FIELD OF THE INVENTION
The present invention relates to an interior wall panel and trim system as a replacement for drywall in flood-prone homes and businesses. More particularly, the present invention relates to a flood resilient, magnetically adhered, wainscot wall panel and trim system that allows for quick and easy removal and reinstallation, by those skilled in the art, without the need for nails, fasteners or power tools.
BACKGROUND OF THE INVENTION
Flooding is one of the most frequent and costly natural disasters in the U.S. The country experiences coastal, fluvial and pluvial flooding. Flood risk is increasing due to escalating heavy precipitation events and rising sea levels caused by climate change, continued development in high-risk areas and ageing infrastructure.
Once a home or business is subjected to a flood event, the lower walls, typically clad with sheetrock, joint compound, joint tape and/or plaster, become saturated with absorbed water. It is from this point forward where these materials provide a substrate for mold and mildew growth as well as becoming compromised structurally.
To remedy this situation, a costly and time-consuming muck-out operation is required to safely remove, and environmentally dispose of, the compromised materials. The significant amount of waste generated also requires sufficient landfill volume to be available in our nation's landfills.
Recently, flood risk management in the U.S. has started to focus on building resilience.
Thus, the need for a flood resilient interior wall panel and trim system for use in residential homes and commercial buildings is the basis for the invention.
The present invention offers a magnetically adhered, flood resilient, waterproof, mold and mildew resistant, insect resistant, interior wainscot wall panel and trim system that is quickly and easily installed.
Due to its magnetically adhered attachment system, the present invention's resilient characteristics enable quick and easy removal and re-installation, in the wake of recurring flood events, by those skilled in the art, without the need for nails, fasteners or power tools.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a new and improved, magnetically adhered, flood resilient wall panel and trim system to replace conventional sheetrock, joint compound, joint tape and/or plaster interior walls in residential and commercial construction.
It is a further object of the invention to provide a new and improved, magnetically adhered wall panel and trim system that can be quickly and easily removed and reinstalled, by those skilled in the art, without the need for nails, fasteners or power tools.
BRIEF SUMMARY OF THE INVENTION
A magnetically adhered, flood resilient wall panel and trim system may broadly include a pair of Galvanized Steel Mounting Strips, a pair of integrally engineered Receiver Trims, each with Magnetic Backing Strips, integrally engineered Base and Chair Rail Moldings, Wall Panels, with upper and lower Magnetic Backing Strips, and integrally engineered Inside and Outside Corner Trims.
The Galvanized Steel Mounting Strips may be fastened, by those skilled in the art, to a selective upper and lower location along the existing room's walls by attachment to wood or steel studs with galvanized steel roofing nails or flathead screws.
The Receiver Trims, each with continuous, adhesive adhered Magnetic Backing Strips, are then mounted, by those skilled in the art, to their selective upper and lower locations on the Galvanized Steel Mounting Strips.
Each Receiver Trim may feature two pairs of continuous female flanges protruding from its base. Each of the flanges may include a plurality of apices particularly formed and located thereon.
The Wall Panel may consist of a PVC, tongue and grooved, beadboard panel with continuous upper and lower, adhesive adhered Magnetic Backing Strips. The Wall Panel with Magnetic Backing Strips may then be magnetically adhered, by those skilled in the art, to the exposed sections of the continuous, upper and lower Galvanized Steel Mounting Strips, between the upper and lower Receiver Trims.
The Base and Chair Rail Moldings may include top and bottom surfaces, a rear surface and an ornate, contoured front surface. The rear surface may feature of a pair of continuous mating male flanges protruding perpendicular and away from its surface. The male flanges of each molding may include several apices particularly formed and located thereon, for proper mating between the paired female flanges of the Receiver Trims, and thereby being retained in place by the interlocking apices of both members.
The Inside Corner Trim consists of a pair of smooth flanges protruding perpendicularly from their intersection in addition to a continuous mating male flange protruding from the same flange intersection point symmetrically away from each flange.
