood that any other suitable fastening mechanism may be used (e.g., adhesive, nails, and/or staples). When touch fasteners are used, the modular wall panels may more easily be taken down for reapplication to a different wall.

FIG. 20 shows an example fence 2000 that may be deconstructed in order to reclaim boards for constructing front boards and/or enhancement boards of a modular wall panel. FIG. 21 shows an example pallet 2100 that may be deconstructed in order to reclaim boards for constructing front boards and/or enhancement boards of a modular wall panel. For example, deck boards 2102 of the pallet 2100 may be used to construct rows having a greater height (e.g., row H1 shown in FIG. 1A) and stringer boards 2104 of the pallet 2100 may be used to construct rows having a lesser height (e.g., H2 shown in FIG. 1A).

FIG. 22 shows an example method for constructing a modular wall panel. In some embodiments where reclaimed wood is used to construct the modular wall panel, at 2202, fencing and/or pallets optionally may be disassembled to reclaim wood for front boards and/or enhancement boards of the modular wood panel. At 2204, one or both faces of the front boards and/or the removable enhancement boards are optionally refinished. For example, the boards may be refinished with a circle saw or a wire brush to provide a uniform, distressed appearance. At 2206, the front boards and/or the removable enhancement boards are milled to the designated dimensions (e.g., heights, widths, thicknesses) for different rows of the modular wall panels. At 2208, the front boards and/or the removable enhancement boards optionally are cut to remove defects and/or voids. In some embodiments, at 2210, the front boards optionally may be refinished. For example, the front boards may be painted or clear-coated. At 2212, the removable enhancement boards are refinished. For example, the removable enhancement boards may be painted or clear-coated. In some examples, the removable enhancement boards may be painted or refinished differently than the front boards, such that the removable enhancement boards have a different visual appearance than the front boards. At 2214, the backer board is optionally painted. At 2216, the front boards are permanently affixed to the backer board such that an enhancement area is created in at least one row of the modular wall panel. In some embodiments, the enhancement area may be positioned in at least one out of every three rows and such that no two adjacent rows include enhancement areas. At 2218, primary touch fasteners optionally are attached to the backer board in the enhancement areas. At 2220, complimentary touch fastener optionally are affixed to the backsides of the removable enhancement boards. At 2222, one or more modular wall panels and/or one or more removable enhancement boards optionally are packaged together.

It will be understood that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The specific processes or methods described herein may represent one or more of any number of construction strategies. As such, various acts illustrated and/or described may be performed in the sequence illustrated and/or described, in other sequences, in parallel, or omitted. Likewise, the order of the above-described processes may be changed.

The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various processes, systems and configurations, and other features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof.

Claims

1. A modular wall panel, comprising:

a backer board;

a plurality of front boards arranged in a plurality of rows on the backer board, wherein at least one row of the plurality of rows includes two or more horizontally-adjacent front boards permanently affixed to the backer board, the two or more horizontally-adjacent front boards collectively spanning an entire width of the backer board, and wherein at least one row of the plurality of rows includes an enhancement area without a permanently-affixed front board, wherein the enhancement area is horizontally adjacent to a front board that is permanently affixed to the backer board; and

a removable enhancement board configured to be reversibly affixed to the backer board to fill the enhancement area.

2. The modular wall panel of claim 1, further comprising a primary touch fastener affixed to a frontside of the backer board in the enhancement area, and further comprising a complimentary touch fastener affixed to a backside of the removable enhancement board, wherein the primary touch fastener and the complimentary touch fastener are reversibly joinable such that the removable enhancement board is reversibly affixable to the backer board to fill the enhancement area.

3. The modular wall panel of claim 2, wherein the primary touch fastener and the complimentary touch fastener collectively constitute a hook-and-loop or hook-and-pile fastener.

4. The modular wall panel of claim 1, wherein the removable enhancement board is one of a plurality of different available removable enhancement boards respectively finished to provide different enhancement colors to the modular wall panel.

