U.S. patent application number 12/162816 was filed with the patent office on 2010-01-28 for modular wall system.
Invention is credited to Kevin P. Kelly.
Application Number | 20100018141 12/162816 |
Document ID | / |
Family ID | 38328020 |
Filed Date | 2010-01-28 |
United States Patent
Application |
20100018141 |
Kind Code |
A1 |
Kelly; Kevin P. |
January 28, 2010 |
MODULAR WALL SYSTEM
Abstract
A modular wall system is provided. The modular wall system
includes a support base, a plurality of horizontal panels, each
having opposite vertical edges, and a plurality of vertical members
secured to the support base. Each of the vertical members has at
least one groove for receiving the opposite vertical edges of the
horizontal panels. A decorative layer is applied on at least the
exterior surfaces of the horizontal panels and the vertical
members.
Inventors: |
Kelly; Kevin P.; (Radnor,
PA) |
Correspondence
Address: |
VOLPE AND KOENIG, P.C.
UNITED PLAZA, SUITE 1600, 30 SOUTH 17TH STREET
PHILADELPHIA
PA
19103
US
|
Family ID: |
38328020 |
Appl. No.: |
12/162816 |
Filed: |
January 31, 2007 |
PCT Filed: |
January 31, 2007 |
PCT NO: |
PCT/US07/02615 |
371 Date: |
September 23, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60763793 |
Jan 31, 2006 |
|
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Current U.S.
Class: |
52/220.7 ;
52/270; 52/783.1 |
Current CPC
Class: |
E04H 17/168
20130101 |
Class at
Publication: |
52/220.7 ;
52/270; 52/783.1 |
International
Class: |
E04B 2/08 20060101
E04B002/08; E04C 2/52 20060101 E04C002/52; E04B 2/02 20060101
E04B002/02 |
Claims
1. A modular wall system comprising: a support base; a plurality of
vertical members secured to said support base, each of said
vertical members defining at least one groove; a plurality of
horizontal panels, each comprising opposite vertical edges that are
recessed in said grooves of said vertical members; and a decorative
layer applied on at least the exterior surfaces of said horizontal
panels and said vertical members; wherein an upper horizontal edge
of each of said horizontal panels comprises an upper horizontal
keyway and a lower horizontal edge of each of said horizontal
panels comprises a lower horizontal key for engagement with a
respective upper horizontal keyway of another of said horizontal
panels in a vertically-stacked configuration, wherein a depth of
said upper horizontal keyways is greater than a height of said
lower horizontal keys, thereby defining, in the vertically stacked
configuration, a horizontal conduit disposed within each of said
horizontal panels.
2. The modular wall system of claim 1, wherein at least one of said
opposite vertical edges of said horizontal panels comprises a
tongue for engagement with said at least one groove of each of said
vertical members.
3. The modular wall system of claim 1, wherein one of said vertical
edges of each of said horizontal panels defines a groove and said
opposite vertical edge of each of said horizontal panels comprises
a tongue for engagement with a respective groove of another of said
horizontal panels in a horizontally-aligned configuration.
4. The modular wall system of claim 3, wherein a depth of said
grooves is greater than a height of said tongues, thereby defining
a vertical conduit disposed within said modular wall system.
5. (canceled)
6. (canceled)
7. The modular wall system of claim 1, wherein each of said
horizontal panels comprises at least one vertical anchor protruding
from a lower horizontal edge thereof, and said support base defines
at least one bore for receiving said at least one vertical
anchor.
8. The modular wall system of claim 3, further comprising a
plurality of horizontal caps covering an upper horizontal edge of
said modular wall system.
9. The modular wall system of claim 8, wherein a lower horizontal
edge of each of said horizontal caps comprises a lower key for
engagement with said upper keyway of an uppermost of said
horizontal panels.
10. The modular wall system of claim 9, wherein a depth of said
upper horizontal keyway is greater than a height of said lower key,
thereby defining a horizontal conduit disposed along a top portion
of said modular wall system.
11. The modular wall system of claim 1, wherein each of said
horizontal panels defines at least one conduit.
12. The modular wall system of claim 1, wherein each of said
vertical members further comprises: a structural vertical member;
and a plurality of pilaster panels covering said structural
vertical member, at least one of said pilaster panels defining a
groove for receiving one of said opposite vertical edges of one of
said horizontal panels.