The Outside Corner Trim consists of a pair of smooth flanges protruding perpendicularly from their intersection in addition to a pair of continuous mating female flanges protruding from the same flange intersection point symmetrically away from each flange.
The mating flanges of the Inside and Outside Corner Trim may include several apices particularly formed and located thereon, for proper mating between their respective male and female flanges, and thereby being retained in place by the interlocking apices of each trim.
Due to a plurality of apices located along the mating flanges of the Receiver Trims, Base, Chair Rail, Inside and Outside Corner Trim moldings, a range of Wall Panel thicknesses may be accommodated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective of a typical room prior to installation of the wall panel and trim system components. A plurality of wood studs are exposed from floor level to the lower elevation, or flood cut height, of the existing upper sheetrock walls.
FIG. 2 shows a cross-sectional view of an exterior wall with a fully installed Wall panel and trim system at its interior face.
FIG. 3 shows a cross-sectional view of an enlarged, exploded view of the lower wall section of wall panel and trim system components shown in FIG. 2.
FIG. 4 shows an enlarged view of the lower wall section of FIG. 2.
FIG. 5 shows a cross-sectional view of an interior wall with a fully installed wall panel and trim system at its interior faces.
FIG. 6 shows an enlarged view of the lower wall section of FIG. 5.
FIG. 7 shows a cross-sectional view through a Tongue and Grooved, Beadboard Wall Panel.
FIG. 8 shows a front elevation view of the Wall Panel referenced in FIG. 7.
FIG. 9 shows a cross-sectional view of the Wall Panel referenced in FIG. 7, shown with continuous, flexible Magnetic Backing Strips, as referenced in FIG. 31, adhered to the upper and lower rear surface of the Wall Panel.
FIG. 10 shows a front elevation view of a wall showing the arrangement of Base and Chair Rail Moldings, Wall Panel and upper sheetrock, as referenced in FIG. 2 and FIG. 5.
FIG. 11 shows a cross-sectional view of the Base Molding.
FIG. 11A shows a cross-sectional view of a mating male flange of the Base Molding, as referenced in FIG. 11.
FIG. 12 shows a perspective view of the Base Molding, as referenced in FIG. 11.
FIG. 13 shows a cross-sectional view of the Chair Rail Molding.
FIG. 13A shows a cross-sectional view of a mating male flange of the Chair Rail Molding, as referenced in FIG. 13.
FIG. 14 shows a perspective view of the Chair Rail Molding, as referenced in FIG. 13.
FIG. 15 shows a cross-sectional view of the Receiver Trim.
FIG. 15A shows a cross-sectional view of a continuous mating female flange protruding perpendicularly from the front face of the Receiver Trim, as referenced in FIG. 15.
FIG. 16 shows a perspective view of the Receiver Trim, as referenced in FIG. 15.
FIG. 17 shows a cross-sectional view of the Receiver Trim, as referenced in FIG. 15, with a continuous, flexible Magnetic Backing Strip, as referenced in FIG. 31, adhered to the rear face of its base.
FIG. 18 shows a cross-sectional view of the mating fit-up between the Base Molding, as referenced in FIG. 11, and the Receiver Trim, with Magnetic Backing Strip, as referenced in FIG. 17.
FIG. 19 shows a perspective view of the mating fit-up between the Base Molding and Receiver Trim, with Magnetic Backing Strip, as referenced in FIG. 18.
FIG. 20 shows a cross-sectional view of the mating fit-up between the Chair Rail Molding, as referenced in FIG. 13, and the Receiver Trim, with Magnetic Backing Strip, as referenced in FIG. 17.
FIG. 21 shows a perspective view of the mating fit-up between the Chair Rail Molding and Receiver Trim, with Magnetic Backing Strip, as referenced in FIG. 20.
FIG. 22 shows a cross-sectional view of the Outside Corner Trim Molding.
FIG. 23 shows a cross-sectional view of the Inside Corner Trim Molding.
FIG. 24 shows a cross-sectional view of the Inside Corner Trim Molding, as referenced in FIG. 23, and the Outside Corner Trim Molding, as referenced in FIG. 22, prior to mating fit-up.
