U.S. patent application number 12/237825 was filed with the patent office on 2009-03-26 for removable wallboard system.
Invention is credited to Howard Jones, Thomas Pettine.
Application Number | 20090077922 12/237825 |
Document ID | / |
Family ID | 40470225 |
Filed Date | 2009-03-26 |
United States Patent
Application |
20090077922 |
Kind Code |
A1 |
Pettine; Thomas ; et
al. |
March 26, 2009 |
Removable Wallboard System
Abstract
The present invention is a novel removable wallboard system. It
includes a plurality of receiver strips [1] which are attached to
framing members [8] of a structure to be paneled. Each receiver
strip has a receiving channel [4]. Wall panels 7 are placed snugly
between the receiver strips [1]. Trim units [2] are elongated
strips having insertion strips [10] which are designed to fit into
and be retained by receiving channels [4] of the receiver strips
[1]. Since the trim units [2] are designed to have a low profile,
and they cover the seams between the wall panels [7], there is no
need for further finishing or caulking. Therefore, these wall
panels [7] may be removed and replaced with minimal effort or
cleanup. The system also includes easily installable, removable and
replaceable base molding [16], crown molding [19], and chair rail
molding [29]. These may be designed to create chase ways [18, 74]
allowing hidden routing of electrical, utility cables, pipes and
hoses. Since the system may interactively be constructed and
removed, it is useful in business settings in which offices are
constantly adjusted.
Inventors: |
Pettine; Thomas;
(Royersford, PA) ; Jones; Howard; (Schwencksville,
PA) |
Correspondence
Address: |
ZALE Patent Law
434 Lackawanna Ave., Suite 200
Scranton
PA
18503-2053
US
|
Family ID: |
40470225 |
Appl. No.: |
12/237825 |
Filed: |
September 25, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60995678 |
Sep 26, 2007 |
|
|
|
Current U.S.
Class: |
52/698 ;
52/741.1 |
Current CPC
Class: |
E04F 19/062 20130101;
E04F 19/067 20130101; E04F 13/0814 20130101; E04F 19/02 20130101;
E04B 2/7457 20130101; E04B 2002/7462 20130101; E04F 19/022
20130101; E04F 19/061 20130101; E04F 19/064 20130101; E04B 2002/725
20130101 |
Class at
Publication: |
52/698 ;
52/741.1 |
International
Class: |
E04B 1/38 20060101
E04B001/38; E04B 1/00 20060101 E04B001/00 |
Claims
1. A removable wallboard system 10 for holding a plurality of wall
panels to a frame having a plurality of frame members, the system
comprising: a) at least one receiver strip having i. a base strip
capable of being attached to said frame member, and ii. a receiving
channel, and b) a trim unit having i. at least one insertion strip
1 which are sized and shaped to fit inside of and be removably
retained by the receiving channel, and ii. a flat top sized and
shaped to retain said wall panels between the flat top and the base
strip of the receiver strip.
2. The system of claim 1 wherein the insertion projection is one of
the group consisting of insertion strip and an insertion tab.
3. The system of claim 1 wherein the base strip further comprises:
a slot capable of receiving flat metal frame members.
4. The system of claim 1 wherein the receiver strip is secured
horizontally near the floor and further comprising: a base molding
having insertion strips 1 shaped and positioned to be received and
secured in receiving channel of receiver strip, the base molding
also having a recess for defining a chase way.
5. The system of claim 1 wherein the recess is formed within the
base molding.
6. The system of claim 1 wherein the receiver strip is secured
horizontally near the ceiling and further comprising: a crown
molding having insertion strips 1 shaped and positioned to be
received and secured in receiving channel of receiver strip, the
crown molding 19] also shaped to support a ceiling panel.
7. The system of claim 1 wherein the crown molding is constructed
of a flexible extruded plastic material.
8. The system of claim 1 wherein said wall panels are drywall
panels.
9. The system of claim 1 wherein said wall panels are gypsum
board.
10. The system of claim 1 wherein said wall panels are constructed
of a material which is paintable.
11. The system of claim 1 wherein said wall panels are removable
and replaceable providing easy access behind them.
