U.S. patent application number 10/925810 was filed with the patent office on 2006-04-20 for wall panel system.
Invention is credited to Steven W. Bledsoe, Michael J. Dobija.
Application Number | 20060080939 10/925810 |
Document ID | / |
Family ID | 35874857 |
Filed Date | 2006-04-20 |
United States Patent
Application |
20060080939 |
Kind Code |
A1 |
Bledsoe; Steven W. ; et
al. |
April 20, 2006 |
Wall panel system
Abstract
A wall panel system comprises an array of panels that provide a
prefinished wall surface. The panels may be of the same or
different sizes and include grooves or reveals supporting inserts
that cooperate to provide rectangular faux panels or other wall
panel designs. A trim system for mounting the panels to a support
wall includes elongated trim strips for completing panel edges and
corners.
Inventors: |
Bledsoe; Steven W.; (San
Clemente, CA) ; Dobija; Michael J.; (Laguna Beach,
CA) |
Correspondence
Address: |
PEARNE & GORDON LLP
1801 EAST 9TH STREET
SUITE 1200
CLEVELAND
OH
44114-3108
US
|
Family ID: |
35874857 |
Appl. No.: |
10/925810 |
Filed: |
August 25, 2004 |
Current U.S.
Class: |
52/750 |
Current CPC
Class: |
E04F 19/06 20130101;
E04F 19/028 20130101; E04F 13/16 20130101; E04F 19/064
20130101 |
Class at
Publication: |
052/750 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A kit for constructing a prefinished wall comprising a plurality
of trim elements for mounting of rectangular panels in an array to
a support wall to form said prefinished wall, said panels having
horizontal edges, vertical edges and substantially planar surfaces
extending between panel edges, said prefinished wall including at
least one outside corner formed by angularly intersecting panels,
said trim elements including horizontal trim elements for mounting
in a horizontal direction along said horizontal panel edges,
vertical trim elements for mounting in a vertical direction along
said vertical panel edges and outside corner trim elements for
mounting along vertical panel edges at said outside corner of said
prefinished wall, each of said trim elements including a base to be
secured to said support wall and a trim wall extending from said
base along the adjacent panel edge, said trim wall having a planar
configuration that is in substantial continuous contact with the
entire area of said panel edge and projects beyond the adjacent
panel surface to a trim surface that is parallel with said panel
surface.
2. The kit of claim 1, wherein said vertical trim element has an
L-shape cross-section, said prefinished wall includes at least one
inside corner formed by abutting first and second panels separated
by a corner mounted vertical trim element having opposed first and
second vertical sides, said corner mounted trim element extending
along an adjacent edge of said first abutting panel with said first
vertical side in substantial contact with said panel edge and said
second vertical side extending along the adjacent surface of said
second abutting panel, said trim surface of said trim element being
spaced from and parallel with said panel surface of said first
abutting panel and extending perpendicularly along said panel
surface of said second abutting panel whereby said inside corner
provides a finished trim appearance similar to that provided by
said trim elements extending along the horizontal and vertical
edges of said panels.
3. The kit of claim 1, wherein said trim surface has a width equal
to less than about 0.1 inch.
4. The kit of claim 1, wherein said trim surface has a width equal
to from about 0.05 inch to about 0.125 inch.
5. The kit of claim 1, wherein said outside corner trim element
comprises a elongate channel having an X shaped cross section
formed by a pair of said trim walls joined at a right angle
intersection, each of said trim walls extending from said
intersection to form said base as a pair of mounting legs.
6. The kit of claim 1, wherein said outside corner trim element
comprises an elongate channel having a double-Y shaped
cross-section formed by a pair of said trim walls joined at a first
right angle intersection to form a common leg extending from said
intersection to a second right angle intersection formed by a pair
of mounting legs projecting away from each other at right angles
and parallel with said trim walls.
7. The kit of claim 1, wherein a said outside corner trim element
includes a central corner element aligned with said intersection
and laterally extending trim portions, said trim portions extending
over adjacent vertical panel edges and including separately mounted
trim pieces selected to match or contrast said planar surfaces of
said panels.
8. The kit of claim 1, wherein said outside corner trim element is
an integrally formed metallic extrusion.
9. The kit of claim 1, wherein a plurality of intersecting grooves
extend in said planar surfaces of said panels, and said kit further
includes a plurality of reveal inserts mounted in said grooves.
