Modular panel system particularly for below grade applications
10100536 ยท 2018-10-16
Inventors
Cpc classification
E04F19/061
FIXED CONSTRUCTIONS
E04F19/0463
FIXED CONSTRUCTIONS
E04F13/0803
FIXED CONSTRUCTIONS
E04F13/0832
FIXED CONSTRUCTIONS
International classification
E04F19/06
FIXED CONSTRUCTIONS
E04F19/04
FIXED CONSTRUCTIONS
Abstract
A modular wall panel system includes a pair of specially formed receiver strips, base and crown moldings, and a panel. The receiver strips are respectively mounted at selective upper and lower wall locations. Each receiver strip has an elongated base for mounting to the wall, and first and second flanges protruding therefrom, with each flange having a pair of apices particularly formed and located thereon. The crown and base moldings have bottom and rear surfaces, an inward facing ornate/sculpted surface, and a mating flange configured to cantilever away from the rear surface. The mating flange includes a pair of apices that are configured to be mated between the first and second flanges of the receiver strip, and be retained by its flange apices. The receiver strip also spaces the rear surface of the moldings away from the wall/studs, for the panel to be inserted behind the rear surface of each.
Claims
1. A modular wall panel system comprising: a first receiver strip and a second receiver strip configured to respectively be secured to a selective upper position and lower position on a wall, each said receiver strip comprising: an elongated base; a first flange and a second flange spaced a first distance (G2) apart; each of said first and second flanges configured to cantilever a second distance (P) from said base to a free end thereof; each of said first and second flanges comprising: a first tapered surface extending away from said free end and a second tapered surface extending from said first tapered surface to form a respective apex positioned at a third distance (T) from said free end; wherein said apex on said first flange is positioned thereon to be disposed towards said second flange, and said apex on said second flange is positioned thereon to be disposed towards said first flange; and wherein said apex of said second flange is positioned at a fourth distance (G) away from said apex of said first flange; a base molding having a bottom surface, a rear surface, and a sculpted surface, said base molding comprising a mating flange configured to cantilever a fifth distance (L) from said rear surface to a free end thereof, said mating flange configured to be mated between said first and second flanges of said second receiver strip at the selective lower wall position; said mating flange comprising: a flange member protruding from said rear surface, formed by a first pair of flange surfaces spaced at least a sixth distance (W) apart; a pair of wedge surfaces that converge to create a wedge shape configured to taper down toward said free end of said mating flange; a second pair of surfaces that converge beginning from a wide end of said wedge shape, down toward said first pair of flange surfaces, to join said first pair of flange surfaces at a seventh distance (D) from said rear surface; and a first apex and a second apex formed by said converging wedge surfaces and said converging second pair of surfaces, with said first and second apices each positioned an eighth distance (W2) apart from each other; a crown molding having a top surface, a rear surface, and a sculpted surface, said crown molding comprising a mating flange configured to be mated between said first and second flanges of said first receiver strip selectively positioned at the upper wall position; said mating flange of said crown molding formed substantially the same as said mating flange for said base molding; a panel, said panel comprising a length, said length configured for a top of said panel to be inserted behind said rear surface of said crown molding, when mated with said receiver strip at said selective upper wall position, and for a bottom of said panel to be subsequently inserted behind said rear surface of said base molding, when mated with said receiver strip at said selective lower wall position, for said panel to be releasably positioned in proximity to the wall, with said panel supported above the floor by said first flange of said second receiver strip, and with said top of said panel and said bottom of said panel respectively covered by said-crown molding and said floor molding; wherein said panel is a composite panel comprising: a magnesium oxide board, a backing sheet, and a foam material sandwiched between said board and said backing sheet; and wherein said backing sheet is formed of a polyvinylchloride material, and said foam material is a closed cell polyisocyanurate foam.
2. The modular wall panel system according to claim 1 wherein said seventh distance (D) of said first and second apices from said rear surface of said molding is equal to or greater than said third distance (T) of said apices from said free end of said first and second flanges of said receiver strips.
3. The modular wall panel system according to claim 2 wherein said eighth distance (W2) between said first and second apices of said mating flange of each of said moldings is equal to or less than said first distance (G2) between said first and second flanges of each said receiver strip.