13. The modular wall system of claim 12, wherein at least one of
said opposite vertical edges of said horizontal panels comprises a
tongue and defines a groove, and at least one pilaster panel on
each of said vertical members comprises a tongue and defines a
groove, each for engaging a respective one of said groove and
tongue of one of said opposite vertical edges of one of said
horizontal panels.
14. The modular wall system of claim 12, further comprising a
plurality of fastener devices that secure said horizontal panels to
said pilaster panels.
15. The modular wall system of claim 14, wherein said fastener
devices are cam-locks.
16. The modular wall system of claim 12, wherein each of said
structural vertical members comprises: a hollow construction; and
at least one bayonet projection projecting upwards from an upper
end of said structural vertical member, said at least one bayonet
configured for engagement with a hollow lower end of another
structural vertical member during a vertically-stacked
configuration of said vertical members, wherein each of said
structural vertical members defines at least one horizontal
aperture in communication with a conduit defined within said
modular wall system.
17. The modular wall system of claim 12, wherein each of said
structural vertical members comprises at least one horizontal
flange at a bottom end thereof, each of said at least one
horizontal flange defining at least one aperture.
18. The modular wall system of claim 17, further comprising: a
plurality of bolts protruding upwardly from said support base, each
of said bolts protruding though a respective one of said apertures
of said horizontal flanges of a lowermost of said structural
vertical members; and at least one adjustment nut threaded onto
each of said bolts, wherein rotation of said at least one
adjustment bolt adjusts the height of said respective structural
vertical member, thereby leveling said modular wall system.
19. The modular wall system of claim 17, further comprising at
least one locking pin protruding upwardly from each of said
pilaster panels, through a respective aperture of said horizontal
flanges of said structural vertical members, and into a respective
pilaster panel, during a vertically-stacked configuration of said
vertical members.
20. The modular wall system of claim 16, further comprising a
plurality of pilaster caps covering an upper end of each of said
vertical members.
21. The modular wall system of claim 20, further comprising at
least one locking pin protruding upwardly from each of said
pilaster panels and into a respective pilaster cap.
22. The modular wall system of claim 20, wherein a lower horizontal
surface of each of said pilaster caps comprises an indentation for
engagement with said bayonet projection of an uppermost of said
structural vertical members.
23. The modular wall system of claim 1, wherein each of said
horizontal panels comprises a closed cell foam panel sandwiched
between two laminate skins.
24. The modular wall system of claim 23, wherein an exterior
surface of said laminate skins is textured.
25. The modular wall system of claim 24, wherein said laminate
skins are moisture resistant.
26. The modular wall system of claim 25, wherein said decorative
layer comprises a film layer laminated on said moisture-resistant
laminate skins.
27. The modular wall system of claim 16, wherein each of said
pilaster panels comprises a closed cell foam panel sandwiched
between two laminate skins.
28. The modular wall system of claim 27, wherein an exterior
surface of said laminate skins is textured.
29. The modular wall system of claim 28, wherein said laminate
skins are moisture resistant.
30. The modular wall system of claim 29, wherein said decorative
layer comprises a film layer laminated on said moisture-resistant
laminate skins.
31. The modular wall system of claim 1, wherein said decorative
layer comprises a film layer laminated on said exterior surfaces of
said horizontal panels and said vertical members.
32. The modular wall system of claim 1, wherein said decorative
layer is bonded directly to said exterior surfaces of said
horizontal panels and said vertical members.
33. The modular wall system of claim 1, wherein said decorative
layer comprises an image of rock, stone, brick, concrete, concrete
block, stucco, terracotta, wood, or metal.
34. A modular wall system comprising: a plurality of support bases
set at predetermined distances from each other; a plurality of
vertical members, each secured to a respective one of said support
bases having at least one vertical groove; a plurality of
horizontal panels, each having an exterior surface that spans the
distance between two vertical members and opposite vertical
projections that extend beyond the exterior surface and are
dimensioned to be received in a respective vertical groove; and a
decorative layer affixed on said exterior surfaces of said
horizontal panels and said vertical members; wherein the plurality
of horizontal panels have a keyway extending along a substantial
upper horizontal length thereof and a key extending along a
substantially lower length thereof, the key and keyway being sized
to matingly engage one another; wherein when the key and keyway are
matingly engaged to one another, the key is sized such that it does
not fill the entire depth of the keyway, thus creating a horizontal
conduit through each horizontal joint between panels.
