Patent Application
20210340773
The present disclosure relates generally to wall panels.
Wall panels provide durable, water-resistant, attractive, and affordable interior walls for commercial and residential spaces. Typically, wall panels are sized at 4′×8′ and 4′×10′. When the wall panels are installed side by side, an unsightly seam is formed between the panels. Attempts to reduce the visibility of the seam include butt-jointing the seams together applying additional trim pieces to the seam, and/or space the seams at very specific intervals and apply a bead of color matching sealant, very precisely along the seam. These techniques require additional time and/or expertise to install the panels. and still result in an unsightly seam along the entire length of the panel.
The following presents a simplified overview of the example embodiments in order to provide a basic understanding of some aspects of the example embodiments. This overview is not an extensive overview of the example embodiments. It is intended to neither identify key or critical elements of the example embodiments nor delineate the scope of the appended claims. Its sole purpose is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that is presented later.
In accordance with an example embodiment, there is disclosed herein, a panel that comprises a plurality of ornamental sections having a predefined shape, the plurality of ornamental sections are arranged in rows that form a staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel. A plurality of interior grooves are located between the ornamental sections, the interior grooves having a first width. A plurality of partial grooves having a second width are located along the at least one edge of the panel. Ornamental sections at an edge of a protruding row comprise convex curves having a first radius at their edges. Ornamental sections at the edge of recessed rows comprise concave curves having a second radius at their edges.
The accompanying drawings incorporated herein and forming a part of the specification illustrate the example embodiments.
This description provides examples not intended to limit the scope of the appended claims. The figures generally indicate the features of the examples, where it is understood and appreciated that like reference numerals are used to refer to like elements. Reference in the specification to “one embodiment” or “an embodiment” or “an example embodiment” means that a particular feature, structure, or characteristic described is included in at least one embodiment described herein and does not imply that the feature, structure, or characteristic is present in all embodiments described herein.
Described in an example embodiment herein are a panel that employ a finger joint for joining adjacent panels. The panels are formed using new and original CNC cutting techniques along with a unique, exclusive design. In an example embodiment, the finger joint panel works like a puzzle piece. The panel is cut in a way that does not leave any partial tiles, resulting in only full tiles on the finished product. Additionally, as will be described herein, partial grooves are cut into the finger jointed edges. These partial grooves give the appearance of uninterrupted grout joints when installed. The finger joint panels install directly into each other, creating a joint that does not require added trim, added color-specified sealant, or additional time or expertise to install. This can reduce up-front accessory costs, installation costs, and results in a wall with seams that are almost invisible to the naked eye.
In an example embodiment, the width of the grooves along the edge (second width) is one-half the width of the interior grooves (first width). When installed next to adjacent panel that also has groove along the edge that is one-half the width of the interior grooves, this will result in a groove between the panels having the same width as the interior grooves.
In the example illustrated in
In an example embodiment, the radius of convex curves 24 (the first radius or outside radius) of ornamental sections 12 at the edge 18 of protruding rows 14 are the same as the radius of the concave curves 26 (the second radius or inside radius) of the ornamental sections 12 at the edge 18 of recessed rows 26. However, as those skilled in the art can readily appreciate that it may be difficult to achieve exactly equal radiuses for the first and second radiuses, in an example embodiment, the length of the second radius is within a specified tolerance (e.g., 15% or machining tolerances) of the length of the first radius.
The ornamental sections 12 of the panel 10 illustrated in
The panel 10 can be made of any suitable material. Examples of suitable materials the panel can be made from include, but are not limited to, Fiberglass Reinforced Plastic (FRP), high density Fiberboard (HDF), Medium-density Fiberboard (MDF), or Plastic Board, or laminated composite board.
In view of the foregoing structural and functional features described above, a methodology 1400 in accordance with an example embodiment will be better appreciated with reference to
At 1402, the panel is formed. The panel can be formed using any suitable technique which can depend on the type of material being employed to make the panel. of suitable materials the panel can be made from include, but are not limited to, Fiberglass Reinforced Plastic (FRP), high density Fiberboard (HDF), Medium-density Fiberboard (MDF), Plastic Board, or laminated composite construction. The rows are formed with staggered rows and the shape of the edges can depend on the desired ornamental sections. For example, as illustrated in
At 1404, the interior grooves are machined into the panel. For example, the interior grooves can be circular, elliptical, V-shaped, or rectangular. CNC machining can be employed for cutting the grooves into the panel.
At 1406, the partial grooves are machined along at least one edge of the panel. In an example embodiment, the partial grooves correspond o the interior grooves of the panel. For example, the partial grooves can be one-half of a circular, elliptical, V-shaped, or rectangular groove. CNC machining can be employed for cutting the partial grooves into the panel.
At 1408, the curves are machined into the outer (protruding or finger) corners of the panel. The curves for the outer panel are convex and have a first radius. CNC machining can be employed for machining he outer corners,
At 1410, the curves are machined into the inner (recessed) corners of the panel. The curves for the inner panel are concave and have a second radius. CNC machining can be employed for machining he outer corners. In an example embodiment, the radius of the inner corner and the radius of the outer corner are equal or within a specified tolerance (e.g., 15%) of each other.
Described above are example embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies, but one of ordinary skill in the art will recognize that many further combinations and permutations of the example embodiments are possible. Accordingly, this application is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