4. The modular wall panel system according to claim 3 wherein said sixth distance (W) for said spacing for said first pair of flange surfaces of each said molding is less than or equal to said fourth distance (G) between said apices of said first and second flanges of each said receiver strip.
5. The modular wall panel system according to claim 4 wherein said fifth distance (L) of said mating flange of each said molding is equal to or less than said cantilevered second distance (P) of each of said first and second flanges of said receiver strips.
6. The modular wall panel system according to claim 5 wherein said second pair of surfaces on said flange member of said moldings is formed at an angle (2) with respect to said first pair of flange surfaces, with said angle (2) being substantially the same as an angle () between said second tapered surface and said cantilevered flanges of said receiver strips.
7. The modular wall panel system according to claim 6 wherein each said surface of said pair of wedge surfaces that converge to create a wedge shape on said flange member of said moldings is formed at an angle (2) with respect to said first pair of flange surfaces, with said angle (2) being substantially the same as an angle () between said first tapered surface and said cantilevered flanges of said receiver strips.
8. The modular wall panel system according to claim 7 wherein said angle () is approximately 50 to 60 degrees.
9. The modular wall panel system according to claim 8 wherein said angle () is approximately 15 to 20 degrees.
10. The modular wall panel system according to claim 7 wherein each said receiver strip is formed of a polyvinylchloride material.
11. The modular wall panel system according to claim 10 wherein said base molding and crown molding is formed of a celuka polyvinylchloride.
12. The modular wall panel system according to claim 11 wherein said first and second flanges of each said receiver strip protrude orthogonally from said base of each said receiver strip.
13. The modular wall panel system according to claim 12 wherein said first and second flanges of each said receiver strip protrude from said base along an entire length of said base.
14. The modular wall panel system according to claim 13 wherein said first and second flanges of each said receiver strip protrude intermittently from said base.
15. A modular wall panel system comprising: a first receiver strip and a second receiver strip configured to respectively be secured to a selective upper position and lower position on a wall, each said receiver strip comprising an elongated base, and a first flange and a second flange, with each said flange configured to protrude a selective distance away from said elongated base; a base molding comprising a mating flange configured to extend a selective distance away from a rear surface of said molding, and to protrude at a selective height above a bottom surface of said base molding; said mating flange configured to releasably mate with said first and second flanges of said second receiver strip; said selective lower position configured to locate said first and second flanges of said mounted second receiver strip to correspond to said selective height of said mating flange, to position said bottom surface of said base molding in proximity to a floor; a crown molding comprising a mating flange configured to extend a selective distance away from a rear surface of said crown molding, and to protrude at a selective height below a top surface of said crown molding; said mating flange of said crown molding configured to releasably mate with said first and second flanges of said first receiver strip; said selective upper position configured to locate said first and second flanges of said mounted first receiver strip to correspond to said selective height below said top surface of said mating flange of said crown molding, to position said top surface of said base molding in proximity to a ceiling; a panel, said panel comprising a length, said length configured for a top of said panel to be inserted behind a portion of said rear surface of said crown molding, when mated with said receiver strip at said selective upper wall position, and for a bottom of said panel to be subsequently inserted behind a portion of said rear surface of said base molding, when mated with said receiver strip at said selective lower wall position, for said panel to be releasably positioned in proximity to the wall, with said panel supported above the floor by said first flange of said second receiver strip, and with said top of said panel and said bottom of said panel respectively covered by said crown molding and said floor molding; wherein said panel is a composite panel comprising: a magnesium oxide board, a backing sheet, and a foam material sandwiched between said board and said backing sheet; and wherein said backing sheet is formed of a polyvinylchloride material, and wherein said foam material is a polyisocyanurate foam.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE INVENTION
(44) As used throughout this specification, the word may is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words include, including, and includes mean including but not limited to.
(45) The phrases at least one, one or more, and and/or are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions at least one of A, B and C, one or more of A, B, and C, and A, B, and/or C mean all of the following possible combinations: A alone: or B alone; or C alone: or A and B together; or A and C together; or B and C together; or A, B and C together.
(46) Also, all references (e.g., patents, published patent applications, and non-patent literature) that are cited within this documents are incorporated herein in their entirety by reference.
