Patent Grant
10865569
The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall.
In order to enhance the look of a wall structure, it is known to secure decorative wall panels to the wall structure. However, the securement of wall panels to the wall structure is generally a long and tedious job since it entails the use of additional fastening devices to secure each wall panel to the wall structure. Examples of such arrangements are shown in applicant's earlier U.S. Pat. Nos. 8,966,849; 9,359,770; 9,562,361; 9,631,372; 9,765,528; 10,011,997; 10,253,505; and 10,260,240.
It would therefore be desirable to provide wall panels that can be secured directly or indirectly to an existing wall, in which the wall panels are easily interlocked with and/or supported by each other to greatly simplify the assembly thereof.
Accordingly, it is an object of the present invention to provide wall panels for securement to a wall that overcomes the aforementioned problems.
It is another object of the present invention to provide wall panels for securement to a wall in which the wall panels are easily interlocked with and/or supported by each other to greatly simplify the assembly thereof.
In accordance with an aspect of the present invention, an interlocking wall panel arrangement for mounting wall panels to an existing wall, includes a plurality of wall panels, each wall panel including a main wall panel section, a first interlocking section at one end of the main wall panel section, and a second interlocking section at an opposite end of the main wall panel section for engaging with a first interlocking section of another the wall panel; and a securing arrangement for securing the first interlocking section to the existing wall.
The first interlocking section includes walls defining a channel, and the second interlocking section includes a projection wall that fits within the channel of another wall panel.
The first and second interlocking sections extend rearwardly from the main wall panel section so as to space the main wall panel section from the existing wall when the respective wall panel is secured to the existing wall.
Each wall panel further includes an intermediary support wall extending rearwardly of the main wall panel section at a position between the first and second interlocking sections.
In addition, it is possible that the main wall panel section has a three-dimensional shape in cross-section.
In one embodiment, the securing arrangement includes a tail wall formed integrally as a single piece with the first interlocking section. In such case, the first interlocking section includes walls defining a channel, the second interlocking section includes a projection wall that fits within the channel of the another wall panel, and the tail wall is formed as an extension of the walls defining the channel.
In another embodiment, the securing arrangement includes clips for holding the first interlocking section and which are adapted to be secured to the existing wall by fastening members.
Each clip includes walls defining a channel, and the first interlocking section includes a projection wall that fits within the channel of each respective clip.
The interlocking wall panel arrangement further includes a starter member for securing the second interlocking section of a first wall panel to the existing wall. The starter member includes a base wall adapted to be secured to the existing wall by fastening members, and an L-shaped wall extending outwardly from a free end of the base wall so as to define a channel with the base wall for receiving and holding the second interlocking section therein.
The interlocking wall panel arrangement further includes a finishing member for securing the first interlocking section of a last wall panel to the existing wall. The finishing member includes a base wall adapted to be secured to the existing wall by fastening members, and an L-shaped wall extending outwardly from a free end of the base wall so as to define a channel with the base wall for receiving and holding the first interlocking section therein.
The interlocking wall panel arrangement further includes a side connecting arrangement for connecting together side edges of adjacent wall panels. The side connecting arrangement includes a connecting base having an elongated base wall adapted to be secured to the existing wall along the side edges of the wall panels, a cover wall adapted to be positioned over adjacent side edges of adjacent wall panels and a securing arrangement for securing the cover wall to the connecting base in order to sandwich the side edges of the wall panels therebetween. The securing arrangement includes at least one first wall formed with the cover wall and extending between adjacent side edges of the adjacent side panels, and at least one second wall formed with the connecting base for engaging with and holding the at least one first wall to secure the cover wall in overlying spaced relation with the connecting base.
The interlocking wall panel arrangement further includes a corner connecting arrangement for connecting together ends of adjacent wall panels at either an outside corner of the existing wall, or an inside corner of existing wall.
A spacing exists between adjacent wall panels, and the spacing is adapted to be adjusted by varying dimensions of walls of the first interlocking section and/or the second interlocking section.
The above and other features of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings.
Referring to the drawings in detail, and initially to
Interlocking wall panel arrangement 10 includes a plurality of wall panels 14. Each wall panel 14 includes a main wall panel section 16, a first interlocking section 18 at a first end 16a of main wall panel section 16 and a second interlocking section 20 at the opposite second end 16b of main wall panel section 16.
