U.S. patent application number 10/944561 was filed with the patent office on 2006-04-06 for modular wall paneling system, wall panels, and method of installation.
Invention is credited to James R. Schiltz.
Application Number | 20060070329 10/944561 |
Document ID | / |
Family ID | 36124174 |
Filed Date | 2006-04-06 |
United States Patent
Application |
20060070329 |
Kind Code |
A1 |
Schiltz; James R. |
April 6, 2006 |
Modular wall paneling system, wall panels, and method of
installation
Abstract
A modular wall paneling system and installation method for
wainscoting and other wall covering applications includes a
plurality of rectangular wall panels each having a decorative front
surface and a convex rear surface which provides line contact with
the wall. A plurality of elongate upper and lower mounting rails
are respectively affixed horizontally along the wall end-to-end at
chair rail height and directly above the base board. Respective
bottom edges of the wall panels fit into an upwardly open channel
formed by the lower mounting rails and a top edge thereof snap-fits
to the upper mounting rails. A plurality of elongate wall trim
pieces snap-fit over the upper mounting rails to provide a finished
look. The upper and lower mounting rails retain the top and bottom
edges of the wall panels against the wall with a slight amount of
interference which slightly warps the wall panels to provide a snug
rattle-free against the wall along the contact line. The wall
paneling system may additionally include corner mounting rails,
corner trim pieces, and corner caps to finish inside and outside
corners of a room. A version of the wall paneling system is
provided for whiteboard and other applications.
Inventors: |
Schiltz; James R.; (Hickory,
NC) |
Correspondence
Address: |
Oltman, Flynn & Kubler;Suite 415
915 Middle River Drive
Fort Lauderdale
FL
33304-3585
US
|
Family ID: |
36124174 |
Appl. No.: |
10/944561 |
Filed: |
September 20, 2004 |
Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
B44C 5/0461 20130101;
E04F 19/022 20130101; E04F 19/0495 20130101; E04F 19/049 20130101;
E04F 13/18 20130101; E04F 19/06 20130101; E04F 19/026 20130101;
E04F 19/064 20130101; E04F 19/028 20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. A modular wall paneling system for application to at least one
wall of a room, comprising: at least one wall panel comprising a
generally flat member of at least limited flexibility having a
front surface, an opposing rear surface, and a peripheral edge; at
least one elongate upper mounting rail having a base adapted to be
affixed along the wall and a top panel attachment device adapted to
retain said peripheral edge of said wall panel to the wall; and at
least one elongate lower mounting rail having a base adapted to be
affixed along the wall and a bottom panel attachment device adapted
to support said wall panel and retain said peripheral edge to the
wall.
2. The wall paneling system of claim 1, wherein the panel
attachment device of at least one of the upper and lower mounting
rails is of a configuration chosen from the group consisting of at
least one locking clip which extends from the base thereof adapted
to resiliently engage the peripheral edge of the wall panel, and an
L-shaped member which extends outwardly from said base thereof to
form an elongate channel defining a pocket therebetween to receive
said peripheral edge of said wall panel.
3. The wall paneling system of claim 1, additionally comprising: at
least one elongate wall trim piece adapted to conceal one of the
mounting rails which includes an outer member and a first half of a
wall trim piece attachment device adapted to connect said outer
member to said mounting rails; and wherein at least one of the
mounting rails includes a second half of said wall trim piece
attachment device adapted to snap-fit to said first half thereof to
retain said wall trim piece to said mounting rail.
4. The wall paneling system of claim 3, additionally comprising at
least one planar corner cap which includes a body having a rear
surface with an outer portion adapted to be disposed along the wall
and an inner portion adapted to be disposed along the wall panel,
said body being of mating configuration adapted to conceal
respective adjoining ends of respective pairs of the mounting rails
and wall trim pieces at an intersection area thereof, and further
includes a cap attachment device adapted to attach said body to at
least one of the mounting rail and the wall trim piece at said
intersection area.
5. The wall paneling system of claim 4, wherein the corner
attachment device is of a type chosen from the group consisting of
a plug type comprising at least one plug which extends from the
body adapted to closely fit within a corresponding open area of the
wall paneling system defined by adjoining pairs of the mounting
rails and the wall trim pieces to retain said planar corner cap
thereto, and a snap-fit type wherein said body is formed in a
substantially hollow configuration with said corner attachment
device comprising at least one locking member which extends
inwardly from said body adapted to resiliently connect to said
mounting rails.
6. The wall paneling system of claim 3, wherein the outer member of
the wall trim piece is formed in a substantially hollow
configuration having an outside edge adapted to engage the wall and
an inside edge adapted to engage the wall panel, and wherein the
first half of the wall trim piece attachment device thereof
comprises at least one locking member which extends from said outer
member thereof adapted to resiliently connect to the mounting
rails, and wherein said outer member is of a cross-sectional shape
chosen from the group consisting of partial rounded C-shape and
partial flat C-shape.
7. The wall paneling system of claim 1, additionally comprising: a
corner mounting rail having a base adapted to be affixed to at
least one of two intersecting walls along a corner of the room and
a first half of a corner trim piece attachment device; a corner
trim piece which includes a base adapted to disposed along the
corner in a relationship to adjacent wall panels chosen from the
group consisting of abutting, overlapping, and both abutting and
overlapping to conceal respective side edges thereof and to conceal
said corner mounting rail, and a second half of the corner trim
piece attachment device which extends rearwardly from said base
adapted to snap-fit to said first half thereof, said corner trim
piece attachment device being adapted to connect said corner trim
piece to said corner mounting rail; and a multi-planar corner cap
which includes a body having an angled rear surface adapted to be
disposed along the intersecting walls at the corner disposed at an
angle corresponding to the intersecting walls, said body being of
mating configuration adapted to conceal respective adjoining ends
of said upper mounting rail, said corner mounting rail, and said
corner trim piece, and further includes a cap attachment device
adapted to attach said body to at least one of said upper mounting
rail, said corner mounting rail, and said corner trim piece.
8. The wall paneling system of claim 7, wherein the second half of
the corner trim piece attachment device of the corner trim piece is
chosen from the group consisting of a center member of mushroom
shaped cross-section and a pair of opposed center arms, and the
first half of said corner trim piece attachment device of the
corner mounting rail is chosen from the group consisting of a
single locking clip and a pair of opposing locking clips which
extend from the base thereof adapted to resiliently engage said
second half of said corner trim piece attachment device.
9. The wall paneling system of claim 7, wherein the bases of the
corner mounting rail and the corner trim piece are of L-shaped
cross-section comprised of respective pairs of legs connected
together edgewise at an angle corresponding to the intersecting
walls at the corner, said legs of said corner mounting rail and
said corner trim piece each having a rear surface adapted
respectively to engage the intersecting walls at the corner and to
engage the front surface of adjacent of the wall panels at the
corner, the first half of the corner trim piece attachment device
of said corner rail being disposed centrally thereon extending
forwardly therefrom and the second half of said corner trim piece
attachment device of said corner trim piece being disposed
centrally thereon extending rearwardly therefrom, and wherein the
rear surface of the corner cap is disposed at angle corresponding
to the intersecting walls at the corner.
10. The wall paneling system of claim 7, wherein the cap attachment
device of the multi-planar corner cap is of a type chosen from the
group consisting of a plug type comprising at least one plug which
extends from said body adapted to closely fit within a
corresponding open area of the wall paneling system defined by
pairs of adjoining components chosen from the group consisting of
the corner mounting rail and the corner trim piece and the upper
mounting rail and a wall trim piece to retain said multi-planar
corner cap thereto, and a snap-fit type wherein said body is formed
in a substantially hollow configuration with said cap attachment
device comprising at least one locking clip which extends from the
body thereof adapted to resiliently engage a second half of said
cap attachment device to snap-fit thereto.
11. The wall paneling system of claim 1, wherein all visible
component parts including the wall panels are of a common genre
chosen from the group consisting of a functional design, an
artistic design, and a theme, and wherein said common genre is
applied thereto using a process chosen from the group consisting of
molding, printing, embossing, and applying a decorative
papering.
12. The wall paneling system of claim 1, additionally comprising:
at least one each of said upper and one of said lower mounting
rails; at least one elongate wall trim piece adapted to conceal one
of the mounting rails which includes an outer member and a first
half of a wall trim piece attachment device adapted to connect said
outer member to said mounting rails, said outer member being formed
in a substantially hollow configuration of a cross-sectional shape
chosen from the group consisting of partial rounded C-shape and
partial flat C-shape having an outside edge adapted to engage the
wall and an inside edge adapted to engage the wall panel, said
first half of said wall trim piece attachment device comprising a
first locking member which extends vertically within said outer
member which terminates at a bulbous end and a second locking
member which extends in a curved horizontal manner within said
outer member which terminates at a bulbous end, each being adapted
to resiliently snap-fit to a second half of said wall trim
attachment device of at least one of said mounting rails to retain
said wall trim piece to said mounting rail; and wherein the wall
panel is of a rectangular shape having a top edge, a bottom edge,
and a pair of side edges with the rear surface thereof being of a
rearwardly convex shape of a configuration chosen from the group
consisting of a curved planar surface adapted for engaging the wall
by creating unbroken line contact therewith, a plurality of
parallel ribs which create broken line contact with the wall, and
other curved configurations which provide line contact with the
wall, said wall panel including at least one additional feature
chosen from the group consisting of a panel edge joining device
wherein the peripheral edge includes respective interlockable
halves of said panel edge joining device to allow adjoining wall
panels to interconnect, a panel edge hiding device wherein the
peripheral edge includes respective indent halves of said panel
edge hiding device which form a full indent at adjoining wall
panels to provide a finished look therebetween, and an erasable
front surface adapted for erasable writing thereon, wherein said
second half of said wall trim attachment device comprises a first
locking clip of S-shaped cross-section which includes a curved base
portion which extends initially parallel with the base thereof then
outwardly and a primary retaining portion of C-shaped cross-section
adapted to resiliently engage said bulbous end of said first
locking member of said wall trim piece, and a second locking clip
of T-shaped cross-section including a base leg which extends
perpendicularly from said base thereof and a cross leg which
terminates at respective ends including a bulbous end adapted to
engage said bulbous end of said second locking member of said wall
trim piece to snap-fit thereto and a wedge end comprising the top
panel attachment device of said upper mounting rail adapted to
engage said top edge by snap-fitting thereto to retain said top
edge of said wall panel to the wall, said base of said upper
mounting rail having a plurality of holes therethrough for
respectively receiving a plurality of attachment devices
therethrough to affix said base along the wall, wherein the bottom
panel attachment device of said lower mounting rail comprises an
L-shaped member which extends outwardly from the base thereof to
form an elongate channel defining a pocket therebetween to receive
said peripheral edge of said wall panel to retain said bottom edge
of said wall panel to the wall, said base of said lower mounting
rail having a plurality of holes therethrough for respectively
receiving a plurality of attachment devices therethrough to affix
said base along the wall, and wherein said wall panel is retained
against the wall at said top and bottom edges respectively by said
upper and lower mounting rails such that there is a slight amount
of interference with the wall so said wall panel bows slightly
outwardly at a middle area thereof between said top and bottom
edges to take out any gap between the wall and said wall panel.