35. The modular wall system of claim 34, wherein each of said
horizontal panels comprises a closed cell foam panel.
36-38. (canceled)
Description
BACKGROUND
[0001] Conventional concrete-like barriers such as those used for
fencing or privacy-walls as part of a landscaping scheme are
typically composed of pre-cast concrete, hand-laid concrete block,
or hand-laid or poured concrete. Such walls often have exterior
surfaces comprised of stone, aggregate, brick, stucco, rock,
marble, or other natural materials. The labor and expense of
building and maintaining these conventional concrete-like barriers
is considerable. Further to the considerable expense, the physical
properties of such barriers (e.g., their substantial weight) make
them virtually "permanent" structures.
[0002] Accordingly, there remains a need for an improved fencing or
privacy-wall system with a natural-looking facade that is easy to
install and maintain, versatile (e.g., the material appearance can
be easily changed, as desired), and cost effective.
SUMMARY
[0003] The present invention provides a modular wall system
including a support base, a plurality of horizontal panels, each
having opposite vertical edges, and a plurality of vertical members
secured to the support base. Each of the vertical members has at
least one groove for receiving opposite vertical edges of the
horizontal panels. A decorative layer is applied on at least the
exterior surfaces of the horizontal panels and the vertical
members.
[0004] The present invention also provides a method of constructing
a modular wall system. A concrete footing is poured and a plurality
of bolts is set within the concrete footing. At least two
structural vertical members are secured to the concrete footing via
the bolts. The structural vertical members are covered with a
plurality of pilaster panels, thereby forming at least two vertical
members. Opposite edges of at least one horizontal panel are
interlocked with respective grooves of pilaster panels of adjacent
vertical members.
BRIEF DESCRIPTION OF THE DRAWING(S)
[0005] FIG. 1 is a perspective view of a modular wall section in
accordance with the present invention;
[0006] FIG. 2 is a front elevation of a modular wall section in
accordance with the present invention;
[0007] FIG. 3 is an end elevation of a horizontal panel of the
modular wall system showing a tongue and a component of an
off-center fastening device in accordance with the present
invention;
[0008] FIG. 4 is a plan section view of the horizontal panel of
FIG. 3;
[0009] FIG. 5 is an end elevation of a horizontal panel of the
modular wall system showing a tongue, a groove, and a component of
a centered fastening device in accordance with the present
invention;
[0010] FIG. 6 is a plan section view of the horizontal panel of
FIG. 5;
[0011] FIG. 7 is a section view of a horizontal panel of the
modular wall system showing a squared keyway and a key in
accordance with the present invention;
[0012] FIG. 8 is a section view of a horizontal cap for covering an
upper edge of the modular wall system as represented in phantom in
FIG. 7;
[0013] FIG. 9 is a section view of a horizontal panel of the
modular wall system showing a rounded keyway and a key in
accordance with the present invention;
[0014] FIG. 10 is a section view of a horizontal cap for covering
an upper edge of the modular wall system as represented in phantom
in FIG. 9;
[0015] FIG. 11 is a section view of a vertical member of the
modular wall system mounted to a support base and showing a
structural vertical member covered by pilaster panels in accordance
with the present invention;
[0016] FIG. 12 is a section view of an alternative installation
method of the vertical member of FIG. 11;
[0017] FIG. 13 is a side elevation of a structural vertical member
of the vertical member of FIG. 11 showing a bayonet projection at
an upper end thereof and horizontal flanges at a bottom end
thereof;
[0018] FIG. 14 is a plan view of the structural vertical member of
FIG. 13;
[0019] FIG. 15 is a side elevation of a structural vertical member
of the vertical member of FIG. 12 showing two bayonet projections
at an upper end thereof and horizontal flanges at a bottom end
thereof;
[0020] FIG. 16 is an end plan view of the structural vertical
member of FIG. 15;
[0021] FIG. 17 is a plan view of the structural vertical member of
FIG. 16;
[0022] FIG. 18 is a partial end elevation of the pilaster panels of
FIG. 11 with a horizontal panel removed for the sake of
clarity;
[0023] FIG. 19 is a section view of a pilaster cap for covering an
upper edge of the vertical member of FIG. 11;
[0024] FIG. 20 is a partial end elevation of the pilaster panels of
FIG. 12 with a horizontal panel removed for the sake of
clarity;
[0025] FIG. 21 is a section view of a pilaster cap for covering an
upper edge of the vertical member of FIG. 12;
[0026] FIG. 22 is a plan section view of the vertical member of
FIG. 11 at a mid-section of the modular wall system in accordance
with the present invention;
[0027] FIG. 23 is a plan section view of the vertical member of
FIG. 11 at an end-section of the modular wall system in accordance
with the present invention;
[0028] FIG. 24 is a plan section view of the vertical member of
FIG. 11 at a corner-section of the modular wall system in
accordance with the present invention;
[0029] FIG. 25 is a plan section view of the vertical member of
FIG. 12 at a mid-section of the modular wall system in accordance
with the present invention;
[0030] FIG. 26 is a detail section view of an attachment of the
vertical members of FIGS. 11 and 12 to their respective support
bases;
[0031] FIG. 27 is a detail section view of a locking pin for use in
a vertically-stacked configuration of the vertical member of FIG.