5. The modular wall panel of claim 1, wherein the plurality of front boards and the removable enhancement board are milled from reclaimed lumber.

6. The modular wall panel of claim 1, wherein the removable enhancement board is made from the same material as the plurality of front boards and has a different finish than the plurality of front boards.

7. The modular wall panel of claim 1, wherein each of the plurality of front boards is unpainted and the removable enhancement board is painted.

8. The modular wall panel of claim 1, wherein the modular wall panel includes a plurality of enhancement areas without permanently-affixed front boards, and wherein the modular wall panel includes a corresponding plurality of removable enhancement boards respectively configured to be reversibly affixed to the backer board to fill the plurality of enhancement areas.

9. The modular wall panel of claim 1, wherein each of the plurality of rows is aligned with the backer board.

10. The modular wall panel of claim 1, wherein a particular row of the plurality of rows is horizontally offset relative the backer board such that a front board and/or removable enhancement board of the modular wall panel horizontally overlaps a horizontally-neighboring modular wall panel on one side of the modular wall panel, and such that a front board and/or removable enhancement board of an opposite horizontally-neighboring wall panel overlaps the modular wall panel on an opposite side of the modular wall panel.

11. The modular wall panel of claim 1, wherein the plurality of rows are vertically offset relative the backer board such that a front board and/or removable enhancement board of the modular wall panel vertically overlaps a vertically-neighboring modular wall panel on one side of the modular wall panel, and such that a front board and/or removable enhancement board of an opposite vertically-neighboring wall panel overlaps the modular wall panel on an opposite side of the modular wall panel.

12. The modular wall panel of claim 1, wherein at least a portion of a row of the plurality of rows includes two lesser-height front boards vertically stacked with a combined height equal to a row height of the row.

13. The modular wall panel of claim 1, further comprising a touch fastener affixed to a backside of the backer board such that the backer board is reversibly affixable to the wall when the wall includes a complimentary touch fastener.

14. The modular wall panel of claim 1, wherein the plurality of rows include rows having different row heights.

15. The modular wall panel of claim 1, wherein the backer board is plywood.

16. The modular wall panel of claim 1, wherein a front side of the backer board is painted black.

17. The modular wall panel of claim 1, wherein the plurality of front boards are permanently affixed to the backer board with glue.

18. The modular wall panel of claim 1, wherein the plurality of front boards are permanently affixed to the backer board with one or both of nails and staples.

19. A modular wall panel, comprising:

a plurality of front boards edge joined in a plurality of rows, wherein at least one row of the plurality of rows includes two or more horizontally-adjacent front boards, the two or more horizontally-adjacent front boards collectively spanning an entire width of the modular wall panel, and wherein at least one row of the plurality of rows includes an enhancement area, wherein the enhancement area is horizontally adjacent to at least one front board; and

a removable enhancement board configured to removably fill the enhancement area.

20. A wall paneling kit, comprising:

a plurality of modular wall panels; and

a corresponding plurality of removable enhancement boards; wherein each modular wall panel of the plurality of modular wall panels includes: a backer board; and a plurality of front boards arranged in a plurality of rows on the backer board, wherein at least one row of the plurality of rows includes two or more horizontally-adjacent front boards permanently affixed to the backer board, the two or more horizontally-adjacent front boards collectively spanning an entire width of the backer board, and wherein at least one row of the plurality of rows includes an enhancement area without a permanently-affixed front board, wherein the enhancement area is horizontally adjacent to a front board that is permanently affixed to the backer board; and wherein at least one enhancement area on one of the plurality of modular wall panels is differently sized and positioned than at least another enhancement area on another of the plurality of modular wall panels; and wherein each removable enhancement board of the corresponding plurality of removable enhancement boards is sized to be reversibly affixed to a corresponding backer board to fill the enhancement area of a corresponding modular wall panel of the plurality of modular wall panels.