10. A wall panel system comprising a plurality of rectangular
panels adapted to be mounted in abutting relationship to a support
wall in a planar array to form a finished wall, each panel having a
generally planar surface extending between panel edges arranged
along horizontally and vertically extending directions, each of
said panels having a plurality of intersecting grooves extending in
the panel surface intermediate said panel edges, and a plurality of
reveal inserts mounted in said grooves to subdivide the panel
surface into a plurality of smaller rectangular faux panels.
11. The wall panel system of claim 10, wherein said intersecting
groove has a cross-section, adjacent panel edges each provide
one-half of said groove cross-section and cooperate to form an edge
groove corresponding in cross-section with said cross-section of
said intersecting groove, and said reveal inserts are also mounted
in said edge groove.
12. The wall panel system of claim 11, wherein said panel array
includes an array edge formed by vertical panel edges and an inside
corner formed by angularly intersecting panels, and identical
elongate trim strips having trim walls for engaging panel edges
form both a vertical trim for said vertical panel edges and an
inside corner trim disposed between said angular and he
intersecting panels.
13. The wall panel system of claim 11, wherein said intersecting
grooves in each of said panels cooperate to form horizontally
aligned grooves in an adjacent panels in said array of panels.
14. The wall panel system of claim 11, wherein said panels are of
at least two different area sizes.
15. The wall panel system of claim 14, wherein said panels are of
the same height and different widths.
16. The wall panel system of claim 15, wherein said panels of
different sizes are arranged in a selected panel sequence and said
panel sequence is repeated to form said panel array of said
prefinished wall.
17. The wall panel system of claim 10, wherein mounting fasteners
extend through said grooves to secure said panel to said support
wall, said mounting fasteners being hidden from view by said reveal
inserts.
18. The wall panel system of claim 17, wherein said panels are
individually mounted to said support wall to provide a
nonprogressive panel system wherein any panel may be removed
without prior removal of an adjacent panel.
19. The wall panel system of claim 10, wherein said intersecting
grooves in each of said panels cooperate to form a plaid-like
pattern of unevenly spaced repeated grooves crossing at right
angles whereby the pattern has an overall linear appearance.
20. The wall panel system of claim 19, wherein said panels are of
at least two different area sizes.
21. The wall panel system of claim 20, wherein said panels are of
the same height and different widths.
22. The wall panel system of claim 20, wherein said panels of
different sizes are arranged in a selected panel sequence and said
panel sequence is repeated to form said panel array of said
prefinished wall.
23. In a wall panel system comprising a plurality of panels adapted
to be mounted to a support wall to form a prefinished wall, each of
said panels having a finished front surface extending between panel
edges lying in vertical and horizontal orientations, said panels
including adjacent vertical edges forming at least one outside
corner at the adjacent edges of intersecting first and second
panels, the improvement comprising an outside corner trim element
mounted to said support wall along said corner, said trim element
including a central corner element aligned with said intersection
and laterally extending trim portions, said trim portions extending
over said adjacent vertical edges and including separately mounted
trim pieces that may be selected to match or contrast said finished
front surfaces of said panels.
24. The wall system of claim 23, wherein said trim portions include
insert channels for receiving said trim pieces.
25. The wall system of claim 24, wherein said insert channel has a
height substantially equal to the height of said outside corner
trim element, a width substantially equal to the lateral extent of
said trim portion and a thickness substantially equal to the
thickness of said trim piece.
26. The wall system of claim 25, wherein said insert channel is
formed with a generally flat bottom and first and second opposed
overhangs for receiving opposite vertical edges of said trim
piece.
27. The wall system of claim 26, wherein said central corner
element includes said first overhang adjacent each of said trim
portions, and a lip projecting from said trim portion provides said
second overhang adjacent a lateral extremity of said trim
portion.
28. The wall system of claim 25, wherein said trim pieces are
formed of a laminated plastic.
29. The wall system of claim 23, wherein said trim portions
resiliently engage said panels.
30. The wall system of claim 23, wherein said trim portions cover
and hide from view said vertical panel edges at said corner.
Description
BACKGROUND OF THE INVENTION AND RELATED ART
[0001] This invention relates to wall systems and, more
particularly, to a wall panel system comprising an array of panels
that cooperatively provide a finished wall surface.
[0002] Systems are known for assembling arrays of individual wall
panels to produce a finished wall surface. U.S. Pat. Nos.
3,838,546, 4,783,941 and 4,854,095 each illustrate examples of such
systems. Similar systems are also disclosed in assignee's prior
U.S. Pat. Nos. 5,417,020 and 5,694,727 wherein panels or tiles of
relatively small size, e.g., one or several feet on edge, are
provided in an upscale more costly wall system. Typically, a frame
or grid is initially installed and the individual panels are then
mounted on the frame or grid in such systems. In some instances,
clips are provided to secure and position the panels on the grid
structure.