11; and
[0032] FIG. 28 is a detail section view of a locking pin for use in
a vertically-stacked configuration of the vertical member of FIG.
12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0033] Certain terminology is used in the following description for
convenience only and is not considered limiting. Words such as
"front," "back," "top," and "bottom" designate directions in the
drawings to which reference is made. This terminology includes the
words specifically noted above, derivatives thereof, and words of
similar import. Additionally, the terms "a" and "one" are defined
as including one or more of the referenced item unless specifically
noted. The phrase "at least one of" followed by a list of two or
more items, such as A, B, or C, means any individual one of A, B,
or C, as well as any combination thereof.
[0034] Referring generally to FIGS. 1-28, the modular wall system
10 includes a support base 12, a plurality of horizontal panels 14,
each having opposite vertical edges 16A, 16B, and a plurality of
vertical members 18 secured to the support base 12. Each of the
vertical members 18 has at least one groove 20 for receiving the
opposite vertical edges 16A, 16B of the horizontal panels 14. A
decorative layer 22 is affixed on the exterior surfaces 24 of the
horizontal panels 14 and the vertical members 18.
[0035] FIG. 1 illustrates, among other things, the stackability of
the horizontal panels 14, as will be discussed in greater detail
below. FIG. 2 represents a modular wall system relative to ground
level G.
[0036] As shown in FIGS. 3 and 4, at least one of the opposite
vertical edges 16A, 16B of the horizontal panels 14 may include a
tongue 26 for engagement with the groove 20 (detailed in FIG. 18)
of each of the vertical members 18. Similarly, and as shown in
FIGS. 5 and 6, at least one of the opposite vertical edges 16A, 16B
of the horizontal panels 14 includes a tongue 26 and defines a
groove 28 for engagement with the groove 20 and a tongue 28
(detailed in FIG. 20) of each of the vertical members 18. FIGS. 3-6
further illustrate a fastening device 30A, 30B to help secure
components together.
[0037] Furthermore, one of the vertical edges 16A of each of the
horizontal panels 14 may define a groove 28 and the opposite
vertical edge 16B of each of the horizontal panels 14 may include a
tongue 26 for engagement with a respective groove 28 of another of
the horizontal panels 14 in a horizontally-aligned configuration. A
variety of interlocking configurations may be utilized to engage
the ends 16A, 16B of the horizontal panels to the vertical members
18, and also to engage the ends 16A, 16B of the horizontal panels
14 to each other. A vertical cover may be used to cover the seam
between two interlocking horizontal panels 14. Such vertical covers
give the modular wall system 10 a finished appearance, and
typically comprise a version of what is referred to herein
(described below with reference to FIGS. 11 and 12) as closed cell
foam pilaster panels. Alternatively, such vertical covers may be
made from "synthetic lumber" materials, i.e., ground, colored,
mixed, and recycled thermoplastic materials molded, extruded, or
machined into desired shapes.
[0038] A depth of the grooves 28 of the vertical edges 16A may be
greater than a height of the tongues 26 of the vertical edges 16B,
thereby defining a vertical conduit (not shown) disposed within the
modular wall system 10. Such conduits may contain electric, fiber
optic, television cable, phone, water, air, gas, or other utility
lines to feed a variety of appliance features, as desired. For
example, lights mounted on the top of the modular wall system or at
the base of the modular wall system may be energized by fiber optic
lines run throughout conduits within the modular wall system
10.
