System for mounting wall panels to a wall structure and wall panels therefor
10253505 ยท 2019-04-09
Inventors
Cpc classification
Y02B10/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S20/69
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E04F13/0871
FIXED CONSTRUCTIONS
Y02E10/44
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04F2203/02
FIXED CONSTRUCTIONS
F24S2025/6004
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E04C2/292
FIXED CONSTRUCTIONS
E04F13/083
FIXED CONSTRUCTIONS
E04F13/12
FIXED CONSTRUCTIONS
Y02E10/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E04F19/065
FIXED CONSTRUCTIONS
International classification
E04F19/06
FIXED CONSTRUCTIONS
F24S20/66
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E04F13/08
FIXED CONSTRUCTIONS
E04C2/292
FIXED CONSTRUCTIONS
Abstract
A system for mounting wall panels to a wall includes wall panels, each including a main wall panel section, and four bent end sections extending from edges of the main wall panel section; a plurality of main fastening extrusions, each including a base secured to the wall, two spaced apart post walls extending from the base section, and two bent end securing walls extending from the base on opposite sides of each post wall, with a spacing between each post wall and an adjacent bent end securing wall being equal to the wall thickness of one bent end section; and a recess at a first surface of each bent end section which faces a second surface of a respective bent end securing wall, and a projection at the second surface of each bent end securing wall which is adapted to be received in a respective recess.
Claims
1. A wall panel construction consisting of: an extrusion adapted to be secured to an existing wall, said extrusion including at least one bent end securing wall; one of a planter box and a lighting arrangement; and a wall panel including: a main wall panel, the main wall panel having an outer exposed surface on a first outer side of the main wall panel, the outer exposed surface having a three-dimensional decorative shape in cross-section when connected to the existing wall, the main wall panel being comprised of a plurality of planar main wall panel sections connected at adjacent edges to each other and extending at different angles and orientations relative to each other, and at least one opening in at least one said main wall panel section, with the one of the plantar box and the lighting arrangement positioned entirely below a respective said opening and entirely below the outer exposed surface of the main wall panel to enable viewing of said one of: the planter box and the lighting arrangement through the respective said opening; and at least two bent end sections extending at an angle from different edges of said main wall panel so as to mount the main wall panel in covering relation to the existing wall so that the outer exposed surfaces of all of the main wall panel sections thereof are exposed; one of: a recess at a first surface of each bent end section which is adapted to face a second surface of a respective said bent end securing wall for engagement with a projection at the second surface of the respective bent end securing wall; and a projection at the first surface of each bent end section for engagement with a recess at the second surface of the respective bent end securing wall.
2. A wall panel according to claim 1, wherein each projection and corresponding recess has a cross-sectional shape selected from the following shapes: a square shape, a rectangular shape, a triangular shape, a triangular shape with a rounded upper surface, a trapezoidal shape, and a cylindrical shape.
3. A wall panel according to claim 1, wherein each recess is formed in the first surface of each bent end section, and each projection is formed at the second surface of each bent end securing wall.
4. A wall panel according to claim 1, wherein the main wall panels have a shape selected from the following shapes: a trapezoidal shape in cross-section; a rectangular in cross-section; a mushroom shape in cress-section; a shape in cross-section defined by outwardly inclined surfaces that meet at a central, upper concave surface; a roof like shape in cross-section; a shape in cross-section defined by outwardly inclined surfaces that meet at a central, wave-like surface; a pyramid shape; and trapezoidal side walls connected at shorter sides of each trapezoidal side wall to a rectangular center section.
5. A wall panel according to claim 1, wherein each said bent end section is removably secured to a respective said bent end securing wall.
6. A wall panel construction consisting of: one of a planter box and a lighting arrangement; and a wall panel including a main wall panel, the main wall panel having an outer exposed surface on a first outer side of the main wall panel, the outer exposed surface having a three-dimensional decorative shape in cross-section when connected to an existing wall, the main wall panel being comprised of a plurality of main wall panel sections connected at adjacent edges to each other and extending at different angles and orientations relative to each other, and at least one opening in at least one said main wall panel section, with the one of the plantar box and the lighting arrangement positioned entirely below a respective said opening and entirely below the outer exposed surface of the main wall panel to enable viewing of said one of: the planter box and the lighting arrangement through the respective said opening.
7. A wall panel construction comprising: one of a planter box and a lighting arrangement; and a wall panel including a main wall panel, the main wall panel having an outer exposed surface on a first outer side of the main wall panel, the outer exposed surface having a three-dimensional decorative shape in cross-section when connected to an existing wall, the main wall panel being comprised of only four main wall panel sections connected at adjacent edges to each other and extending at different angles and orientations relative to each other, and at least one opening in at least one said main wall panel section, with the one of the plantar box and the lighting arrangement positioned entirely below a respective said opening and entirely below the outer exposed surface of the main wall panel to enable viewing of said one of: the planter box and the lighting arrangement through the respective said opening.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(28) Referring to the drawings in detail, and initially to
(29) As shown in
(30) Further, each bent end section 18 has a lower beveled end 18a.
