U.S. patent application number 13/489623 was filed with the patent office on 2013-12-12 for wall panel system.
This patent application is currently assigned to MARLITE, INC.. The applicant listed for this patent is Kevin Krieger. Invention is credited to Kevin Krieger.
Application Number | 20130326987 13/489623 |
Document ID | / |
Family ID | 49518560 |
Filed Date | 2013-12-12 |
United States Patent
Application |
20130326987 |
Kind Code |
A1 |
Krieger; Kevin |
December 12, 2013 |
WALL PANEL SYSTEM
Abstract
A wall panel system that includes a plurality of rails
positioned substantially parallel to each other, a plurality of
panels wherein each panel extends between two adjacent rails, and a
cross spline is positioned between each pair of panels and
extending substantially perpendicular to adjacent rails is
provided. The rails are attachable to a wall support structure. The
rails receive the panels and maintain the panels in a spaced-apart
relationship. Each panel includes a peripheral edge having a groove
formed into the peripheral edge such that the groove is continuous
and extends about the entire peripheral edge of the panel. Both the
rails and the cross spline include a tongue that is insertable into
the groove of each panel to allow the rails and cross splines to be
in engagement with the panels.
Inventors: |
Krieger; Kevin; (New
Philadelphia, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Krieger; Kevin |
New Philadelphia |
OH |
US |
|
|
Assignee: |
MARLITE, INC.
Dover
OH
|
Family ID: |
49518560 |
Appl. No.: |
13/489623 |
Filed: |
June 6, 2012 |
Current U.S.
Class: |
52/483.1 ;
52/588.1 |
Current CPC
Class: |
E04F 13/0826
20130101 |
Class at
Publication: |
52/483.1 ;
52/588.1 |
International
Class: |
E04B 2/32 20060101
E04B002/32; E04B 2/02 20060101 E04B002/02 |
Claims
1. A wall panel system comprising: at least two rails, wherein said
rails are aligned in a substantially parallel manner; at least two
panels, wherein each of said panels includes a front surface, a
rear surface, a peripheral edge extending between said front and
rear surfaces, each of said at least two panels being positioned
adjacent to another panel, and each of said at least two panels
extending between two of said at least two rails that are
positioned adjacent to each other; and at least one cross spline,
wherein each cross spline is positioned between a pair of adjacent
panels, said cross spline being oriented in a substantially normal
manner relative to said adjacent rails; wherein each panel includes
a continuous groove formed into said peripheral edge of said panel,
and wherein said adjacent rails and at least one cross spline
engage said groove.
2. The wall panel system of claim 1, wherein said peripheral edge
includes a pair of opposing horizontal edges and a pair of opposing
vertical edges, and said continuous groove is formed into each of
said horizontal edges and each of said vertical edges.
3. The wall panel system of claim 1, wherein at least one rail
includes a tongue that is receivable within said groove said
adjacent panels.
4. The wall panel system of claim 3, wherein said tongue includes a
first securing member and an opposing second securing member, at
least one of said first securing member and said second securing
member is receivable within said groove of both of said adjacent
panels.
5. The wall panel system of claim 3, wherein said tongue is
non-linear.
6. The wall panel system of claim 1, wherein said cross spline
includes a decorative member positioned between adjacent
panels.
7. The wall panel system of claim 1, wherein each of said at least
two rails includes a base, a buffer extending from one distal end
of said base, an arm extending from an opposing distal end of said
base, said arm extending from said base at an angle
therebetween.
8. The wall panel system of claim 7, wherein said arm includes a
support member, a tongue, and a decorative member, said tongue
being disposed between said support member and said decorative
member, and said support member being disposed adjacent to said
base.
9. A wall panel system comprising: a plurality of panels positioned
adjacent to each other, wherein each of said plurality of panels
includes a peripheral edge and a continuous groove formed into the
entire peripheral edge; a first rail operatively connected to a
wall support structure, wherein at least a portion of said first
rail is receivable within said groove of at least two panels
positioned adjacent to each other; a second rail operatively
connected to said wall support structure and spaced apart from said
first rail in a substantially parallel manner, wherein at least a
portion of said second rail is receivable in said groove of said
adjacent panels; and a cross spline oriented substantially
perpendicular to said first and second rails, wherein at least a
portion of said cross spline is receivable within said groove of
said adjacent panels.
10. The wall panel system of claim 9, wherein at least one of said
first rail and said second rail includes a buffer that contacts a
rear surface of each panel, wherein contact with said buffer spaces
each of said panels away from said wall support structure.
11. The wall panel system of claim 9, wherein at least one of said
first rail and said second rail includes a base having a buffer
extending from a distal end of said base and an arm extending from
an opposing distal end of said base, said arm including a support
member and a tongue extending therefrom.
12. The wall panel system of claim 11, wherein said arm further
including a decorative member extending therefrom.
13. The wall panel system of claim 11, wherein said tongue is
non-linear.
14. The wall panel system of claim 9, wherein said plurality of
panels are arranged in at least one horizontally-aligned row.
15. A wall panel system comprising: a first panel having a core, a
front surface attached to said core, a rear surface attached to
said core, and a peripheral edge extending between said front and
rear surfaces, wherein a continuous groove is formed into said
peripheral edge; a second panel positioned adjacent to said first
panel, said second panel having a core, a front surface attached to
said core, a rear surface attached to said core, and a peripheral
edge extending between said front and rear surfaces, wherein a
continuous groove is formed into said peripheral edge; a first rail
engaging said groove formed into said first panel and said groove
formed into said second panel; a second rail positioned adjacent to
said first rail, wherein said first and second panels extend
between said first rail and said second rail, and said second rail
engages said groove formed into said first panel and said groove
formed into said second panel; and a cross spline positioned
between said first panel and said second panel, wherein said cross
spline engages said groove formed into said first panel and said
groove formed into said second panel.
16. The wall panel system of claim 15, wherein said cross spline is
oriented substantially perpendicular to said first rail and said
second rail.
17. The wall panel system of claim 15, wherein said first rail
includes a first tongue receivable within said groove of said first
panel and said groove of said second panel, said second rail
includes a second tongue receivable within said groove of said
first panel and said groove of said second panel, and said cross
spline includes a third tongue receivable within said groove of
said first panel and said groove of said second panel.
18. The wall panel system of claim 17, wherein said first rail
further includes a first decorative member, said second rail
further includes a second decorative member, and said cross spline
further includes a third decorative member.
19. The wall panel system of claim 17, wherein none of said first
rail, said second rail, or said third rail further includes a
decorative member.
20. The wall panel system of claim 15, wherein said first rail and
said second rail are oriented in a substantially horizontal
direction, and said cross spline is oriented in a substantially
vertical direction.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to wall construction and, more
particularly, to a wall system formed of an array of pre-finished
panels held together in a modular system for creating a decorated
or finished wall.
BACKGROUND OF THE INVENTION
[0002] It is well known to construct a wall surface for a room or
other structure with a plurality of pre-fabricated panels that are
positioned in rows and columns to cover the structure. Such
constructions use decorative panels that typically include a wood
or other type of decorative veneer with a solid core. In these wall
systems, a plurality of rails are often attached to a wall to
provide support for the system as well as a guide for the panels
that attach to these rails. Typically, a plurality of brackets are
attached to the rear surface of the panel by way of a mechanical
fixing means such as a bolt or the like. Each bracket provides a
gap between the bracket and the wall panel, wherein this gap is
configured to receive the rail. The plurality of brackets are
arranged such that they engage both an upper and lower rail. A
plurality of panels are then arranged in an adjacent manner along
each pair of rails to form a row of panels; and a plurality of
rails are vertically spaced apart to create multiple rows of
panels. A transverse aesthetic member is disposed between each pair
of panels to separate the panels, and these transverse members can
be aligned such that the panels are aligned in both rows and
columns against the structure.
BRIEF SUMMARY OF THE INVENTION
[0003] In one aspect of the present invention, a wall panel system
is provided. The wall panel system includes at least two rails,
wherein the rails are aligned in a substantially parallel manner.
