System for mounting wall panels to a wall structure

Abstract

A system for mounting wall panels to a wall, includes wall panels, each including a main wall panel, and at least two bent end sections with a cut-out section and a wall thickness; and a plurality of main fastening extrusions, each including a base section to be secured to the wall, and two parallel, spaced apart flexible and resilient bent end securing walls extending from the base section, each bent end securing wall including a projection facing the other bent end securing wall, the bent end securing walls spaced apart corresponding to the wall thickness of two bent end sections, such that pressing of the bent end sections into the spacing between the bent end securing walls causes biasing away of the bent end securing walls until the projections engage in respective cut-out sections.

Claims

1. A system for mounting wall panels to an existing wall structure, comprising: a plurality of wall panels, each wall panel including: a main wall panel having an outer facing surface, and at least two bent end sections extending at an angle from different edges of said main wall panel, each bent end section having a wall thickness; and at least one main fastening extrusion, each fastening extrusion including: at least one base section adapted to be secured to the existing wall structure, two spaced apart flexible and resilient bent end securing walls extending at an angle from said at least one base section, the two bent end securing walls having a first spacing therebetween substantially greater than the wall thickness of two said bent end sections, and at least one further wall positioned between said spaced apart bent end securing walls, with a second spacing between said at least one said further wall and each bent end securing wall being substantially equal to the wall thickness of one said bent end section such that facing surfaces of two bent end sections assembled between said at least one further wall and respective said bent end securing walls are parallel with each other and out of contact with each other and spaced apart by a gap equal to at least a width of the at least one further wall from each other entirely along said facing surfaces thereof, said at least one further wall having a distal end that extends to a position spaced from said outer facing surfaces when said wall panels are assembled with said main fastening extrusion; a cut-out recess at a first surface of at least one said bent end section which faces a second surface of a respective said bent end securing wall; a projection at the second surface of each said bent end securing wall that faces a respective said cut-out recess, with a third spacing between the projection of each bent end securing wall and the at least one further wall being less than the wall thickness of one said bent end section; wherein pressing of each said bent end section into a respective said second spacing between one said bent end securing wall and said at least one further wall causes said bent end securing wall to be biased away from said at least one further wall until the respective said projection engages in a respective said cut-out recess to permit said bent end securing wall to spring back to lock said bent end section in said second spacing, with the two bent end sections being completely out of contact with each other.

2. A system according to claim 1, wherein: each cut-out recess has a cut-out holding surface that is one of: substantially parallel to said main wall panel, and extending at an angle away from said main wall panel; each projection has a projection holding surface for engaging with a respective said cut-out holding surface.

3. A system according to claim 2, wherein each said projection has an inclined surface which terminates in the projection holding surface thereof, and each said cut-out has an inclined surface which terminates in the cut-out holding surface thereof.

4. A system according to claim 3, wherein: each said bent end section has a lower end with a beveled surface for engaging with said inclined surface of the respective said projection when said bent end section is pressed into said spacing between said bent end securing walls to cause the respective said bent end securing wall to be biased away from the other bent end securing wall until said projection engages in the respective said cut-out recess.

5. A system according to claim 1, wherein each said fastening extrusion is formed as a one-piece, unitary construction.

6. A system according to claim 1, wherein each fastening extrusion includes: at least two separate base sections adapted to be secured to the existing wall structure; and at least two spaced apart flexible and resilient bent end securing walls, each extending at an angle from one of said base sections.

7. A system according to claim 1, further comprising: a plurality of corner fastening extrusions, each corner fastening extrusion including: a corner base section adapted to be secured to one corner wall of the existing wall structure, and a flexible and resilient corner bent end securing wall extending at an angle from said base section, each said corner bent end securing wall including a corner projection at one surface thereof facing another adjacent corner wall of the existing wall structure when the base section is secured to said one corner wall, the corner base section having dimensions to space the flexible and resilient corner bent end securing wall from said adjacent corner wall such that a spacing between the adjacent corner wall and the corner projection is less than the wall thickness of one said bent end section, wherein pressing of a said bent end section into said spacing between said corner bent end securing wall and said adjacent corner wall causes said corner bent end securing wall to be biased away from said adjacent corner wall until said corner projection engages in a respective said cut-out recess to lock said bent end section in said spacing in a manner that an outer wall of said bent end section is least in near abutting relation with the adjacent corner wall.

8. A system according to claim 1, wherein: said at least one base section includes two spaced apart base sections adapted to be secured to the existing wall structure, with a said flexible and resilient bent end securing wall extending at an angle from each base section, and said at least one further wall includes a spacer member positioned between said two base sections, with said spacer member having opposite ends, each end separated from a respective said bent end securing wall by a distance substantially equal to the wall thickness of one said bent end section, wherein each said bent end section has dimensions such that pressing of said bent end section into said second spacing causes the respective said bent end securing wall to be biased away from the spacer member until said projection engages in the respective said cut-out recess.