12. A removable wallboard system for holding a plurality of wall
panels to at least one frame member having two surfaces which meet
at a corner, the system comprising: a) at least one inner support
attached to said frame member corner having: i. a first inner arm
attached to one surface of said frame member, ii. a second inner
arm attached to said second surface of said frame member, iii. an
inner junction piece connecting the first and second inner legs at
an angle approximately the same as the angle of surfaces of the
frame supports to which inner support is attached, the inner
junction piece 56] also having a receiving channel projecting
outward from the inner junction piece, and b) at least one outer
support having: i. a first outer arm, ii. a second outer arm, iii.
an outer junction piece connecting the first and second outer arms,
at approximately the same relative angle between the inner arms,
the outer junction piece also having an insertion projection
projecting inward from the outer junction piece, which is received
and secured in the receiving channel thereby holding outer support
to inner support sandwiching wall boards and securing them to said
frame member.
13. The system of claim 12 wherein the insertion projection is one
of the group consisting of insertion strip and an insertion
tab.
14. A method of constructing removable walls on a frame having a
plurality of frame members comprising the steps of: a) attaching a
receiver strip having a base strip capable of being attached to
said frame members and a receiving channel, to at least one frame
member, b) providing a trim unit having at least one insertion
strip which are sized and shaped to fit inside of, and be removably
retained by the receiving channel, c) providing wall panels and
placing the wall panels between the receiver strips, d) pressing
the insertion strip 1 of the trim units into the receiving channels
of the receiver strips to removeably retain said panels between the
trim unit 2] and the receiver strip.
15. The method of constructing removable walls of claim 14 wherein
the step of attaching to at least one frame member comprises the
step of: a) providing a receiver strip having a base strip with a
slot 2 for receiving a metal frame member, b) sliding the metal
frame member into the slot of base strip to attach said receiver
strip to said frame member.
16. The method of constructing removable walls of claim 14 wherein
the step of providing wall panels comprises the step of providing
drywall panels.
17. The method of constructing removable walls of claim 14 wherein
the step of providing wall panels comprises the step of providing
gypsum board.
18. The method of constructing removable walls of claim 14 further
comprising the step of: a) attaching a receiver strip horizontally
at a floor level which would be under a wall panel, b) providing a
base molding having at least one insertion strip which is sized and
shaped to fit inside of, and be removably retained by the receiving
channel, the base molding also having and upper edge capable of
supporting the wall panel and recesses for creating chase ways, c)
pressing the insertion strip of the base molding into the receiving
channels of the receiver strips to removeably retain and support
said wall panels on the upper edge of base molding.
19. The method of constructing removable walls of claim 14 further
comprising the step of: a) attaching a receiver strip horizontally
at ceiling height, b) providing a crown molding having at least one
insertion strip which is sized and shaped to fit inside of, and be
removably retained by the receiving channel, the crown molding also
capable of supporting a ceiling panel, c) pressing the insertion
strip of the crown molding into the receiving channels of the
receiver strips to removeably retain and support said ceiling
panel.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of U.S.
Provisional Patent Application 60/995,678 "Removable Wallboard
System" by the same inventors as this application. It therefore,
claims priority from the filing date of this earlier-filed
Provisional Patent Application being the Sep. 26, 2008.
FEDERAL SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to a removable wallboard system for
homes and businesses.
[0006] 2. Discussion of Prior Art
[0007] Present drywall installing, hanging and finishing methods do
not provide accessibility behind the wall, are time-consuming and
labor-intensive and therefore expensive.
[0008] Drywall is installed as follows: A sheet of drywall is held
up against a previously framed wall. The edges are normally nailed
with drywall nails temporarily securing the sheet to the framed
wall. The middle of the sheet then has drywall screws placed every
10 to 12 inches permanently securing the sheet in place.
[0009] Sequential sheets are butted up to each other and installed
using the same method until all wall area is covered.
[0010] A thin coat of a spackle or joint compound is placed over
every seam between the drywall sections and paper seam tape is
pressed into the spackle to cover each seem and inside corner while
corner bead is installed to cover each outside corner.