FIG. 24A shows a cross-sectional view of the mated fit-up between the Inside Corner Trim Molding, as referenced in FIG. 23, and the Outside Corner Trim Molding, as referenced in FIG. 22.
FIG. 25 shows a cross-sectional view of a wall inside corner detail showing the installed relationship between the Wall Panel, as referenced in FIG. 7, the Inside Corner Trim Molding, as referenced in FIG. 23, and the Outside Corner Trim Molding, utilized as a receiver, as referenced in FIG. 22.
FIG. 26 shows a cross-sectional view of a wall outside corner detail showing the installed relationship between the Wall Panel, as referenced in FIG. 7, the Outside Corner Trim Molding, as referenced in FIG. 22, and the Inside Corner Trim Molding, utilized as a receiver, as referenced in FIG. 23.
FIG. 27 shows a perspective view of a prefabricated outside corner detail showing the intersection of two Chair Rail Moldings, as referenced in FIG. 13.
FIG. 28 shows a perspective view of a prefabricated outside corner detail showing the intersection of two Base Moldings, as referenced in FIG. 11.
FIG. 29 shows a perspective view of a prefabricated inside corner detail showing the intersection of two Chair Rail Moldings, as referenced in FIG. 13.
FIG. 30 shows a perspective view of a prefabricated inside corner detail showing the intersection of two Base Moldings, as referenced in FIG. 11.
FIG. 31 shows a cross-sectional view of the continuously adhered Magnetic Backing Strip.
FIG. 32 shows a cross-sectional view of the Galvanized Steel Mounting Strip.
FIG. 33 shows a perspective of the room upon installation of the upper and lower Galvanized Steel Mounting Strips, FIG. 32, fastened to the existing wall wood or steel studs with galvanized steel roofing nails or flathead screws.
FIG. 34 shows a perspective of the room upon installation of the upper and lower Receiver Trims, FIG. 15, each with continuously adhered Magnetic Backing Strip, FIG. 31, mounted to a selective upper and lower location on the Galvanized Steel Mounting Strips, FIG. 32.
FIG. 35 shows a perspective of the room upon placement of the magnetically adhered, Beadboard Wall Panel, FIG. 7, each with continuously adhered upper and lower Magnetic Backing Strips, FIG. 9 and FIG. 31, to upper and lower Galvanized Steel Mounting Strips, FIG. 32. The Inside and Outside Corner Trim receivers, FIG. 22 and FIG. 23, are held in place by sandwiching their legs behind the vertical edges of the adjacent magnetically adhered Wall Panels, FIG. 7, at wall inside and outside corner locations, as referenced in FIG. 25 and FIG. 26.
FIG. 36 shows a perspective of the room upon placement of the Base Molding, FIG. 11, and Chair Rail Molding, FIG. 13, press-fit into upper & lower Receiver Trims, FIG. 15, as referenced in FIG. 18 and FIG. 20. Also shown is the placement of the Inside and Outside Corner Trim moldings, FIG. 23 and FIG. 22, press-fit into respective corner trim receivers, as referenced in FIG. 24 and FIG. 24A.
DETAILED DESCRIPTION OF THE INVENTION
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.
As used herein, the term “molding” is intended to refer generally to a decorative plane or curved strip that is used for ornamentation or finishing. Such decorative planes or curved strips may be formed of a rigid PVC or similar material having sufficient resilient properties.
As used herein, the term ‘wainscot’ is intended to refer generally to the lower one third height of an interior wall when finished differently from the upper sections of the wall.
As used herein, the term ‘flood cut’ is a term used in water remediation and construction to describe the partial removal of drywall up to a certain height. The obvious purpose is to allow the removal of water damaged drywall, insulation and other building materials and allow access to framing and salvageable materials for drying.
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.
It is an object of the invention to provide a new and improved, magnetically adhered, flood resilient wall panel and trim system to replace conventional sheetrock, joint compound, joint tape and/or plaster interior walls in residential and commercial construction below a sheetrock flood cut elevation.