(47) Furthermore, the described features, advantages, and characteristics of any particular embodiment disclosed in the following specification, may be combined in any suitable manner with any of the other embodiments disclosed herein.
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(49) The present invention is particularly adapted to eliminate the drawbacks of installing conventional drywall, and makes use of unique molding pieces and a panel, which may be supported by a receiver strip, in accordance with the following disclosure.
(50) A first embodiment of a receiver strip 20 in accordance with the present invention is shown in
(51) As seen in
(52) The flange 25 may similarly have tapered surfaces 25A and 25B formed thereon to create an apex 25P, and these surfaces may generally mirror the tapered surfaces of flange 24.
(53) The tapered surfaces 24A and 25A on flanges 24 and 25 may each preferably be at a fairly shallow angle, and the angle shown in
(54) As seen in
(55) To be able to produce a finished interior wall, a specially configured molding is used with (i.e., joined to) the receiver strips 20. These specially configured moldings are shown within
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(57) The straight molding sections may be formed of various different materials, including but not limited to, a celuka PVC (Polyvinyl chloride). Also the corner moldings may similarly be formed of various different materials, including but not limited to, ABS plastic.
(58) The base molding of
(59) The flange 37 may protrude to a length L, which may be the same as, or is more preferably slightly smaller than, the protruding distance P of the flanges 24/25 of the receiver strip 20. The flange 37 may generally be straight, except that the flat top and bottom surfaces 37T and 37B may transition to surfaces 38A and 39A, which taper outwardly and may be configured to match the corresponding surfaces 24B and 25B of the receiver strip 20 (i.e., may be at roughly the same angle). The distance D between the start of the tapered surfaces 38A/39A and the surface 36 may be the same as the distance T for the tapered surfaces 24A/25A shown in
(60) It should be noted that the flange 37 and its associated features, when used on a molding formed to finish an inside corner (e.g.,
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(63) At this point in the installation, the framing members attached to the concrete walls are still not covered. However,
(64) To ensure that the top corner of the panel 100 does not get caught by, or hung up on, the corner of the base 23 of receiver 20, the top of the panel may be radiused or chamfered, and/or the lower corner of the base 23 of receiver 20 may also taper down to a substantially small thickness (i.e., 0.010 inches) or may even taper down into a knife edge.
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(67) For the panel 100 to be able to cover the exposed wall 11, the height H of the panel should be greater than the opening V between the bottom of the crown molding 70 and the top of the base molding 30, as shown in
(68) Multiple panel sections may be needed to laterally cover the full extent of a wall, and any vertically oriented panel-to-panel joint may be concealed using a floor-to-ceiling trim piece that may be secured to one or both of the panels at the joint using for example, but not limited to, adhesive, nails, screws, etc.
(69) Where a chair rail molding is utilized, two separate panels would similarly be installed to complete the finished wall. Typical panel sizes would be a 6448 top panel and a 3248 bottom panel. The receiver strip 20 for the chair rail may thus be appropriately positioned to accommodate those standard panel sizes.
(70) The disclosed arrangement permits easy access behind the wall panels, if necessary to effect repairs to electrical wiring, or to add wiring, etc., simply by removing the panel in a reverse manner (i.e., by raising the panel 100, by angling its lower end 100L outwardly, and by next removing the upper end of the panel 100U from behind the crown molding 70). The moldings may also be readily removed, if necessary, particularly where a non-ninety-degree angle is used for the surfaces 24B and 25B on the receiver strips 20, which may help facilitate the outward deflection of the flanges 24 and 25 needed to dislodge the flange 37.
(71) It should also be noted that the disclosed arrangement may similarly be utilized for the above-grade finishing of a framed room, rather than using drywall.
(72) Additionally, in an alternate embodiment, the receiver strips 20 may be mounted directly to a concrete wall without any wood framing, using concrete nails. In this embodiment, the PVC backing 100PV of the panel 100, being a strong but light-weight plastic, may be suitably positioned to face the rough concrete.
(73) The examples and descriptions provided merely illustrate a preferred embodiment of the present invention. Those skilled in the art and having the benefit of the present disclosure will appreciate that further embodiments may be implemented with various changes within the scope of the present invention. Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or proportions, operating conditions, assembly sequence, or arrangement or positioning of elements and members of the preferred embodiment without departing from the spirit of this invention.