Wall panel with rain screen

Abstract

A wall panel for installation on a supporting wall includes a facing surface that includes a plurality of separate and spaced apart design elements. The design elements define a channel therebetween. The panel also includes a backing surface having at least one rib opposite the channel. The rib extends transversely across the backing surface, such as a parallel to one of the upper or lower edges of the panel or at an angle between 0 and 90 relative to one of the upper or lower edges of panel. Fasteners are engagable through the channel and the rib for securing the wall panel to the supporting wall. Upon installation of the wall panel on the supporting wall, one or more air gaps are defined by the rib and the backing surface opposite the design elements. The rib provides additional material opposite the channel to prevent the panel from breaking during installation.

Claims

1. A wall panel for installation on a supporting wall, the wall panel comprising: a facing surface comprising at least one design element integral with the facing surface and extending outwardly in a first direction; and a backing surface comprising a plurality of ribs extending in a second direction opposite the first direction, wherein the plurality of ribs includes a first rib and a second rib extending laterally adjacent to each other continuously across an entire width of the wall panel, each rib having a longitudinal axis, and the longitudinal axes of the plurality of ribs extending parallel to each other, and wherein the first rib and the second rib each define a plurality of drainage channels spaced apart and extending along an axis perpendicular to the longitudinal axes of the ribs, each drainage channel of the first rib being laterally offset from each drainage channel of the second rib.

2. The wall panel of claim 1, wherein the longitudinal axes of the plurality of ribs extend parallel to an upper edge or a lower edge of the wall panel.

3. The wall panel of claim 1, wherein the longitudinal axes of the plurality of ribs extend at an angle between 0 and 90 relative to an upper edge or a lower edge of the wall panel.

4. The wall panel of claim 1, further comprising a lower edge surface having a first thickness and an upper edge surface having a second thickness, the lower edge surface and the upper edge surface being opposite and spaced apart from each other, wherein an edge rib extends from one of the lower edge surface or the upper edge surface in a direction parallel to the first and second directions.

5. The wall panel of claim 4, wherein the edge rib defines a groove, a second plane that is parallel to the backing surface extends through a central portion of the groove, and the other of the lower edge surface or upper edge surface defines a tongue that extends outwardly from the other edge surface in a direction parallel to the second plane, wherein the tongue of a first wall panel is configured for engaging the groove of a second wall panel.

6. The wall panel of claim 1, wherein the backing surface and the facing surface define at least one opening extending through the wall panel, a central axis of the at least one opening extending through the at least one design element.

7. The wall panel of claim 6, wherein the backing surface and the facing surface define at least two openings behind the at least one design element.

8. The wall panel of claim 6, wherein the at least one opening has a first diameter at the backing surface and a second diameter at the facing surface, and the first diameter is larger than the second diameter.

9. The wall panel of claim 1, wherein at least one of the first rib or the second rib comprises a proximal surface adjacent the backing surface and a distal surface spaced apart from the proximal surface, a thickness of the at least one of the first rib or the second rib at the proximal surface being greater than a thickness of the at least one of the first rib or the second rib at the distal surface.

10. The wall panel of claim 9, wherein at least one of the first rib or the second rib defines a trapezoidal shaped cross section as viewed from a side edge of the wall panel.

11. The wall panel of claim 1, wherein a thickness defined between the facing surface and the backing surface is between about inches to about 1 inch.

12. The wall panel of claim 11, wherein a thickness defined between a proximal surface of at least one of the first rib or the second rib and a distal end of the at least one of the first rib or the second rib is about inches to about 1 inch.

13. The wall panel of claim 11, wherein an overall thickness of the wall panel between the facing surface and a distal end of at least one of the first rib or the second rib is about to about 2 inches.

14. The wall panel of claim 1, wherein the at least one design element includes a plurality of design elements, and a channel between two adjacent design elements includes a plurality of visual markers, each visual marker being disposed opposite a rib of the plurality of ribs.

15. The wall panel of claim 14, wherein the visual markers are spaced apart at regular intervals along the width of the wall panel.

16. The wall panel of claim 1, wherein the at least one design element includes a plurality of design elements, and wherein at least one of the first rib or the second rib is disposed opposite at least a portion of a channel between two adjacent design elements, such that a plane extending parallel to the first and second directions extends through a central portion of the channel and the at least one of the first rib or the second rib.