[0011] Then every nail and screw hole is filled with spackle. This
first coat of spackle is left to dry completely for at least 24
hours. Once the first coat of spackle is dry all said spackled
surfaces must be sanded smooth. All said wall surfaces must then be
cleaned of all dust and dirt.
[0012] A second coat of spackle is then applied over all said nail
holes, screw holes and seams. This second coat is then left to dry
for at least 24 hours. Once this second coat is dry all said nail
holes, screw holes and seams are again sanded smooth. All said wall
surfaces must again be cleaned of all dust and dirt.
[0013] Now, a third coat of spackle must be applied to all said
nail holes, screw holes and seams. This third coat of spackle on
said walls must again be left to dry completely for at least 24
hours. After completely drying, this third coat of spackle must
again be sanded smooth. Now all surfaces of said wall must be
thoroughly inspected, cleaned and prepared for paint. Before paint
can be applied to the walls, you must install all necessary wood
trim (i.e. base molding, crown molding, chair rail, window casing,
window sill and door casing) to all necessary locations on said
walls.
[0014] After all necessary trim is installed the walls are finally
ready for paint. After three coats of paint are complete and dry
all said walls must be inspected again. At this point all
imperfections on said wall must be repaired. The imperfections on
said walls are filled and feathered with the same spackle. This
coat of spackle is again left for at least 24 hours to dry. After
the spackle is completely dry all said repairs must be sanded
smooth. All dirt and dust on said walls must be cleaned completely.
Now all said repaired imperfections are painted trying to blend the
paint as best as possible. This procedure repeats until the desired
finish is achieved.
[0015] Once finished this system provides permanently fixed and
secured wall panels. Electrical, mechanical and structural features
behind the wall panels are difficult to locate. Once located these
are difficult to access. Damaged panels results in replacement and
wasted time.
[0016] There are existing inventions for construction assemblies to
hang specialized wall panels. The wall panels are designed as a
specific part of the assembly and will work only with said
assembly. U.S. Pat. Nos. 5,715,638 and 6,918,212 describe such
fabric wall panel systems. These systems are designed to handle
specialized fabric with synthetic backing wall panels. These
systems provide limited use. All panels are just 8 feet tall and
they come in only one finish and only one color, are difficult to
install and are expensive to construct.
[0017] Other patents have been issued for designs for supporting
wall panels. These systems are designed to finish exterior walls
and need specialized use of weatherproofing and caulk. These
systems can be extruded aluminum, other metal components or PVC.
The panels are attached to building walls using various types of
mounting devices.
[0018] For example, installation requires first installing a corner
or terminal support, then a panel, then a center seam or "H"
support with another panel and so on until another corner or
terminal support is reached. If the panels are misaligned or a
panel becomes damaged, the panels must be removed in sequence in
the backward direction. An individual panel cannot be accessed out
of sequence.
[0019] U.S. Pat. Nos. 3,380,210, 3,932,974, 4,184,297, 5107647 and
Canadian Patent 1,066,472 are constructed of aluminum or other
metal components and are used for store fronts, sunrooms,
greenhouses and curtain walls. They all make specialized use of the
mechanical strength of metals. They are not suited for drywall or
for finishing interior walls. These systems do not produce the soft
and warm finish necessary when finishing interior residential and
office space. These systems also are expensive to construct.
[0020] U.S. Pat. No. 6,558,165 B1 discloses a system for holding
wall panels and allowing removal of the panels. It should be noted
that "receiver flanges 24" of the figures receives "outer cap 10".
It also shows in FIG. 1C that there is a gap between wall panel
marked "wp" and "receiver flanges 24". This gap is filled with
calking marked "cc". It becomes time consuming to calk, wait for it
to dry, then sand the wall panels with this system.
[0021] Also, upon removal of the panel, the calking must be removed
and reapplied upon assembly. The calking typically crumbles as it
is removed; creating calking powder and a mess that is required to
be cleaned.
[0022] Therefore, there is a current need for an easy to use,
inexpensive to construct, clean, removable wall assembly.