13. The wall paneling system of claim 12, additionally comprising:
a corner mounting rail having a base adapted to be affixed to at
least one of two intersecting walls along a corner of the room and
a first half of a corner trim piece attachment device; a corner
trim piece which includes a base adapted to disposed along the
corner in a relationship to adjacent wall panels chosen from the
group consisting of abutting, overlapping, and both abutting and
overlapping to conceal respective side edges thereof and to conceal
said corner mounting rail, and a second half of the corner trim
piece attachment device which extends rearwardly from said base
adapted to snap-fit to said first half thereof, said corner trim
piece attachment device being adapted to connect said corner trim
piece to said corner mounting rail; a multi-planar corner cap which
includes a body having an angled rear surface adapted to be
disposed along the intersecting walls at the corner disposed at an
angle corresponding to the intersecting walls, said body being of
mating configuration adapted to conceal respective adjoining ends
of said upper mounting rail, said wall trim piece, said corner
mounting rail, and said corner trim piece, and further includes a
cap attachment device adapted to attach said body to at least one
of said upper mounting rail, said wall trim piece, said corner
mounting rail, and said corner trim piece; and wherein said bases
of said corner mounting rail and the corner trim piece are of
L-shaped cross-section comprised of respective pairs of legs
connected together edgewise at an angle corresponding to the
intersecting walls at the corner, said legs of said corner mounting
rail and said corner trim piece each having a rear surface adapted
respectively to engage the intersecting walls at the corner and to
engage the front surface of adjacent of the wall panels at the
corner, said first half of said corner trim piece attachment device
of said corner rail being disposed centrally thereon extending
forwardly therefrom and said second half of said corner trim piece
attachment device of said corner trim piece being disposed
centrally thereon extending rearwardly therefrom, said rear surface
of said corner cap being disposed at angle corresponding to the
intersecting walls at the corner, said base of said corner mounting
rail having a plurality of holes therethrough for respectively
receiving a plurality of attachment devices therethrough to affix
said base along the wall, wherein said second half of said corner
trim piece attachment device of said corner trim piece is chosen
from the group consisting of a center member of mushroom shaped
cross-section and a pair of opposed center arms, and said first
half of said corner trim piece attachment device of said corner
mounting rail is chosen from the group consisting of a single
locking clip and a pair of opposing locking clips which extend from
said base thereof adapted to resiliently snap-fit to said second
half of said corner trim piece attachment device, and wherein said
cap attachment device of said multi-planar corner cap is of a type
chosen from the group consisting of a plug type comprising at least
one plug which extends from said body adapted to closely fit within
a corresponding open area of the wall paneling system defined by
pairs of adjoining components chosen from the group consisting of
said corner mounting rail and said corner trim piece and said upper
mounting rail and said wall trim piece to retain said multi-planar
corner cap thereto, and a snap-fit type wherein said body is formed
in a substantially hollow configuration with said cap attachment
device comprising a first locking member which extends downwardly
within said body which terminates at a bulbous end adapted to
resiliently engage the primary retaining portion of the first
locking clip of the second half of said wall trim attachment device
to snap-fit thereto and a second locking member which extends
horizontally within said body in a curved manner from said body
which terminates at a bulbous end adapted to resiliently engage the
bulbous end of the second locking clip of the upper mounting rail
to snap-fit thereto.
14. The wall paneling system of claim 12, additionally comprising:
at least one planar corner cap which includes a body having a rear
surface with an outer portion adapted to be disposed along the wall
and an inner portion adapted to be disposed along the wall panel,
said body being of mating configuration adapted to conceal
respective adjoining ends of respective pairs of the mounting rails
and wall trim pieces at an intersection area thereof, and further
includes a cap attachment device adapted to attach said body to at
least one of the mounting rail and the wall trim piece at said
intersection area; wherein the cap attachment device is of a type
chosen from the group consisting of a plug type comprising at least
one plug which extends from the body adapted to closely fit within
a corresponding open area of the wall paneling system defined by
adjoining pairs of the mounting rails and the wall trim pieces to
retain said planar corner cap thereto, and a snap-fit type wherein
said body is formed in a substantially hollow configuration with
said cap attachment device comprising a first locking member which
extends downwardly within said body which terminates at a bulbous
end adapted to resiliently engage an end retaining portion of
C-shaped cross-section of the first locking clip of the second half
of said wall trim attachment device to snap-fit thereto and a
second locking member which extends horizontally within said body
in a curved manner from said body which terminates at a bulbous end
adapted to resiliently engage the bulbous end of the second locking
clip of the upper mounting rail to snap-fit thereto.
15. A modular wall panel for application to a wall of a room,
comprising a generally flat member of at least limited flexibility
having a front surface, an opposing rear surface, and a peripheral
edge, said rear surface being of a rearwardly convex shape of a
configuration chosen from the group consisting of a curved planar
surface adapted for engaging the wall by creating unbroken line
contact therewith, a plurality of parallel ribs which create broken
line contact with the wall, and other curved configurations which
provide line contact with the wall, said wall panel being adapted
to be retained against the wall at opposite portions of said
peripheral edge such that there is a slight amount of interference
with the wall so said wall panel bows slightly outwardly at a
middle area thereof to take out any gap between the wall and said
wall panel.
16. The wall paneling system of claim 15, wherein the wall panel is
of a rectangular shape with the peripheral edge comprising a top
edge, a bottom edge, and a pair of side edges.
17. The wall paneling system of claim 15, wherein the wall panel
includes at least one additional feature chosen from the group
consisting of a panel edge joining device wherein the peripheral
edge includes respective interlockable halves of said panel edge
joining device to allow adjoining wall panels to interconnect, a
panel edge hiding device wherein the peripheral edge includes
respective indent halves of said panel edge hiding device which
form a full indent at adjoining wall panels to provide a finished
look therebetween, and an erasable front surface adapted for
erasable writing thereon.
18. A method of installing a modular wall paneling system for
application to at least one wall of a room, comprising the steps
of: providing at least one wall panel of at least limited
flexibility having a front surface, an opposing rear surface, and a
peripheral edge, the rear surface being of a rearwardly convex
shape of a configuration which provides line contact with the wall;
and restraining opposite portions of the peripheral edge of the
wall panel against the wall in an upright position such that there
is a slight amount of interference with the wall so the wall panel
bows slightly outwardly at a middle area thereof to take out any
gap between the wall and the wall panel.
19. The method of claim 18, additionally comprising the steps of:
providing at least one elongate upper mounting rail having a base
adapted to be affixed along the wall and an attachment device
adapted to retain the peripheral edge of the wall panel to the
wall; providing at least one elongate lower mounting rail having a
base adapted to be affixed along the wall and an attachment device
to support the wall panel and retain the peripheral edge to the
wall; securing the lower mounting rail to the wall; securing the
upper mounting rail to the wall at a measured distance above the
lower mounting rails for the particular height of the wall panels
to snap-fit to the trim mounting rails; and wherein the wall panel
provided is of a rectangular shape with the peripheral edge
comprising a top edge, a bottom edge, and a pair of side edges, and
wherein the step of restraining the wall panel against the wall
includes engaging the bottom edge of the wall panel with the lower
mounting rail and pivoting the top edge into engagement with the
upper mounting rail.
20. The method of claim 19, wherein the attachment device of the
upper mounting rail provided comprises an elongate locking clip
which extends from the base thereof adapted to resiliently snap-fit
to the top edge of the wall panel, the attachment device of the
lower mounting rail provided comprises an elongate L-shaped member
which extends outwardly from the base thereof to form an elongate
channel defining a pocket therebetween to receive the peripheral
edge of the wall panel, and the and wherein the engaging the bottom
edge of the wall panel with the lower mounting rail comprises
inserting the bottom edge of the wall panel into the pocket of the
lower mounting rail, and the pivoting the top edge into engagement
with the upper mounting rail includes pushing the top edge past the
locking clip which deflects slightly to allow passing thereunder to
lock the top edge in place.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of wall
paneling for application to one or more walls of a room to provide
a decorative look and to protect the walls. More specifically the
present invention relates to a modular wall paneling system and
installation method for wainscoting and other wall covering
applications. The wall paneling system is of a type which includes
a plurality of rectangular wall panels each having a decorative
front surface and a rear surface. A plurality of elongate upper and
lower mounting rails each include a base adapted to be affixed
horizontally along the walls end-to-end respectively at chair rail
height and directly above the base board trim pieces. Top and
bottom edges of the wall panels are respectively retained to the
upper and lower mounting rails by attachment devices thereof which
retain the wall panels to the walls. A plurality of elongate wall
trim pieces attach over the upper mounting rails to provide a
finished look. The wall paneling system may additionally include
corner mounting rails, corner trim pieces, and corner caps to
finish inside and outside corners of a room.
[0003] 2. Description of the Prior Art
[0004] Traditional wall paneling systems include a plurality of
wall panels made of a solid sheet of wood formed by gluing together
and planing a plurality of individual wood boards to form panel
sheets. The panel sheets are often stained and lightly waxed to
enhance the appearance of the wood and form the finished wall
panels. Alternatively, the panel sheets may be painted. The wall
panels may further be milled with vertical grooves to simulate a
plurality of individual wood planks and to hide joints between
adjacent wall panels, or the joints may be covered by vertical
stiles. The wall panels are nailed to the walls of a room or
optionally glued thereto using conventional adhesives designed for
that purpose in order to eliminate the nail holes. The wall panels
may be of full height extending upwardly from the base board trim
piece to a ceiling or crown molding trim piece. Alternatively, the
wall panels may be of partial height extending from the base board
trim pieces to a height of about three to five feet and terminating
at a horizontal wall trim piece or chair rail for classical
wainscoting. The chair rail is typically stained or painted to
complement the paneling. While such wood wall panels look nice,
they are expensive to produce due to the cost of the solid wood
used in the construction thereof Additionally, skilled labor is
required to make the wood boards into panel sheets, cutting the
panel sheets to finished size, routing, sanding, staining, and
waxing which further increasing the finished cost thereof
Installation is typically done by a skilled carpenter due to the
amount of cutting, fitting to the walls, and finishing
required.
[0005] More recently designed wall panels are made from
conventional plywood sheets covered by a thin hardwood veneer to
lower the cost of the wall panels. This allows lower quality wood
to be used in the construction of the plywood sheets which is
covered by the thin hardwood veneer of high quality wood. While
these wall panels are much less expensive to manufacture than the
solid sheet type wall panels, installation by a skilled carpenter
is still typically required.