[0039] An upper horizontal edge 32 of each of the horizontal panels
14 defines an upper horizontal keyway 34. A lower horizontal edge
36 of each of the horizontal panels 14 includes a lower horizontal
key 38 for engagement with a respective upper horizontal keyway 34
of another of the horizontal panels 14 in a vertically-stacked
configuration. The depth of the upper horizontal keyways 34 is
greater than the height of the lower horizontal keys 38, thereby
defining a horizontal conduit (not shown) disposed within each of
the horizontal panels 14. The function of such conduits is the same
as that of the above-described vertical conduits. The inside
surface of the keyway may be square (FIGS. 3 and 7), rounded (FIGS.
5 and 9), or any other shape that will result in a suitable void to
define the conduit.
[0040] The support base 12 is constructed like conventional
footings, typically from conventional concrete materials. Each of
the horizontal panels 14 may include vertical anchors (not shown)
protruding from a lower horizontal edge 40 thereof and the support
base 12 defines bores (not shown) for receiving the respective
vertical anchors. Such vertical anchors may be molded into the
horizontal panels 14 during manufacturing of the horizontal panels
14, or they may be installed during construction of the modular
wall system 10.
[0041] The modular wall system 10 further includes horizontal caps
42 covering an upper horizontal edge 44 of the modular wall system
10, as shown in FIG. 2. FIGS. 5 and 7-10 illustrate that a lower
horizontal edge 46 of each of the horizontal caps 42 has a lower
key 48 for engagement with the upper keyway 34 of an uppermost of
the horizontal panels 14. Such horizontal caps 42 give the modular
wall system 10 a finished appearance, and are typically made from
"synthetic lumber" materials, i.e., ground, colored, mixed, and
recycled thermoplastic materials molded, extruded, or machined into
desired shapes. Such horizontal caps 42 may also be thermoformed or
vacuum formed from thermoplastic materials.
[0042] The depth of the upper horizontal keyway 34 of the modular
wall system 10 is greater than the height of the lower key 48 of
the horizontal cap 42, thereby defining a horizontal conduit 50
disposed along a top portion 44 of the modular wall system 10. The
function of such conduits 50 is the same as that of the
above-described vertical conduits.
[0043] Referring to FIGS. 11 and 12, the vertical members 18 are
typically constructed from a structural vertical member 52 and
pilaster panels 54 covering the structural vertical member 52. At
least one of the pilaster panels 54 may define a groove 28 for
receiving one of the opposite vertical edges 16A, 16B of one of the
horizontal panels 14, as described with reference to FIGS. 3 and 4.
Similarly, at least one pilaster panel 54 on each of the vertical
members 18 may have a tongue 20 and define a groove 28, each for
engaging a respective one of the groove 28 and tongue 20 of one of
the opposite vertical edges 16A, 16B of one of the horizontal
panels 14, as described above with respect to FIGS. 5 and 6. As
described above, a variety of interlocking configurations may be
utilized to engage the ends of the horizontal panels 14 to the
vertical members 18.
[0044] Further to a variety of interlocking configurations, the
modular wall system 10 may also include fastener devices 30A, 30B
that secure the horizontal panels 14 to the pilaster panels 54,
and/or to secure the horizontal panels 14 to each other. The
fastener devices 30A, 30B represented in the figures are
"twist-lock" fasteners or cam-locks, but the present invention may
include any fastening device that achieves the desired securing
feature.
[0045] As shown in FIGS. 14 and 17, the structural vertical members
52 are hollow. FIGS. 11, 13, and 14 illustrate one bayonet
projection 56A projecting upwards from the upper end 58 of the
structural vertical member, and FIGS. 12 and 15-17 illustrate two
bayonet projections 56B (one is hidden in FIGS. 12 and 16)
projecting upwards from the upper end 58 of the structural vertical
member 52. The bayonets 56A, 56B are configured for engagement with
the hollow lower end 60 of another structural vertical member 52
during a vertically-stacked configuration of the vertical members
18, as shown in FIGS. 11 and 12. The present invention may include
any number of bayonet projections or similar type of projection(s)
suitable to support a vertically-stacked configuration.