[0003] Such systems tend to be relatively complex and require a
number of different structural elements which must be assembled by
skilled installers. The systems do not readily lend themselves to
alternative assembly techniques which may provide different overall
appearances in accordance with designer aesthetic preferences.
Similarly, the systems do not tend to easily accommodate unique
support wall configurations.
[0004] Frequently, such systems are so-called progressive systems
in that assembly and disassembly of the wall system must be
sequential beginning with an edge or periphery panel. That is, in
order to remove an intermediate panel, neighboring panels must
first be removed beginning at an extremity of the wall panel
system. This is a time consuming process, and it is especially
disadvantageous in wall panel systems having locations of high wear
or incidence of damage since frequently worn or damaged panels are
not individually and easily replaced. For example, panel
installations in public buildings, a hallway, door adjacent
locations or the like tend to require frequent replacement of
individual panels.
SUMMARY OF THE INVENTION
[0005] The invention provides an improved panel system which offers
flexibility of configuration and enables combinations of panels of
various area sizes. The panels are rectangular which includes
square for purposes herein.
[0006] The panels may be scored vertically and horizontally in
square, rectangular or linear patterns. The panels are mechanically
fastened to the wall through the horizontal reveals.
[0007] The wall panel system may include repeating sequences of
panels of different area sizes which cooperate to provide a
prefinished wall surface. The panels are typically formed of a
high-pressure laminate on a wood fiber substrate. The laminate may
be provided with a wood grain or colored front or exposed
surface.
[0008] The panels may be sized for floor-to-ceiling, wainscot or
column-wrap installations. Accordingly, full wall panels may be 4'
or 5' wide by 8' or 10' tall, wainscot may be 4' by 4', 8' by 4' or
10' by 4' and column-wrap panels may be 2' by 8' or 2' by 10'. As
described below, panels of different sizes may be combined to
provide a finished wall surface. The panels include reveals and
reveal inserts that may be arranged to provide a repeating uniform
pattern from panel-to-panel or a combined panel comprehensive
pattern.
[0009] As indicated, the prefinished wall surface may be provided
with a repeating design characterized by a plurality of smaller
faux panel surfaces. For example, a 4'.times.4' panel may be
provided with horizontal and vertical grooves fitted with reveal
inserts that cooperate to provide the prefinished wall surface with
the appearance of an array of four 2' by 2' square faux panels. In
this manner, the panels provide the appearance of smaller,
individually installed panels or tiles, and the advantages of large
panel installation.
[0010] In another arrangement, the prefinished wall surface may be
provided with an overall integrated design appearance wherein
adjacent panels provide different portions of a comprehensive
design pattern extending over a plurality of panels. For example, a
repeating array of three adjacent panels may include an aligned
pair of horizontally extending reveal inserts extending along the
surfaces of all three panels and intersecting vertical reveal
inserts in only one or more of the panels. Of course, the pattern
of reveal inserts may be identical in all three panels.
[0011] The panel system is directly fastened to a support wall, as
by fasteners within the grooves, and covered by the reveal inserts.
In addition, a trim system cooperates in the panel mounting.
[0012] The trim system complements the appearance of both the faux
panel designs and the integrated plural panel designs. To that end,
the trim system includes elongate trim strips or elements
characterized by substantially planar flat trim walls. The trim
wall engages substantially the entire area of the associated panel
edge to provide effective protection against panel edge impacts
that might otherwise tend to delaminate the panel.
[0013] The flat trim wall extends slightly beyond the surface of
the panel to a flat trim surface that is substantially parallel
with the panel wall surface. The trim system forms a dimensional
outline of the panel disposed in a plane different from that of the
panel surface.
[0014] In addition to providing a finished trim appearance that is
aesthetically pleasing, the trim system is also efficient in that
the strips thereof may be used for multiple purposes. For example,
the vertical trim strips may also be used as inside corner trim
strips as described below.
[0015] The outside corner trim strips or elements similarly outline
the panel edges while providing protection against side impacts. To
that end, the outside corner trim strips also include planar trim
walls engaging adjacent panel edges and terminating in trim
surfaces that are parallel with the adjacent panel surface. The
trim strips are provided with simple geometric configurations that
are easily manufactured, as metallic extrusions.
[0016] In an alternative arrangement, the trim system may include
an array edge trim strip having a channel shape. The edge of the
panel array is received in the channel shape to present a trim
surface of increased width. For example, the front surface of the
edge trim may have a width substantially equal to that of the
reveal insert. This may be used with faux panel surfaces to
complete the appearance of an array of smaller panels.