The wall panel system also includes at least two panels, wherein
each of the panels includes a front surface, a rear surface, a
peripheral edge extending between the front and rear surfaces. Each
of the two panels is positioned adjacent to another panel, and each
of the panels extends between two rails that are positioned
adjacent to each other. The wall panel system further includes at
least one cross spline, wherein each cross spline is positioned
between adjacent panels. The cross spline is oriented in a
substantially normal manner relative to the adjacent rails. Each
panel includes a continuous groove formed into the peripheral edge
of the panel. The adjacent rails and the cross spline engage the
groove.
[0004] In another aspect of the preset invention, a wall panel
system is provided. The wall panel system includes a plurality of
panels positioned adjacent to each other, wherein each of the
panels includes a peripheral edge and a continuous groove formed
into the entire peripheral edge. The wall panel system also
includes a first rail operatively connected to a wall support
structure, wherein at least a portion of the first rail is
receivable within the groove of at least two panels positioned
adjacent to each other. The wall panel system further includes a
second rail operatively connected to the wall support structure and
spaced apart from the first rail in a substantially parallel
manner, wherein at least a portion of the second rail is receivable
in the groove of the adjacent panels. The wall panel system also
includes a cross spline oriented substantially perpendicular to the
first and second rails, wherein at least a portion of the cross
spline is receivable within the groove of the adjacent panels.
[0005] In yet another aspect of the present invention, a wall panel
system is provided. The wall panel system includes a first panel
having a core, a front surface attached to the core, a rear surface
attached to the core, and a peripheral edge extending between the
front and rear surfaces, wherein a continuous groove is formed into
the peripheral edge. The wall panel system also includes a second
panel positioned adjacent to the first panel. The second panel has
a core, a front surface attached to the core, a rear surface
attached to the core, and a peripheral edge extending between the
front and rear surfaces, wherein a continuous groove is formed into
the peripheral edge. A first rail engages the groove formed into
the first panel and the groove formed into the second panel. A
second rail is positioned adjacent to the first rail, wherein the
first and second panels extend between the first rail and the
second rail, and the second rail engages the groove formed into the
first panel and the groove formed into the second panel. A cross
spline is positioned between the first panel and the second panel,
wherein the cross spline engages the groove formed into the first
panel and the groove formed into the second panel.
[0006] Advantages of the present invention will become more
apparent to those skilled in the art from the following description
of the embodiments of the invention which have been shown and
described by way of illustration. As will be realized, the
invention is capable of other and different embodiments, and its
details are capable of modification in various respects.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0007] These and other features of the present invention, and their
advantages, are illustrated specifically in embodiments of the
invention now to be described, by way of example, with reference to
the accompanying diagrammatic drawings, in which:
[0008] FIG. 1 is a perspective view of an embodiment of a wall
panel system;
[0009] FIG. 2A is a magnified cross-sectional view of a portion of
the wall panel system shown in FIG. 1;
[0010] FIG. 2B is a magnified cross-sectional view of a portion of
the wall panel system shown in FIG. 1;
[0011] FIG. 3A is a plan view of a panel;
[0012] FIG. 3B is a side view of the panel shown in FIG. 3A;
[0013] FIG. 4A is a perspective view of an embodiment of an edge
rail;
[0014] FIG. 4B is a cross-sectional view of the edge rail shown in
FIG. 4A;
[0015] FIG. 5A is a perspective view of the rail shown in FIG.
1;
[0016] FIG. 5B is a cross-sectional view of the rail shown in FIG.
5A;
[0017] FIG. 5C is a perspective view of the cross spline shown in
FIG. 1;
[0018] FIG. 5D is a cross-sectional view of the cross spline shown
in FIG. 5C;
[0019] FIG. 6A is another embodiment of a wall panel system;
[0020] FIG. 6B is a perspective view of the rail shown in FIG.
6A;
[0021] FIG. 6C is a cross-sectional view of the rail shown in FIG.
6B;
[0022] FIG. 6D is a perspective view of the cross spline shown in
FIG. 6A;
[0023] FIG. 6E is a cross-sectional view of the cross spline shown
in FIG. 6D;
[0024] FIG. 7A is yet another embodiment of a wall panel
system;
[0025] FIG. 7B is a perspective view of the rail shown in FIG.
7A;
[0026] FIG. 7C is a cross-sectional view of the rail shown in FIG.
7B;
[0027] FIG. 7D is a perspective view of the cross spline shown in
FIG. 7A;
[0028] FIG. 7E is a cross-sectional view of the cross spline shown
in FIG. 7D;
[0029] FIG. 8A is a further embodiment of a wall panel system;
[0030] FIG. 8B is a perspective view of the rail shown in FIG.
8A;
[0031] FIG. 8C is a cross-sectional view of the rail shown in FIG.
8B;
[0032] FIG. 8D is a perspective view of the cross spline shown in
FIG. 8A;
[0033] FIG. 8E is a cross-sectional view of the cross spline shown
in FIG. 8D;
[0034] FIG. 9A is an embodiment of a corner rail;
[0035] FIG. 9B is the corner rail shown in FIG. 9A operatively
connected to adjacent wall support structures.
[0036] It should be noted that all the drawings are diagrammatic
and not drawn to scale. Relative dimensions and proportions of
parts of these figures have been shown exaggerated or reduced in
size for the sake of clarity and convenience in the drawings. The
same reference numbers are generally used to refer to corresponding
or similar features in the different embodiments. Accordingly, the
drawing(s) and description are to be regarded as illustrative in
nature and not as restrictive.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] Referring to FIG. 1, an exemplary embodiment of a wall panel
system 10 is shown. The wall panel system is designed to allow for
easy installation of a durable wall in a variety of different
locations. The wall panel system 10 can be used to cover a full
wall, a portion of a wall, or the system may be used as wainscoting
to cover a portion of a wall. The wall panel system 10 provides a
finished look using a modular system which can be easily replaced
or updated with a new or more modern appearance. For example, the
wall panel system 10 may be used to provide a decorated or finished
looking wall in terminal corridors at airports, public areas or in
locker rooms at sport arenas, classrooms or meeting areas at
universities, grocery or other stores, a waiting room in a doctor's
office, the support wall under a bar countertop, and the like.
[0038] In an embodiment, illustrated in FIG. 1, the wall panel
system 10 includes a plurality of rails 12 oriented substantially
horizontally in a spaced-apart manner and fixedly attached to a
wall support structure 14. The wall support structure 14 may be
formed of a plurality of wall studs 16 having drywall 18 or other
covering layer attached to the studs 16. It should be understood by
one of ordinary skill in the art that the wall support structure 14
can be any form of supporting structure sufficient to allow the
wall panel system 10 to be securely mounted thereon, which includes
various locations for which the wall panel system 10 may be used. A
plurality of panels 20 are operatively attached to the
horizontally-aligned rails 12 in a releasably locking manner.
Vertically-aligned cross splines 22 are disposed between adjacent
panels 20 to provide both a physical as well as a visual division
between panels 20. The rails 12, panels 20, and cross splines 22
are pieced together to provide a finished appearance for a
wall.
[0039] FIGS. 2A-2B illustrate an exemplary embodiment of an edge
rail 24, which is one embodiment of a horizontally-aligned rail 12.
The edge rail 24 can be positionable along the floor 26, ceiling
(not shown), or side edge of the finished wall panel system 10. The
edge rail 24 is configured to provide a clean-looking boundary
edge, as illustrated in FIG. 1. As shown in FIG. 2A, the edge rail
24 can be disposed at the junction between the support structure 14
and the floor 26, and the edge rail 24 is secured to the support
structure 14 by way of a plurality of bolts 28 (FIG. 1) or other
attachment means sufficient to fixedly attach the edge rail 24 to
the support structure 14. When positioned adjacent to the floor 26,
the edge rail 24 is configured to extend horizontally along
substantially the entire length of the support structure 14,
thereby providing a lower structural member configured to receive
the first horizontally-aligned row of panels 20. Alternatively,
multiple edge rails 24 can be placed end-to-end to extend along the
entire length of the support structure 14, or a portion of the
length thereof. When the edge rail 24 is positioned in a vertical
manner either along a transition between two walls or at the
terminal end of a wall, the edge rail 24 is configured to extend at
least a portion of the height of the support structure 14 to
provide a lateral end cap to at least one row of panels 20.