First interlocking section 18 includes a first L-shaped wall 22 connected to the first end 16a of main wall panel section 16 and a second L-shaped wall 24 connected to first L-shaped wall 22.
Specifically, first L-shaped wall 22 includes a first wall 26 extending at an angle, preferably a right angle, from the first end 16a, rearwardly of main wall panel section 16, and a second wall 28 extending at an angle, preferably a right angle, from the opposite free end of first wall 26, in a direction away from main wall panel section 16 and preferably, in parallel, offset relation from main wall panel section 16.
Second L-shaped wall 24 includes a third wall 30 extending at an angle, preferably a right angle, rearwardly from second wall 28, in a direction away from main wall panel section 16, at a position spaced inwardly from the free end of second wall 28 and preferably in parallel offset relation from first wall 26, and a fourth wall 32 extending at an angle, preferably a right angle, from the opposite free end of first wall 30, in a direction away from main wall panel section 16 and preferably, in parallel, offset relation from both second wall 28 and main wall panel section 16.
It will be appreciated that the free portion of second wall 28, third wall 30 and the connected portion of fourth wall 32 together form a U-shaped channel 35 therebetween.
A lip 34 extends transversely across fourth wall 32 so as to define a tail section 36 between lip 34 and the free end of fourth wall 32.
Fourth wall 32 seats flush against the outer surface of existing wall 12 and spaced apart screws 38 secure tail section 36 to existing wall 12. With this arrangement, main wall panel section 16 extends in parallel, spaced apart relation from the outer surface of existing wall 12.
Second interlocking section 20 includes a third L-shaped wall 40 extending from the rear surface of main wall panel section 16 spaced slightly inwardly from second end 16b.
Specifically, third L-shaped wall 40 includes a fifth wall 42 extending at an angle, preferably a right angle, from the rear surface of main wall panel section 16 at a position spaced slightly inwardly from second end 16b, and a sixth wall 44 extending at an angle, preferably a right angle, from the opposite free end of fifth wall 42, in a direction away from first L-shaped wall 22 and preferably, in parallel, offset relation from main wall panel section 16.
Further, a lip 46 extends rearwardly at an angle, preferably a right angle, from the second free end 16b of main wall panel section 16.
Lastly, to provide additional support, an intermediary support wall 48 extends rearwardly from main wall panel section 16 at a position substantially midway between first interlocking section 18 and second interlocking section 20, with the free end of intermediary support wall 48 preferably seating flush against existing wall 12.
With this arrangement, a first wall panel 14a is positioned against exterior wall 12 and secured thereto by spaced apart screws 38 extending through tail section 36. Then, a U-shaped rubber seal 50 is positioned within U-shaped channel 35. Thereafter, a second wall panel 14b is assembled in interlocking relation with first wall panel 14a. Specifically, sixth wall 44 of second wall panel 14b is positioned within rubber seal 50 within U-shaped channel 35 of first wall panel 14a. In such position, the free end of lip 46 seats on the outer exposed surface of second wall 28 of first wall panel 14a, and the rear surface of fourth wall 32 of second wall panel 14b seats flush against existing wall 12 at a higher position. Then, tail section 36 of second wall panel 14b is secured to existing wall 12 by spaced apart screws 38. It will be appreciated that, during this procedure, second wall panel 14b is supported at its lower end in interlocking relation on first wall panel 14a. Thereafter, a third wall panel 14c is secured with second wall panel 14b in the same manner, and so on.
As will be described in other embodiments hereafter, a starter member is preferably provided at the lower end of the first wall panel 14a for supporting the same on existing wall 12, and a finishing member is preferably provided at the upper end of the uppermost wall 14c for covering and supporting the upper end thereof.
With the above arrangement, assembly of the wall panels 14 on existing wall 12 is greatly simplified, with the lower end of each wall panel 14 being supported during assembly, and the wall panels 14 interlocking with each other.
Wall panel arrangement 110 differs from wall panel arrangement 10 by the replacement of the single intermediary support wall 48 with a U-shaped intermediary support wall 148.
Wall panel arrangement 210 differs from wall panel arrangement 10 by the elimination of the single intermediary support wall 48. In addition, main wall panel section 216 is not planar, but rather, has a three-dimensional shape. In wall panel arrangement 210, main wall panel section 216 has a square wave shape in cross-section. This provides additional rigidity to main wall panel section 216, while also presenting a three-dimensional appearance.