[0017] In yet another arrangement, the trim system may include an
outside corner trim strip or element having a central trim portion
aligned with the intersection line of the corner and laterally
extending trim portions overhanging and engaging the adjacent panel
surfaces. The trim portions include separately mounted trim pieces
that may be selected to match or contrast panel surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a fragmentary perspective view illustrating a
portion of a wall panel system in accordance with a first
embodiment of the invention, with parts-omitted for clarity of
illustration;
[0019] FIG. 2 is a fragmentary front elevational view of the wall
panel system of FIG. 1;
[0020] FIG. 3 is a fragmentary sectional view on an enlarged scale
taken along the line 3-3 in FIG. 2 showing a mid-wall fastening in
the array of panels of the first embodiment and illustrating one
form of a reveal insert that may be used to cover the finished
fastening;
[0021] FIG. 4 is a fragmentary sectional view on an enlarged scale
taken along the line 4-4 in FIG. 2 showing a vertical butt joint
between two panels in the array of panels;
[0022] FIG. 5 is a fragmentary sectional view on an enlarged scale
taken along the line 5-5 in FIG. 2 showing a vertical edge of the
array of panels and one form of trim that may be used to provide a
finished vertical edge trim;
[0023] FIG. 6 is a fragmentary sectional view on an enlarged scale
taken along the line 6-6 in FIG. 2 showing a top edge of the array
of panels and one form of trim that may be used to provide a
finished top edge trim;
[0024] FIG. 7 is a fragmentary-sectional view on an enlarged scale
taken along the line 7-7 in FIG. 2 showing a horizontal joint
between lower and upper panels in the array of panels of the first
embodiment and illustrating a stacking rail trim strip that may be
used to provide a finished horizontal joint;
[0025] FIG. 8 is a sectional view on an enlarged scale showing the
reveal insert used in the first embodiment of the invention;
[0026] FIG. 9 is a fragmentary sectional view on an enlarged scale
showing an inside corner in an array of panels of the first
embodiment and illustrating one form of trim that may be used to
provide a finished inside corner trim;
[0027] FIG. 10 is a fragmentary sectional view on an enlarged scale
showing an outside corner in an array of panels of the first
embodiment and illustrating one form of trim that may be used to
provide a finished outside corner trim;
[0028] FIG. 11 is a fragmentary sectional view on an enlarged scale
showing an outside corner in an array of panels of a second
embodiment and illustrating one form of trim that may be used to
provide a finished outside corner trim;
[0029] FIG. 12 is a sectional view on an enlarged scale showing
another form of a reveal insert used in the second embodiment of
the invention;
[0030] FIG. 13 is a sectional view through a panel showing
alternative forms of an upper trim edge, a lower trim edge and a
mid-wall fastening arrangement used in the second embodiment of the
invention;
[0031] FIG. 14 is a sectional view similar to FIG. 13 showing an
alternative form of a lower trim edge used in the second embodiment
of the invention;
[0032] FIG. 15 is a sectional view similar to FIG. 13 showing
additional alternative forms of an upper trim edge and a lower trim
edge arrangement used in the second embodiment of the
invention;
[0033] FIG. 16 is an elevational front view of a wall surface
formed by a three panel array having reveal inserts in each panel
forming portions of a more comprehensive combined or integrated
design;
[0034] FIG. 17 is a fragmentary sectional view taken along the line
17-17 in FIG. 16;
[0035] FIG. 18 is an elevational front view of a wall surface
formed by a three panel array having reveal inserts in each panel
forming portions of a more comprehensive combined or integrated
design;
[0036] FIG. 19 is a fragmentary sectional view taken along the line
19-19 in FIG. 18;
[0037] FIG. 20 is a fragmentary sectional taken along an outside
corner in an array of panels illustrating another form of trim that
may be used to provide a finished outside corner trim; and
[0038] FIG. 21 is a fragmentary perspective view showing the
outside corner of the array of panels shown in FIG. 19.
DETAILED DESCRIPTION OF THE DRAWINGS
[0039] In accordance with the invention, a wall panel system
includes a plurality of rectangular panels consisting of rows or
courses of horizontally aligned panels assembled and mounted to
provide a finished wall surface. As required, the courses may be of
indefinite length and panels may be stacked in columns to provide a
desired height.