The present invention's resilient characteristics enable quick and easy removal and re-installation, in the wake of future flooding events, by those skilled in the art, without the need for nails, fasteners or power tools. Its unique, new and improved, magnetically adhered attachment system, Receiver Trims, Moldings and Wall Panel, are further described in accordance with the following disclosure.
FIG. 1 is a perspective of a typical room prior to installation of the new wall panel and trim system components. A plurality of existing wood studs 10 are shown exposed from floor level 11 to the lower elevation of the existing upper sheetrock walls 9.
FIG. 2 is a cross-sectional view of an exterior wall consisting of existing interior upper sheetrock 9, a plurality of 2″×4″ wood studs 10, an exterior sheathing 13, floor 11 and ceiling 12, with a new wall panel and trim system installed at the lower interior wall face. FIG. 5 is a cross-sectional view of an interior wall consisting of existing interior upper sheetrock 9, a plurality of 2″×4″ wood studs 10, floor 11 and ceiling 12, with a new wall panel and trim system installed at the lower interior wall face.
Wall framing members may also consist of various sized wood studs, as well as galvanized steel studs of varying profiles and gage thicknesses. The arrangement of components making up the wall panel and trim system can further be seen in the enlarged cross-sectional views of FIG. 3, FIG. 4 and FIG. 6.
The system installation begins with the upper Galvanized Steel Mounting Strip 1, as referenced in FIG. 32, being secured to the existing wall studs 10 at a position flush with the lower edge of existing upper sheetrock wall 9, while the lower Galvanized Steel Mounting Strip 1 may be secured to the existing wall studs 10 at a position flush with the surface of the finished floor 11, as referenced in FIG. 3.
FIG. 33 shows a perspective of the room upon installation of the upper and lower Galvanized Steel Mounting Strips 1 fastened to the existing wall studs 10 with galvanized roofing nails or flathead screws 1A, as referenced in FIG. 3.
The Galvanized Steel Mounting Strips 1 may have a thickness T of 32 gage, width S of 10 inches, as referenced in FIG. 32, and be cut to the horizontal length of each of the walls from outside corner to inside corner to door jambs 14, as may be the situation. For long walls requiring continuous upper and lower Galvanized Steel Mounting Strips 1, the mating edges of adjacent strips may be abutted at the centerline of any particular wall stud 10.
Once upper and lower Galvanized Steel Mounting Strips 1 are in place, installation of magnetically adhered Receiver Trims 6 may begin.
The Receiver Trim 6, in accordance with the present invention, as shown in FIG. 3, FIG. 15, FIG. 15A, and FIG. 16 may be formed of different resilient materials, including, but not limited to, rigid PVC (polyvinylchloride).
The Receiver Trim 15 may have a width G and extend to a length G6 as shown in the perspective view of FIG. 16, and may consist of two pairs of continuous, symmetrical female flanges protruding perpendicularly from the front surface of the Receiver Trim 6, as shown in FIG. 15A, from the front surface to a distance G5. Each flange may have opposing tapered surfaces 32 and 35 at their free ends which may form an angle G11 with the smooth faces 31 and 36 of each flange, as shown in FIG. 15A. The tapered surfaces 32 and 35 may transition into a series of equally sized and spaced teeth with height G9, faces 33, apex radius G14, valley radius G13, distance between adjacent apices G10 and angle between faces 33 equal to G12. Angle G12 may be 90 degrees, which may be sufficient to secure the mating male flanges of the Base Molding 4 and Chair Rail Molding 5, as referenced in FIG. 11 and FIG. 13, respectively, as depicted in FIG. 18 and FIG. 20, of the present invention thereto, while also permitting its removal with the application of a reasonable amount of force as discussed hereinafter. The radiused apices of the teeth of opposite flanges may be at a distance G7 apart which produces a desired gap between female flange surfaces, as per FIG. 11A and FIG. 13A, and of mating male flange surfaces, as per FIG. 15A, as shown in FIG. 18 and FIG. 20.