[0006] There have been various wall paneling systems developed and
patented in attempts to lower the cost of wall paneling systems and
decrease the skill required for installation thereof. For example,
a raised panel paneling system is disclosed in U.S. Pat. No.
4,736,559 issued on Apr. 12, 1988 to Young. The paneling system
includes a plurality of paneling sheets securable to a substrate
such as walls with respective side edges of adjacent sheets forming
permissible gaps of from zero (i.e. paneling sheets abutting) to a
predetermined maximum gap to minimize the amount of cutting needed
to fit the paneling sheets to the walls. A chair rail is affixed to
the walls over the paneling sheets to divide the paneling sheets
into respective top and bottom. A plurality of stiles are affixed
to the walls respectively covering the gaps between the adjacent
paneling sheets. A plurality of base board trim pieces are affixed
to the walls covering respective bottoms of the paneling sheets and
a plurality of ceiling trim pieces are affixed to the walls
covering respective tops of the paneling sheets. A plurality of
moldings are affixed to the walls covering respective intersections
of the chair rails and the stiles and joints which are mitered to
provide a finished look for the paneling system. While the paneling
system of Young may be easier to install due to less cutting of the
wall panels being required, it still requires a relatively high
skill level to install and is relatively costly to manufacture.
[0007] Traditional wall panels have further drawbacks, including
limitation in available shapes and styles, lack of changeability of
the wall panels without ruining the underlying walls upon removal.
This is particularly problematic when the wall panels are affixed
to the walls using adhesives and the edges are caulked to provide a
more finished look at time of installation thereof These wall
panels further typically require special tools for installation
such as saws and saw guides due to the exact cuts which must be
made to the wall panels to fit around doors, windows, electrical
outlets, and the like. The wood construction of the wall panels is
not environmentally friendly and is susceptible to mold and mildew
damage particularly in wet environments. The wall panels are not
readily cleanable due to the rough wood surface finish thereof and
they are not durable, requiring periodic maintenance such as
application of protective waxes or oils, repainting, re-caulking,
and the like to maintain them.
[0008] Therefore, there is a continuing need for a modular wall
paneling system which solves the problems with the traditional wall
paneling systems and which provides additional benefits and
features.
[0009] It is thus an object of the present invention to provide a
modular wall paneling system which is of low cost to manufacture
and easy to install.
[0010] It is another object of the present invention to provide a
modular wall paneling system which is available in a wide variety
of shapes and styles which may be mixed and matched at initial
installation, which requires no adhesives or caulking of the edges
of the wall panels and the trim pieces, and which may be changed
without ruining the underlying walls.
[0011] It is a still further object of the present invention to
provide a modular wall paneling system in which no special tools
are needed for installation and which requires no exact cuts for
the wall panels to fit around doors, windows, electrical outlets,
and the like.
[0012] It is another object of the present invention to provide a
modular wall paneling system which is more environmentally friendly
by not using wood products and capable of using recycled or
biodegradable plastic.
[0013] It is another object of the present invention to provide a
modular wall paneling system which can be removed and reinstalled
in another dwelling if so needed such as for apartment dwellers and
other residents of rental property.
[0014] It is a still further object of the present invention to
provide a modular wall paneling system in which mounting thereof
does minimal damage to the walls and other building structure.
[0015] It is still another object of the present invention to
provide such a modular wall paneling system in which virtually no
preparation of the walls such as removal of the existing base
molding rim pieces and ceiling trim pieces is required.
[0016] It is yet another object of the present invention to provide
such a modular wall paneling system in which the wall panels may be
easily interchanged following installation to change the entire
look of the room.
[0017] It is still another object of the present invention to
provide such a modular wall paneling system which is designed to be
flexible enough to accommodate any size and shape of room including
non-square corners and wavy or otherwise irregular walls.
[0018] It is yet another object of the present invention to provide
such a modular wall paneling system which may be installed over
virtually any type of wall including drywall, brick, concrete
block, and previously installed paneling.
[0019] It is yet another object of the present invention to provide
such a modular wall paneling system in which installation time is
quicker than traditional wall finishing by paneling or
painting.
[0020] It is a still further object of the present invention to
provide a modular wall paneling system in which the wall panels are
impact resistant and durable for use in highly abused rooms such as
garages, children's rooms, offices, mud rooms, and foyers.
[0021] It is yet another object of the present invention to provide
such a modular wall paneling system which is mold and mildew
resistant for use in bathrooms and other wet areas.
[0022] It is finally an object of the present invention to provide
such a modular wall paneling system which does not require painting
and requires only minima cleaning so as to be virtually maintenance
free.
SUMMARY OF THE INVENTION
[0023] The present invention accomplishes the above-stated
objectives, as well as others, as may be determined by a fair
reading and interpretation of the entire specification.
[0024] A modular wall paneling system for application to at least
one wall of a room, modular wall panels, and a method of installing
the modular wall paneling system are provided.
[0025] The modular wall paneling system comprises at least one wall
panel comprising a generally flat member of at least limited
flexibility having a front surface, an opposing rear surface, and a
peripheral edge. At least one elongate upper mounting rail is
included having a base adapted to be affixed along the wall and a
top panel attachment device adapted to retain the peripheral edge
of the wall panel to the wall. At least one elongate lower mounting
rail is included having a base adapted to be affixed along the wall
and a bottom panel attachment device adapted to support the wall
panel and retain the peripheral edge to the wall.
[0026] The wall paneling system preferably additionally comprises
at least one elongate wall trim piece adapted to conceal one of the
mounting rails. The wall trim piece includes an outer member and a
first half of a wall trim piece attachment device adapted to
connect the outer member to the mounting rails. At least one of the
mounting rails includes a second half of the wall trim piece
attachment device adapted to snap-fit to the first half thereof to
retain the wall trim piece to the mounting rail.
[0027] For use in wainscoting applications at the corners of rooms,
the wall paneling system includes a corner mounting rail having a
base adapted to be affixed to at least one of two intersecting
wails along a corner of the room and a first half of a corner trim
piece attachment device. A corner trim piece includes a base
adapted to disposed along the corner in an abutting and/or
overlapping relationship to adjacent wall panels to conceal
respective side edges thereof and to conceal the corner mounting
rail. A second half of the corner trim piece attachment device
extends rearwardly from the base adapted to snap-fit to the first
half thereof The corner trim piece attachment device is adapted to
connect the corner trim piece to the corner mounting rail. A
multi-planar corner cap includes a body having an angled rear
surface adapted to be disposed along the intersecting walls at the
corner disposed at an angle corresponding to the intersecting
walls. The body is of mating configuration adapted to conceal
respective adjoining ends of the upper mounting rail, the corner
mounting rail, and the corner trim piece. A cap attachment device
is adapted to attach the body to at least one of the upper mounting
rail, the corner mounting rail, and the corner trim piece.
[0028] For use in whiteboard applications on a single wall, the
wall paneling system includes at least one planar corner cap which
includes a body having a rear surface with an outer portion adapted
to be disposed along the wall and an inner portion adapted to be
disposed along the wall panel. The body is of mating configuration
adapted to conceal respective adjoining ends of respective pairs of
the mounting rails and wall trim pieces at an intersection area
thereof A cap attachment device is adapted to attach the body to at
least one of the mounting rail and the wall trim piece at the
intersection area. The wall panels have an erasable front surface
adapted for erasable writing thereon.
[0029] The modular wall panels comprise a generally flat member of
at least limited flexibility having a front surface, an opposing
rear surface, and a peripheral edge. The rear surface is of a
rearwardly convex shape in the configuration of a curved planar
surface adapted for engaging the wall by creating unbroken line
contact therewith, a plurality of parallel ribs which create broken
line contact with the wall, or other curved configurations which
provide line contact with the wall. The wall panel is adapted to be
retained against the wall at opposite portions of the peripheral
edge such that there is a slight amount of interference with the
wall so the wall panel bows slightly outwardly at a middle area
thereof to take out any gap between the wall and the wall
panel.
[0030] A preferred wall panel is of a rectangular shape with the
peripheral edge comprising a top edge, a bottom edge, and a pair of
side edges. The wall panel includes one or more additional features
such as a panel edge joining device wherein the peripheral edge
includes respective interlockable halves of the panel edge joining
device to allow adjoining wall panels to interconnect, a panel edge
hiding device wherein the peripheral edge includes respective
indent halves of the panel edge hiding device which form a full
indent at adjoining wall panels to provide a finished look
therebetween, or an erasable front surface adapted for erasable
writing thereon.
[0031] The method of installing a modular wall paneling system
comprises the steps of: 1) providing at least one wall panel of at
least limited flexibility having a front surface, an opposing rear
surface, and a peripheral edge, the rear surface being of a
rearwardly convex shape of a configuration which provides line
contact with the wall; and 2) restraining opposite portions of the
peripheral edge of the wall panel against the wall in an upright
position such that there is a slight amount of interference with
the wall so the wall panel bows slightly outwardly at a middle area
thereof to take out any gap between the wall and the wall
panel.
[0032] A preferred method additionally comprises the steps of: 1)
providing at least one elongate upper mounting rail having a base
adapted to be affixed along the wall and an attachment device
adapted to retain the peripheral edge of the wall panel to the
wall; 2) providing at least one elongate lower mounting rail having
a base adapted to be affixed along the wall and an attachment
device to support the wall panel and retain the peripheral edge to
the wall; 3) securing the lower mounting rail to the wall; and 4)
securing the upper mounting rail to the wall at a measured distance
above the lower mounting rails for the particular height of the
wall panels to snap-fit to the trim mounting rails. The wall panel
provided is of a rectangular shape with the peripheral edge
comprising a top edge, a bottom edge, and a pair of side edges. The
step of restraining the wall panel against the wall includes
engaging the bottom edge of the wall panel with the lower mounting
rail and pivoting the top edge into engagement with the upper
mounting rail. The attachment device of the upper mounting rail
provided comprises an elongate locking clip which extends from the
base thereof adapted to resiliently snap-fit to the top edge of the
wall panel. The attachment device of the lower mounting rail
provided comprises an elongate L-shaped member which extends
outwardly from the base thereof to form an elongate channel
defining a pocket therebetween to receive the peripheral edge of
the wall panel. The engaging the bottom edge of the wall panel with
the lower mounting rail comprises inserting the bottom edge of the
wall panel into the pocket of the lower mounting rail. The pivoting
the top edge into engagement with the upper mounting rail includes
pushing the top edge past the locking clip which deflects slightly
to allow passing thereunder to lock the top edge in place.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] Various other objects, advantages, and features of the
invention will become apparent to those skilled in the art from the
following discussion taken in conjunction with the following
drawings, in which:
[0034] FIG. 1 is a perspective view of a first preferred embodiment
modular wall paneling system of the present invention in the form
of a wainscoting, shown as fully installed in a room along three
walls at an inside corner and an outside corner, above a floor and
base molding of the room, and around a window, and with a plurality
of interlocking wall panels, lower mounting rails, wall trim
pieces, a horizontal wall trim piece, an inside corner trim piece,
a multi-planar inside corner cap, an outside corner trim piece, and
a multi-planar outside corner cap thereof being visible.