[0040] The panels may be provided with substantially any desired
surface finish and appearance. For example, the exposed panel
surface may be provided with a simulated wood grain, a single or
multicolor, abstract or like surface. Similarly, the panels may be
provided with a wood veneer, a metal finish, or a high pressure
laminate construction including a medium density fiberboard core or
a particle board core and a backer layer.
[0041] FIGS. 1 through 10 illustrate a first embodiment of the
present invention. In this embodiment, a wall system 10 comprises a
plurality of panels 12a and 12b mounted by a trim system 14 to a
support wall 16. The support wall 16 may comprise a conventional
drywall structure supported by studs, such as the stud 18.
[0042] With particular reference to FIG. 2, the panels 12a are
arranged in a lower course 20 and the panels 12b are arranged in an
upper course 22. The panels 12a are 4' by 8' and the panels 12b are
4' by 4' so that a wall system 10 provides a 12' tall prefinished
wall surface 24 of indefinite length.
[0043] A plurality of reveals or grooves 26 are provided in the
front or exposed surfaces of the panels 12a and 12b. In this
embodiment, the grooves 26 are arranged to intersect at right
angles in a spaced pattern that divides the surface of each panel
12a into eight squares and the surface of each panel 12b into four
squares, all squares being of the same size.
[0044] Reveal inserts 28 are mounted within the grooves 26 to
further enhance the appearance of the surface. In this manner, the
panels 12a, 12b cooperate to provide the prefinished wall surface
24 with a repeating pattern of relatively smaller square faux
panels 30 that simulate the appearance of individual panels or
tiles.
[0045] The wall panel system 10 is fastened directly to the support
wall 16 by fasteners 32 mounted within the grooves 26 as shown in
FIG. 1. The fasteners 32 may comprise screws or nails. For purposes
of added reinforcement, the trim system 14 includes aluminum
furring strips 34 aligned with the grooves 26 and disposed at array
edges. The strips 34 may be of a suitable thickness, such as 16
gauge. If a vertical groove 26 is aligned with a stud, such as stud
18, furring strip 34 is not required. The fasteners are covered by
the reveal inserts 28 as shown in FIG. 2. The reveal inserts 28 are
adhesively mounted within the grooves 26.
[0046] Referring to FIGS. 2 through 4, the grooves 26 include
mid-wall grooves 26a as shown in FIG. 3. Mid-wall grooves 26a are
provided for purposes of design and/or fastening the panel to the
support wall. In addition to mid-wall grooves 26a, vertical butt
joint grooves 26b are provided between the edges of adjacent panels
as shown in FIG. 4. The butt joint grooves 26b are formed by mating
router-cut channels or half-grooves 56 extending along the edges of
the panels 12a.
[0047] The vertical edge of the wall panel system 10 is mounted to
the support wall 16 with a vertical edge trim strip 36 as shown in
FIGS. 1 and 5. The horizontal lower and top edges of the wall panel
system 10 are respectively mounted with horizontal edge trim strips
38 as shown in FIGS. 1 and 6. The trim strips 36 and 38 may also be
secured to the support wall 16 by the fasteners 32 comprising
rails.
[0048] The trim strip 36 has an L-shaped cross-section including a
base 40 and a perpendicularly extending trim wall 42 of
substantially flat or planar configuration. The trim wall 42 is in
substantial contact with the adjacent edge of the panel 12a or 12b,
and protects the edge against delamination. The trim wall 42 is
relatively thin, 1/16'' to 3/16'' thick, and projects beyond the
surface on the panels about 0.03'' to a trim surface 44 that is
substantially parallel when the wall panel surface 24.
[0049] The trim strip 38 has an L-shaped cross-section including a
base 46 and a perpendicularly extending trim wall 48. The trim wall
48 also extends about 0.03'' beyond the wall surface 24 to a trim
surface 50 that is parallel with the wall surface 24. The trim wall
48 also has a substantially flat or planar configuration, but
includes a laterally projecting tongue 52 sized to be received
within a mating kerf or groove 54 in the horizontal edge of the
panel 12b.
[0050] As best shown in FIG. 7, the panels 12b of the upper course
22 are connected to the panels 12a of the lower course 20 by a
stacking joint rail 60. The rail 60 has an H-shape cross-section
including a base 62 secured to the support wall 16 by fasteners 32.
A central connector 64 extends from the base 62 to a joining leg 66
that is disposed in a vertical plane. The leg 66 includes lower and
upper tongues 66a and 66b respectively received in mating kerfs or
grooves 54 cut in the horizontal edges of the panels 12a and 12b.
The leg 66 and the kerfs 54 are sized to space apart the adjacent
panel edges at the front surface of the array a distance
corresponding with the thickness of the reveal insert 28.