17. A wall panel for installation on a supporting wall, the wall panel comprising: a facing surface comprising a plurality of design elements and a plurality of channels between adjacent design elements, each design element of the plurality of design elements extending in a first direction; and a backing surface comprising a first rib and a second rib each extending in a second direction opposite the first direction, wherein: each of the first rib and the second rib extends continuously across an entire width of the wall panel and has a longitudinal axis, the longitudinal axes of the first rib and the second rib extending parallel and laterally adjacent to each other, each of the first rib and the second rib defines a plurality of drainage channels spaced apart and extending along an axis perpendicular to the longitudinal axes, each drainage channel of the first rib being laterally offset from each drainage channel of the second rib, and each channel of the facing surface includes a plurality of visual markers spaced apart from each other, each visual marker being disposed opposite a corresponding rib of the plurality of ribs of the backing surface.

18. A wall panel for installation on a supporting wall, the wall panel comprising: a facing surface comprising a plurality of design elements formed integrally with the facing surface and a plurality of channels between adjacent design elements, each design element of the plurality of design elements extending in a first direction; and a backing surface comprising a first rib and a second rib each extending in a second direction opposite the first direction, wherein each of the first rib and the second rib extends continuously across an entire width of the wall panel, the first rib being adjacent to the second rib in a lateral direction; wherein each of the first rib and the second rib defines a plurality of drainage channels spaced apart and extending along an axis perpendicular to the longitudinal axes, each drainage channel of the first rib being laterally offset from each drainage channel of the second rib, and wherein each channel of the facing surface includes a plurality of visual markers spaced apart at regular intervals along the width of the wall panel, each visual marker being disposed opposite the first rib or the second rib of the backing surface, such that a plane extending parallel to the first and second directions extends through a central portion of the channel and the corresponding first rib or second rib.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The systems and methods are explained in detail in the following exemplary drawings. The drawings are merely exemplary to illustrate the structure of exemplary systems and methods and certain features that may be used singularly or in combination with other features. The invention should not be limited to the implementations shown.

(2) FIG. 1 illustrates a front view of a wall panel according to one implementation.

(3) FIG. 2 illustrates a side view of the wall panel shown in FIG. 1.

(4) FIG. 3 illustrates a rear view of the wall panel shown in FIG. 1.

(5) FIG. 4 illustrates an end view of a plurality of wall panels according to the implementation shown in FIG. 1 that are stacked together.

(6) FIG. 5 illustrates a front view of a wall panel according to another implementation.

DETAILED DESCRIPTION

(7) According to various implementations, an improved wall panel for installation on a supporting wall includes a plurality of design elements on a facing surface and one or more ribs on a backing surface. The ribs are disposed opposite thinner portions of the panel to improve the panel's flexural strength, reduce material usage, and prevent breakage and provide strength during and after installation. The ribs also allow moisture to drain or escape from the air gap defined by the ribs, the backing surface between the ribs, and the wall structure on which the panel is installed.

(8) In particular, the design elements extend outwardly in a first direction from the facing surface and are separate and spaced apart from each other, defining a channel between them. Each rib extends outwardly from the backing surface in a second direction that is opposite the first direction. The ribs are disposed opposite at least a portion of one or more of the channels defined between the design elements such that a plane extending parallel to the first and second directions extends through a central portion of the respective channel and rib.

(9) The wall panel is secured to the supporting wall by engaging one or more fasteners through one or more of the channels and the rib opposite the respective channel. Upon installation of the wall panel on the supporting wall, one or more air gaps are defined by each rib and the backing surface opposite the design elements. And, in some implementations, the ribs also define drainage channels that allow moisture to escape from these air gaps.

(10) By having the ribs be disposed opposite the channels on the facing surface, the amount of material used is optimized to provide increased strength opposite the fastening areas to prevent breakage during installation and to provide increased flexural strength for the panel during shipping and installation.

(11) A wall panel 100 according to one implementation in shown in FIGS. 1 through 4. The wall panel 100 includes a facing surface 110 and a backing surface 112. A plurality of design elements 114 extend outwardly from the facing surface 110 in a first direction A, and a plurality of horizontally oriented channels 116 are defined between adjacent courses of the design elements 114. Opposite the horizontally oriented channels 116 are one or more ribs 118 that extend outwardly from the backing surface 112 in a second direction B, which is opposite of direction A. In some implementations, a height h.sub.c of each channel 116 may be about 0.5 inches.