[0035] FIG. 2 is a perspective view of the first modular wall
paneling system shown as partially installed in the room along the
walls, with a plurality of upper and lower mounting rails, an
inside corner mounting rail, and an outside corner mounting rail
thereof visible.
[0036] FIG. 3 is a fragmentary lateral vertical cross-sectional
view of the modular wall paneling system as mounted to one wall
above the base molding trim piece to an enlarged scale taken on the
line 3-3 of FIG. 1 showing one wall panel removably retained
between the upper and lower mounting rails, and the horizontal wall
trim piece attached to the upper mounting rail.
[0037] FIG. 4 is a fragmentary longitudinal horizontal
cross-sectional view of the wall panels mounted to one wall
interconnected by a panel joining device thereof to a further
enlarged scale taken on the line 4-4 of FIG. 1 showing a tongue of
the panel joining device integral with a side edge of one wall
panel and a groove of the panel joining device integral with a side
edge of an adjoining wall panel.
[0038] FIG. 5 is a fragmentary longitudinal horizontal
cross-sectional view of the modular wall paneling system mounted to
the walls at the inside corner of the room to the enlarged scale
taken on the line 5-5 of FIG. 1 showing the inside corner mounting
rail attached to two walls, a pair of the wall panels, and the
inside corner trim piece covering an inside corner gap between the
wall panels.
[0039] FIG. 6 is a fragmentary top plan view of the modular wall
paneling system mounted to the walls at the inside corner of the
room to the enlarged scale taken on the line 6-6 of FIG. 1 showing
the pair of the wall panels and the multi-planar inside corner cap
covering the inside corner gap between the wall panels.
[0040] FIG. 7 is a fragmentary longitudinal horizontal
cross-sectional view of the modular wall paneling system mounted to
the walls at the outside corner of the room to the enlarged scale
taken on the line 7-7 of FIG. 1 showing the outside corner mounting
rail attached to two walls, a pair of the wall panels, and the
outside corner trim piece covering an outside corner gap between
the wall panels.
[0041] FIG. 8 is a fragmentary top plan view of the modular wall
paneling system mounted to the walls at the outside corner of the
room to the enlarged scale taken on the line 8-8 of FIG. 1 showing
the pair of the modular wall panels and the multi-planar outside
corner cap covering the outside corner gap between the wall
panels.
[0042] FIG. 9 is a perspective view of a second preferred
embodiment modular wall paneling system of the present invention in
the form of a whiteboard shown as fully installed in a room
centrally on a wall above a floor and a base molding of the room,
and with a pair of interlocking whiteboard wall panels, a
peripheral wall trim piece system comprised of a pair of horizontal
wall trim pieces and a pair of vertical wall trim pieces, and a
plurality of planar corner caps thereof visible.
[0043] FIG. 10 is a fragmentary lateral vertical cross-sectional
view of the modular wall paneling system mounted on the wall to an
enlarged scale taken on the line 10-10 of FIG. 9 showing one
whiteboard wall panel removably retained to a horizontal mounting
rail of a peripheral trim mounting rail system thereof and one
horizontal wall trim piece attached to the horizontal mounting
rail.
[0044] FIG. 11 is a fragmentary lateral vertical cross-sectional
view of the modular wall paneling system mounted on the wall to a
slightly lesser enlarged scale taken on the line 11-11 of FIG. 9
showing one whiteboard wall panel removably retained between the
horizontal mounting rails and the horizontal wall trim pieces
attached thereto.
[0045] FIG. 12 is a fragmentary lateral vertical cross-sectional
view of the modular wall paneling system mounted on the wall to the
slightly lesser enlarged scale taken on the line 12-12 of FIG. 9
showing one whiteboard wall panel removably retained between the
horizontal mounting rails and two of the planar corner caps
attached thereto.
[0046] FIG. 13 is a rear elevational view of one planar corner cap
to the enlarged scale showing a body of a mating configuration to
adjoining of the horizontal and vertical wall trim pieces which
snap-fits to pairs of the horizontal and vertical mounting
rails.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0047] As required, detailed embodiments of the present invention
are disclosed herein, however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention which
may be embodied in various forms. Therefore, specific structural
and functional details disclosed herein are not to be interpreted
as limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the present invention in virtually any
appropriately detailed structure.
[0048] Reference is now made to the drawings, wherein like
characteristics and features of the present invention shown in the
various FIGURES are designated by the same reference numerals.
First Preferred Embodiment
[0049] Referring to FIGS. 1-8, a first embodiment modular wall
paneling system 20 for application to at least one wall of a room,
preferably in the form of wainscoting is disclosed. The wall
paneling system 20 is shown as installed in a room 23 along a pair
of walls 26 and 29 at an inside corner 32 of an angle "A" of ninety
degrees above a floor 34 and a base molding 35, around window
molding 36 of a window 37, and abutting door molding 38 of a
doorway 39 surrounding a door 40. A "modular wall paneling system"
for purposes of this application is understood to include not only
wainscoting installations, but also other applications including
but not limited to whiteboards, dry erase boards, chalkboards, cork
boards, modular shelving, clothing racks, coat hooks, hat racks,
photo or artwork frames, padded upholstered panels and picture or
other artwork frames, and the like.
[0050] As best shown in FIG. 3, the modular wall paneling system 20
includes a plurality of generally flat members in the form of
modular wall panels 41 each being of at least limited flexibility
and preferably being semi-rigid, elongate upper mounting rails 44,
elongate lower mounting rails 47, and elongate wall trim pieces 50
commonly referred to as a chair trim rails.
[0051] The wall panels 41 are preferably of the rectangular shape
shown of a height "H", though other shapes may be used which have
flat sides such as triangles, octagons, and the like which allow
attachment to the upper and lower mounting rails 44 and 47. The
wall panels 41 are adapted for application to the walls 26 and 29
of the room 23, each including a front panel 53 with a front
surface 56, an opposing rear surface 59 of a rearwardly convex
shape formed by a plurality of parallel ribs 62 which create broken
line contact with the walls 26 and 29 at respective collinear
contact lines 63, and a peripheral edge 64 comprising a top edge
65, a bottom edge 68, a side edge 71, and a side edge 74. The ribs
62 stiffen the wall panels 41 for durability and create essentially
point contact at the contact lines 63 with the walls 26 and 29. The
wall panels 41 are adapted to be retained against respective of the
walls 26 and 29 by the upper mounting rail 44 and the lower
mounting rail 47 at opposite portions of the peripheral edge 64
comprising the top edge 65 and bottom edge 68 such that there is a
slight amount of interference with respective of the walls 26 and
29. This causes the wall panels 41 to bow slightly outwardly at
respective middle areas 80 thereof between the top and bottom edges
65 and 68 to take out any potential gap between the walls 26 and 29
and the wall panel 41 if the walls 26 and 29 are uneven. This
allows the wall panels 41 to stay tight against the walls 26 and 29
and not rattle upon contact therewith or other situations such as
when a door (not shown) is shut. Alternatively, the rear surface 59
may be of other rearwardly convex configurations which provide line
contact with the walls 26 and 29. These include a curved planar
rear surface 81 (FIG. 4 dotted lines) adapted for engaging the wall
by creating unbroken line contact therewith or other curved
configurations which provide limited contact with the walls 26 and
29.
[0052] As best shown in FIG. 4, the wall panel 41 preferably
includes a first additional feature in the form of a panel edge
joining device 83 in which the side edges 71 and 74 are of mutually
interlocking design, each having respective interlockable halves of
the panel edge joining device 83 to allow adjoining wall panels 41
to interconnect. The edge joining device 83 comprises of a tongue
86 integral with side edge 71 and a groove 89 integral with side
edge 74. The tongue 86 and groove 89 preferably extend the length
of the side edges 71 and 74 to ensure that the wall panels 41 are
flush with each other from top edge 65 to bottom edge 68 even if
the walls 26 and 29 are uneven such as by being wavy. The tongue 86
is mounted to the groove 89 by sliding downwardly thereinto.
Alternatively, tongue 86 may be designed to snap-fit into groove 89
by pressing edgewise thereinto to slightly deflect side edge 74.
The wall panels 41 may form a waterproof joint if so desired by
being a tight fit or using an adhesive or sealant therebetween. The
tongue 86 and groove 89 are rounded to provide easy sliding
together and removal without using tools and without damaging the
wall panels 41. Likewise, the components of wall paneling system 20
are rounded as needed so assembly and disassembly is done without
damaging any component.
[0053] The wall panel 41 preferably includes a second additional
feature in the form of a panel edge hiding device 90 wherein the
side edges 71 and 74 include respective indent halves 92 and 95 of
the panel edge hiding device 90. The indent halves 92 and 95 are
each of quarter-round cross-section which form a full indent 98 of
half-round cross-section at adjoining wall panels 41 to provide a
finished look therebetween and to control any possible gap (not
shown) between the wall panels 41 where the side edges 71 and 74 do
not fit together exactly flush.
[0054] As best shown in FIG. 3, the upper mounting rail 44 includes
a flat base 101 adapted to be affixed along respective of the walls
26 and 29 by having a plurality of holes 104 therethrough for
receiving a plurality of wall attachment devices comprising screws
107. Other such attachment devices such as nails may be used to
attach upper mounting rail 44 to the walls 26 and 29. A first half
108 of a wall trim piece attachment device 109 comprising a first
locking clip 110 of S-shaped cross-section includes a curved base
portion 113 which extends initially parallel with base 101 then
outwardly, a primary retaining portion 116 of C-shaped
cross-section is adapted to engage the wall trim piece 50, and an
end retaining portion 119 of C-shaped cross-section. The first half
108 of the wall trim piece attachment device 109 further comprises
a second locking clip 122 of T-shaped cross-section which extends
from the base 101 thereof including a base leg 125 which extends
perpendicularly from base 101 and a cross leg 128 which terminates
at a bulbous end 131 adapted to engage the wall trim piece 50. The
upper mounting rail 44 includes a top panel attachment device 132
comprising a wedge end 134 of cross leg 128 of second locking clip
122 adapted to resiliently engage the top edge 65 of the wall panel
41 to retain the top edge 65 to the walls 26 and 29.
[0055] The lower mounting rail 47 is of J-shaped cross-section
having a flat base 137 adapted to be affixed along the walls 26 and
29 having a plurality of holes 138 therethrough for receiving a
plurality of the screws 107 to attach lower mounting rail 47 to the
walls 26 and 29. The lower mounting rail 47 further includes a
bottom panel attachment device 139 comprised of an L-shaped member
140 which extends outwardly from the base 137 thereof adapted to
support the wall panel 41 and retain the bottom edge 68 to the
walls 26 and 29. The L-shaped member 140 comprises a short leg 143
which extends perpendicularly from base 137 and a long leg 146
which extends parallel to walls 26 and 29. The base 137 and
L-shaped member 140 form an elongate channel 147 defining a pocket
149 therebetween to receive the bottom edge 68 of the wall panel
41.