OBJECTS OF THE INVENTION
[0023] Accordingly, it is an object of the present invention:
[0024] (a) to provide a less complicated wall system for
constructing walls; [0025] (b) to provide an easier to use wall
installation system; [0026] (c) to provide a quicker wall
installation system; [0027] (d) to provide a cleaner wall
installation system; [0028] (e) to provide a more economical wall
installation system; [0029] (f) to provide a wall system which
eliminates the need for wall nails and screws to construct walls;
[0030] (g) to provide a wall system which eliminates the need for
joint compound or spackle in constructing walls; [0031] (h) to
provide a wall system which eliminates the need for traditional
joint tape and corner bead when constructing walls; [0032] (i) to
provide a system which minimizes sanding when constructing walls;
[0033] (j) to provide a wall system which allows easy removal of
each wall panel; [0034] (k) to provide a wall system which allows
easy access to plumbing, HVAC, electric and structural components
behind the wall panels; [0035] (l) to provide to provide a wall
system which allows easier wire, cable and utility installation
after wall completion; [0036] (m) to provide a wall system which
allows for easy inspection and modification behind the walls;
[0037] (n) to provide a wall system which is moisture, mildew and
mold resistant; [0038] (o) to provide a wall system which reduces
post installation maintenance; [0039] (p) to provide a wall system
which allows attachment of removable trim; [0040] (q) to provide a
wall system which allows easy storm proofing of homes and
businesses; [0041] (r) to provide a wall system which allows easy
clean up and repair; [0042] (s) to provide a wall system which
allows a healthier indoor air environment; [0043] (t) to provide a
wall system which allows for quicker, cleaner and easier retail,
office, restaurant and commercial wall modifications; and [0044]
(u) to provide a wall system which is reusable.
SUMMARY OF THE INVENTION
[0045] The present invention may be embodied as a removable
wallboard system for holding a plurality of wall panels to a frame
having a plurality of frame members, the system comprising: [0046]
a) at least one receiver strip 1 having [0047] i. a base strip
capable of being attached to said frame, and [0048] ii. a receiving
channel, and [0049] b) a trim unit having [0050] i. at least one
insertion strip which are sized and shaped to fit inside of and be
removably retained by the receiving channel, and [0051] ii. a flat
top sized and shaped to retain said wall panels between the flat
top and the base strip of the receiver strip.
[0052] The present invention may also be embodied as a method of
constructing removable walls on a frame having a plurality of frame
members comprising the steps of: [0053] a) attaching a receiver
strip having a base strip capable of being attached to said frame
and a receiving channel to at least one frame member, [0054] b)
providing a trim unit having at least one insertion strip which are
sized and shaped to fit inside of, and be removably retained by the
receiving channel, and a flat top, [0055] c) providing wall panels
and placing the wall panels between the receiver strips, [0056] d)
pressing the insertion strip of the trim units into the receiving
channels of the receiver strips to removeably retain said panels
between the trim unit and the receiver strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] While the novel features of the invention are set forth with
particularity in the appended claims, the invention, both as to
organization and content, will be better understood and
appreciated, along with other objects and features thereof, from
the following detailed description taken in conjunction with the
drawing, in which:
[0058] FIG. 1 is a perspective view of a room having walls that
show walls partially installed using the system of the present
invention.
[0059] FIG. 2 is an enlarged cross-sectional view of the major
components of the removable wallboard system according to the
present invention, before attachment of the trim unit.
[0060] FIG. 3 is an enlarged cross-sectional view of the major
components of the removable wallboard system of FIG. 2, after
attachment of the trim unit holding two wall panels in place.
[0061] FIG. 4 is an enlarged cross-sectional view of another
embodiment of the major components of the removable wall system
according to the present invention before attachment of the trim
unit.
[0062] FIG. 5 is an enlarged cross-sectional view of the major
components of the removable wall system of an embodiment according
to the present invention intended to be used with thinner wall
panels.
[0063] FIG. 6 shows a side view of one of the many types of base
molding assemblies and a side view of one of the many types of
crown molding assemblies.
[0064] FIG. 7 shows base molding of a removable wallboard system
according to the present invention prior to attachment.