Attached to the rear face of the Receiver Trim base 30 may be a fully-adhered flexible Magnetic Backing Strip 3, as shown in FIG. 17. The flexible Magnetic Backing Strip 3 may be of thickness R and width Q, as referenced in FIG. 31, which may be equal to the Receiver Trim width G, and continuously adhered to the rear face 30 of the Receiver Trim 6 with a waterproof acrylic adhesive. The magnetic backing strip may yield a minimum pulling force of 85 pounds per square foot, based on contact area with the Galvanized Steel Mounting Strips.
The upper and lower Receiver Trims 6 may be serially installed by magnetic adhesion to the upper and lower Galvanized Steel Mounting Strips 1. The lower Receiver Trim 6 may be mounted flush with the top surface of the room's finished floor 11. The upper Receiver Trim 6 may be mounted flush to the underside of the sheetrock 9 flood cut.
The Receiver Trim 6 may be cut to a length 2.25″ shorter than the full length of the wall as measured from outside corner to inside corner, inside corner to inside corner or outside corner to outside corner, as may be required to allow for clearance between the smooth flange legs of the Inside and Outside Corner Trim receivers 7 and 8, respectively, as per corner details shown in FIG. 25 and FIG. 26.
FIG. 34 shows a perspective of the room upon installation of the upper and lower Receiver Trims 6, FIG. 15, each with continuously adhered Magnetic Backing Strip 3, as referenced in FIG. 17, as mounted to a selective upper and lower location on the Galvanized Steel Mounting Strips 1.
Once Receiver Trims 6 are in place, installation of Wall Panels 2 may begin.
FIG. 7 shows a cross-sectional view of a Tongue and Groove, Beadboard Wall Panel 2, but may be formed of a wide variety of wall panel surface profiles and finishes of equally resilient materials, including but not limited to, cellular PVC (polyvinylchloride).
The Wall Panel 2 may be cut to length D to accommodate the required Flood Cut height A, as shown in FIG. 2, FIG. 3, FIG. 4, FIG. 5, FIG. 6 and FIG. 8. FIG. 8 shows a front elevation view of the Wall Panel 2, as referenced in FIG. 7. Attached to the upper and lower rear faces of each Wall Panel 2 may be a fully-adhered flexible Magnetic Backing Strip 3, as shown in FIG. 9. The length of each flexible Magnetic Backing Strip 3 may be equal to Wall Panel 2 width B, as referenced in FIG. 7, strip height Q and strip thickness R, as referenced in FIG. 31, as installed with a waterproof acrylic adhesive.
FIG. 35 shows a perspective of the room upon placement of the magnetically adhered, Wall Panel 2, referenced in FIG. 7, each with continuously adhered upper and lower Magnetic Backing Strips 3, as referenced in FIG. 9, to upper and lower Galvanized Steel Mounting Strips 1. Additionally, each serially mounted Wall Panel 2 is vertically tongue and groove joined, as shown in FIG. 7.
At room inside corners, an Inside Corner Trim Receiver 7 may be cut to fit between the upper and lower Receiver Trims 6 and held in place by the magnetically adhered Wall Panels 2 intersecting at each leg of the inside corner, as shown is FIG. 25.
FIG. 25 shows a horizontal, cross-sectional view of a wall inside corner detail showing the installed relationship between the Wall Panel 2, as referenced in FIG. 7, the Inside Corner Trim Molding 8, as referenced in FIG. 23, and the Outside Corner Trim Molding 7, utilized as a receiver, as referenced in FIG. 22.
At room outside corners, an Outside Corner Trim Receiver 8 may be cut to fit between the upper and lower Receiver Trims 6 and held in place by the magnetically adhered Wall Panels 2 intersecting at each leg of the outside corner, as shown is FIG. 26.
FIG. 26 shows a horizontal, cross-sectional view of a wall outside corner detail showing the installed relationship between the Wall Panel 2, as referenced in FIG. 7, the Outside Corner Trim Molding 7, as referenced in FIG. 22, and the Inside Corner Trim Molding 8, utilized as a receiver, as referenced in FIG. 23.