[0056] The wall trim piece 50 is adapted to conceal the upper
mounting rails 44 and includes a substantially hollow outer member
152 of a partial flat C-shaped cross-sectional shape.
Alternatively, an outer member 153 (dotted lines) of partial
rounded C-shape may be used or of other cross-sectional shapes. The
outer member 152 includes a base leg 155 which extends parallel to
the walls 26 and 29, a long leg 158 dependent therefrom which
terminates at an outside edge 161 of outer member 152 adapted to
engage the walls 26 and 29, and a short leg 164 dependent therefrom
which terminates at an inside edge 167 of outer member 152 adapted
to engage the wall panel 41. A second half 168 of the wall trim
piece attachment device 109 adapted to connect the outer member 152
to the upper mounting rails 44 comprises a first locking member 170
which extends inwardly from the outer member 152 perpendicularly
from short leg 164 having a bulbous end 173 adapted to resiliently
connect to the first half 108 of the wall trim piece attachment
device 109. The second half 168 further comprises a second locking
member 176 which extends inwardly from the outer member 152 in a
curved manner from base leg 155 having a bulbous end 179 adapted to
resiliently connect to the first half 108 of the wall trim piece
attachment device 109. The wall trim pieces 50 snap-fit to the
upper mounting rails 44 by positioning slightly thereabove and
pushing downwardly and rearwardly. The bulbous end 173 of first
locking member 170 engages the end retaining portion 119 to deflect
the first locking clip 110 outwardly to seat in the primary
retaining portion 116. The bulbous end 179 of second locking member
176 engages the bulbous end 131 to deflect the second locking clip
122 downwardly to seat therebelow.
[0057] As best shown in FIGS. 5 and 6, the wall paneling system 20
further includes an inside corner mounting rail 182, an inside
corner trim piece 185, and a multi-planar inside corner cap 188 to
finish the inside corner 32.
[0058] The inside corner mounting rail 182 includes a base 191 of
L-shaped cross-section adapted to be affixed to at least one of two
intersecting walls 26 and 29 along the inside corner 32 of the room
23. The inside corner mounting rail comprises a pair of
perpendicular legs 194 and 197 connected together edgewise at the
angle "A" of the intersecting walls 26 and 29 at the inside corner
32. Respective pluralities of holes 200 and 203 extend therethrough
for receiving a plurality of the screws 107 to attach inside corner
mounting rail 182 to the walls 26 and 29. The legs 194 and 197 have
respective rear surfaces 205 and 206 adapted respectively to engage
the intersecting walls 26 and 29 at the inside corner 32. The
inside corner mounting rail 182 further includes a first half 207
of a corner trim piece attachment device 208 disposed centrally
thereon extending forwardly therefrom adapted to connect the inside
corner trim piece 185 to the inside corner mounting rail 182. The
first half 207 of the corner trim piece attachment device 208
comprises a pair of opposing first and second locking clips 209 and
210 of S-shaped cross-section which extend from the base 191. The
first and second locking clips 209 and 210 include respective
oppositely outwardly curved base portions 212 and 215 which extend
from respective of the legs 194 and 197, and respective opposing
inwardly curved retaining portions 218 and 221 adapted to
resiliently engage the inside corner trim piece 185.
[0059] The inside corner trim piece 185 includes a base 224 of a
curved L-shaped cross-section adapted to be disposed along the
inside corner 32 in overlapping relationship to adjacent wall
panels 41 to conceal respective of the side edges 71 and 74 thereof
and to conceal the inside corner mounting rail 182. Alternatively,
base 224 may be disposed in an abutting or in both an abutting and
overlapping relationship therewith. The base 224 comprises a pair
of legs 227 and 230 which have respective rear surfaces 234 and 235
adapted respectively to engage the front surface 56 of adjacent of
the wall panels 41 at the inside corner 32. The legs 227 and 230
are interconnected by a concave curved middle portion 233 disposed
at an angle slightly greater than the angle "A" of the intersecting
walls 26 and 29. The inside corner trim piece 185 is designed to be
at least somewhat flexible to ensure a tight fit against the wall
panels 41 at inside corner 32 even if the walls 26 and 29 are not
exactly perpendicular either in an obtuse or acute direction. A
second half 236 of the corner trim piece attachment device 207 is
disposed centrally thereon extending rearwardly from the base 224
adapted to snap-fit to the first half 207 thereof. The second half
236 of the corner trim piece attachment device 207 comprises a
center member 237 of mushroom-shaped cross-section which extends
rearwardly from the middle portion 233. Center member 237 has an
inwardly curved stem 239 and a rounded head 242 adapted to snap-fit
to between the first and second locking clips 209 and 210 of first
half 207 of corner trim piece attachment device 208 by pressing
perpendicularly thereinto. Alternatively, the inside corner trim
piece 185 may mounted to the inside corner mounting rail 182 by
sliding the center member 237 thereof downwardly between the first
and second locking clips 209 and 210 of first half 207 of corner
trim piece attachment device 208.
[0060] The multi-planar inside corner cap 188 is labeled as such
due to it's angled configuration to engage both of walls 26 and 29.
The inside corner cap 188 includes a body 245 of a mating
configuration to adjoining of the upper mounting rails 44, the wall
trim pieces 50, the inside corner mounting rail 182, and the inside
corner trim pieces 185 and is adapted to conceal respective
adjoining cut ends thereof Body 245 has a curved right angle front
surface 248, a bent right angle rear surface 251 disposed at the
angle "A" of the intersecting walls 26 and 29 at the inside corner
32, a curved L-shaped top surface 254, a curved L-shaped bottom
surface 257 adapted to engage the inside corner mounting rail 182
and the inside corner trim piece 185, and respective rectangular
side surfaces 260 and 263 adapted to engage adjoining of the upper
mounting rails 44 and the wall trim pieces 50. The inside corner
cap 188 further includes a cap attachment device 264 adapted to
attach the body 245 to at least one of the upper mounting rail 44,
the wall trim piece 50, the inside corner mounting rail 182, and
the inside corner trim piece 185. The cap attachment device 264 is
of a plug type comprising a pair of bottom plugs 266 and 267
integral with body 245 which extend downwardly from body 245 at
bottom surface 257. The bottom plugs 266 and 267 are adapted to
closely fit within corresponding open areas 275 and 278 of the wall
paneling system 20 defined by the adjoining inside corner mounting
rail 182 and inside corner trim piece 185 to retain the inside
corner cap 188 thereto. The cap attachment device 264 further
comprises a pair of side plugs 284 and 287 integral with body 245
which extend outwardly from body 245 at respective of side surfaces
260 and 263. The side plugs 284 and 287 are adapted to closely fit
within a corresponding open area 290 of the wall paneling system 20
defined by adjoining pairs of the upper mounting rails 44 and the
wall trim pieces 50 to retain the inside corner cap 188 thereto.
Alternatively to the plug type cap attachment device 264, a
snap-fit type (see below) may be used wherein the body 245 is
formed in a partially or completely hollow configuration.
[0061] As best shown in FIGS. 7 and 8, the wall paneling system 20
further includes an outside corner mounting rail 293, an outside
corner trim piece 296, and a multi-planar outside corner cap 299 to
finish an outside corner 302 of an angle "Al" of
two-hundred-seventy degrees formed by respective walls 26 and
305.
[0062] The outside corner mounting rail 293 includes a base 311 of
L-shaped cross-section adapted to be affixed to at least one of two
intersecting walls 26 and 305 along the outside corner 302 of the
room 23. The outside corner mounting rail comprises of a pair of
perpendicular legs 314 and 317 connected together edgewise at the
angle "Al" of the intersecting walls 26 and 305 at the outside
corner 302. Legs 314 and 317 have respective pluralities of holes
320 and 323 therethrough for receiving a plurality of the screws
107 to attach outside corner mounting rail 293 to the walls 26 and
305. The legs 314 and 317 of the outside corner mounting rail 293
have respective rear surfaces 324 and 325 adapted respectively to
engage the intersecting walls 26 and 305 at the outside corner 302.
A first half 326 of a corner trim piece attachment device 327
comprising a pair of opposing first and second locking clips 328
and 329 of elongate S-shaped cross-section is disposed centrally
thereof extending forwardly therefrom. The first half 326 includes
respective oppositely outwardly curved base portions 332 and 335
which extend from respective of the legs 314 and 317, and
respective opposing inwardly curved retaining portions 338 and 341
adapted resiliently to engage the outside corner trim piece
296.
[0063] The outside corner trim piece 296 includes a base 344 of a
curved L-shaped cross-section adapted to be disposed along the
outside corner 302 in overlapping relationship to adjacent wall
panels 41 to conceal respective of the side edges 71 and 74 thereof
and to conceal the outside corner mounting rail 293. Alternatively,
base 344 may be disposed in an abutting or both abutting and
overlapping relationship therewith. The base 344 comprises a pair
of legs 347 and 350 interconnected by a convex curved middle
portion 353. Legs 347 and 350 terminate at respective rearwardly
curved ends 354 and 355 having respective rear surfaces 358 and 361
adapted to engage the front surface 56 of adjacent of the wall
panels 41 at the outside corner 302. The legs 347 and 350 are
disposed at an angle slightly greater than the angle "A1" of the
intersecting walls 26 and 305 at the outside corner 302. The
outside corner trim piece 296 is designed to be flexible to ensure
a tight fit against the wall panels 41 at outside corner 302 even
if the walls 26 and 305 are not exactly perpendicular either in an
obtuse or acute direction. A second half 362 of the corner trim
piece attachment device 327 is disposed centrally thereon extending
rearwardly from the base 344 adapted to snap-fit to the first half
326 thereof. The second half 362 of the corner trim piece
attachment device 327 comprises a pair of opposed center arms 363
and 365 which extend rearwardly from the middle portion 353 adapted
to snap-fit to between the first and second locking clips 328 and
329 of first half 326 of corner trim piece attachment device 327 by
pressing perpendicularly thereinto. Alternatively, the outside
corner trim piece 296 may mounted to the outside corner mounting
rail 293 by sliding the center arms 363 and 365 thereof downwardly
between the first and second locking clips 328 and 329 of first
half 326 of corner trim piece attachment device 327.