(12) In the implementation shown in FIGS. 1 through 4, each rib 118 extends continuously and transversely across a width of the panel. For example, as shown in FIGS. 1 through 4, a longitudinal axis C-C of each rib 118 extends parallel to an upper edge 120 and a lower edge 122 of the panel 100. However, in other implementations, the longitudinal axis C-C may be at an angle between 0 and 90 relative to the upper 120 or lower edges 122. For example, in one implementation, the longitudinal axis of the ribs may be at an angle of about 45 relative to the upper and lower edges of the panel. In addition, the ribs may be discontinuous along the width of the panel. In other words, the ribs may include two or more sections of ribs that extend opposite a particular channel.

(13) Furthermore, in some implementations, the channels 116 may include visual marks 150 that indicate where fasteners are to be engaged through the channels 116. For example, the marks 150 may be spaced apart 16 inches for installations in which the fasteners are to be engaged 16 inches apart.

(14) In addition, each rib 118 includes a proximal surface 124 adjacent the backing surface 112 and a distal surface 126 spaced apart from the proximal surface 124. A height of each rib 118 at the proximal surface 124 is greater than a height of the rib 118 at the distal surface 126. For example, in the implementation shown in FIGS. 1 through 4, the rib 118 defines a trapezoidal shaped cross section as viewed from a side edge 128, 130 of the wall panel 100. However, in other implementations, the shape of the ribs may have an arcuate shaped cross section, a triangular shaped cross section, a rectangular shaped cross section, or any other suitable shape.

(15) According to some implementations, a thickness t.sub.r of the ribs 118 as measured from the proximal surface 124 to the distal surface 126 may be about 0.4 inches, and a height h.sub.r of each rib 118 as measured at the proximal surface 124 may be about 0.4 inches. Furthermore, ribs 118 may be spaced apart about 3 to about 3.5 inches from center, according to some implementations.

(16) In addition, each rib 118 defines one or more drainage channels 132 along the distal surface 126 of the rib 118, according to certain implementations. The drainage channels 132 extend vertically along the ribs 118, relative to the supporting wall upon installation of the wall panel 100 on the supporting wall, to allow moisture between the wall panel 100 and the supporting wall to flow. In implementations in which there are a plurality of drainage channels 132, the drainage channels 132 may be spaced apart from each other along the width of the rib 118. In particular, as shown in FIG. 3, a longitudinal axis D-D of each drainage channel 132 extends in a direction between the upper edge 120 and the lower edge 122. For example, the longitudinal axis D-D may extend parallel to a plane that includes the backing surface 112 and substantially perpendicular to axis C-C of the respective rib 118. In other implementations, the axis D-D may extend at another angle relative to the plane that includes the backing surface 112 and/or at another angle relative to the axis C-C of the respective rib 118 to allow moisture to flow behind the panel 100. Furthermore, according to some implementations, the width w.sub.ch and thickness t.sub.ch of each drainage channel 132 may be about inches, and the drainage channels 132 may be spaced apart s.sub.dc about 2.71 inches from center to center along the ribs 118.

(17) In some implementations, the design elements 114 are separately formed from the facing surface 110 and are coupled to the facing surface 110. In another implementation, adjacent channels 122 may define a recessed portion between the channels 116 on the facing surface 110 that is shaped to receive an inner surface of respective design element 114. And, in other implementations, the design elements may be formed integrally with the facing surface, such as in a monolithic structure.

(18) The wall panel 100 also includes a lower edge surface 136 adjacent the lower edge 122 having a first thickness and an upper edge surface 138 adjacent the upper edge 120 having a second thickness, according to certain implementations. The lower edge surface 136 and the upper edge surface 138 are opposite and spaced apart from each other, and an edge rib 140 extends from the backing surface 112 adjacent the lower edge surface 136 in a direction parallel to the first and second directions. The edge rib 140 and/or the lower edge surface 136 define a groove 142, and a plane that is parallel to the backing surface 112 extends through a central portion of the groove 142. The upper edge surface 138 defines a tongue 144 that extends outwardly from the upper edge surface 138 in a direction parallel to the backing surface 112. And, the tongue 144 of a first wall panel 100 is configured for engaging the groove 142 of a second wall panel 100. In other implementations, the tongue and groove may not be included. Furthermore, in other alternative implementations, the edge rib may be extend adjacent the upper edge surface 138 instead of adjacent the lower edge surface 136 and define the groove 142, and the lower edge surface 136 may define the tongue 144. In addition, according to some implementations, a height h.sub.t of the tongue 144 and of the groove 142 may be about 0.21 inches, a thickness t.sub.t of the tongue 144 and of the groove 142 as measured at the thickest part of each may be about 0.31 inches, and a height h.sub.er of the edge rib 140 measured at its proximal surface may be about 0.5 inches.