Once Receiver Trims 6 are in place, installation of Base Molding 4 and Chair Rail Molding 5 may begin. Base & Chair Rail Moldings inside and outside corners may be prefabricated with mitered inside and outside corners, as referenced in FIG. 27, FIG. 28, FIG. 29, and FIG. 30, with equal leg lengths U, V, W and X, respectively.
The Base Molding 4 and Chair Rail Molding 5, as referenced in FIG. 11 and FIG. 13, respectively, are installed by applying a reasonable amount of pressure to their front contoured surfaces, as may be required to secure the mating male flanges of the Base Molding 4 and Chair Rail Molding 5 to the two pairs of continuous, symmetrical female flanges protruding perpendicularly from the front surface of the upper and lower Receiver Trims 6, thereby producing their desired fit-ups, as depicted in FIG. 18 and FIG. 20, respectively. Once installed, if necessary, the Base Molding 4 or Chair Rail Molding 5 can be hand separated from the Receiver Trim 6, with the application of a reasonable amount of force beginning at either end of the moldings.
Once Base Molding 4 and Chair Rail Molding 5 are in place, installation of the Inside Corner Trim 8, FIG. 23, and Outside Corner Trim 7, FIG. 22, may begin as the final step in the installation process of the proposed invention.
Inside Corner Trim 8 and Outside Corner Trim 7 are cut to vertical measurements between lower face 27 of Chair Rail Molding 5 and upper face 24 of Base Molding 4.
Inside Corner Trim 8 and Outside Corner Trim 7 are installed by applying a reasonable amount of pressure to their front exposed surfaces thereby press-fitting their flanges with those of their respective corner trim receivers.
FIG. 36 shows a perspective of the room upon placement of the Base Molding 4, Chair Rail Molding 5, Inside Corner Trim 8 and Outside Corner Trim 7 all press-fit into their respective receivers, thereby completing the installation process of the invention.
While each component of the invention, as described above, may be manufactured from resilient materials, it may be the easy removal and re-installation of the magnetically adhered components that further define the invention's novel resilience.
Once installed, if necessary, the Base Molding 4 and lower Receiver Trim 6 with Magnetic Backing Strip 3, as shown in FIG. 18, may be removed as a single composite unit from the lower Galvanized Steel Mounting Strip by hand separation, by one skilled in the art, with the application of a reasonable amount of force beginning at either end of the Base Molding 4/Receiver Trim 6/Magnetic Backing Strip 3 composite unit.
Once installed, if necessary, the Chair Rail Molding 5 and upper Receiver Trim 6 with Magnetic Backing Strip 3, as shown in FIG. 20, may be removed as a single composite unit from the upper Galvanized Steel Mounting Strip by hand separation, by one skilled in the art, with the application of a reasonable amount of force beginning at either end of the Chair Rail Molding 5/Receiver Trim 6/Magnetic Backing Strip 3 composite unit.
If necessary, the Wall Panel 2, with upper and lower Magnetic Backing Strips 3, as referenced in FIG. 9, may be removed as a single composite unit from the upper and lower Galvanized Steel Mounting Strips by hand separation, by one skilled in the art, with the application of a reasonable amount of force beginning at the tongue edge of the Wall Panel 2/Magnetic Backing Strip 3 composite unit.
The reinstallation process may be quickly accomplished, by one skilled in the art, without the need for tools, by first serially magnetically adhering the Base Molding 4/Receiver Trim 6/Magnetic Backing Strip 3 composite unit to the lower Galvanized Steel Mounting Strip.
Next, the Wall Panel 2/Magnetic Backing Strip 3 composite unit may then be serially re-installed by magnetic adhesion to the upper and lower Galvanized Steel Mounting Strips. Composite Inside Corner Trims 8 and Outside Corner Trims 7, with their respective receivers intact, may be re-installed to the vertical edges of Wall Panels 2 at each inside and outside corner transition.
The Chair Rail Molding 5/Receiver Trim 6/Magnetic Backing Strip 3 composite unit may then be serially re-installed by magnetic adhesion to the upper Galvanized Steel Mounting Strip thereby completing the re-installation of the proposed invention.
Patent Application
20210317668