[0040] The edge rail 24 is configured to provide a cap or an
aesthetic boundary to the edges of a wall panel system 10 as well
as aligning the first row of panels 20. At least one
horizontally-aligned rail 12 is securable to the wall support
structure 14 in a spaced-apart and parallel manner relative to the
edge rail 24, as shown in FIG. 1. These spaced-apart rails 12 are
configured to provide substantially horizontal alignment and
support for the second and each successive row of panels 20
adjacent to the first row. As shown in FIGS. 1 and 2B, the rail 12
is positioned adjacent to the support structure 14 and is secured
to the wall support structure 14 by way of a plurality of bolts 28.
The rails 12 are spaced in the vertical direction a distance
sufficient to allow the entire row of panels 20 to be operatively
connected to a pair of opposing rails 12 that are configured to
engage the upper and lower edges of the panels 20. Each adjacent
horizontally-aligned row of panels 20 is separated by a rail 12
positioned therebetween. In an embodiment, both the uppermost and
lowermost horizontally-aligned rows of panels 20 are bounded by an
edge rail 24.
[0041] As the panels 20 are positioned along the horizontal row, a
vertically-aligned cross spline 22 is positioned between each
adjacent panel 20, as shown in FIG. 1. The cross splines 22 are
configured to engage a vertical edge of each adjacent panel to
provide a vertical differentiation between the panels. As
successive horizontal rows of panels 20 are installed, the cross
splines 22 should be substantially aligned such that they provide
the appearance of a single vertical cross spline. The cross splines
22 are configured to extend in a substantially perpendicular manner
relative to the horizontally-aligned rails 12, and each cross
spline 22 extends between adjacent rails 12 such that the height of
the cross spline 22 is approximately the length of the vertical
edge of the panel 20 to which the cross spline 22 engages. The
rails 12 and cross splines 22 provide the skeletal framework for
the panels 20 in the wall panel system 10.
[0042] FIGS. 3A-3B illustrate an exemplary embodiment of a panel 20
for use in the wall panel system 10. The panel 20 includes a core
30 having a front surface 32 and an opposing rear surface 34,
wherein the core 30 is sandwiched between the front and rear
surfaces 32, 34. In an embodiment, the core 30 is formed of
plywood, fiber-reinforced plastic (FRP), cement board, sheet rock
or any other material that provides a reinforced center for the
panel 20. The front surface 32 of the panel 20 may be formed of a
decorative layer or any other type of layer that provides an
aesthetic appearance of the panel 20. In an embodiment, the rear
surface 34 is formed of the same material as the front surface 32
such that the panel 20 is substantially reversible in case either
the front or rear surface 32, 34 becomes damaged. In another
embodiment, the rear surface 34 is formed of a different material
than the front surface 32. It should be understood by one of
ordinary skill in the art that the panel 20 may be formed of any
number of layers, and the 3-layer panel 20 described above is for
illustrative purposes only.
[0043] In an exemplary embodiment, as shown in FIGS. 3A-3B, each
panel 20 has a substantially square or rectangular shape. The panel
20 includes a pair of opposing vertical edges 36 and a pair of
horizontal edges 38 that extend between the vertical edges 36. The
vertical and horizontal edges 36, 38 of the panel 20 extend between
the front and rear surfaces 32, 24 to form a thickness T. The
distance between opposing vertical edges 36 provides the width W of
the panel, and the distance between the opposing horizontal edges
38 provides the height H of the panel. It should be understood by
one of ordinary skill in the art that the dimensions of the panel
20 may vary and depend upon the materials used for the panel, the
physical properties of the panel, or the location or purpose for
which the panel will be used, among other factors. The peripheral
edge of the panel 20 is a combination of each of the individual
side edges or lateral edges that extend between the front and rear
surfaces 32, 34 of the panel 20. Although the terms "horizontal"
and "vertical" are used to describe the components of the
peripheral edge of the panel 20, these terms are only used as
references with respect to the adjacent edges and to differentiate
between the adjacent edges and should not be interpreted as an
absolute direction or orientation of the particular edge.
[0044] Each panel 20 includes a kerf, or groove 40, formed into
each of the vertical and horizontal edges 36, 38, as shown in FIGS.
3A-3B, to form a continuous groove about the entire peripheral edge
of the panel 20. Each groove 40 is formed into a peripheral edge of
the panel 20 between the front and rear surface 32, 34 and extends
into the thickness of the panel 20 from the peripheral edge
thereof. The groove 40 extends from each edge toward the center of
the panel 20. Grooves 40 formed along adjacent edges intersect each
other to form a continuous groove around the entire peripheral edge
of the panel 20, as illustrated in dashed lines in FIG. 3A. In an
embodiment, the groove 40 is a U-shaped groove having a rounded
interior edge. In another embodiment, the groove 40 is a square
groove in which the interior edge is substantially perpendicular to
the side walls of the groove. It should be understood by one of
ordinary skill in the art that the grooves 40 can have any shape
sufficient to receive a portion of a rail 12 or cross spline 22 for
providing a tongue-and-groove-type engagement between the rail 12
or cross spline 22 and the panel 22, as will be explained in more
detail below. It should also be understood by one of ordinary skill
in the art that the depth of the groove 40 should be sufficient to
receive a portion of a rail 12 or cross spline 22. The panels 20
are positioned between rails 12 and the cross splines 22 such that
each panel 20 engages opposing cross splines 22 and rails 12 in a
tongue-and-groove attachment means.
[0045] FIGS. 1, 2A-2B, and 4A-4B illustrate an exemplary embodiment
of an edge rail 24 for use in the wall panel system 10. The
illustrated edge rail 24 includes an elongated base 42, a cap 44
extending from one end of the base 42, a cover 46 extending from
the cap 44, and a buffer 48 extending from the opposing end of the
base 42 relative to the cap 44. The base 42 is an elongated,
substantially straight member that is configured to be positioned
adjacent to a support structure 14 such as a wall or the like. The
base 42 can be fixedly attached, removably attached, or simply
abutting the support structure 14 (FIG. 1). In an embodiment, the
base 42 of the edge rail 24 is fixedly attached to wall support
structure 14 by a plurality of bolts 28. However, it should be
understood by one of ordinary skill in the art that the edge rail
24 can also be removably attached to the wall support structure 14.
It should also be understood by one of ordinary skill in the art
that any mechanical fastener can be used to attach the edge rail 24
to the wall support structure 14.
[0046] The buffer 48 of the edge rail 24 extends from a distal end
of the base 42 and, as shown in FIGS. 1, 2A-2B, and 4A-4B. In the
illustrated embodiment, the buffer 48 is shown as contacting the
rear surface of the panel 20, but it should be understood by one of
ordinary skill in the art that the buffer 48 may also be spaced
apart from the panel 20, particularly due to the differences in
thickness of the panels 20 that can be used with the wall panel
system 10. The buffer 48 is configured to provide and allow the
panels 20 that are supported thereby to be spaced from the support
structure 14 the same distance as the adjacent row of panels 20. In
an embodiment, the buffer 48 has a semi-circular cross-sectional
shape. In another embodiment, the buffer 48 has a square-like
cross-sectional shape. It should be understood by one of ordinary
skill in the art that the buffer 48 may have any cross-sectional
shape sufficient to provide a similar spacing between the panels 20
and the support structure 14. When installed, the buffer 48 extends
away from the support structure 14 to provide a first contact
surface 50 against which the panel 20 can abut when installed. The
first contact surface 50 can maintain the panel 20 in a
spaced-apart relationship relative to the support structure 14 if
the first contact surface 50 is abutting the panel 20.