(31) In addition, preferably, although not required by the present invention, the opposite ends of each bent end section 18 have a rectangular cut-away section 30, as shown in
(32) As shown in
(33) Base section 34 includes a central planar wall 38 that seats flush against existing wall structure 14, and which has a plurality of linearly aligned openings 40 extending therealong and through which screws (not shown) can be inserted to secure central planar wall 38 to existing wall structure 14.
(34) Supporting section 36 includes two, parallel, spaced apart, elongated post walls 42 extending outwardly at right angles from central planar wall 38 and extending the length of each main fastening extrusion 32. A first bent end securing wall 44a extends outwardly at right angles from central planar wall 38 on an outer side of each post wall 42, with the spacing between each post wall 42 and each adjacent bent end securing wall 44a being equal to the thickness of one bent end section 18, and a second bent end securing wall 44b extends outwardly at right angles from central planar wall 38 on an inner side of each post wall 42, with the spacing between each post wall 42 and each adjacent bent end securing wall 44b being equal to the thickness of one bent end section 18. A spacing 45 is provided between adjacent bent end securing walls 44b.
(35) Each bent end securing wall 44a and 44b includes a projection 46 at the surface thereof in facing relation to the adjacent post wall 42, with each projection 46 having a nose-shaped configuration in cross-section, which corresponds in shape and dimensions to nose-shaped cut-out recess 26, although the present invention is not limited thereby. Specifically, each projection 46 has an inclined surface 46a that slopes in a direction toward base section 34 and terminates at a holding surface 46b that extends parallel to central planar wall 38. Projection 46 preferably extends along the entire length of the respective bent end securing wall 44a or 44b, although the present invention is not so limited, that is, projection 46 can extend along only a part of the length of the respective bent end securing wall 44a or 44b, or there may be a plurality of spaced apart projections 46.
(36) The inclined surface 46a of each inwardly directed projection 46 continues upwardly at an angle with an inclined wall 50, the free end 50a of which is intended to abut against the undersurface of main wall panel section 16 when inwardly directed projection 46 is positioned in cut out recess 26 so as to provide a snap-tight like action with a tight fit so that there is little or no play, whereby primary wall panels 12 are tightly held in position. However, inclined walls 50 are not a requirement of the present invention, and can be eliminated.
(37) To assemble primary wall panels 12 with main fastening extrusions 32, it is only necessary to press bent end sections 18 into the space between a post wall 42 and an adjacent bent end securing wall 44a, whereby the bent end securing wall 44a is biased away from the post wall 42, until holding surface 26b passes by holding surface 46b, whereupon bent end securing wall 44a springs back to its original position due to its resilience, whereby nose-shaped inwardly directed projection 46 engages in nose-shaped cut out recess 26. This is due to the resilient nature of bent end securing walls 44a, 44b. In such case, holding surface 46b engages holding surface 26b to prevent escape of bent end section 18. In such position, free end 50a of inclined wall 50 is in abutting or near abutting relation with the underside of the respective planar main panel section 16.
(38) In accordance with the present invention, a secondary plug wall panel 52 is also snapped into position into extrusion 32 in covering relation to the space 45 between adjacent primary wall panels 12. In its simplest form, each secondary plug wall panel 52 is formed in the same manner as each wall panel 12, but is of much smaller dimensions, as shown best in
(39) Further, each bent end section 56 has a lower beveled end 56a.
(40) The inclined surface 58a of each inwardly directed projection 58 continues upwardly at an angle with an inclined wall 60, the free end 60a of which is intended to abut against the undersurface of main plug panel section 54 when inwardly directed projection 46 is positioned in cut out recess 58 so as to provide a snap-tight like action with a tight fit so that there is little or no play, whereby secondary plug wall panels 52 are tightly held in position. However, inclined walls 60 are not a requirement of the present invention, and can be eliminated.
(41) To assemble secondary plug wall panels 52 with main fastening extrusions 32, it is only necessary to press bent end sections 56 into the space between a post wall 42 and an adjacent bent end securing wall 44b, whereby the bent end securing wall 44b is biased away from the post wall 42, until holding surface 58b passes by holding surface 46b, whereupon bent end securing wall 44b springs back to its original position, whereby nose-shaped inwardly directed projection 46 engages in nose-shaped cut-out recess 58. In such case, holding surface 46b engages holding surface 58b to prevent escape of bent end section 56. In such position, free end 60a of inclined wall 60 is in abutting or near abutting relation with the underside of the respective planar main plug panel section 54.
(42) Further, main plug panel section 54 can have a plurality of openings 55 through which light projects outwardly from a light source 57, such as a bulb, LED lights, etc., in spacing 45, as well as providing ventilation for spacing 45. Alternatively, openings 55 can be closed by transparent windows 59. In addition, other elements 61, such as electrical systems, such as cables, pipes for carrying various gases and/or liquids, solar panel pipes, a heat exchanger system, etc. can extend within spacing 45, being hidden by reason of main plug panel section 54.