9. A system according to claim 1, wherein: said at least one further wall includes two inner walls, each connected to one of: one said bent end securing wall, and said at least one base section; each said inner wall connected inwardly of a respective said bent end securing wall, with the second spacing between each bent end securing wall and the respective inner wall of said at least one further wall being substantially equal to the wall thickness of one said bent end section.

10. A system according to claim 9, wherein each inner wall is connected by a lateral connecting wall to a respective said bent end securing wall with a fourth spacing between each lateral connecting wall and said at least one base section, and further comprising a closure member extends in said third spacing.

11. A system according to claim 9, wherein each inner wall is connected to said at least one base section, and a free inner surface of each inner wall is provided with at least one barb that is angled toward said at least one base section, and further comprising a plug inserted between said inner walls and engaged by said barbs.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an elevational view of a plurality of wall panels mounted to an existing wall structure;

(2) FIG. 2 is a perspective view of a frame extrusion according to the present invention;

(3) FIG. 3 is a cross-sectional view showing two wall panels connected together by the frame extrusion of FIG. 2;

(4) FIG. 4 is a cross-sectional view showing two wall panels connected together by a corner fastening extrusion;

(5) FIG. 5 is a cross-sectional view of a wall panel;

(6) FIG. 6 is a perspective view of a frame extrusion according to another embodiment of the present invention;

(7) FIG. 7 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(8) FIG. 8 is a cross-sectional view showing two wall panels connected together by the frame extrusion of FIG. 7;

(9) FIG. 9 is a cross-sectional view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(10) FIG. 10 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(11) FIG. 11 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(12) FIG. 12 is a perspective view of a frame extrusion according to another embodiment of the present invention;

(13) FIG. 13 is a perspective view of a frame extrusion according to another embodiment of the present invention;

(14) FIG. 14 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(15) FIG. 15 is a perspective view of the wall panels and spacer member of FIG. 14;

(16) FIG. 16 is a perspective view of the frame extrusion of FIG. 16;

(17) FIG. 17 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(18) FIG. 17A is a perspective view showing two wall panels connected together by a frame extrusion which is the same as FIG. 17, but with a modified spacer member;

(19) FIG. 17B is a perspective view showing a main fastening extrusion similar to FIG. 17, except that the U-shaped spacer member is replaced by a spacer post member;

(20) FIG. 17C is a perspective view showing a corner fastening extrusion corresponding to the main fastening extrusion of FIG. 17B;

(21) FIG. 17D is a cross-sectional view of a modified main fastening extrusion and corner fastening extrusion;

(22) FIG. 17E is a cross-sectional view of a modified main fastening extrusion and corner fastening extrusion;

(23) FIG. 17F is a cross-sectional view of a modified corner fastening extrusion;

(24) FIG. 17G is a cross-sectional view of a modified corner fastening extrusion;

(25) FIG. 17H is a cross-sectional view of a modified corner fastening extrusion;

(26) FIG. 17I is a cross-sectional view of a modified corner fastening extrusion;

(27) FIG. 18 is a perspective view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(28) FIG. 19 is a cross-sectional view showing two wall panels connected together by a frame extrusion according to another embodiment of the present invention;

(29) FIG. 19A is a cross-sectional view showing wall panels connected together by the frame extrusion of FIG. 19 at an inner wall surface, along with a corner fastening extrusion therefor;

(30) FIG. 19B is a cross-sectional view showing two wall panels connected together at a corner of an inner wall surface by the corner fastening extrusions of FIG. 19A;

(31) FIG. 19C is a cross-sectional view showing wall panels connected together by the frame extrusion of FIG. 19 at an outer wall surface;

(32) FIG. 19D is a cross-sectional view showing a modified frame extrusion of FIG. 19, with a partially beveled end of the bent end section of the wall panel;

(33) FIG. 19E is a cross-sectional view showing a modified frame extrusion of FIG. 19, with a different partially beveled end of the bent end section of the wall panel;

(34) FIG. 20 is a top plan view of a planar blank used for forming a wall panel;

(35) FIG. 20A is a top plan view of a modified planar blank used for forming a wall panel;

(36) FIG. 21 is a cross-sectional view of the planar blank of FIG. 20, taken along line 21-21 thereof;

(37) FIG. 22 is a cross-sectional view of the planar blank of FIG. 20, taken along line 22-22 thereof;

(38) FIG. 23 is a perspective view of the blank of FIG. 20, with three bent end sections bent at right angles with respect to the planar main panel section;