[0047] The cap 44 of the edge rail 24 extends from the opposing
distal end of the base 42 with respect to the buffer 48, as shown
in FIG. 4B. The cap 44 extends from the base 42 in a substantially
planar and perpendicular manner, thereby forming an L-shaped
cross-section therebetween. The cap 44 is configured to be
positioned immediately adjacent to a horizontal edge 38 of a panel
20 (FIG. 2A) received by the edge rail 24. The cap 44 extends
between the base 42 and the cover 46. When the edge rail 24 is
installed along a wall support structure 14, the cap 44 is spaced
apart from the wall support structure 14 and is positioned
immediately adjacent to the floor 26. In an embodiment, the cap 44
is fixedly attached to the floor 26. In another embodiment the cap
44 is in an abutting relationship with the floor 26 without being
attached thereto. When the edge rail 24 is installed vertically at
the terminal end of a wall or horizontally at a location spaced
from the ceiling or top surface of the support structure 14, the
cap 44 is directed outwardly and exposed. When the edge rail 24 is
installed along the base of a wall support structure 14 along the
floor 26 or the ceiling, the cap 44 is hidden by the panel 20.
[0048] The distance that the cap 44 extends between the base 42 and
the cover 46 should be slightly larger than the thickness of the
panel 20 received by the edge rail 24, as shown in FIGS. 2A-2B. The
cover 46 extends from the end of the cap 44 opposite the end of the
cap 44 attached to the base 42. The cover 46 is oriented in a
substantially parallel manner relative to the base 42, wherein the
base 42, cap 44, and cover 46 together form a generally U-shaped
cross-section. The surface of the cover 46 directed toward the base
42, or the second contact surface 52, is spaced apart from the
plane formed by the first contact surface 36 of the buffer 48 by a
first distance D.sub.1, wherein the first distance D.sub.1 is
substantially equivalent to the thickness of the panel 20 received
by the edge rail 24. When the edge rail 24 is installed, the cover
46 is positioned immediately adjacent to the outward-directed
surface of the panel 20 received by the edge rail 24. The first
contact surface 50 contacts the rear surface 34 of the panel 20 and
the second contact surface 52 contacts the front surface 32 of the
panel 20 to stabilize the lower portion of the panel 20 in a
cantilever-like manner.
[0049] The edge rail 24 illustrated in FIGS. 4A-4B can be formed of
aluminum, steel, plastic, polymer, metal, or any material
sufficient to provide a clean yet durable edge to the wall panel
system 10. In an embodiment, the edge rail 24 is formed of an
aluminum sheet that is pressed or extruded to generate the desired
cross-sectional shape. The length of the edge rail 24 can be
between about one inch (1 in.) and about twenty feet (20 ft.) or
more. The thickness of each portion of the edge rail 24 can be
substantially uniform, or as shown in the exemplary embodiment of
FIGS. 4A-4B, portions such as the cover 46 can have a larger or
different thickness than other portions of the edge rail 24. In an
embodiment, the thickness of the edge rail is between about
one-tenth of an inch (0.10 in.) and about four-tenths of an inch
(0.40 in). In an embodiment, the first distance D.sub.1 is about
0.127 inches. Although these are exemplary measurements, it should
be understood by one of ordinary skill in the art that the
measurements of the edge rail 24 can be any distance sufficient to
provide a foundation or edge of a wall panel system 10 and receive
at least one panel 20. The edge rail 24 is typically positioned at
the top and/or bottom of a wall support structure 14 and typically
forms the upper and/or lower boundaries of the wall panel system
10, whereas the rails 12 and the cross splines 22 provide the
interior structure supports for the wall panel system 10.
[0050] FIGS. 1 and 5A-5D illustrate one embodiment of a portion of
a wall panel system 10. The illustrated wall panel system 10
includes an edge rail 24, a plurality of horizontally-aligned rails
12 secured to a wall support structure 14 by way of bolts 28, a
plurality of vertically-aligned cross splines 22, and a plurality
of panels 20 positioned between and engaged with the rails 12 and
cross splines 22. FIGS. 5A-5B illustrate an embodiment of a rail
12, wherein the rail 12 are elongated members having a base 60 that
is a substantially planar portion that is configured to be
positioned immediately adjacent to a wall support structure 14 in
an abutting manner. Bolts 28 can be used to fixedly attach the
rails 12 to the wall support structure 14, wherein the bolts 28
pass through the thickness of the base 60.
[0051] The embodiment of the rail 12 shown in FIGS. 1 and 5A-5B
also includes a buffer 62 extending from a distal end of the base
60. The buffer 62 is configured to contact or abut the
rearward-facing surface of a panel 20 received by the rail 12 so as
to provide a gap between the rear surface 34 (FIG. 3B) of the panel
20 and the wall support structure 14. In the illustrated
embodiment, the buffer 62 has a semi-circular cross-sectional
shape. In another embodiment, the buffer 62 has a square-like
cross-sectional shape. It should be understood by one of ordinary
skill in the art that the buffer 62 may have any cross-sectional
shape sufficient to contact the panel 20 to maintain at least a
portion of the panel in a spaced-apart relationship relative to the
wall support structure 14. When installed, the buffer 62 extends
away from the wall support structure 14 to provide a first contact
surface 64 against which the panel 20 abuts when installed, wherein
the first contact surface 64 thus maintains the panel 20 in a
spaced-apart relationship relative to the support structure 14.
[0052] An arm 66 extends from the opposing distal end of the base
60 of the rail 12 with respect to the buffer 62, as shown in FIGS.
5A-5B. The arm 66 is oriented substantially perpendicular with
respect to the base 60. The arm 66 extends the length of the rail
12 and provides support for a panel 20 positioned above the arm 66
as well as engaging the panel 20 positioned below the arm 66 when
the rail 12 is installed in a substantially horizontal manner. The
arm 66 includes a support member 68, a tongue 70, and a decorative
member 72 extending therefrom. The support member 68 extends in
opposing directions from the arm 66 in a substantially
perpendicular manner. In an embodiment, the support member 68 is
formed as opposing nubs or protrusions. Each of these protrusions
of the support member 68 is configured to contact an adjacent panel
20. The support member 68 is configured to maintain the adjacent
panels 20 in a spaced-apart relationship relative to each other as
well as the arm 66 of the rail 12. The support member 68 provides
an aesthetic, but visible gap 78 (FIG. 2B) between horizontally
adjacent panels 20. The support member 68 is positioned adjacent
to, but spaced apart from, the intersection between the arm 66 and
the base 60.
[0053] In an embodiment, the tongue 70 is located along the arm 66
adjacent to the first support member 68 but laterally outward
relative to the intersection between the arm 66 and the base 60, as
shown in FIGS. 5A-5B. The tongue 70 extends in opposing directions
from the arm 66 to provide a first securing member 74 and a second
securing member 76. The first and second securing members 74, 76
extending from the arm 66 in a manner such that they are generally
aligned and spaced apart from the base 60. In an embodiment, the
first and second securing members 74, 76 are linear projections
extending in opposing directions from the arm 66. In another
embodiment, the first and second securing member 74, 76 project
from the arm 66 in a non-linear manner, wherein the first and
second securing members 74, 76 each include at least one bend or
curve along the length as they extend from the arm 66. The first
and second securing members 74, 76 are configured to be received
within the groove 40 of adjacent panels 20, and the bend or curve
in the first and second securing members 74, 76 is configured to
ensure that the respective securing member contacts both opposing
side walls of the groove 40. The non-linear shape of the first and
second securing members 74, 76 provides opposing contact surfaces
on each securing member to contact both side walls of a groove
without having to have a precise thickness to ensure contact with
both side walls. Accordingly, the manufacturing tolerances of the
grooves 40 in the panels 20 as well as the thickness of the
securing members 74, 76 need not be so exacting due to the inherent
flexing that the non-linear securing members 74, 76 provide. The
non-linear shape and flexibility of the first and second securing
members 74, 76 also act similar to an outwardly-biasing spring to
positively contact and grip the opposing side walls of the groove
40 into which each is disposed. In an embodiment, the first and
second securing members 74, 76 are a mirrored shape relative to the
other. In another embodiment, the first and second securing members
74, 76 are not a mirrored shape relative to the other. The first
and second securing members 74, 76 of the tongue 70 are positioned
on the arm 66 between the first support member 68 and the
decorative member 72.