(19) In addition, upon installation of the wall panel 100 on the supporting wall, the ribs 118 and the edge rib 140 are disposed against the supporting wall, and the ribs 118, the edge rib 140, and the backing surface 112 between adjacent ribs 118 and between the edge rib 140 and the rib 118 adjacent thereto define air gaps with the supporting wall. In other implementations (not shown), the groove is defined by the upper edge surface 138 and/or an edge rib that extends adjacent the upper edge surface 138, and the tongue is defined by the lower edge surface 136.

(20) In the implementation shown in FIGS. 1 through 4, the design elements 114 are separately formed from the base substrate that includes the facing surface 110 and backing surface 112. For example, the design elements 114 may be formed of clay, wood, stone, plastic, concrete, ceramic, or other suitable materials. In addition, the base substrate may be formed of a poly ash material, wood, concrete, or other suitable material. In addition, the design elements 114 may be secured to the facing surface 110 using adhesives, such as moisture cured urethane, hot melt, epoxy, a two part urethane adhesive, or other suitable adhesive or fastening mechanism. Alternatively, the base substrate may be cast around the design elements 114, which may eliminate the need for a separate mechanism for coupling the design elements 114 to the base substrate.

(21) The backing surface 112 and facing surface 110 may also define at least one opening 146 extending through the wall panel 100. A central axis of each opening 146 extends through one of the design elements 114. As such, the design elements 114 hide the openings 146 when the wall panel 100 is installed on the wall structure. In addition, the openings 146 may taper in diameter from the backing surface 112 toward the facing surface 110 to allow for easier molding and demolding. For example, the backer openings 146 may have a diameter d.sub.b of about 1.61 inches adjacent the backing surface 112 and a diameter d.sub.f of about 1.5 inches adjacent the facing surface 110.

(22) The openings 146 reduce the amount of material used for the wall panel 100, which reduces the weight of the wall panel 100, and provides more surface area for the adhesive that is used to secure the design elements 114 to the facing surface 110 of the wall panel 100. However, in other implementations, the wall panel 100 may include one or more openings behind each design element 114, the wall panel 100 may include one or more openings behind some but not all of the design elements 114, or the wall panel 100 may not include any openings behind the design elements 114.

(23) The wall panel 100 may have a relatively thin thickness between the facing surface 110 and the backing surface 112 as compared to known wall panels, according to some implementations. Thinner panels typically use less material and weigh less. For example, the wall panel 100 may have a thickness t.sub.t as measured between the facing surface 110 and the backing surface 112 of between about inches to about 1 inch. In addition, a thickness t.sub.r defined between the proximal surface 124 of each rib 118 and the distal surface 126 of each rib 118 is between about inches and about 1 inch. And, an overall thickness of the wall panel 100 between the facing surface 110 and the distal surface 126 of each rib 118 is between about and about 2 inches. In some implementations, the height h.sub.p of the panel 100 may be about 10.01 inches. In addition, the design elements 114 may be relatively thin as compared to known design elements. For example, a thickness t.sub.b of each design element 114 may be about inches.

(24) Side edges of the wall panel 100 and/or design elements adjacent the side edges may form a discontinuous profile. In particular, the side edges 128, 130 shown in FIGS. 1 through 4 form a discontinuous profile because the design elements 114 in adjacent courses are arranged at an offset to each other. For example, in the implementation shown in FIGS. 1 and 3, a left side edge 128 of the panel 100 adjacent the second course of design elements 114b aligns with a center of the leftmost design element 114a in the first course and the leftmost design element 14c in the third course. And, a right side edge 130 of the design element 114e in the first course and the right side edge 130 of the design element 114g in the third course align with each other and a center of the rightmost design element 114f in the second course. The staggered edge may be formed by the panel 100 and/or the design elements 114. By staggering the edges of these courses, horizontally adjacent wall panels may be installed together to provide a staggered masonry installation appearance.