(39) FIG. 23A is a perspective view of the blank of FIG. 20A, with the bent end sections bent at right angles with respect to the planar main panel section;

(40) FIG. 23B is a plan view of a portion of one bent end section of a modified wall panel with a combination slot and cut-away section;

(41) FIG. 23C is a plan view of a portion of one bent end section of a modified wall panel with a combination slot and cut-away section;

(42) FIG. 24 is an elevational view of the blank of FIG. 23, viewed along line 24-24;

(43) FIG. 25 is a top plan view of one of the corners which is circled in FIG. 23 where two bent end sections are both bent at rights angles with respect to the planar main panel section;

(44) FIG. 26 is a top plan view of one of the corners which is circled in FIG. 23 where only one bent end section is bent at a rights angle with respect to the planar main panel section; and

(45) FIG. 27 is an end elevational view of a wall panel hung on a main fastening extrusion for sliding therealong.

DETAILED DESCRIPTION

(46) Referring to the drawings in detail, there is shown a system 10 according to the present invention for easily mounting wall panels 12 over an existing wall structure 14. Wall structure 14 preferably includes any planar wall. Each panel 12 includes a rectangular shaped, planar main panel section 16 and at least two bent end sections 18 bent at a right angle in the same direction at edges of main panel section 16. Main panel 16, however, need not be planar, and in fact, can have different shapes, such as a wave shape, etc. to provide different aesthetic appearances. Preferably, there are four bent end sections 18 at each edge of main panel section 16 which form an L-shaped cross-sectional shape thereat. However, the invention is not limited thereby and wall panels 12 can be formed with two, three or four bent end sections 18. Wall panels 12 are formed preferably by, but not limited to, a polyethylene core 20 with a thin aluminum wall 22 covering opposite sides thereof, as shown in FIG. 5. However, for the sake of simplicity in the drawings, FIGS. 3 and 4 show wall panels 12 formed of only a single material.

(47) As shown in FIGS. 2 and 4, each bent end section 18 is formed with a lower beveled or inclined surface 24 at the inner surface 26 thereof and extending to a line edge 28 at the distal end of the bent end section 18 at the outer surface 30 thereof. As a result, there is a reduction in thickness of the bent end section 18 at the lower end thereof. Lower beveled surface 24 preferably extends along the entire length of the bent end section 18, although the present invention is not so limited, that is, lower beveled surface 24 can extend along only a part of the length of bent end section 18.

(48) In addition, each bent end section 18 includes a cut-out section 32 at the inner surface 26 thereof and spaced slightly away from main panel section 16. Each cut-out section 32 preferably has a nose-shaped configuration in cross-section, although the present invention is not limited thereby. Specifically, each cut-out section 32 has an inclined surface 34 that extends toward the distal end of the bent end section 18 at the outer surface 30 thereof, and terminates at a holding surface 36 that extends parallel to main panel section 16. As a result, cut-out section 32 effectively forms a notch in the inner surface of bent end section 18. Cut-out section 32 preferably extends along the entire length of the bent end section 18, although the present invention is not so limited, that is, cut-out section 32 can extend along only a part of the length of bent end section 18, or there may be a plurality of spaced apart cut-out sections 32.

(49) As shown in FIGS. 2 and 3, main fastening extrusions 38 are provided for securing each wall panel 12 to existing wall structure 14. Each main fastening extrusion 38 is preferably formed as a single, one-piece, unitary member that includes a base section 40 secured to existing wall structure 14 and a supporting section 42 that connects to a side edge of each panel 12. As with each panel 12, each main fastening extrusion 32 is formed preferably by, but not limited to, a polyethylene core 28 with a thin aluminum wall 30 covering opposite sides thereof. More preferably, each main fastening extrusion 12 is formed by polyvinyl chloride (PVC), aluminum or any other deformable and resilient material. However, for the sake of simplicity in the drawings, FIGS. 2 and 4 show main fastening extrusions 38 formed of only a single material.

(50) Base section 40 includes a central planar wall 44 that seats flush against existing wall structure 14, and which has a plurality of linearly aligned openings 46 extending therealong and through which screws 48 can be inserted to secure central wall panel 44 to existing wall structure 14. Two, parallel, spaced apart, bent end securing walls 50 extend outwardly at right angles from opposite ends of central planar wall 44 for securing bent end sections 18 of two adjacent wall panels 12 thereto. As will be understood from the discussion hereafter, bent end securing walls 50 are flexible and resilient, so that they can be bent away from each other and when the bending force is removed, return to their original positions shown in FIGS. 2 and 3.