[0054] In an embodiment, the decorative member 72 extends from the
distal end of the arm 66 opposite the end of the arm 66 connected
to the base 60, as shown in FIGS. 5A-5B. Because the first support
member 68 provides a gap 78 (FIG. 2B) between adjacent panels 20,
the decorative member 72 is configured to provide an aesthetic
division or filler within the gap 78 generated by the first support
member 68. In the illustrated embodiment, the decorative member 72
includes a pair of lateral projections and a spacer projection that
extends from the arm 66 and is substantially linearly aligned
therewith. The lateral projections of the decorative member 72 are
positioned adjacent to the tongue 70, and the spacer projection
extends from the lateral projections in a direction away from the
tongue 70. When installed, the lateral projections of the
decorative member 72 are positioned within the gap between
vertically-adjacent panels 20, and the spacer projection of the
decorative member 72 is positioned adjacent to the front surface 32
of those panels 20. In an embodiment, the spacer projection of the
decorative member 72 extends beyond the front surface 32 of
adjacent panels 20 when installed.
[0055] An embodiment of a cross spline 22 of the wall panel system
10 is illustrated in FIGS. 1 and 5C-5D. In an embodiment, the cross
spline 22 includes a tongue 80, a support member 86, and a
decorative member 88 forming a single structural member. The
illustrated cross spline 22 includes a tongue 80 formed of a first
securing member 82 and an opposing second securing member 84. The
first and second securing members 82, 84 extend in opposing
directions, and each of the first and second securing members 82,
84 is configured to be received within a groove 40 formed into the
vertical edge 36 of horizontally-adjacent panels 20. The first and
second securing members 82, 84 of the cross spline 22 are generally
aligned in opposing directions. In an embodiment, the first and
second securing members 82, 84 are linear projections. In another
embodiment, the first and second securing member 82, 84 are
non-linear projections, wherein the first and second securing
members 82, 84 each include at least one bend or curve along their
length. The bend or curve in the first and second securing members
82, 84 is configured to ensure that the respective securing member
contacts both opposing side walls of the corresponding groove 40.
The non-linear shape of the first and second securing members 82,
84 provides opposing contact surfaces on each securing member to
contact both side walls of a groove 40 without having to have a
precise thickness to ensure contact with both side walls. The
non-linear shape and flexibility of the first and second securing
members 82, 84 also act similar to an outwardly-biasing spring to
positively contact and grip the opposing side walls of the groove
40 into which each is disposed. The first and second securing
members 82, 84 of the tongue 80 are positioned between the support
member 86 and the decorative member 88.
[0056] The support member 86 of the cross spline 22 extends
rearwardly from the tongue 80, as shown in FIGS. 5C-5E. The support
member 86 includes a pair of spaced-apart and opposing projections
90 having a gap 92 therebetween. In an embodiment, each projection
90 of the support member 86 is curved as it extends away from the
tongue 80. In another embodiment, each projection 90 extends away
from the tongue 80 in a substantially linear manner. As shown in
FIG. 5E, the projections 90 are configured to contact adjacent
panels 20 to provide a gap therebetween.
[0057] In an embodiment, the decorative member 88 extends from the
tongue 80 in the direction opposite the support member 86, as shown
in FIGS. 5C-5E. In the illustrated embodiment, the decorative
member 88 includes a pair of lateral projections and a
substantially linear spacer projection that extends from the tongue
80. The lateral projections of the decorative member 88 are
positioned adjacent to the tongue 80, and the spacer projection
extends from the lateral projections in a direction away from the
tongue 80. When installed, the lateral projections of the
decorative member 88 are positioned within the gap between
horizontally-adjacent panels 20, and the spacer projection of the
decorative member 88 is positioned adjacent to the front surface 32
of those panels 20. In an embodiment, the spacer projection of the
decorative member 88 extends beyond the front surface 32 of
adjacent panels 20 when installed. As shown in FIG. 1, a portion of
the decorative member 88 extends longitudinally beyond the edge of
the tongue 80 and the support member 86 in both opposing
directions. When the cross spline 22 extends between adjacent rails
12, these extensions of the decorative member 88 overlap the second
securing member 76 of the rail 12 positioned thereabove as well as
the first securing member 74 of the rail 12 positioned therebelow.
In an embodiment, this extension of the decorative member 88 of the
cross spline 22 contacts a lateral projection of the decorative
member 72 of both adjacent rails 12. In an embodiment, the
decorative member 88 of the cross spline 22 provides substantially
the same visual appearance between adjacent horizontally-aligned
panels 20 with respect to the visual appearance the decorative
member 72 of the rail 12 provides between adjacent
vertically-aligned panels 20.
[0058] Another exemplary embodiment of a wall panel system 10 is
illustrated in FIGS. 6A-6E. The illustrated wall panel system 10
includes a plurality of horizontally-aligned rails 12,
vertically-aligned cross splines 22, panels 20 generally arranged
in rows and columns, and a wall support structure 14 to which the
rails 12 are attached. The panels 20 illustrated in FIG. 6A are the
same panels illustrated in FIG. 1. The rail 12 illustrated in FIGS.
6B-6C and the cross spline 22 illustrated in 6D-6E provide the same
structural support as the corresponding rail 12 illustrated in
FIGS. 5A-5B and cross spline 22 illustrated in FIGS. 5C-5D, but the
different embodiments provide different aesthetics the wall panel
system 10 is fully installed. The rail 12 and cross spline 22
described below for the embodiment illustrated in FIGS. 6A-6E will
include similar reference numerals for portions of these components
that correspond to like portions in the embodiment described above
and shown in FIGS. 1 and 5A-5E.
[0059] FIGS. 6B-6C show another embodiment of a rail 12 for a wall
panel system 10. The rail 12 includes a base 160, a buffer 162
extending from one end of the base 160, and an arm 166 extending
from the opposing end of the base 160. The base 160 is an
elongated, substantially planar member configured to be positioned
immediately adjacent to a wall support structure 14 for attachment
thereto.
[0060] The embodiment of the rail 12 shown in FIGS. 6A-6C also
includes a buffer 162 extending from a distal end of the base 160.
In the illustrated embodiment, the buffer 162 has a semi-circular
cross-sectional shape. In another embodiment, the buffer 162 has a
square-like cross-sectional shape. It should be understood by one
of ordinary skill in the art that the buffer 162 may have any
cross-sectional shape sufficient to contact the panel 20 to
maintain at least a portion of the panel 20 in a spaced-apart
relationship relative to the wall support structure 14. When
installed, the buffer 162 extends away from the wall support
structure 14 to provide a contact surface 164 against which the
panel 20 abuts when installed, wherein the contact surface 164 thus
maintains the panel 20 in a spaced-apart relationship relative to
the support structure 14.
[0061] An arm 166 extends from the opposing distal end of the base
160 of the rail 12 with respect to the buffer 162, as shown in
FIGS. 6A-6B. The arm 166 is a U-shaped member having an upper
portion 193, a lower portion 194, and a web portion 195 extending
between and connecting the upper and lower portions 193, 194. Each
of the portions of the arm 166 is oriented substantially
perpendicular relative to the adjacent portion of the arm 166. The
arm 166 includes a support member 168, a tongue 170, and a
decorative member 172 extending therefrom. The support member 168
includes a first protrusion 169a that extends outwardly from the
upper portion 193 of the arm 166 and a second protrusion 169b that
extends outwardly from the lower portion 194 of the arm 166. Each
of these protrusions 169a, 169b of the support member 168 is
configured to contact an adjacent panel 20. The support member 168
is positioned adjacent to, but spaced apart from, the intersection
between the arm 166 and the base 160.
[0062] In an embodiment, the tongue 170 is located along the arm
166 adjacent to the first support member 168 but laterally outward
relative to the base 160, as shown in FIGS. 6A-6C. The tongue 170
includes a first securing member 174 extending from the upper
portion 193 of the arm 166 and a second securing member 176
extending from the lower portion 194 of the arm 166. The first and
second securing members 174, 176 extending from the arm 166 in a
manner such that they are generally aligned and spaced apart by
approximately the length of the web portion 195 of the arm 166. In
an embodiment, the first and second securing members 174, 176 are
linear projections extending in opposing directions from the arm
166. In another embodiment, the first and second securing member
174, 176 project from the arm 166 in a non-linear manner, wherein
the first and second securing members 174, 176 each include at
least one bend or curve along their length as they extend from the
arm 166. The non-linear shape and flexibility of the first and
second securing members 174, 176 act similarly to an
outwardly-biasing spring to positively contact and grip the
opposing side walls of the groove 40 into which each is disposed.