[0064] The multi-planar outside corner cap 299 is labeled as such
due to it's angled configuration to engage both of walls 26 and
305. Outside corner cap 299 includes a body 368 of a mating
configuration to adjoining of the upper mounting rails 44, the wall
trim pieces 50, the outside corner mounting rail 293, and the
outside corner trim pieces 296 and is being adapted to conceal
respective adjoining cut ends thereof Body 368 has a curved right
angle front surface 371, a bent right angle rear surface 374
disposed at the angle "A1" of the intersecting walls 26 and 305,
and a curved L-shaped top surface 377. A curved L-shaped bottom
surface 380 is adapted to engage the outside corner mounting rail
293 and the outside corner trim piece 296. Respective rectangular
side surfaces 383 and 386 are adapted to engage adjoining of the
upper mounting rails 44 and the wall trim pieces 50. The outside
corner cap 299 further includes a cap attachment device 390 adapted
to attach the body 368 to at least one of the upper mounting rail
44, the wall trim piece 50, the outside corner mounting rail 293,
and the outside corner trim piece 296. The cap attachment device
390 is of the plug type comprising a pair of bottom plugs 395 and
398 integral with body 368 which extend downwardly from body 368 at
bottom surface 380. The bottom plugs 395 and 398 are adapted to
closely fit within corresponding open areas 401 and 404 of the wall
paneling system 20 defined by the adjoining outside corner mounting
rail 293 and outside corner trim piece 296 to retain the outside
corner cap 299 thereto. The cap attachment device 390 further
comprises a pair of side plugs 407 and 410 integral with body 368
which extend outwardly from body 368 at respective of side surfaces
383 and 386. Side plugs 407 and 410 are adapted to closely fit
within the corresponding open areas 290 of the wall paneling system
20 defined by adjoining pairs of the upper mounting rails 44 and
the wall trim pieces 50 to retain the outside corner cap 299
thereto. Alternatively to the plug type cap attachment device 390,
a snap-fit type (see below) may be used wherein the body 368 is
formed in a partially or completely hollow configuration.
[0065] The modular wall panels 41, upper mounting rails 44, lower
mounting rails 47, wall trim pieces 50, inside corner mounting
rails 182, inside corner trim pieces 185, inside corner caps 188,
outside corner mounting rails 293, outside corner trim pieces 296,
and outside corner caps 299 are preferably made from a plastic
polymer material such as high impact polystyrene, polypropylene,
high density polyethylene, or other suitable material having a
suitable combination of impact resistance, cost, flexibility,
scratch resistance, and molding characteristics. These materials,
as well as other suitable aluminum, steel, or other metal, or other
suitable materials, have a suitable combination of impact
resistance, cost, limited flexibility, scratch resistance, and
molding characteristics. The upper mounting rails 44, wall trim
pieces 50, inside corner mounting rails 182, inside corner trim
pieces 185, outside corner mounting rails 293, and outside corner
trim pieces 296 are preferably made using a plastic or metal
extrusion process due to the ability of such extrusion processes to
make complex linear shapes at low cost. The wall panels 41, inside
corner caps 188, and outside corner caps 299 are preferably
injection molded from plastic polymer material. Secondary processes
such as in-mold decorating, painting, anodizing, hydro-coloring,
and the like may be used on all to achieve the desired colors and
decoration thereon.
[0066] The modular wall paneling system 20, particularly the
visible component parts such as the wall panels 41, wall trim
pieces 50, inside corner trim pieces 185, inside corner caps 188,
outside corner trim pieces 296, and outside corner caps 299 may be
of a common genre such as a common functional design as in standard
routed molding designs, an artistic design, or a theme. The common
genre may be applied thereto using a process such as molding,
printing, embossing, applying a decorative papering such as wall
paper, or other conventional process. Examples include simulated
wood, murals, a diamond plate pattern, a white beadboard, picture
frame molding, faux brick, faux rock, camouflage, and upholstered
padded panels for soundproofing or as soft walls for children's
rooms or nurseries. Examples of licensed cartoon and other
characters, corporate logos, and trademarks include such as Mickey
Mouse, Dora the Explorer, Harley-Davidson, Ferrari, Spongebob
Squarepants, Clifford the Big Red Dog, Winnie the Pooh, Barbie,
Disney princesses, Bob the Builder, NASCAR, All sports teams, Movie
themes, TV shows, and the like.
[0067] The modular wall paneling system 20 is installed by cutting
to length and mounting the lower mounting rails 47 to respective of
the walls 26, 29, and 305 just above the base molding 35 using the
screws 107. The lower mounting rails 47 are mounted to the walls
26, 29, and 305 so as to just touch at the inside and outside
corners 32 and 302. The upper mounting rails 44 are then cut to
length and mounted to respective of the walls 26, 29, and 305 using
the screws 107 at a measured height "H1" above the lower mounting
rails 47 for the particular height "H" of the wall panels 41 to
snap-fit to the upper mounting rails 44. The upper mounting rails
44 are mounted to respective of the walls 26, 29, and 305 spaced
from the inside and outside corners 32 and 302 a distance "S" to
allow room for the inside and outside corner caps 188 and 299. The
inside and outside corner mounting rails 182 and 293 are then cut
to length and respectively mounted to the walls 26, 29, and 305 at
corners 32 and 302 using the screws 107. The corner mounting rails
182 and 293 are of a height "H2" which is the same as the distance
to the bottom of the wall trim pieces 50 when installed which
allows room for the inside and outside corner caps 188 and 299.
[0068] One or more of the wall panels 41, typically the endmost of
panels 41, may be vertically cut to fit the particular walls 26,
29, and 305 so as to have respective of the side edges 71 and 74
spaced from adjacent of the walls 26, 29, and 305 at the distance
"S" from the inside and outside corners 32 and 302. This is later
covered by respective of the inside and outside corner trim pieces
185 and 296. The endmost of panels 41 are typically cut so that
they roughly meet the end edge of the associated upper mounting
rail 44. The cut doesn't have to be perfect or precise, as the
corner caps 188 and 299 will cover the cuts.
[0069] The wall panels 41 are mounted to the upper mounting rails
44 and lower mounting rails 47 by inserting the bottom edge 68
thereof into pocket 149 of lower mounting rail 47 and rotating the
top edge 65 towards respective of the walls 26, 29, and 305. The
top edge 65 is pushed against the wedge end 134 of the second
locking clip 122 of upper mounting rail 44 which deflects slightly
to allow passing thereunder to lock top edge 65 in place. This
snap-fit feature of upper mounting rails 44 easily and securely
retains the wall panels 41 in an upright position against the walls
26, 29, and 305. The wall panels 41 are preferably retained against
respective of the walls 26, 29, and 305 by the upper mounting rail
44 and the lower mounting rail 47 such that there is a slight
amount of interference with respective of walls 26, 29, and 305 so
the wall panels 41 bow slightly outwardly at the middle area 80
between the top and bottom edges 65 and 68. This is done to take
out any potential gap between respective of walls 26, 29, and 305
and the wall panels 41 if the walls 26, 29, and 305 are uneven so
the wall panels 41 stay tight against respective of the walls 26,
29, and 305 and not rattle upon contact therewith or when a door
(not shown) is shut. The indent halves 92 and 95 of the adjoining
wall panels 41 form the full indent 98 to provide a finished
look.
[0070] After the wall panels 41 are mounted, the inside and outside
corner trim pieces 185 and 296 are cut to length and mounted to
respective of the inside and outside corner mounting rails 182 and
293 as described above. The corner trim pieces 185 and 296 are of
the height "H2" which is the same as the inside and outside corner
mounting rails 182 and 293 which allows room for the inside and
outside corner caps 188 and 299. Respective of legs 227 and 230,
and 347 and 350 of the inside and outside corner trim pieces 185
and 296 overlap the wall panels 41 to provide a finished look.
[0071] After the inside and outside corner trim pieces 185 and 296
are mounted, the wall trim pieces 50 are mounted by snap-fitting to
the upper mounting rails 44 as described above. The inside and
outside corner caps 188 and 299 are installed next. The inside
corner caps 188 are installed by inserting the bottom plugs 266 and
267 into the open areas 275 and 278 of wall paneling system 20, and
inserting the side plugs 284 and 287 thereof into the open areas
290 of wall paneling system 20. Each corner cap 188 abuts
respective of the wall trim pieces 50 to provide a finished look
and to concealing the cut ends of the upper mounting rails 44, the
wall trim pieces 50, the inside corner mounting rails 182, and the
inside corner trim pieces 185. The outside corner caps 299 are
installed by inserting the bottom plugs 395 and 398 thereof into
the open areas 401 and 404 of wall paneling system 20, and
inserting the side plugs 407 and 410 thereof into the open areas
290 of wall paneling system 20. Each corner cap 299 abuts
respective of the wall trim pieces 50 to provide a finished look
and to concealing the cut ends of the upper mounting rails 44, the
wall trim pieces 50, the outside corner mounting rails 293, and the
outside corner trim pieces 296.
[0072] The modular wall paneling system 20 solves the problem of
obtaining a finished look such as obtaining an exact cut for the
endmost of wall panels 41 since the inside and outside corner trim
pieces 185 and 296 cover the cut edges thereof. The finished look
is further obtained by the cut ends of the upper mounting rails 44,
the wall trim pieces 50, the inside and outside corner mounting
rails 182 and 293, and the inside and outside corner trim pieces
185 and 296 being covered by the inside and outside corner caps 188
and 299.
Second Preferred Embodiment
[0073] Referring to FIGS. 10-13, a second embodiment modular wall
paneling system 413 for application to a wall of a room, preferably
in the form of a whiteboard, is disclosed. The wall paneling system
413 is shown as installed in a room 416 along a wall 419, adjacent
a wall 422 and an inside corner 425 thereof, above a floor 428 and
base molding trim pieces 431. This illustrates how the modular wall
paneling system of the present invention is not isolated only to
wainscoting type installations. Exemplary modular wall panels that
may be used here include whiteboard, chalkboard, corkboard, modular
shelving panels, clothing hooks and racks, padded upholstered
panels and picture or other artwork frames.
[0074] The wall paneling system 413 includes a plurality of
generally flat members in the form of modular whiteboard wall
panels 434 each of at least limited flexibility and preferably
being semi-rigid, a peripheral trim mounting rail system 437
comprised of a pair of elongate horizontal mounting rails 440 and a
pair of elongate vertical mounting rails 443, a peripheral wall
trim piece system 446 comprised of a pair of elongate horizontal
wall trim pieces 449 and a pair of elongate vertical wall trim
pieces 452, and a plurality of planar corner caps 455.