(51) Each bent end securing wall 50 includes an inwardly directed projection 52 at the inner surface 54 of the respective bent end securing wall 50, with each projection having a nose-shaped configuration in cross-section, which corresponds in shape and dimensions to nose-shaped cut-out section 32, although the present invention is not limited thereby. Specifically, each projection 52 has an inclined surface 56 that slopes in a direction toward base section 40 and terminates at a holding surface 58 that extends parallel to central planar wall 44. Projection 52 preferably extends along the entire length of the bent end securing wall 50, although the present invention is not so limited, that is, projection 52 can extend along only a part of the length of bent end securing wall 50, or there may be a plurality of spaced apart projections 52.

(52) As shown in FIGS. 2 and 3, the outer surface 60 of each bent end securing wall 50 includes a nose-shaped cut-out section 62 corresponding in position to nose-shaped projection 52, in order to save material, although the present invention is not limited thereby, and nose-shaped cut-out section 62 can be eliminated.

(53) The upper free end of each bent end securing wall 50 includes an outwardly extending stub wall 64 that is perpendicular to the respective bent end securing wall 50 and parallel to central planar wall 44.

(54) In addition, although not essential to the present invention, two outwardly extending wing walls 66 extend outwardly from opposite ends of central planar wall 44, that is, outwardly and extending from opposite sides of the lower ends of bent end securing walls 50. Each wing wall 66 is coplanar with central planar wall 44 so as to lie flush against existing wall structure 14, and each wing wall 66 includes a plurality of linearly aligned openings 68 extending therealong and through which screws 70 can be inserted to secure central wall panel wing walls 66 to existing wall structure 14. This provides additional securement of main fastening extrusions 38 to existing wall structure 14. Each wing wall 66 terminates in a bent end stub wall 72, although the present invention is not limited thereby.

(55) With this arrangement, main extrusions 38 are secured to existing wall structure 14 by screws 46 and 70 at predetermined spacing intervals determined by the dimensions of wall panels 12. Thereafter, it is only necessary to push bent end sections 18 of wall panels 12 into the gap between spaced apart bent end securing walls 50. This can be performed with bent end section 18 of one wall panel 12, followed by a bent end section 18 of an adjacent wall panel 12, or with the two bent ends sections 18 of adjacent wall panels 12 simultaneously. In such case, lower beveled surface 24 of each bent end securing wall 50 first hits against inclined surface 56 and biases the respective bent end securing wall 50 outwardly away from the other bent end securing wall 50, whereby the distal end of each bent end section 18 can pass into the space between central planar wall 44 and inwardly directed projection 52. Once holding surface 36 passes holding surface 58, the respective bent end securing wall 50 springs back to its original position, whereby nose-shaped inwardly directed projection 52 engages in nose-shaped cut-out section 32. In such case, holding surface 58 engages holding surface 36 to prevent escape of bent end section 18. In such position, outwardly extending stub walls 64 are in abutting or near abutting relation with the respective planar main panel sections 16.

(56) An important aspect of the present invention is that the outer surfaces 30 of adjacent bent end sections 18 are in abutting or near abutting relation, that is, they are at least in near abutting relation. As shown in FIG. 3, there is only a very small gap between adjacent outer surfaces so that they are in near abutting relation, but in fact, they can be, and preferably are, in abutting or touching relation with each other. In other words, the gap 74 between the adjacent outer surfaces 30 is so small that it does not permit bent end sections to be pulled out. With this arrangement, there is no need to provide any sealants or plugs in gap 74, and in fact, no such sealants or plugs would even fit within gap 74.

(57) In other words, the two bent end securing walls 50 have a spacing therebetween corresponding substantially to the wall thickness of the two bent end sections 18 held therein.

(58) In this regard, it is very easy to assemble wall panels 12 by merely pressing bent end sections 18 into the space between adjacent bent end securing walls 50.

(59) As shown in FIG. 4, at a corner of existing wall structure 14, corner fastening extrusions 76 are provided, which merely constitute one-half of a main fastening extrusion 38. Thus, each corner fastening extrusion 76 includes one-half of base section 40, and one wing wall 66 having openings 68, and with only one bent end securing wall 50 having an inwardly directed nose-shaped projection 52 formed by inclined surface 56 at the inner surface 54 thereof and terminating in holding surface 58, along with outwardly extending stub wall 64 at the free end thereof.