In an embodiment, the first and second securing members 174, 176
are a mirrored shape relative to the other. In another embodiment,
the first and second securing members 174, 176 are not a mirrored
shape relative to the other. The first and second securing members
174, 176 of the tongue 170 are positioned on the arm 166 between
the support member 168 and the decorative member 172.
[0063] In an embodiment, the decorative member 172 extends
laterally outward from the web portion 195 of the arm 166, as shown
in FIGS. 6A-6C. In the illustrated embodiment, the decorative
member 172 includes a pair of lateral projections as well as a
longitudinal spacer projection that extend from the arm 166. The
lateral projections of the decorative member 172 are positioned
adjacent to the tongue 170, and the longitudinal spacer projection
extends from the web portion 195 of the arm 166 in a direction away
from the tongue 170. In an embodiment, the spacer projection of the
decorative member 172 is formed of a pair of spaced-apart
extensions 196 forming a channel 197 therebetween. In an
embodiment, the extensions 196 are linear members extending from
the arm 166. In another embodiment, the extensions 196 are
non-linear members extending from the arm 166. In an embodiment,
the extensions 196 of the decorative member 172 extend beyond the
front surface 32 of adjacent panels 20 when installed. In another
embodiment, the extensions 196 of the decorative member 172 are
aligned in a substantially planar manner with the front surface 32
of adjacent panels 20 when installed.
[0064] FIGS. 6D-6E show another embodiment of a cross spline 22 for
a wall panel system 10. In an embodiment, the cross spline 22
includes a tongue 180, a support member 186, and a decorative
member 188 forming a single structural member. The illustrated
tongue 180 includes a first securing member 182 and an opposing
second securing member 184, wherein the first and second securing
members 182, 184 are connected by a web member 198. The first and
second securing members 182, 184 of the cross spline 22 are
generally aligned in opposing directions. In an embodiment, the
first and second securing members 182, 184 are linear projections.
In another embodiment, the first and second securing member 182,
184 are non-linear projections, wherein the first and second
securing members 182, 184 each include at least one bend or curve
along their length. The first and second securing members 182, 184
of the tongue 180 are positioned between the support member 186 and
the decorative member 188.
[0065] The support member 186 of the cross spline 22 extends
rearwardly from the tongue 180, as shown in FIGS. 6D-6E. The
support member 186 includes a pair of spaced-apart and opposing
projections 190 having a gap 192 therebetween. In an embodiment,
each projection 190 of the support member 186 is curved as it
extends away from the tongue 180. In another embodiment, each
projection 190 extends away from the tongue 180 in a substantially
linear manner.
[0066] In an embodiment, the decorative member 188 extends from the
tongue 180 in the direction opposite the support member 186, as
shown in FIGS. 6D-6E. In the illustrated embodiment, the decorative
member 172 includes a pair of lateral projections as well as a
longitudinal spacer projection. The lateral projections of the
decorative member 188 are positioned adjacent to the tongue 180,
and the longitudinal spacer projection extends from the web member
198 in a direction away from the tongue 180. In an embodiment, the
spacer projection of the decorative member 188 is formed of a pair
of spaced-apart hook members 199 forming a channel 200
therebetween. In an embodiment, the hook members 199 of the
decorative member 188 of the cross spline 22 extend beyond the
front surface 32 of adjacent panels 20 when installed. In another
embodiment, the hook members 199 of the decorative member 188 are
aligned in a substantially planar manner with the front surface 32
of adjacent panels 20 when installed. As shown in FIG. 6A, a
portion of the decorative member 188 extends longitudinally beyond
the edge of the tongue 180 and the support member 186 in both
opposing directions. In another embodiment, the decorative member
188 is the same longitudinal length as the tongue 180 and the
support member 186 such that there is no extending portion of the
decorative member 188.
[0067] Yet another exemplary embodiment of a wall panel system 10
is illustrated in FIGS. 7A-7E. The illustrated wall panel system 10
includes a plurality of horizontally-aligned rails 12,
vertically-aligned cross splines 22, panels 20 generally arranged
in rows and columns, and a wall support structure 14 to which the
rails 12 are attached. The panels 20 illustrated in FIG. 7A are the
same panels illustrated in FIG. 1. The rail 12 illustrated in FIGS.
7B-7C and the cross spline 22 illustrated in 7D-7E provide the same
structural support as the corresponding rail 12 illustrated in
FIGS. 5A-5B and cross spline 22 illustrated in FIGS. 5C-5D, but the
different embodiments provide different aesthetics the wall panel
system 10 is fully installed. The rail 12 and cross spline 22
described below for the embodiment illustrated in FIGS. 7A-7E will
include similar reference numerals for portions of these components
that correspond to like portions in the embodiment described above
and shown in FIGS. 1 and 5A-5E.
[0068] FIGS. 7B-7C show another embodiment of a rail 12 for a wall
panel system 10. The rail 12 includes a base 260, a buffer 262
extending from one end of the base 260, and an arm 266 extending
from the opposing end of the base 260. The base 260 is an
elongated, substantially planar member configured to be positioned
immediately adjacent to a wall support structure 14 for attachment
thereto.
[0069] The embodiment of the rail 12 shown in FIGS. 7A-7C also
includes a buffer 262 extending from a distal end of the base 260.
In the illustrated embodiment, the buffer 262 has a semi-circular
cross-sectional shape. In another embodiment, the buffer 262 has a
square-like cross-sectional shape. It should be understood by one
of ordinary skill in the art that the buffer 262 may have any
cross-sectional shape sufficient to contact the panel 20 to
maintain at least a portion of the panel 20 in a spaced-apart
relationship relative to the wall support structure 14. When
installed, the buffer 262 extends away from the wall support
structure 14 to provide a contact surface 264 against which the
panel 20 abuts when installed, wherein the contact surface 264 thus
maintains the panel 20 in a spaced-apart relationship relative to
the support structure 14.
[0070] An arm 266 extends from the opposing distal end of the base
260 of the rail 12 with respect to the buffer 262, as shown in
FIGS. 7A-7B. The arm 266 is a U-shaped member having an upper
portion 293, a lower portion 294, and a web portion 295 extending
between and connecting the upper and lower portions 293, 294. Each
of the portions of the arm 266 is oriented substantially
perpendicular relative to the adjacent portion of the arm 266. The
arm 266 includes a support member 268, a tongue 270, and a
decorative member 272 extending therefrom. The support member 268
includes a first protrusion 269a that extends outwardly from the
upper portion 293 of the arm 266 and a second protrusion 269b that
extends outwardly from the lower portion 294 of the arm 266. Each
of these protrusions 269a, 269b of the support member 268 is
configured to contact an adjacent panel 20. The support member 268
is positioned adjacent to, but spaced apart from, the intersection
between the arm 266 and the base 260.
[0071] In an embodiment, the tongue 270 is located along the arm
266 adjacent to the first support member 268 but laterally outward
relative to the base 260, as shown in FIGS. 7A-7C. The tongue 270
includes a first securing member 274 extending from the upper
portion 193 of the arm 266 and a second securing member 276
extending from the lower portion 294 of the arm 266. The first and
second securing members 274, 276 extending from the arm 266 in a
manner such that they are generally aligned and spaced apart by
approximately the length of the web portion 295 of the arm 266. In
an embodiment, the first and second securing members 274, 276 are
linear projections extending in opposing directions from the arm
266. In another embodiment, the first and second securing member
274, 276 project from the arm 266 in a non-linear manner, wherein
the first and second securing members 274, 276 each include at
least one bend or curve along their length as they extend from the
arm 266. In an embodiment, the first and second securing members
274, 276 are a mirrored shape relative to the other. In another
embodiment, the first and second securing members 274, 276 are not
a mirrored shape relative to the other. The first and second
securing members 274, 276 of the tongue 270 are positioned on the
arm 266 between the support member 268 and the decorative member
272.