[0046] The structural vertical members 52 may define a horizontal
aperture 62 in communication with a conduit 50 defined within the
modular wall system 10, as previously described. More specifically,
utility lines may extend axially through the hollow structural
vertical members 52, through the horizontal aperture 62, and
through a conduit 50 or any of the other conduits described above
to feed a variety of appliance features mounted on or near the
modular wall system 10, as desired. Although shown toward the upper
end 58 of the structural vertical member 52 in FIGS. 11, 12, 13,
and 15, the location of the horizontal aperture 62 may be anywhere
along the height of the structural vertical member 52 to
accommodate a variety of conduit configurations. Similarly, a
structural vertical member 52 may define more than one horizontal
aperture 62 in communication with a variety of conduits, as
desired.
[0047] FIGS. 13-17 show that each of the structural vertical
members 52 includes horizontal flanges 64A, 64B (four in FIGS. 11,
13, and 14, and two in FIGS. 12 and 15-17) at the bottom end 60
thereof. The horizontal flanges 64A, 64B include apertures or holes
66. Bolts 68 protrude upwardly from the support base 12, as
represented in FIGS. 11 and 12. Each of the bolts 68 protrudes
though a respective one of the holes 66 of the horizontal flanges
64A, 64B of the lowermost structural vertical members 52.
Adjustment nuts 70 are threaded onto each of the bolts 68, wherein
rotation of the adjustment bolts 70 adjusts the height of the
respective structural vertical member 52, thereby leveling the
modular wall system 10. In other words, rotation of the adjustment
bolts 70 causes the respective flanges 64A, 64B to travel up and
down the bolts 68 which are secured to the support base 12. The
flanges 64A, 64B are part of the structural vertical members 52.
Thus, the structural vertical support members 52 move in
conjunction with the flanges 64A, 64B, and the interconnected
pilaster panels 54 and horizontal panels 14 move accordingly. This
feature enables proper leveling of the modular wall system 10. A
detail view of the attachment configuration is shown in FIG.
26.
[0048] Referring to FIGS. 18 and 20, locking pins 72A, 72B may
protrude upwardly from each of the pilaster panels 54, through a
respective hole 66 of the horizontal flanges 64A, 64B of the
structural vertical members 54, and into a respective pilaster
panel 54, during a vertically-stacked configuration of the vertical
members, as shown in FIGS. 11 and 12. Detail views of the locking
pins 72A, 72B are shown in FIGS. 27 and 28, respectively.
[0049] The modular wall system 10 further includes pilaster caps
74A, 74B (detailed in FIGS. 19 and 21) covering an upper end 58 of
each of the vertical members 18, as shown in FIG. 1. The locking
pins 72A, 72B may protrude upwardly from each of the pilaster
panels 54 and into a respective pilaster cap 74A, 74B. A lower
horizontal surface 76 of each of the pilaster caps 74A, 74B
comprises an indentation 78 for engagement with the bayonet
projection(s) 56A, 56B of the structural vertical members 52. The
pilaster cap 74A of FIG. 19 is configured to cover the vertical
support 18 of FIG. 11, and the pilaster cap 74B of FIG. 21 is
configured to cover the vertical support 18 of FIG. 12. Similar to
the above-described horizontal caps 42, such pilaster caps 74A, 74B
give the modular wall system 10 a finished appearance, and are
typically made from "synthetic lumber" materials, i.e., ground,
colored, mixed, and recycled thermoplastic materials molded or
machined into desired shapes. Such pilaster caps 74A, 74B may also
be thermoformed or vacuum formed from thermoplastic materials.
[0050] The vertical members 18 may be configured in a variety of
arrangements to accommodate different wall configurations. For
example, the vertical member 18A represented in FIGS. 22 and 25
accommodates a straight connection between two horizontal panels 14
of a modular wall system 10. More specifically, the shapes of the
pilaster panels 54 in this straight arrangement engage the tongue
26 (FIGS. 3, 4, and 22) or tongue 26 and groove 28 (FIGS. 5, 6, and
25) of horizontal panels 14 horizontally aligned in a straight
configuration, as shown in FIGS. 1 and 2.
[0051] Similarly, the vertical member 18B represented in FIG. 23
accommodates an end of a modular wall system 10. More specifically,
the shape of the pilaster panel 54 in this end arrangement engages
the tongue 26 of the horizontal panel 14 of FIGS. 3 and 4. An
alternate shaped pilaster panel 54 (not shown) in this end
arrangement could engage the tongue 26 and groove 28 of the
horizontal panel 14 of FIGS. 5 and 6.