(60) During assembly at each corner, a first corner fastening extrusion 76 is secured to one wall 14a of existing wall structure 14 by screws 70 extending through openings 68 of the wing 66, such that the free end of base section 40 is in abutting relation to the other wall 14b of the corner which is perpendicular to wall 14a. In this arrangement, there is a space between the bent end securing wall 50 thereof and the parallel other wall 14b. A bent end section 18 is then press fit into this space, whereby the bent end securing wall 50 is biased away from the other wall 14b, until holding surface 36 passes by holding surface 58, whereupon bent end securing wall 50 springs back to its original position, whereby nose-shaped inwardly directed projection 52 engages in nose-shaped cut-out section 32. In such case, holding surface 58 engages holding surface 36 to prevent escape of bent end section 18. In such position, outwardly extending stub walls 64 are in abutting or near abutting relation with the respective planar main panel section 16.

(61) In this position, the outer surface 30 of the bent end section 18 is in abutting or near abutting relation with the adjacent corner wall 14b, that is, it is at least in near abutting relation.

(62) Then, a second corner fastening extrusion 76 is secured to the other wall 14b of existing wall structure 14 by screws 70 extending through openings 68 of the wing 66, such that the free end of base section 40 is in abutting relation to planar main panel section 16 of the already assembled wall panel 12. In this arrangement, there is a space between the bent end securing wall 50 thereof and planar main panel section 16 of the already assembled wall panel 12. A bent end section 18 of another wall panel 12 is then press fit into this space, whereby the bent end securing wall 50 is biased away from planar main panel section 16 of the already assembled wall panel 12, until holding surface 36 passes by holding surface 58, whereupon bent end securing wall 50 springs back to its original position, whereby nose-shaped inwardly directed projection 52 engages in nose-shaped cut-out section 32. In such case, holding surface 58 engages holding surface 36 to prevent escape of bent end section 18. In such position, outwardly extending stub walls 64 are in abutting or near abutting relation with the respective planar main panel section 16.

(63) In this position, the outer surface 30 of the bent end section 18 is in abutting or near abutting relation with the adjacent planar main panel section 16, that is, it is at least in near abutting relation.

(64) It will be appreciated that the present invention can be varied within the scope of the claims. In all of the following embodiments, the bend end securing walls 50 are biased outwardly when the bend end sections 18 are pressed into engagement therewith, whereby the bent end sections 18 snap back and are then locked with the bent end securing walls 50.

(65) Thus, FIG. 6 shows a modification of the embodiment of FIG. 2 in which the inclined surface 56a of each inwardly directed projection 52a continues upwardly at an angle with an inclined wall 53a ends in outwardly extending stub wall 64 that is perpendicular to the respective bent end securing wall 50 and parallel to central planar wall 44, rather than changing direction and running parallel to each bent end securing wall 50. Preferably, although not required, outwardly extending stub wall 64 is in contact with the underside of planar main panel section 16 when inwardly directed projection 52b is positioned in cut-out section 32 so as to provide a snap-tight like action with a tight fit so that there is little or no play, whereby wall panels 12 are tightly held in position. This is due to the combination of cut-out section 32 having a holding surface 36 that is substantially parallel to planar main panel section 16 when wall panels 12 are assembled, and the engagement of the stub walls 64 with the underside of planar main panel section 16, which is different from known arrangements which provide arcuate cut-out sections 32.

(66) Of course, it will be appreciated that outwardly extending stub walls 64 can be eliminated, and the free end of inclined wall 53a could be used to contact the underside of planar main panel section 16. In either case, stub wall 64 or the free end of inclined wall 53a where stub wall 64 is eliminated, it is the free end of bent end section 18 that contacts the underside of planar main panel section 16 to provide the aforementioned tight fit without any play.

(67) FIGS. 7 and 8 shows a modification of the FIG. 6 embodiment in which outwardly extending stub walls 64 are eliminated and in which each bent end securing wall 50b has an outward curvature, terminating in an inwardly directed projection 52b. Further, the inclined surface 56b of each inwardly directed projection 52b continues upwardly at an angle with an inclined wall 53b that abuts against the inner surface or undersurface of planar main panel section 16 since the outwardly extending stub wall is eliminated. As will be understood from the discussion hereafter, bent end securing walls 50b are also flexible and resilient, so that they can be bent away from each other and when the bending force is removed, return to their original positions so that inwardly directed projections 52b engage in cut-out sections 32 in FIG. 7. In addition, a center platform section 51b is provided along the center of base section 40, on which the lower ends of two bent end sections 18 rest. Screws (not shown) can be inserted through center platform section 51b to secure the extrusion to the wall.

(68) As will be appreciated from the latter embodiment, the two inwardly directed projections 52b have a spacing therebetween which is less than the wall thickness of two said bent end sections 18.

(69) As with the embodiment of FIG. 6, a tight fit is obtained with little play. In both embodiments of FIG. 6 and FIGS. 7 and 8, and contrary to known arrangements, holding surface 36 would be substantially parallel to planar main panel section 16 when wall panels 12 are assembled. However, it is possible that the holding surface is angled in a direction away from the respective main panel section, 16 starting from inner surface 26 of bent end section 18, as shown by dashed line holding surface 36 in FIG. 7. Of course, in the latter situation, holding surface 58 of inwardly directed projection 52 would have a similar slope.