[0051] The details of the cross-section of the reveal insert 28 are
shown in FIG. 8. The insert 28 is reversibly mountable within the
grooves 26, and therefore includes opposed alternate finish
surfaces 68 and 69. The surface 68 is provided with a concave
configuration. The surface 69 includes a pair of spaced grooves 69a
and 69b. In addition to providing desired aesthetics, the concave
configuration of the surface 68 and the grooves 69a and 69b of the
surface 69 serve to retain adhesive used to mount the insert 28 in
the groove 26.
[0052] Referring to FIG. 9, the wall panel system 10 is shown
applied to an inside corner generally indicated at 70. The support
wall 16 includes walls 16a and 16b that intersect at substantially
a right angle to form the inside corner 70. In this instance, a
first panel 12', which may be a panel 12a or 12b, is mounted to the
surface of the wall 16a, as by fasteners 32. The edge of the panel
12' received in the corner 70 is tightly abutted against the
surface of the support wall 16b.
[0053] A vertical edge trim strip 36 is mounted to the wall 16b by
securing the base 40 of the strip to the wall surface. A first side
42a of the trim wall 42 is positioned against the front or exposed
surface of the panel 12'. A second panel 12'', which also may be a
panel 12a or 12b, is then mounted to the surface of the wall 16b.
The edge of the panel 12'' is tightly butted against a second side
42b of the trim wall 42.
[0054] The trim wall 42 extends beyond the front or exposed surface
of the panel 12'' to dispose the trim surface 44 in parallel and
spaced relationship with the front surface of the panel. It should
be appreciated that the exposed portion of the trim wall 42
provides a similar trim appearance with respect to the front or
exposed surface of the panel 12'.
[0055] Referring to FIG. 10, an outside corner generally indicated
at 72 is formed by the right angle intersection of walls 16c and
16d of the support wall 16. An outside corner trim strip 74 is
mounted along the corner. The trim strip 74 has an X-shaped
cross-section formed by a pair of trim walls 76 and 78 that are
joined at a right angle. The trim walls extend to form base
mounting legs 80 and 82 that are respectively secured to the
surfaces of the walls 16c and 16b by fasteners 32. The trim strip
74 is particularly adapted for use with panels having a thickness
of about 7/16''.
[0056] For purposes of illustration, panels 12' and 12'' are also
shown forming the outside corner 72. Accordingly, the edge of the
panel 12' abuts the trim wall 76 and the edge of the panel 12''
abuts the trim wall 78. Each of the trim walls 76, 78 extends
slightly beyond the adjacent surface of the panel to form trim
surfaces 84, 86. The trim surfaces 84, 86 are respectively spaced
from and parallel with the adjacent surfaces of the panels 12' and
12''.
[0057] With particular reference to FIGS. 1 and 2, the installation
of the wall panel system 10 is described. Initially, vertical trim
strips 36 and lower horizontal trim strips 38 together with furring
strips 34 are secured to the support wall 16 at one extremity of
the wall system. A first lower course 20 of adjacent panels 12a is
engaged with the trim strip 38 and fixed to the support wall with
fasteners 32. Adjacent panels 12a are butted with half-grooves 56
joined to form a groove 26 for receipt of an insert 28. An upper or
second course of panels 12b may be mounted to the top edge of the
panels 12a with stacking joint rail 60 and fasteners 32. Any inside
corners 70 and outside corners 72 may be completed as described
above.
[0058] The wall panel system 10 is then completed by application of
horizontal trim strip 38 to the upper edge of the panel array and
vertical trim strip 36 to the remaining vertical edge of the panel
array. The reveal inserts 28 are adhesively mounted within the
grooves 26 of the panels 12. The adhesive mounting of the inserts
28 is primarily intended to avoid tampering. Accordingly, the
inserts may be removed without damage to the panels.
[0059] As noted above, the wall panel system 10 is non-progressive
since a single panel may be removed without prior removal of a
neighboring course panel. However, in some cases, it may be
necessary to remove an upper course panel before removing a lower
course panel. Even such limited disassembly of upper and lower
course panels provides considerable time and cost savings as
compared with the disassembly required in progressive systems.
[0060] Referring to FIG. 11, an outside corner 90 is completed by
an outside corner trim strip 92 in accordance with a further
embodiment of the invention. This embodiment is particularly
adapted for use with thicker panels, e.g., 3/4'' thick.
[0061] The trim strip 92 has a double-Y shaped cross section formed
by a pair of trim walls 94 and 96 joined at a right angle
intersection to form a common leg 98. The leg 98 extends toward the
support wall 16 to a pair of perpendicularly disposed base mounting
legs 100 and 102. The mounting legs 100 and 102 are secured to the
support wall by fasteners 32.