[0052] Alternatively, the vertical member 18C represented in FIG.
24 accommodates a corner of a modular wall system 10. More
specifically, the shape of the pilaster panel 54 in this corner
arrangement engages the tongue 26 of the horizontal panel 14 of
FIGS. 3 and 4. An alternate shaped pilaster panel 54 (not shown) in
this corner arrangement could engage the tongue 26 and groove 28 of
the horizontal panel 14 of FIGS. 5 and 6. The present invention is
not limited to a corner vertical member 18C with an angle of
90.degree. as represented in FIG. 24, and may include corner
vertical members comprising a variety of angles to suit a variety
of modular wall system 10 configurations.
[0053] Similarly, the present invention is not limited to flat
horizontal panels 14, and may include rounded horizontal panels
comprising a variety of curvatures to suit a variety of modular
wall system 10 configurations.
[0054] The horizontal panels 14 and the pilaster panels 54 are
constructed from a closed cell foam panel 80 sandwiched between two
moisture-resistant laminate skins 82. For the sake of clarity,
these features are labeled in FIG. 7 only. In addition to the
conduits 50 defined between mating components (as described above),
the horizontal panels 14 may define conduits molded therein. The
closed cell foam 80 provides sound absorption and thermal
insulation, as desired. The moisture-resistant laminate skins 82
are typically textured and composed of a rigid polymer vinyl film
such as polyvinyl chloride (PVC) with a thickness of about
0.010-inch to 0.050-inch such as PENTALAN SF M 254/04. The PVC film
is an ultra-violet-enhanced material specially formulated for
outdoor use.
[0055] The decorative layer 22 may be a film layer laminated on the
moisture-resistant laminate skins 82 with an adhesive system such
as, for example, adhesives made by Bostik. Alternatively, the
decorative layer 22 may be bonded directly to the exterior surfaces
24 of the horizontal panels 14 and the vertical members 18.
[0056] The decorative layer 22 may be an image of rock, stone,
brick, concrete, concrete block, stucco, terracotta, wood, metal,
or other natural or synthetic materials and finishes. The laminated
decorative layer 22 may be replaced or changed to an alternate
image resulting in a completely new appearance for an existing
modular wall system 10. Similarly, a modular wall system 10 in
accordance with the present invention may have different decorative
layers 22 resulting in a stone-looking exterior and a brick-looking
interior.
[0057] The laminated layer 22 is typically composed of an acrylic
outer film with a thickness of about 0.002-inch to 0.020-inch that
is reverse-side printed such as Solarkote.RTM., Kynar.RTM., or
Korad.RTM. acrylic film, but may be composed of any digital imaging
material in any thickness suitable for achieving the
above-described functions.
[0058] The horizontal wall panels 14 are typically 2-feet high, 6
to 8-feet long, and 4 to 6-inches thick for ease of handling. As
described above, the horizontal panels 14 may be vertically stacked
to increase the overall height of the modular wall system 10. The
present invention is not limited to these dimensions, however, and
the horizontal panels 14 may range from 4-feet, 6-feet, or 8-feet
high, 4-feet long, and 8-inches thick or any other dimensions as
desired for a particular application. For example, a desirable
configuration for a garden wall may be 2-feet high, while one for a
property wall or security divider may be 6-feet high.
[0059] The modular wall system 10 may also include doors, as
desired. The construction and properties of the doors is virtually
identical as those described above with respect to the horizontal
panels 14, with a difference in the hardware required for hinging
and securing a door that opens and closes within a wall structure.
It may be desirable for a door to include a decorative layer 22
different from that of the surrounding wall. When a door interrupts
a conduit passage, the conduit may extend underground below the
door opening.
[0060] The modular wall system 10 of the present invention is
lightweight, easy to install and maintain, versatile (e.g., the
material appearance can be easily changed, as desired), and cost
effective. The configuration of the modular wall system 10 can be
adapted to suit specific needs, i.e., different heights and lengths
of various wall sections are easily achieved, as well as the shapes
of the various wall sections (straight walls, angled corners,
curved walls, etc.).
[0061] While the preferred embodiments of the invention have been
described in detail above, the invention is not limited to the
specific embodiments described which should be considered as merely
exemplary. Further modifications and extensions of the present
invention may be developed and all such modifications are deemed to
be within the scope of the present invention as defined by the
appended claims.
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