(70) FIG. 9 shows a modification of the FIG. 7 embodiment in which platform 51b and inclined walls 53b are eliminated. In addition, as with all of the embodiments in the present application, main fastening extrusions 38 can each be formed as a unitary, one piece structure or of two separate main fastening extrusion sections 38a and 38b divided, as shown, by dashed line 55c in FIG. 9.

(71) FIG. 10 shows a modification of the FIG. 9 embodiment in which the only change has been changing the arc of outwardly curved bent end securing walls 50d so that the free ends thereof engage in cut-out sections 32 at positions close to the inner surfaces of bent end sections 18.

(72) FIG. 11 shows a modification of the FIGS. 7 and 8 embodiment in which the bent end securing walls 50e are inclined inwardly in an opposite direction from outwardly inclined walls 53e and meet at a cylindrical inwardly directed projection 52e which is engaged in a part cylindrical cut-out section 32e which has a circumference that extends over an angle greater than 180 degrees. Cylindrical inwardly directed projection 52e also has a circumference that extends over an angle greater than 180 degrees and has a diameter similar to the diameter of cylindrical cut-out section 32e so that it is force fit and snaps into part cylindrical cut-out section 32e in order to lock wall panels 12 and extrusions 38 together. It will be appreciated that, contrary to known arrangements, part cylindrical cut-out section 32e and cylindrical inwardly directed projection 52e extend over an angle greater than 180 degrees in order to provide this snap fitting arrangement. Of course, because of the snap fitting engagement, inclined wall 53e can be eliminated, although it is preferable to include inclined wall 53a for purposes of stability of the structural arrangement.

(73) With this embodiment, pressing of bent end sections 18e into the spacing between bent end securing walls 50e causes bent end securing walls 50e to be biased away from each other until projections 52e snap engage into respective cut-out sections 32e to lock bent end sections 18e in the spacing in a manner that outer walls of bent end sections 18e are at least in near abutting relation with each other. It will be appreciated, however, that the spacing between bent end sections 18e can be much greater such that bent end securing walls 50e need not be biased. This is because of the snap fitting relation of projections 52e into part cylindrical cut-out sections 32e. In the latter case, bent end securing walls 50e need not be biased outwardly.

(74) Further, it will be appreciated that, because part cylindrical cut-out section 32e extends over an angle greater than 180 degrees, part cylindrical cut-out section 32e defines a holding surface 36e which is slightly inclined at an angle away from said main panel section 16, starting from the inner wall surface 26e of the bent end section 18e. Therefore, a positive engagement is provided with little or no room for play or movement of wall panels 12.

(75) As discussed above with respect to FIG. 9, main fastening extrusions 38e of FIG. 11 can each be formed as a unitary, one piece structure or of two separate main fastening extrusion sections 38e1 and 38e2 divided, as shown, by dashed line 55c in FIG. 9. In addition, each separate main fastening extrusion section 38e1 and 38e2 can be formed from a plurality of discrete main fastening extrusions 38f, as shown in FIG. 12, which are secured to the wall in parallel, spaced apart relation to each other. This applies to all of the embodiments of the present application.

(76) It will be appreciated that, with the above embodiments, the respective cut-out section 32 has been continuous. However, it is possible that a plurality of spaced apart cut-out sections 12 can be provided along the length of bent end sections 18, and in such case, each inwardly directed projection 52 would be formed of a plurality of spaced apart inwardly directed teeth 52f, as shown in FIG. 13, which is a variation of the embodiment of FIGS. 7 and 8. This applies to all of the embodiments in the present application.

(77) As discussed above, U.S. Pat. No. 4,344,267 to Sukolics, U.S. Pat. No. 4,829,740 to Hutchison and U.S. Pat. No. 5,809,729 to Mitchell, provide a wall system with L-shaped ends of the panels that include recesses in the bent ends that engage with projections of the extrusions secured by screws to the walls, in which there is a large gap between adjacent bent ends. The present invention provides further advances over these systems.

(78) Specifically, as shown in FIGS. 14-16, two separate main fastening extrusion sections 38g1 and 38g2 are provided, which are of a similar configuration to the main fastening extrusion of FIG. 6, divided along a center line. In the embodiment of FIG. 14, a further spacer member 78 in the shape of a rectangular parallelepiped is first secured to the wall 14 by a double sided adhesive strip 80. Then, separate main fastening extrusion sections 38g1 and 38g2 are secured to wall 14 by screws, such that the inner surfaces of bent end securing walls 50 thereof are spaced away from the side edges of spacer member 78 by a distance equal substantially to the thickness of a bent end section 18.