[0075] The whiteboard wall panels 434 are preferably of a
rectangular shape, though other shapes may be used which have flat
sides such as triangles, octagons, and the like which allow
attachment to the horizontal and vertical mounting rails 440 and
443. The whiteboard wall panels 434 are of similar construction to
wall panels 41 adapted for application to the wall 419 of the room
416 including a front panel 458 with a front surface 461 and an
opposing rear surface 467 of a rearwardly convex shape formed by a
plurality of parallel ribs 470 which create broken line contact
with the wall 419 at respective collinear contact lines 471. The
wall panels 434 include a peripheral edge 472 comprising a top edge
473, a bottom edge 476, a side edge 479, and a side edge 482. The
ribs 470 stiffen the whiteboard wall panels 434 for durability and
create essentially point contact at the contact lines 471 with the
wall 419. The whiteboard wall panels 434 are adapted to be retained
against the wall 419 by the trim mounting rail system 437 at
opposite portions of the peripheral edge 472 comprising the top
edge 473 and bottom edge 476 such that there is a slight amount of
interference with the wall 419. The wall panels 434 bow slightly
outwardly at a middle area 488 between the top and bottom edges 473
and 476 to take out any potential gap between the wall 419 and the
wall panels 434 if the wall 419 is uneven so the wall panels 434
stay tight against the wall 419 and not rattle upon contact
therewith or other situations such as when a door (not shown) is
shut. Alternatively, the rear surface 467 may be of other
rearwardly convex configurations which provide line contact with
the wall 419. These include a curved planar surface 491 adapted for
engaging the wall by creating unbroken line contact therewith or
other curved configurations which provide limited contact with the
wall 419.
[0076] The whiteboard wall panels 434 include a first additional
feature in the form of erasable ink receiving layer 492 disposed
over the front surface 461 such as used on conventional whiteboards
adapted for erasable writing thereon.
[0077] The whiteboard wall panels 434 preferably include a second
additional feature in the form of a panel edge joining device 493
wherein the side edges 479 and 482 are of mutually interlocking
design. Side edges 479 and 482 have respective interlockable halves
of the panel edge joining device 493 comprised of a tongue (not
shown) integral with side edge 479 and a groove (not shown)
integral with side edge 482 to allow adjoining wall panels 434 to
interconnect. The tongue and groove preferably extend the length of
the side edges 479 and 482 to ensure that the whiteboard wall
panels 434 are flush with each other from top edge 473 to bottom
edge 476 even if the wall 419 is uneven such as by being wavy. The
tongue and groove are rounded to provide easy sliding together and
removal without using tools and without damaging the wall panels
434. The tongue may mounted to the groove by sliding downwardly
thereinto. Alternatively, the tongue may be designed to snap-fit
into groove by pressing edgewise thereinto to slightly deflect side
edge 482. The panels 434 may form a waterproof joint if so desired
by being a tight fit or using an adhesive or sealant therebetween.
The tongue and groove are rounded to provide easy sliding together
and removal without using tools and without damaging the wall
panels 434. Likewise, the components of wall paneling system 413
are rounded as needed so assembly and disassembly is done without
damaging any component.
[0078] The whiteboard wall panels 434 preferably includes a third
additional feature in the form of a panel edge hiding device 498
wherein the side edges 479 and 482 include respective indent halves
501 and 504 of the panel edge hiding device 498. The indent halves
501 and 504 are each of quarter-round cross-section which form a
full indent 506 of half-round cross-section at adjoining whiteboard
wall panels 434 to provide a finished look therebetween and to
control any possible gap (not shown) between the whiteboard wall
panels 434 where the side edges 479 and 482 do not fit together
exactly flush.
[0079] The horizontal and vertical mounting rails 440 and 443 of
the peripheral trim mounting rail system 437 are of the same
cross-sectional configuration, being cut to differing lengths from
a generic mounting rail 509. The generic mounting rail 509 is of
similar construction to upper mounting rail 44 but of a shorter
height "H3" than a height "H4" thereof The generic mounting rail
509 includes a flat base 512 adapted to be affixed along the wall
419 having a plurality of holes 515 therethrough for receiving a
plurality of the screws 107 to attach generic mounting rail 509 to
the wall 419. A first half 516 of a wall trim piece attachment
device 517 comprises a first locking clip 518 of S-shaped
cross-section includes a curved base portion 521 which extends
initially parallel with base 512 then outwardly, a primary
retaining portion 524 of C-shaped cross-section adapted to engage
the horizontal and vertical wall trim pieces 449 and 452 of
peripheral wall trim piece system 446, and an end retaining portion
527 of C-shaped cross-section. The first half 516 of a wall trim
piece attachment device 517 further comprises a second locking clip
530 of T-shaped cross-section which extends from the base 512
thereof including a base leg 533 which extends perpendicularly from
base 512 and a cross leg 536 which terminates at a bulbous end 539
adapted to engage the horizontal and vertical wall trim pieces 449
and 452. The generic mounting rail 509 includes a top panel
attachment device 540 comprising a wedge end 542 of cross leg 536
of second locking clip 530 adapted to resiliently engage the top
edge 473 of the whiteboard wall panel 434 to retain the top edge
473 to the wall 419.
[0080] The horizontal and vertical wall trim pieces 449 and 452 of
the peripheral wall trim piece system 446 are of the same
cross-sectional configuration, being cut to differing lengths from
a generic wall trim piece 545. The generic wall trim piece 545 is
of similar construction to wall trim piece 50 but of a shorter
height "H5" than the height "H6" thereof. The generic wall trim
piece 545 is adapted to conceal the horizontal and vertical
mounting rails 440 and 443 and includes a substantially hollow
outer member 548 of a partial flat C-shaped cross-sectional shape.
Alternatively, an outer member 549 (dotted lines) of partial
rounded C-shape may be used or of other cross-sectional shapes. The
outer member 548 includes a base leg 551 which extends parallel to
the wall 419, a long leg 554 dependent therefrom which terminates
at an outside edge 557 of outer member 548 adapted to engage the
wall 419, and a short leg 560 dependent therefrom which terminates
at an inside edge 563 of outer member 548 adapted to engage the
wall panel 434. A second half 564 of the wall trim piece attachment
device 517 adapted to connect the outer member 548 to the
horizontal and vertical mounting rails 440 and 443 comprises a
first locking member 566 which extends inwardly from the outer
member 548 perpendicularly from short leg 560 having a bulbous end
569 adapted to resiliently connect to the first half 516 of the
wall trim piece attachment device 517. The second half 564 further
comprises a second locking member 572 which extends inwardly from
the outer member 548 in a curved manner from base leg 551 having a
bulbous end 575 adapted to resiliently connect to the first half
516 of the wall trim piece attachment device 517. The generic wall
trim pieces 545 snap-fit to the horizontal and vertical trim
mounting rails 440 and 443 by positioning slightly forwardly and
outwardly therefrom and pushing inwardly and rearwardly such that
the bulbous end 569 of first locking member 566 engages the end
retaining portion 527 to deflect the first locking clip 518
outwardly to seat in the primary retaining portion 524. The bulbous
end 575 of second locking clip 572 engages the bulbous end 539 to
deflect the second locking clip 530 to seat therebehind.
[0081] The planar corner caps 455 are labeled as such due to it's
non-angled configuration to engage one walls 419. Corner caps 455
include a hollow body 578 of partial C-shaped cross-section of a
mating configuration to adjoining of the horizontal and vertical
mounting rails 440 and 443, and the horizontal and vertical wall
trim pieces 449 and 452 adapted to conceal the cut ends thereof
Body 578 has a curved L-shaped front surface 579, a curve L-shaped
rear surface 580 comprised of an outer portion 581 adapted to
engage the wall 419 and an inner portion 582 is adapted to engage
the whiteboard wall panels 434, a bent right angle outer surface
583, and a bent right angle inner surface 584. Respective U-shaped
side and bottom surfaces 585 and 586 are adapted to respectively
engage the horizontal mounting rail 440 and the horizontal wall
trim piece 449, and the vertical mounting rail 443 and the vertical
wall trim piece 452 at an intersection area 587 thereof. Body 578
comprises a front wall 588 having the front surface 579 which
extends parallel to the wall 419, an outside wall 589 having the
outer surface 583 rearwardly dependent from front wall 588
terminating at a rear edge 590 which comprises the outer portion
581 of rear surface 580, and an inside wall 591 having the inner
surface 584 rearwardly dependent from front wall 588 terminating at
a rear edge 593 comprising the inner portion 582 of rear surface
580.
[0082] The planar corner caps 455 further include a cap attachment
device in the form of another second half 596 of the wall trim
piece attachment device 517 adapted to attach the body 578 to the
horizontal and vertical mounting rails 440 and 443 at the
intersection area 587. The second half 596 comprises a first
locking member 602 which extends inwardly from the body 578
perpendicularly from outside wall 584 having a bulbous end 605
adapted to resiliently connect to the first half 516 of the wall
trim piece attachment device 517. The second half 596 further
comprises a second locking member 608 which extends inwardly from
the body 578 in a curved manner from front wall 588 having a
bulbous end 611 adapted to resiliently connect to the first half
516 of the wall trim piece attachment device 517. The corner caps
455 snap-fit to the horizontal and vertical mounting rails 440 and
443 by positioning slightly outwardly therefrom and pushing
inwardly and rearwardly such that the bulbous end 605 of first
locking member 602 engages the end retaining portion 527 to deflect
the first locking clip 518 outwardly to seat in the primary
retaining portion 524. The bulbous end 611 of second locking member
608 engages the bulbous end 539 to deflect the second locking clip
530 to seat therebehind. The use of end retaining portion 527 to
receive the bulbous end 605 rather than the primary retaining
portion 524 allows the corner caps 455 to snap-fit to the adjoining
perpendicularly disposed horizontal and vertical wall trim pieces
449 and 452 more easily while firmly retaining thereto.
Alternatively to the snap-fit type corner attachment device or
alternate second half 596, a plug type (see above) may be used.
[0083] The whiteboard wall panels 434, horizontal mounting rails
440, vertical mounting rails 443, horizontal wall trim pieces 449,
vertical wall trim pieces 452, and planar corner caps 455 are
preferably made from a plastic polymer material such as high impact
polystyrene, polypropylene, high density polyethylene, or other
suitable material having a suitable combination of impact
resistance, cost, flexibility, scratch resistance, and molding
characteristics. These materials, as well as other suitable
aluminum, steel, or other metal, or other suitable materials, have
a suitable combination of impact resistance, cost, limited
flexibility, scratch resistance, and molding characteristics. The
horizontal and vertical mounting rails 440 and 443, and horizontal
and vertical wall trim pieces 449 and 452 are preferably made using
a plastic or metal extrusion process due to the ability of such
extrusion processes to make complex linear shapes at low cost. The
whiteboard wall panels 434 and planar corner caps 455 are
preferably injection molded from plastic polymer material.
Secondary processes such as in-mold decorating, painting,
anodizing, hydro-coloring, and the like may be used on all to
achieve the desired colors and decorations.
[0084] The modular wall paneling system 413 may be of various
artistic designs or themes as described above for modular wall
paneling system 20 wherein the whiteboard wall panels 434, and the
horizontal and vertical wall trim pieces 449 and 452 are molded,
printed, embossed, or otherwise adapted for such artistic design or
theme. The whiteboard wall panels 434 preferably have any artistic
design or theme is printed thereon rather than molded or embossed
so the ink receiving layer 492 remains flat for writing and erasing
thereon.