(43) It will be appreciated that many variations can be provided with the present invention within the scope of the claims. For example, the shapes of the projections 46 and the corresponding cut-out recesses 26, 58 can vary in accordance with any of the different shapes and sizes of the same elements disclosed in the aforementioned U.S. Pat. Nos. 8,739,483, 8,925,271 and 8,966,849 to the same inventor herein, the entire disclosures of which are incorporated herein by reference. Thus, for example, recesses 26, 58 can be square shaped recesses as shown in FIGS. 14 and 17 of U.S. Pat. No. 8,739,483 and FIG. 10 of U.S. Pat. No. 8,925,271 for engagement with nose-shaped projections 46. Alternatively, rather than pressing bent end sections 18, 56 into the spacing between post walls 42 and bent end securing walls 44a, 44b, bent end sections 18, 56 can be slid lengthwise therein. In such case, both projections 46 and cut-out recesses 26, 58 can have, for example, a square cross-sectional shape as shown in FIG. 7 of U.S. Pat. No. 8,925,271 or a trapezoidal cross-sectional shape as shown in FIGS. 11 and 12 of U.S. Pat. No. 8,925,271, or the like. Alternatively, rather than permanently locking in place, bent end sections 18 can be formed to be removed from extrusions 32 to replace a wall panel 12. In such case, V-shaped cut-out recesses 26, 58 would be provided, and projections 46 would have a similar V-shape, for example, of the type disclosed in U.S. patent application Ser. No. 14/044,606 to the same applicant herein, and the entire disclosure of which is incorporated herein by reference. Thus, recesses 26 can have a shape, for example, of a square shape, a rectangular shape, a triangular shape, a triangular shape with a rounded upper surface, a trapezoidal shape, and a cylindrical shape.
(44) Further, although bent end securing walls 44a, 44b are shown to be straight walls, extending at right angles from base section 34, they can have other configurations, such as the curved shapes as shown in U.S. Pat. No. 8,739,483. It will be appreciated that, with this arrangement, the plug elements can assume various shapes and sizes, to provide different aesthetic appearances. For example, as shown in
(45) Another variation is shown in
(46) Another variation is shown in
(47) Another variation is shown in
(48) The advantage of main plug panel sections 154, 254, 354, 454 overlying upper surfaces of main panel sections 16 of the adjacent wall panels 12, is that a seal is provided thereat to prevent liquids from entering therein. This can be further enhanced by a sealant between these elements.
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(50) Because it is difficult to form plug wall panel 552 in a single piece, surfaces 564, 566 and 568 are formed as a single piece element 572, as shown in
(51) In like manner, trapezoidal surface 562 is formed with three edge strips 576a, 576b and 576c connected to the non-parallel sides 562c, 562b of the trapezoid shape and to the shorter 570 of the parallel sides of the trapezoid shape. Each strip 576a, 576b and 576c is bendable inwardly at a right angle along a respective fold line 578a, 578b and 578c.
(52) Further, each strip 572a, 572b and 572c and each strip 576a, 576b and 576c includes a plurality of spaced openings 580 therealong.
(53) To assemble trapezoidal surface 562 with single piece element 572, and with each strip 572a, 572b and 572c and each strip 576a, 576b and 576c folded inwardly, strips 572a, 576a; strips 572b, 576b; and strips 572c, 576c are brought into contact with other, with the openings 580 in alignment, and screws, rivets or the like 582 are inserted therein. Alternatively, rather than using screws, rivets or the like 582, any other suitable securing means can be used, for example, clamps, structural adhesives, structural caulking, aluminum strip flashing or tape secured by a structural adhesive or structural caulking or itself having a self-sticking material, or the like. Because each strip 572a, 572b and 572c and each strip 576a, 576b and 576c is folded inwardly, they are hidden from view when installed on the existing wall 14.
(54) Alternatively, a sixth modified plug wall panel 1552 can be formed from a single stamped or cut element, as shown in
(55) Another variation is shown in
(56) Another variation is shown in
(57) Another variation is shown in
(58) Another variation is shown in
(59) Another variation is shown in
(60) Another variation is shown in
(61) Another variation is shown in
(62) Another variation is shown in
(63) As a result of the above structure, the secondary plug wall panels 152-1552 provide a relief effect to the wall, enhancing the aesthetic appearance thereof. Specifically, main plug panel sections 154-1554 thereof are not coplanar with main panel sections 16 of primary wall panels 12, and thereby provide a three dimensional effect.
(64) It will be appreciated, however, that the present invention is not limited to the use of secondary plug wall panels 52-1552 between adjacent primary wall panels 12, but instead, secondary plug wall panels 52-1552 can be used alone in varied arrangements on existing wall structure 14 as the sole wall panels, for example, as shown by the different sizes of fifth modified plug wall panels 552 assembled in the wall structure shown in
(65) Another variation is shown in
(66) It will be appreciated that, while only one projection 48 has been shown in each bent end securing wall 44a, 44b, and only one cut-out recess 26 and 58 has been shown in each bent section 18, 56, a plurality of spaced apart projections 48 can be provided in each bent end securing wall 44a, 44b, and a plurality of spaced apart cut-out recesses 26 and 58 can likewise be provided each bent section 18, 56, to provide better securement of the wall panels.
(67) Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to those precise embodiments and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.