(79) Alternatively, as shown in FIG. 17, a thin walled, inverted U-shaped spacer member 82 is provided in place of spacer member 78 for the same purpose, with U-shaped spacer member 82 including outwardly extending wing sections 84 that extend between separate main fastening extrusion sections 38g1 and 38g2 and wall 14.

(80) FIG. 17A shows a modified spacer member 182 with U-shaped spacer member 182 and outwardly extending wing sections 184 being of a greater thickness than corresponding elements 82 and 84 of FIG. 17. In addition, there is a central connecting section 183 between wing sections 184. As shown by dashed lines in FIG. 17A, the upper corners 182a of U-shaped spacer member 182 can be curved or arcuate.

(81) FIG. 17B shows an embodiment similar to FIG. 17, except that U-shaped spacer member 82 is replaced by a spacer post member 282 that is formed integrally as a single piece with main fastening extrusion 238. Thus, each bent end section 18 of a wall panel 12 is fit between a respective bent end securing wall 50 and spacer post member 282.

(82) FIG. 17C shows a corner fastening extrusion 276 corresponding to main fastening extrusion 238 in which spacer post member 282 is positioned flush against the existing wall structure 14.

(83) FIG. 17D shows a modified main fastening extrusion 338 and correspondingly modified corner fastening extrusion 376 from those shown in FIGS. 17B and 17C, in which the only difference is that inclined wall 53a of main fastening extrusion 238 and correspondingly modified corner fastening extrusion 276 are replaced by S-shaped walls 353a extending at about a 45 degree angle, with the free ends thereof contacting main panel section 16.

(84) FIG. 17E shows a modified main fastening extrusion 438 and correspondingly modified corner fastening extrusion 476 from those shown in FIGS. 17B and 17C, in which the only difference is that inclined wall 53a of main fastening extrusion 238 and correspondingly modified corner fastening extrusion 276 are replaced by slightly arcuate walls 453a which do not contact main panel section 16.

(85) FIG. 17F shows a corner fastening extrusion 576 similar to corner fastening extrusion 276 of FIG. 40, except that post member 282 is replaced with a Z-shaped spacer member 582;

(86) FIG. 17G shows a corner fastening extrusion 676 similar to corner fastening extrusion 276 of FIG. 40, except that post member 282 is replaced with an outwardly facing U-shaped spacer member 682;

(87) FIG. 17H shows a corner fastening extrusion 776 similar to corner fastening extrusion 276 of FIG. 40, except that post member 282 is replaced with an outwardly facing I-shaped spacer member 782;

(88) FIG. 17I shows a corner fastening extrusion 876 similar to corner fastening extrusion 276 of FIG. 40, except that post member 282 is replaced with an outwardly facing C-shaped spacer member 882;

(89) FIG. 18 shows another embodiment which is similar to that of FIG. 6, except that bent end securing walls 50h are spaced apart further than that in the embodiment of FIG. 6. With this embodiment, an upwardly extending L-shaped extension 86 extends includes a first leg 88 as a lateral connecting wall that extends inwardly from a lower portion of bent end securing wall 50h and a second leg 90 as an inner wall that extends upwardly from the free end of first leg 88 and in parallel spaced apart relation to the respective securing wall 50h with a spacing substantially equal to the thickness of a bent end section 18 which fits therein. In this manner, bent end sections 18 are inserted in the gap between a securing wall 50h and respective second leg 90. With this arrangement, there is a space 89 between central planar wall 44 and each first leg 88. A closure plate 91 of the same material and structure as wall panel 12 and of a rectangular parallelepiped shape is inserted in spaces 89 and also spans the distance between second legs 90 so as to form an aesthetic closure.

(90) FIG. 19 shows another embodiment similar to that of FIG. 18, in which the main fastening extrusion 138 includes second legs 90 extending upwardly from central planar wall 44 of base section 40, and first legs 88 are eliminated. The inner facing surfaces of second legs 90 are further provided with barbs 92 that are angled toward base section 44. In this manner, a plug 94 can be inserted within the gap between second legs 90 for closing off the gap and providing an aesthetic appearance, with the plug 94 engaged by barbs 92.