[0085] The modular wall paneling system 413 is installed by cutting
to length and mounting the horizontal and vertical mounting rails
440 and 443 to the wall 419 centrally thereon using the screws 107
so as to just touch together. The horizontal mounting rails 440 are
mounted such that the horizontal wall trim pieces 449 of the
peripheral wall trim piece system 446 are at a vertical spacing
"DV" such that the top and bottom edges 473 and 476 of the
whiteboard wall panels 434 snap-fit between the wedge ends 542 of
the horizontal mounting rails 440. The vertical mounting rails 443
are mounted such that the vertical wall trim pieces 452 of the
peripheral wall trim piece system 446 are at a horizontal spacing
"DH" such that respective side edges 479 and 482 of the wall panels
434 just clear the wedge ends 542 of the vertical mounting rails
443 to allow slight outward bowing of the wall panels 434 between
the horizontal mounting rails 440 as described above without
interference to the bowing from the vertical mounting rails 443.
The horizontal and vertical mounting rails 440 and 443, and the
horizontal and vertical wall trim pieces 449 and 452 are spaced at
a distance "S2" from each other to allow assembly of the corner
caps 455 thereto.
[0086] One or more of the whiteboard wall panels 434, typically the
endmost of whiteboard wall panels 434, may be vertically cut to fit
the particular size of modular wall paneling system 413 desired.
The endmost of whiteboard wall panels 434 are typically cut so that
they roughly meet the cut ends of the associated horizontal
mounting rail 440. The cut doesn't have to be perfect or precise,
as the corner caps 455 covers the cut ends.
[0087] The wall panels 434 snap-fit to the horizontal mounting
rails 440 by inserting the bottom edge 476 thereof under the wedge
end 542 of the second locking clip 530 of the lowermost of
horizontal mounting rails 440 and rotating the top edge 473 towards
the wall 419. The top edge 473 is pushed against the wedge end 542
of the second locking clip 530 of the uppermost of horizontal
mounting rails 440 which deflects slightly to allow passing
thereunder to lock top edge 473 in place. This snap-fit feature of
the mounting rails 440 easily and securely retains the whiteboard
wall panels 434 in an upright position against the wall 419. The
whiteboard wall panels 434 fit between the wedge end 542 of the
second locking member 530 of the vertical mounting rails 443
without deflecting due to the larger spacing "DH". This allows the
whiteboard wall panels 434 to preferably be retained against the
wall 419 by the horizontal mounting rails 440 such that there is a
slight amount of interference with the wall 419 so the wall panels
434 bow slightly outwardly at the middle area 488 between the top
and bottom edges 473 and 476. This is done to take out any possible
gap between the wall 419 and the whiteboard wall panels 434 if the
wall 419 is uneven so the whiteboard wall panels 434 stay tight
against the wall 419 and not rattle upon contact therewith or when
a door (not shown) is shut. The indent halves 500 and 503 of the
adjoining wall panels 434 form the full indent 506 to provide a
finished look, or may be omitted if desired to provide easier
writing thereon. Alternatively, the vertical mount rails 443 may be
spaced closer together to allow all of the horizontal and vertical
mounting rails 440 and 443 to grip the wall panels 434 by bowing
the whiteboard wall panels 434 in two planes.
[0088] After the wall panels 434 are mounted, the horizontal and
vertical wall trim pieces 449 and 452 are cut to length and mounted
by snap-fitting to respective of the horizontal and vertical
mounting rails 440 and 443 as described above. The corner caps 455
are installed next by snap-fitting to respective of the horizontal
and vertical mounting rails 440 and 443 as described above. Each
corner cap 455 abuts respective of the horizontal and vertical wall
trim pieces 449 and 452 to provide a finished look and to
concealing the cut ends of the horizontal and vertical mounting
rails 440 and 443, and the horizontal and vertical wall trim pieces
449 and 452.
[0089] The modular wall paneling system 413 solves the problem of
obtaining a finished look such as obtaining an exact cut for the
endmost of wall panels 434 since the vertical wall trim pieces 452
cover the cut edges thereof. The finished look is further obtained
by the cut ends of the horizontal and vertical mounting rails 440
and 443, and the horizontal and vertical wall trim pieces 449 and
452 being covered by the corner caps 455.
[0090] A method of the present invention of installing a modular
wall paneling system for application to at least one wall of a
room, comprises the steps of: 1) providing at least one wall panel
of at least limited flexibility having a front surface, an opposing
rear surface, and a peripheral edge, the rear surface being of a
rearwardly convex shape of a configuration which provides line
contact with the wall; and 2) restraining opposite portions of the
peripheral edge of the wall panel against the wall in an upright
position such that there is a slight amount of interference with
the wall so the wall panel bows slightly outwardly at a middle area
thereof to take out any gap between the wall and the wall
panel.
[0091] The method may additionally comprise the steps of: 4)
providing at least one elongate upper mounting rail having a base
adapted to be affixed along the wall and an attachment device
adapted to retain the peripheral edge of the wall panel to the
wall; 5) providing at least one elongate lower mounting rail having
a base adapted to be affixed along the wall and an attachment
device to support the wall panel and retain the peripheral edge to
the wall; 6) securing the lower mounting rail to the wall; and 7)
securing the upper mounting rail to the wall at a measured distance
above the lower mounting rails for the particular height of the
wall panels to snap-fit to the trim mounting rails.
[0092] The method may be conducted wherein the wall panel provided
is of a rectangular shape with the peripheral edge comprising a top
edge, a bottom edge, and a pair of side edges, and wherein the step
of restraining the wall panel against the wall includes engaging
the bottom edge of the wall panel with the lower mounting rail and
pivoting the top edge into engagement with the upper mounting rail.
The attachment device of the upper mounting rail provided may
comprise an elongate locking clip which extends from the base
thereof adapted to resiliently snap-fit to the top edge of the wall
panel. The attachment device of the lower mounting rail provided
may comprise an elongate L-shaped member which extends outwardly
from the base thereof to form an elongate channel defining a pocket
therebetween to receive the peripheral edge of the wall panel. The
engaging the bottom edge of the wall panel with the lower mounting
rail may comprise inserting the bottom edge of the wall panel into
the pocket of the lower mounting rail. The pivoting the top edge
into engagement with the upper mounting rail may include pushing
the top edge past the locking clip which deflects slightly to allow
passing thereunder to lock the top edge in place.
[0093] Many modifications to the present invention are possible
while staying within the same inventive concept. For example, the
modular wall paneling system may be adapted for use on forty-five
degree inside and outside corners, and corners of other angles.
Various attachment devices may be used to attach the modular wall
panels to the mounting rails other than the snap-fit type and/or
directly to the walls such as patches of hook and loop fasteners
commonly sold under the trade name Velcro.TM., magnets or magnetic
strips, double-side adhesive tape, liquid adhesives, and snap-fit
type pins or hooks. One or more of the various component parts of
the wall paneling system may be molded together such as the wall
trim pieces with the wall panels and the like. Other materials may
be used besides pure polymer plastic materials such as wood, wood
products, cement board, ceramic, and metals such as aluminum,
stainless steel, and the like. Other exemplary materials include
polymer composites such as a polymer with reinforcing fibers of
glass, graphite, wood, flax or other such material. Yet other
exemplary materials include a water resistant material such as
pressed particle board which is wood particles impregnated with a
resin that is subsequently covered with a waterproof surface layer
such as paint, a sheet of polyethylene, polypropylene or polyvinyl
chloride, or a thermosetting laminate. The wall panels may be
attached together using other tongue and groove designs, pins (both
for vertical and horizontal attachment), lap joints, C-type channel
hooks, and the like. Other designs of ribs may be used which
stiffens the wall panel and which function as described above. The
ribs may be replaced by pins, suitably shaped spacers, foam or
rubber blocks, and the like. The wall paneling system may extend
from floor to ceiling by extending the height of the wall panels
with or without using the horizontal wall trim pieces (chair rail)
intermediate the floor and the ceiling. The wall paneling system
may be available as kits designed to fit predetermined room sizes
including wall lengths and heights, door frames, window frames, and
the like. The wall panels may have the tongue and groove molded
integrally therewith or separate pieces affixed thereto. The tongue
and/or the groove may be coated or impregnated with an adhesive
such as any commercially available two part micro-encapsulated
epoxy which rupture and harden automatically upon assembly together
or other adhesive, or a waterproofing material to assure no water
passes therebetween. The component parts may be of different
colors, designs, and the like which are mixed and matched as
desired upon initial installation and which may be subsequently
rearranged to change the look of a room.
[0094] The modular wall paneling system, wall panels, and method of
the present invention solve all of the above-enumerated objectives.
The system is of low cost to manufacture due to the plastic
construction and easy to install due to the snapfit design thereof.
The wall panels are available in a wide variety of shapes and
styles which may be mixed and matched at initial installation and
subsequently. The system requires no adhesives or caulking of the
edges of the panels and the trim pieces due to the use of nails to
affix the mounting rails to the walls and the covering of the cut
edges which would normally require caulking. The snap-fit features
allow changing of the wall panels and other snap-fit components
without ruining the walls. The system requires no special tools for
installation, only a hammer, tape measure, pencil, and saw to do
only minimal cutting. The system is more environmentally friendly
by using plastic rather than wood products to preserve the forests.
The system may be made from recycled plastic or made to be
biodegradable such as by adding starch or other ingredients to the
plastic material. The plastic material used is inherently not
susceptible to damage from mold and mildew in wet environments. The
plastic material requires no painting or cleaning except occasional
wiping with a damp cloth to remove dust. The entire wall paneling
system can be removed and reinstalled in another dwelling if so
needed by removing the nails which hid the mounting rails. The
nails do minimal damage to the walls and no adhesives are used for
installation which can cause substantial damage thereto. There is
virtually no preparation required of the walls required, the system
fitting around the existing base moldings and other trim pieces
which need not be removed. The snap-fit features allow the wall
panels to be easily interchanged to change the entire look of the
room. The system accommodates any size and shape of room including
non-square corners and wavy or otherwise irregular walls and may be
installed over virtually any type of wall including drywall, brick,
concrete block, and previously installed paneling by using
appropriate fasteners other than conventional nails as appropriate,
such as concrete nails, screws and anchors, and the like. The
installation time is quicker than traditional wall finishing due to
the use of nails for affixing the mounting rails to the walls and
by requiring no subsequent finishing such as staining or painting.
The plastic material is impact resistant and durable enough for use
in highly abused rooms, and is ideal for bathrooms and other wet
areas due to the inherent resistance of the plastic material to
mold and mildew. The system is environmentally friendly by using no
wood or wood products and capable of using recycled or
biodegradable plastic.
[0095] While the invention has been described, disclosed,
illustrated and shown in various terms or certain embodiments or
modifications which it has assumed in practice, the scope of the
invention is not intended to be, nor should it be deemed to be,
limited thereby and such other modifications or embodiments as may
be suggested by the teaching herein are particularly reversed
especially as they fall within the breadth and scope of the claims
here appended.
* * * * *