[0062] In this embodiment, corner-forming panels 108 and 110, which
may comprise panels 12a and 12b, have shaped edges 108a and 110a
engaging the trim strip 92. More particularly, the rearward
portions of the edges 108a and 110a are chamfered to accommodate
the angular intersection of the connecting leg 98. The forward
portions of the edges 108a and 110a are cut at right angles to the
panel surface to assure a tight abutting relationship with the trim
walls 94 and 96. It should be appreciated that the rearward
portions of the edges 108a and 110a may be cut at any angle to
clear the leg 98 and that such cuts need not be finish cuts.
[0063] Referring to FIG. 12, a reveal insert 112 especially adapted
for use in connection with relatively thicker panel systems is
shown. The insert 112 has a rectangular U-shaped cross-section
including a concave connecting wall 114 joining opposed walls 116.
The walls 116 are spaced to form an opening 118. The insert 112 may
be mounted in a panel reveal with either the wall 114 or the
opening 118 adjacent the front or exposed surface of the panel.
[0064] Referring to FIG. 13, a 3/4'' thick panel 120 is shown
mounted to a support wall 122. To that end, a furring strip 124 is
provided and fasteners 32 are used. The lower edge of the panel 120
is supported by a horizontal edge trim strip 126 having a
construction similar to the strip 38. A mid-wall fastening 128
includes a reveal or groove 130. The fasteners 32 extend through
the bottom of the groove 130, and they are covered by the reveal
insert 112. In this embodiment, the reveal insert 112 is mounted
with the concave connecting wall 114 exposed.
[0065] The top edge of the panel 120 is secured to the support wall
122 by a modified horizontal edge trim strip 132. The trim strip
132 has a J-shape including a base mounting leg 134 extending along
and fastened to the support wall 122. A laterally extending
connecting wall 136 projects from the base mounting leg 134 to a
trim face wall 138 which overlies a portion of the upper surface of
the panel 120. The trim face wall 138 may have a vertical dimension
corresponding with that of the reveal insert 112.
[0066] The panel 120 is shown in FIG. 14 with a router cut forming
a lower edge channel 140 for receiving an insert 112. The resulting
panel has matching mid-wall and lower edge trims. The top edge of
the panel may be completed with another trim strip 126 or an
L-shaped trim strip 132 may be used as illustrated.
[0067] Referring to FIG. 15, the panel 120 is further modified to
include a router cut at its top edge to form an upper edge channel
142 which also receives an insert 112. In this arrangement, the
panel now has three identical inserts mounted at the top, mid and
lower regions of the panel. The inserts 112 may be mounted as shown
or reversed to expose openings 118.
[0068] Referring to FIGS. 16 and 17, a wall panel system 150
includes a selected panel sequence comprising a central 4' by 8'
wall panel 152 and a 2' by 8' column panel 154 on each side
thereof. The adjacent vertical panel edges are router cut to form
half-grooves that cooperate to form grooves 156. Horizontal grooves
156 are vertically spaced at 2' intervals.
[0069] Reveal inserts 158, such as inserts 28 or 112, are mounted
within the grooves 156. In this manner, the panels 152 and 154
cooperate to provide the wall panel system 150 with a wall panel
surface 160. As shown, the wall panel surface 160 is formed of four
2' by 4' rectangular faux panels and eight 2' by 2' square faux
panels.
[0070] The wall panel system 150 may be provided with an indefinite
length by repeating the selected panel sequence or three array
pattern of wall panels 152 and 154. The vertical and horizontal
edges of the panel array may be completed with trim strips 36, 38,
126, with or without a mated reveal insert, or 132.
[0071] Referring to FIGS. 18 and 19, a wall panel system 162 is
shown. The wall panel system includes a three panel sequence
comprising a central 4' by 8' panel 164 and a 2' by 8' column panel
166 on each side thereof. Once again, vertical and horizontal
grooves 168 are scored in the surface of the panels and the
adjacent vertical panel edges are router cut to form half-grooves
that cooperate to form vertical grooves 168. Reveal inserts 170,
such as inserts 28 or 112, are mounted within the grooves 168.
[0072] Each of the panels includes a first pair of lower horizontal
grooves 168 containing inserts 170 located at a height of about 3'
from the panel bottom edges and vertically spaced apart about 2''.