[0072] In an embodiment, the decorative member 272 extends
laterally outward from the web portion 295 of the arm 266, as shown
in FIGS. 7A-7C. In the illustrated embodiment, the decorative
member 272 includes a pair of lateral projections as well as a
longitudinal spacer projection that extend from the arm 266. The
lateral projections of the decorative member 272 are positioned
adjacent to the tongue 270, and the longitudinal spacer projection
extends from the web portion 295 of the arm 266 in a direction away
from the tongue 270. In an embodiment, the spacer projection of the
decorative member 272 is formed of a pair of spaced-apart
extensions 296 forming a channel 297 therebetween. The channel 297
of the rail 12 illustrated in FIGS. 7A-7C is significantly wider
than the channel 197 illustrated in FIGS. 6A-6C. In an embodiment,
the extensions 296 are linear members extending from the arm 266.
In another embodiment, the extensions 296 are non-linear members
extending from the arm 266. In an embodiment, the extensions 296 of
the decorative member 272 extend beyond the front surface 32 of
adjacent panels 20 when installed. In another embodiment, the
extensions 296 of the decorative member 272 are aligned in a
substantially planar manner with the front surface 32 of adjacent
panels 20 when installed.
[0073] FIGS. 7D-7E show another embodiment of a cross spline 22 for
a wall panel system 10. In an embodiment, the cross spline 22
includes a tongue 280, a support member 286, and a decorative
member 288 forming a single structural member. The illustrated
tongue 280 includes a first securing member 282 and an opposing
second securing member 284, wherein the first and second securing
members 282, 284 are connected by a web member 298. The first and
second securing members 282, 284 of the cross spline 22 are
generally aligned in opposing directions. In an embodiment, the
first and second securing members 282, 284 are linear projections.
In another embodiment, the first and second securing member 282,
284 are non-linear projections, wherein the first and second
securing members 282, 284 each include at least one bend or curve
along their length. The first and second securing members 282, 284
of the tongue 280 are positioned between the support member 286 and
the decorative member 288.
[0074] The support member 286 of the cross spline 22 extends
rearwardly from the tongue 280, as shown in FIGS. 7D-7E. The
support member 286 includes a pair of spaced-apart and opposing
projections 290 having a gap 292 therebetween. In an embodiment,
each projection 290 of the support member 286 is curved as it
extends away from the tongue 280. In another embodiment, each
projection 290 extends away from the tongue 280 in a substantially
linear manner.
[0075] In an embodiment, the decorative member 288 extends from the
tongue 280 in the direction opposite the support member 286, as
shown in FIGS. 7D-7E. In the illustrated embodiment, the decorative
member 272 includes a pair of lateral projections as well as a
longitudinal spacer projection. The lateral projections of the
decorative member 288 are positioned adjacent to the tongue 280,
and the longitudinal spacer projection extends from the web member
298 in a direction away from the tongue 280. In an embodiment, the
spacer projection of the decorative member 288 is formed of a pair
of spaced-apart extensions 299 forming a channel 300 therebetween.
The channel 300 of the cross spline 22 illustrated in FIGS. 7D-7E
is significantly wider than the channel 200 illustrated in FIGS.
6D-6E. In an embodiment, the extensions 299 are linear members
extending from the tongue 280. In another embodiment, the
extensions 299 are non-linear members extending from the tongue
280. In an embodiment, the extensions 299 of the decorative member
288 of the cross spline 22 extend beyond the front surface 32 of
adjacent panels 20 when installed. In another embodiment, the hook
members 299 of the decorative member 288 are aligned in a
substantially planar manner with the front surface 32 of adjacent
panels 20 when installed. As shown in FIG. 7A, a portion of the
decorative member 288 extends longitudinally beyond the edge of the
tongue 280 and the support member 286 in both opposing directions.
In another embodiment, the decorative member 288 is the same
longitudinal length as the tongue 280 and the support member 286
such that there is no extending portion of the decorative member
288.
[0076] A further exemplary embodiment of a wall panel system 10 is
illustrated in FIGS. 8A-8E. The illustrated wall panel system 10
includes a plurality of horizontally-aligned rails 12,
vertically-aligned cross splines 22, panels 20 generally arranged
in rows and columns, and a wall support structure 14 to which the
rails 12 are attached. The panels 20 illustrated in FIG. 8A are the
same panels illustrated in FIG. 1. The rail 12 illustrated in FIGS.
8B-8C and the cross spline 22 illustrated in 8D-8E provide the same
structural support as the corresponding rail 12 illustrated in
FIGS. 5A-5B and cross spline 22 illustrated in FIGS. 5C-5D, but the
different embodiments provide different aesthetics the wall panel
system 10 is fully installed. The rail 12 and cross spline 22
described below for the embodiment illustrated in FIGS. 8A-8E will
include similar reference numerals for portions of these components
that correspond to like portions in the embodiment described above
and shown in FIGS. 1 and 5A-5E.
[0077] FIGS. 8B-8C illustrate another embodiment of a rail 12 for a
wall panel system 10. The rail 12 includes a base 360, a buffer 362
extending from one end of the base 360, and an arm 366 extending
from the opposing end of the base 360. The base 360 is an
elongated, substantially planar member configured to be positioned
immediately adjacent to a wall support structure 14 for attachment
thereto.
[0078] The embodiment of the rail 12 shown in FIGS. 8A-8C also
includes a buffer 362 extending from a distal end of the base 360.
In the illustrated embodiment, the buffer 362 has a semi-circular
cross-sectional shape. In another embodiment, the buffer 362 has a
square-like cross-sectional shape. It should be understood by one
of ordinary skill in the art that the buffer 362 may have any
cross-sectional shape sufficient to contact the panel 20 to
maintain at least a portion of the panel 20 in a spaced-apart
relationship relative to the wall support structure 14. When
installed, the buffer 362 extends away from the wall support
structure 14 to provide a contact surface 364 against which the
panel 20 abuts when installed, wherein the contact surface 364 thus
maintains the panel 20 in a spaced-apart relationship relative to
the support structure 14.
[0079] An arm 366 extends from the opposing distal end of the base
360 of the rail 12 with respect to the buffer 362, as shown in
FIGS. 8B-8C. The arm 366 is oriented substantially perpendicular
with respect to the base 360. The arm 366 extends the length of the
rail 12 and provides support for a panel 20 positioned above the
arm 366 as well as engaging the panel 20 positioned below the arm
366 when the rail 12 is installed in a substantially horizontal
manner. The arm 366 includes a tongue 370 extending therefrom.
[0080] In an embodiment, the tongue 370 is positioned the arm 66
laterally outward relative to the intersection between the arm 366
and the base 360, as shown in FIGS. 8B-8C. The tongue 370 extends
in opposing directions from the arm 366 to provide a first securing
member 374 and a second securing member 376. The first and second
securing members 374, 376 extending from the arm 66 in a manner
such that they are generally aligned and spaced apart from the base
360. In an embodiment, the first and second securing members 374,
376 are linear projections extending in opposing directions from
the arm 366. In another embodiment, the first and second securing
member 374, 376 project from the arm 366 in a non-linear manner,
wherein the first and second securing members 374, 376 each include
at least one bend or curve along the length as they extend from the
arm 366. In an embodiment, the first and second securing members
374, 76 are a mirrored shape relative to the other. In another
embodiment, the first and second securing members 374, 376 are not
a mirrored shape relative to the other.
[0081] The embodiment of the rail 12 illustrated in FIGS. 8A-8C
does not include a support member for providing a gap between
adjacent panels 20 or a decorative member that provides an
aesthetic element between adjacent panels. Without the support
member on the arm 366 of the rail 12, the tongue 370 is received
within the corresponding panels 20 such that the edge of each
adjacent panel 20 contacts the arm 366 of the rail 20. Thus, the
gap between vertically-adjacent panels 20 is substantially
equivalent to the thickness of the arm 366. Also, without a
decorative member, the visible division between vertically-adjacent
panels 20 is the gap generated by the thickness of the arm 366 of
the rail.