[0065] FIG. 8 shows an enlarged view of one embodiment of crown
molding according to the present invention.
[0066] FIG. 9 shows another embodiment of base strip of the present
invention used for metal stud framing.
[0067] FIG. 10 shows a construction assembly for one type of many
chair rail moldings.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0068] FIG. 1 is a perspective view of a section of a room having
partially installed walls using the system of the present
invention. A plurality of frame members 8 are installed using a
traditional installation method.
[0069] Multiple receiver strips 1 are attached to support frame
members 8 a specific distance apart. Wall panels 7 are positioned
adjacent to a receiver strip 1 and held in place.
[0070] Trim units 2 are pressed into the receiver strips 1 such
that they secure wall panels 7. Trim units 2 also act to cover the
vertical seams.
[0071] Wall panel 7 is typically made of gypsum, commonly called
drywall. Since this drywall is inexpensive and plentiful, this
system is very cost effective. Other types of panels may also be
used.
[0072] A receiver strip 1 is installed horizontally at floor
height.
[0073] Base molding 16 is pressed into receiver strips 1.
[0074] Similarly, a receiver strip 1 is mounted horizontally at
ceiling level. A crown molding 19 is pressed into receiver strip 1
near the ceiling.
[0075] FIG. 2 is an enlarged cross-sectional view of the major
components of the removable wall system according to the present
invention, before attachment of the trim unit.
[0076] The cross section of trim unit 2 is generally "T" shaped. It
includes a flat top section 1 1 attached to at least one generally
perpendicular insertion strip 10.
[0077] There is also a receiver strip 1 having an elongated base
strip 3 having means to attach the elongated base strip 3 to a
frame member 8. For example, a frame member 8 being formed by
2''.times.4'' or 2''.times.6'' lumber. Frame member 8 may also be
formed with metal studs or any other framed wall assembly.
[0078] Attaching means 9 may include various fasteners, such as
nails, screws and the like, attaching base strip 3 to frame member
8.
[0079] Here it can be seen that a pair of flanges 5 define a
receiving channel 4. Each flange 5 has one or more securing ridges
6.
[0080] Similarly, insertion strips 10 of trim unit 2 have one or
more securing notches 12 positioned and spaced to match the
securing ridges 6. Wall panels 7 are shown here in position prior
to being secured.
[0081] FIG. 3 is an enlarged cross-sectional view of the major
components of the removable wallboard system of FIG. 2, after
attachment of the trim unit 2 holding two wall panels 7 in
place.
[0082] Here it can be seen that the plurality of securing ridges 6
fit into securing notches 12 to tightly hold trim unit 2 to
receiver strip 1. In doing so, it clamps wall panels 7 between base
strip 3 and flat top 11.
[0083] Since trim unit 2 is removeably attached to receiver strip
1, trim unit 2 may be removed to allow wall panel 7 to be removed,
then reattached after wall panel 7 is replaced. It is also shown
how flat top 11 covers the vertical seam between the wall panels 7
without the need of caulking or other process.
[0084] FIG. 4 is an enlarged cross sectional view of another
embodiment of the major components of the removable wall system
according to the present invention designed for use with metal
framing.
[0085] Here metal frame base strip 13 is created to include a slot
20 running the length of metal frame base strip 13. Slot 20 of
metal frame base strip 13 is designed to slide over and receive
metal support frame 8.
[0086] FIG. 5 is an enlarged cross-sectional view of the major
components of the removable wall system of an embodiment according
to the present invention, intended to be used with thinner wall
panels.
[0087] Here two elongated spacers 14 hold the wall panels 7 away
from base strip 3 such that wall panels are pressed securely
against flat top 11 of trim unit 2. This allows securing of thinner
wall panels 7 while allowing full sized insertion strips 10 for
more secure attachment.
[0088] FIG. 6 illustrates an enlarged cross-sectional view of the
top and bottom of a wall assembly according to one embodiment of
the present invention.