(91) FIG. 19A shows main fastening extrusion 138 of FIG. 19 used for securing wall panels 12 to an inner surface of an existing wall structure 14 of a building. In this case, each corner fastening extrusion 176 essentially corresponds to one-half of main fastening extrusion 138, and further includes a third leg 178 extending upwardly from planar wall 144 in spaced, parallel relation to second leg 90, and into which a plug 94 can be fit. In this regard, the inner surface of third leg 178 also includes barbs 92 which face the barbs 92 of second leg 90. In FIG. 19A, the corner at which planar main panel section 16 and a bent end section 18 meet abuts against the top of third leg 178 and is coplanar therewith. However, the present invention is not limited thereby, and as shown in FIG. 19B, the top surface of planar main panel section 16 at the end thereof can be positioned against the outer surface of third leg 178 at the upper edge thereof. FIG. 19C shows main fastening extrusion 138 of FIG. 19 used for securing wall panels 12 to an outer surface of an existing wall structure 14 of a building.

(92) It will be appreciated that the securement of the wall panels in FIGS. 14-19 occurs in the same manner discussed above with respect to the embodiments of FIGS. 6-8.

(93) It will be further appreciated that, in accordance with the present invention, the cut-out section can be provided in the inner facing surface of each bent end section 18 and the projection can be provided in the outer facing surface of the extrusion.

(94) It will be still further appreciated that, in each of the above embodiments, it is preferable that cut-out sections 32 extend through the outer facing thin aluminum wall 22 and through most or all of polyethylene core 20.

(95) With all of the above embodiments, each wall panel 12 is preferably formed from a planar blank 100 shown in FIG. 20, which is formed preferably by, but not limited to, a polyethylene core 20 with a thin aluminum wall 22 covering opposite sides thereof, as shown in FIGS. 5, 21 and 22. Each planar blank 100 can be stamped from or cut from a larger sheet of the respective material.

(96) Specifically, each planar blank 100 is formed by planar main panel section 16 which is preferably, but not limited to, a square shape with all sides being equal. There are four bent end sections 18, each formed as one piece at a respective side edge of planar main panel section 16, and coplanar therewith. A V-shaped cut-out 102 extends through one thin aluminum wall 22 and polyethylene core 20 at the connecting edge of each bend end section 18 to the side edge of planar main panel section 16, as best shown in FIG. 21. This permits each bent end section 18 to be bent along its respective V-shaped cut-out 102 at a right angle to planar main panel section 16 in the manner shown, for example, in FIG. 3. Each bent end section 18 further includes cut-out section 32 at the inner surface 26 thereof and spaced slightly away from main panel section 16. Each cut-out section 32 can take any suitable shape, such as the nose-shaped configuration in cross-section of FIG. 3, the rectangular configuration in cross-section of FIG. 15, the part-cylindrical configuration in cross-section of FIG. 11, etc., or any other suitable configuration.

(97) In accordance with an important aspect of the present invention, the opposite ends of each bent end section 18 have a rectangular cut-away section 104. Three of the bent end sections 18 are bent along V-shaped cut-outs 102 in FIG. 23 for illustration purposes only, and as.shown in FIGS. 23-25, at the corners where bent end sections 18 are bent at right angles to planar main panel section 16, corner openings or cut-away sections 106 are provided. As a result, when a main fastening extrusion 38, such as the one shown in FIGS. 6 and 27, is secured to an existing wall structure 14, such that it extends along the entire length of the existing wall structure 14, wall panels 12 can merely be hung thereon in the manner shown in FIG. 27 and slid therealong, as a result of corner openings 106.

(98) Of course, it will be appreciated that each corner opening 106 can be formed by a single cut-away section 104, that is, one bent end section 18 at a corner may not include a cut-away section 104.

(99) Further, it will be appreciated that the use of corner openings 106 is used with each of the above embodiments. This is a great advantage over known systems in which the panels have to be carefully placed over the extrusions. With this system, the extrusions are mounted to a wall, and the panels are placed on the extrusions and can be slid therealong so as to be easily adjusted in position. Therefore, there is a great savings in time during construction.

(100) As shown in FIGS. 20A and 23A, it will be appreciated that, in place of cut-away sections 104 that from corner openings 106, it is only necessary to provide slots 206 at opposite ends of each bent end section 18 for sliding the wall panels along the extrusions. Thus, a wall panel can be fit on an elongated extrusion and then slid therealong to a desired position, and then snap fit into a parallel, spaced apart extrusion at the opposite end of the wall panel. Alternatively, the wall panel can be snap fit onto two parallel, elongated extrusions and slid therealong to a desired position. Further, the shapes of the slots can vary, as shown in FIGS. 23B and 23C, which take the form of a combination of slot 306, 406 and cut-away sections 304, 404.

(101) With all of the above embodiments, the free ends of bent end sections 18 can be formed with a fully beveled end 24, as shown in FIG. 3, a flat end as shown in FIG. 19, or any variation in between, for example, the partially beveled ends having inclined surfaces 24a and 24b shown in FIGS. 19D and 19E, respectively.

(102) 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.