[0082] FIGS. 8D-8E show another embodiment of a cross spline 22 for
a wall panel system 10. In an embodiment, the cross spline 22
includes a tongue 380 and a support member 386 that form a single
structural member. The illustrated tongue 380 includes a first
securing member 382 and an opposing second securing member 384. The
first and second securing members 382, 384 of the cross spline 22
are generally aligned in opposing directions. In an embodiment, the
first and second securing members 382, 384 are linear projections.
In another embodiment, the first and second securing member 382,
384 are non-linear projections, wherein the first and second
securing members 382, 384 each include at least one bend or curve
along their length.
[0083] The support member 386 of the cross spline 22 extends
rearwardly from the tongue 380, as shown in FIGS. 8D-8E. In an
embodiment, the support member 386 includes a single projection
390. In another embodiment, the support member 386 is formed as a
plurality of spaced-apart projections extending from the tongue
380. In the illustrated embodiment, the projection 390 extends away
from the tongue 380 in a substantially linear manner. The
projection 390 is configured to provide a gap between
horizontally-adjacent panels 20. The corresponding edges of the
adjacent panels 20 contact the projection 390 such that the gap
between the panels 20 is substantially the same distance as the
thickness of the projection 390.
[0084] The embodiment of the cross spline 22 illustrated in FIGS.
8D-8E does not include a decorative member that provides an
aesthetic element between horizontally-adjacent panels 20. Without
a decorative member, the visible division between
horizontally-adjacent panels 20 is the gap generated by the
thickness of the support member 386. In addition, because the cross
spline 22 does not include a decorative member, the support member
386 and the tongue 380 provide the entire longitudinal length of
the cross spline 22 without an extension of a decorative member
extending beyond either end of the support member 386 and tongue
380. It should be understood by one of ordinary skill in the art
that the cross spline 22 in any of the previously discussed
embodiments may include a decorative member that extends
longitudinally beyond the support member and tongue or the
decorative member may terminate in a relatively co-planar manner
relative to the support member and tongue at each distal end of the
cross spline 22.
[0085] While the wall panel system 10 illustrated in FIGS. 1, 6A,
7A, and 8A are shown as extending adjacent to a single wall support
structure 14, it should be understood by one of ordinary skill in
the art that the wall panel system 10 may also be installed on
adjacent wall support structures 14. In particular, the wall panel
system 10 can be installed on two or more walls that form an angle
therebetween. FIGS. 9A-9B illustrate an exemplary embodiment of a
corner rail 402 that is configured to provide an aesthetic terminal
edge to two adjacent wall support structures 14 while also
providing a transition therebetween. The corner rail 402 is
illustrated as being configured to provide a transition for
adjacent wall support structures 14 oriented at a right angle
relative to each other, but it should be understood by one of
ordinary skill in the art that the corner rail 402 can be
configured to provide a transition to adjacent wall support
structures 14 oriented at any angle relative to each other.
[0086] In an embodiment, the corner rail 402 includes a first base
404 and a second base 406 extending from the first base 404 at a
right angle relative to an intersection 408 therebetween, as shown
in FIGS. 9A-9B. The first and second bases 404, 406 are configured
to be positioned adjacent to a wall support structure 14. A buffer
410 extends from the end of each of the first and second bases 404,
406 opposite the intersection 408. The buffer 410 provides a
contact surface 411 that contacts a rear surface 34 of a panel 20.
In an embodiment, the surface of the base 404, 406 directed away
from the wall support structure 14 is substantially coplanar with
respect to the contact surface 411. In another embodiment, the
surface of the base 404, 406 directed away from the wall support
structure 14 is generally parallel with respect to the contact
surface 411. A pair of caps 412 extend from the intersection 408 at
an angle relative to a corresponding base 404, 406. In an
embodiment, each cap 412 extends from the intersection 408 at a
right angle relative to a corresponding base 404, 406. At the end
of each cap 412, opposite the end connected to the intersection
408, a cover 414 extends from the cap 412 to form a substantially
U-shaped member along with a cap 412 and base 404, 406. The
U-shaped portions of the corner rail 402 are configured to receive
adjacent panels 20 to form an intersection between two angled
portions of a wall support structure 14.
[0087] To install an embodiment of the wall panel system 10 on a
wall support structure 14, at least one edge rail 24 is positioned
at the intersection between the floor 26 and the wall, which may
include drywall 18. The edge rail 24 is positioned such that the
base 42 is adjacent to the drywall 18 and the cap 44 is adjacent to
the floor 26. The edge rail 24 is attached to the wall support
structure 14 by a plurality of mechanical fasteners. It should be
understand that the edge rail 24 should be securely attached to the
wall support structure 14, but the edge rail 24 can also be removed
therefrom. This edge rail 24 is configured to provide the lower
alignment for a horizontal row of panels 20.
[0088] Once the edge rail 24 has been secured to the wall support
structure 14, an adjacent rail 12 is positioned in a substantially
parallel and spaced-apart orientation with respect to the edge rail
24. The adjacent rail 12 is positioned such that the lower
horizontal edge 38 of a panel 20 is positioned immediately adjacent
to the upwardly-directed surface of the cap 44, wherein the rear
surface 34 of the panel 20 contacts the first contact surface 50 of
the rail 12 and the front surface 36 of the panel 20 contacts the
second contact surface 52 of the rail 12, as shown in FIGS. 2A-2B.
Typically, the panel 20 is positioned such that the lower
horizontal edge 38 of the panel 20 contacts the cap 44 such that
the rail 12 supports the panel 20 from below and the first and
second contact surfaces 52 of the rail 12 secure the bottom portion
of the panel 20 and prevent significant movement thereof. The rail
12 is spaced from the edge rail 24 a distance sufficient to allow
the second securing member 76 of the tongue 70 to be inserted into
the groove 40 formed into the upper horizontal edge 38 of the panel
20 and the support member 68 to contact the same upper horizontal
edge 38 of the panel 20. The rail 12 is then secured to the wall
support structure 14 by a plurality of mechanical fastening
means.
[0089] Having an end rail 24 and adjacent rail 12 secured the wall
support structure 14, a panel 20 can be positioned therebetween and
slid along both rails 12, 24 to a position adjacent to a distal end
of thereof. A second panel 20 is then positioned between the end
rail 24 and the adjacent rail 12 and slid to a position adjacent to
the first panel 20. A cross spline 22 is inserted between the first
and second panels such that the first securing member 182 is
inserted into the groove 40 formed into the vertical edge 36 of the
first panel 20 that is directed toward the second panel, and the
second securing member 184 is inserted into the groove 40 formed
into the vertical edge 36 of the second panel 20 that is directed
toward the first panel. The first and second panels 20 are then
pushed together until the support member 86 contacts the
corresponding vertical edges 36 of the first and second panels 20.
The cross spline 22 is oriented such that the support member 86 is
directed toward the wall support structure 14 and the decorative
member 88 (if it includes such) is directed away from the wall
support structure 14. When assembled, the cross spline 22 is
oriented transversely with respect to, or normal to, the adjacent
rails 12. Additional panels, if necessary, are then slid between
the end rail 24 and the rail 12 in a similar manner with a cross
spline 22 positioned between each panel 20 in a like manner until
the first row of panels 20 is completed. If more than one row of
panels 20 is required or desired, these same steps are followed to
add additional rows in a parallel manner to the first row. In an
embodiment, the panels of each row are also aligned vertically into
columns. In another embodiment, the panels of each adjacent row can
be aligned such that the panels form a non-parallel pattern in the
vertical direction. Once all rows of panels are in place, the side
edges as well as the upper edge of the wall panel system 10 can be
capped with an end rail 12 or other capping member to provide an
aesthetic boundary on each edge.
[0090] In another embodiment, the end rail 24 and at least one
other rail 12 can be vertically-aligned such that the panels 20 are
positioned between the rails to form a column.
[0091] While preferred embodiments of the present invention have
been described, it should be understood that the present invention
is not so limited and modifications may be made without departing
from the present invention. The scope of the present invention is
defined by the appended claims, and all devices, processes, and
methods that come within the meaning of the claims, either
literally or by equivalence, are intended to be embraced
therein.
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