The panels also include a second pair of lower horizontal grooves
and inserts, also at about a 2'' spacing, and positioned about 4''
above the first pair of lower horizontal grooves. The groove
pattern is completed by an upper groove 168 and inserts 170 spaced
about 8'' form the top edge of each panel.
[0073] The panels 164 and 166 cooperate to provide the wall panel
system 162 with a wall panel surface 172. In this arrangement, the
faux panels and multiple reveal inserts cooperate to provide the
surface 172 with a plaid-like pattern characterized by groups of
horizontal inserts and groups of vertical inserts forming a pattern
of unevenly spaced repeated stripes crossing at right angles. The
plaid-like pattern has a linear appearance as opposed to a
geometric pattern of squares, rectangles or other closed simple
shapes.
[0074] The three panel sequence or array may be repeated to provide
the wall panel system 162 with an indefinite length. The vertical
and horizontal edges of the panel array may be completed with trim
strips 36, 38, 126, with or without a mated reveal insert, or
132.
[0075] Referring to FIGS. 20 and 21, an outside corner, generally
indicated at 178, is formed by the walls 16c and 16d of the support
wall 16. An outside corner trim strip 180 is mounted along the
corner to an outside corner mounting base 182. The strip 180 and
the base 182 typically extend the full height of the wall.
[0076] The mounting base 182 includes mounting legs 184 and 186
secured to the adjacent walls 16c and 16d by fasteners 32. The legs
184 and 186 are joined to a U-shape female mounting coupler 188
that is aligned with the intersection of the corner and opens
outwardly to form a female mounting channel 190 that extends along
the full length of corner 178. The interior surface of the mounting
channel is provided with teeth or grooves 192.
[0077] The trim strip 180 includes a central corner portion 194
having a rearwardly projecting male mounting rib 196 and laterally
projecting trim portions 198 and 200. The rib 196 has teeth or
grooves 201 extending along its exterior surface.
[0078] The rib 196 is sized to be laterally inserted or pushed into
the channel 190. The engaging teeth or grooves 192 and 198 form a
mechanical interlock that secures the trim strip 180 to the
mounting base 182.
[0079] The outside corner is finished with wall panels 12' and
12'', which may be provided by panels 12a or 12b. The adjacent
corner edge of the panel 12' is cut at an acute angle to fit
against the mounting coupler 188. For purposes of illustration, the
adjacent corner edge of the panel 12'' is not specially finished,
but rather, extends at a right angle as formed during manufacture.
In both cases, the trim portions 198 and 200 are provided with a
sufficient lateral dimension to extend beyond the finished surface
edges of the panels 12' and 12'' so that no special finish edge cut
is required. Also, the trim portions 198 and 200 are configured to
tightly abut against the surface on the panels 12' and 12'', and
thereby provide a finished joint.
[0080] The trim portions 198 and 200 respectively include laterally
disposed and vertically extending insert channels or trim slots 202
and 204. The trim slots 202 and 204 may have a lateral dimension of
less than an inch, e.g., 5/8, as desired, and generally extend
along substantially the entire lateral width of the trim portion.
The vertical height of the trim slots 202 and 204 generally
corresponds with that of the outside corner trim strip 180.
[0081] The trim slots 202 and 204 have flat bottoms provided by the
trim portions 198 and 200. The trim slots 202 and 204 are bounded
by overhangs 206 and 208 and, respectively associated, lips 210 and
212. The lips project from the trim portions 198 and 200, and have
a slight reverse bend to provide a J-shape cross-section and
overhang.
[0082] The trim slots 202 and 2Q4 have a thickness or depth equal
to thickness of commercially available laminate materials such as
FORMICA brand laminate, e.g., 0.030'' TO 0.060''. Laminate trim
pieces 214 and 216 are mounted in the trim slots 202 and 204. The
trim pieces 214 and 216 may be inserted longitudinally into the
trim slots prior to-the mounting of the trim strip 180, or they may
be laterally flexed and pushed into the trim slots.
[0083] The front or exposed surfaces of the trim pieces 214 and 216
are finished and may match or contrast the front or exposed
surfaces of the panels 12' and 12''. In most cases, the trim pieces
214 and 216 will match each other, but this is not necessary.
[0084] While the invention has been shown and described with
respect to particular embodiments thereof, this is for the purpose
of illustration rather than limitation, and other variations and
modifications of the specific embodiments herein shown and
described will be apparent to those skilled in the art all within
the intended spirit and scope of the invention. Accordingly, the
patent is not to be limited in scope and effect to the specific
embodiments herein shown and described nor in any other way that is
inconsistent with the extent to which the progress in the art has
been advanced by the invention.
* * * * *