[0089] The bottom of FIG. 6 and FIG. 7 show a molding receiver
strip 15 attached to frame members 8 at floor height. Molding
receiver strip 15 has receiving channels 4 defined by flanges 5,
which receive the insertion strips 10 with their securing notches
12 of base molding 16. This secures base molding 16 to receiver
strip 1 such that an upper edge 17 provides vertical support to
wall panel 7.
[0090] Chase ways 18 are created between base molding 16 and
molding receiver strip 15. These allow hoses, pipes, cabling and
wires to run along through the walls. Since base molding 16 is
easily removed and replaced, one can easily run and re-route wiring
through the system of the present invention.
[0091] The top of FIG. 6 shows a receiver strip 1 installed at the
top at ceiling height. Receiver strip 1 includes a receiving
channel 4 defined by flanges 5. The flanges 5 include securing
ridges 6.
[0092] Crown molding 19 includes at least one insertion strip 10
received by receiving channel 4. Crown molding 19 is shaped to
receive wall panel 7 from below and also to support a ceiling panel
22.
[0093] An enlarged view of one embodiment of the crown molding is
shown in FIG. 8.
[0094] FIG. 9 shows another embodiment of the base strip 13 of a
receiver strip 1 according to the present invention used for metal
stud framing.
[0095] FIG. 10 illustrates an enlarged cross-sectional view of one
type of chair rail molding 29. A receiver strip 1 is secured in
place horizontally at the desired height. Chair rail molding 29
having the same color and finish as trim unit 2 is attached to
receiver strip 1. Chair rail molding 29 has insertion strips 10
which snap into the receiving channels 4 of the receiver strip 1.
Chair rail molding 29 can support the center horizontal seam of
drywall wall panels or act solely as decorative trim. Chase ways 18
are created when using chair rail molding 29 as a decorative
trim.
[0096] FIG. 11 shows a cross sectional view of an outside corner
piece as it would appear installed.
[0097] Here, several frame members 8 are shown. These are made of
metal and have an open rectangular shape. An inner support 50 has
an inner arm 52 and another inner arm 54 connected at an inner
junction piece 56 shaped to fit around, and secure to an outside
corner of at least one of the frame members 8. Inner support 50
also includes a pair of flanges 5 which define a receiving channel
4 facing outward from the inner junction piece 56.
[0098] Wall panels 7 are placed against the inner support 56 and
are further secured by inner ridges 54.
[0099] Outer support 60 includes an outer arm 62 and another outer
arm 64 connected at outer junction piece 66. An insertion tab 40
extends inwardly from outer junction piece 66.
[0100] The insertion tab 40 is pressed into and retained by
receiving channel 4 to hold outer support 60 to inner support 50
thereby sandwiching and securing wall panels 7. Inner claws 58 and
outer claws 68 press into and further secure wall boards 7 holding
them in place.
[0101] Since insertion tab 40 may be removed from receiving channel
4, this is system in which wall panels 7 may easily be constructed
and disassembled.
[0102] FIG. 12 shows a cross section of another embodiment of a
base board piece 70 according to the present invention. In this
view the baseboard is sideways with the upper side to the left and
the lower side to the right.
[0103] Here flanges 5 create two receiving channels 4. These
receiving channels are secured to insertion strips which extend
from a receiver strip, such as receiver strip 15 that shown in FIG.
6.
[0104] A recess 72 receives the edge of wall panel 7. A chase way
74 is provided to allow wires, cables, pipes and tubes to run along
the baseboard without being seen.
[0105] FIG. 13 shows an alternative embodiment of a crown molding
constructed as a hollowed piece.
[0106] In this embodiment, crown molding 30 is formed with a hollow
center 32 to save material and reduce weight. It includes an
insertion tab 40 having securing notches 42.
[0107] Even though a crown molding piece was used here for
illustrative purposes, it is understood that any of the larger
pieces may be constructed with a hollow center to reduce cost of
manufacture, and weight.
[0108] While specific embodiments of the invention have been
illustrated and described herein, it is realized that modifications
and changes will occur to those skilled in the art. It is therefore
to be understood that the appended claims are intended to cover all
such modifications and changes as fall within the true spirit and
scope of the invention.
* * * * *