(25) In addition, to further enhance the appearance of a masonry installation, a lower left corner of the design element 114a in the first course and an upper left corner of the design element 114c in the third course may extend outwardly relative to the left side edge 128. This extended portion of each design element 114a, 114c overlaps a portion of the facing surface 110 adjacent the right side edge 130 of a horizontally adjacent panel 100. In addition, the left edges of design elements 114a and 114c and the left side edge 128 define a vertical channel therebetween, and the right edges of design elements 114e and 114g extend to the right side edge 130 of the panel 100. And, the left side edge of the design element 114b in the second course extends to the left side edge 128 of the panel 100 adjacent thereto, and the right side edge of the design element 114f in the second course and the right side edge 130 of the panel 100 adjacent thereto define a vertical channel therebetween. The width of the vertical channels are substantially equal to the width of the vertical channels defined between adjacent design elements 114 on the panel between the side edges 128, 130 such that when the left edge 128 of one panel 100 is installed horizontally adjacent the right edge 130 of another panel 100, the width between the design elements 114 on adjacent panels 100 is maintained.

(26) In alternative implementations, the design elements 114a and 114c do not overhang the left side edge 128. For example, in one implementation, the left most edges of design elements 114a, 114b, and 114c stop short of the left edge 128 a distance substantially equal to half of the width of the channels defined between adjacent design elements 114 on the panel between side edges 128, 130. Similarly, the right most edges of design elements 114e, 114f, and 114g stop short of the right edge 13 a distance substantially equal to half of the width of the channels defined between adjacent design elements 114 on the panel between side edges 128, 130. By installing the left edge 128 of one panel 100 against the right edge 130 of a horizontal adjacent panel 100, the distance between horizontally adjacent design elements 114 is substantially the same across two or more panels 100.

(27) In other implementations, the left most edges of one or more of design elements 114a, 114b, and 114c may stop short of the left edge 128 by a distance substantially equal to the width of the channels defined between adjacent design elements 114 on the panel between the side edges 128, 130, and the right most edges of one or more of design elements 114e, 114f, and 114g may extend to the right edge 130, or vice versa. For example, in the implementation shown in FIG. 5, the left most edges of design elements 114a and 114c extend to the left edge 128 of the panel 100, and the left most edge of design element 114b is spaced apart from the left edge 128 by the distance substantially equal to the width of the channels defined between adjacent design elements 114. In addition, the right most edges of design elements 114d and 114f are spaced apart from the right edge 130 by the distance substantially equal to the width of the channels defined between adjacent design elements 114, and the right most edge of design element 114e extends to the right edge 130.

(28) The width of the panel 100 may vary depending on installation requirements and the desired look of the panels, but in the exemplary implementation shown in FIG. 1, the width w.sub.pu of the panel 100 between the side edges 128, 130 of the uppermost course may be about 40 inches, and the width of the panel w.sub.ps between the side edge 128 of the uppermost course and the side edge 130 of the course just below it may be about 44 3/16 inches.

(29) Furthermore, as shown in FIG. 4, the geometry of the wall panels 100 described above allows multiple wall panels 100 to be stacked together for shipment in a manner that prevents damage of the panels 100. In particular, a first wall panel 100a is stacked such that the ribs 118, 140 are disposed on the shipping pallet 200, and a second wall panel 100b is stacked above the first wall panel 100a. The ribs 118 of the second wall panel 100b are disposed between the design elements 114 of the first wall panel 100a, and the backing surface 112 between the ribs 118 engages the design elements 114. This stacking arrangement reduces the space taken up by a plurality of stacked wall panels and prevents them from moving relative to each other during shipment, which prevents them from breaking.

(30) During installation, the panels 100 may be cut along the horizontal channels 116 to provide a specific height needed. In addition, after the fasteners are engaged through the panels 100, a joining material, such as mortar, grout, caulk, plastic, or other suitable material, may be disposed within the vertical channels and horizontal channels 116 between the design elements 114 to hide the fasteners and joints between adjacent panels 100 and to provide an aesthetically pleasing look.

(31) While the foregoing description and drawings represent the certain implementations of the present invention, it will be understood that various additions, modifications, combinations and/or substitutions may be made therein without departing from the spirit and scope of the present invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will appreciate that the invention may be used with many modifications of structure, arrangement, proportions, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. In addition, features described herein may be used singularly or in combination with other features. The presently disclosed implementations are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims and not limited to the foregoing description.

(32) It will be appreciated by those skilled in the art that changes could be made to the implementations described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular implementations disclosed, but it is intended to cover modifications within the spirit and scope of the present invention, as defined by the following claims.