It will be appreciated, however, that any three-dimensional shape can be used for the main wall panel section, for example, three-dimensional shapes of the type shown in applicant's U.S. Pat. No. 9,631,372.
As shown in
With this arrangement, as shown in
At the upper end of the last, uppermost wall panel 14u, a finishing member is provided which can be identical to starter member 66 but turned 180 degrees, in order to hold the upper end of the uppermost wall panel 14u to existing wall 12.
A different arrangement for a starter member and finishing member is shown in
A further wall 378 extends downwardly in a coplanar manner from second wall 374, and a closure wall 380 extends inwardly from the lower end of further wall 378.
With this arrangement, as shown in
The assembly continues in the same manner as previously described. At the upper end of the last, uppermost wall panel 14u, a finishing member 400 is provided. As shown in
Finishing member 400 includes a finishing member base 401 and a finishing member cover 402. Finishing member base 401 includes a base wall 403 secured to existing wall 12 by screws 38 at the lower end thereof, and two parallel, spaced apart walls 405 and 406 extending outwardly from the upper end of base wall 403, one above the other. A barb 407 is formed at the free end on the outer facing surface of each wall 405 and 406.
Finishing member cover 402 includes an L-shaped wall 409. Specifically, L-shaped wall 409 includes a first wall 411 in parallel covering relation to uppermost wall 405, and a second wall 413 connected at an angle, preferably a right angle, to the outer free end of first wall 411 so as to be in parallel, spaced apart relation to base wall 403. In this manner, second wall 413 is in covering relation to base wall 403 and lies flush over the free end of main wall panel section 16 of uppermost wall panel 14u, so as to retain uppermost wall panel 14u in position.
A short stub wall 415 extends inwardly from the inner surface of second wall 413 so as to be positioned to the outside of wall 406 when first wall 411 is positioned to the outside of uppermost wall 405. Both first wall 411 and stub wall 415 include barbs 417 which snap onto and engage barbs 407 in order to retain finishing wall cover 402 on finishing wall securement 401.
Referring now to
Specifically, side connecting arrangement 500 includes a connecting base 502 having an elongated base wall 504 secured to existing wall 12 along the entire side edges of wall panels 14x and 14y by screws 506. Two parallel, spaced apart stub walls 508 and 510 extend outwardly from base wall 504 at the center thereof, and extend along the length of base wall 504. Each stub wall 508 and 510 includes an outwardly extending barb 512 at the upper end thereof. Stub walls 508 and 510 thereby define a left base wall section 504a and a right base wall section 504b.
Side connecting arrangement 500 further includes a cover 514 formed by an elongated upper cover wall 516 of the same width as elongated base wall 504. Two parallel, spaced apart securing walls 518 and 520 extend outwardly from cover wall 516 at the center thereof, and extend along the length of cover wall 516. The spacing between walls 518 and 520 is slightly greater than the spacing between walls 508 and 510 to permit walls 508 and 510 to extend between walls 518 and 520. Each wall 518 and 520 includes an inwardly extending barb 522 at the lower end thereof for engagement with barbs 512 in order to secure cover 514 to base 502. Walls 518 and 520 thereby define a left cover wall section 516a and a right cover wall section 516b.
With this arrangement, base wall 504 is secured to existing wall 12 by screws 506 along the entire side edges of two adjacent wall panels 14x and 14y. In this regard, left base wall section 504a is sandwiched between existing wall 12 and first interlocking section 18, second interlocking section 20 and intermediary support wall 48 of wall panel 14x, as shown in
When wall panels 14 meet at a corner, they must be connected together as well. In this regard, as shown in
Specifically, outer corner connecting member 600 includes a corner connecting base 602 having an L-shaped base wall 604 secured to the outside corner of existing wall 12. L-shaped base wall 604 includes a first planar wall 604a and a second planar wall 604b connected to first planar wall 604a at a right angle, with both planar walls 604a and 604b connected to existing wall 12 by screws 606. Corner connecting base 602 includes an elongated fork wall 608 extending outwardly from the juncture of first and second planar walls 604a and 604b. Elongated fork wall 608 includes two parallel, spaced apart connecting walls 610 and 612, each including an outwardly extending barb 614 at the upper end thereof.
Outer corner connecting member 600 further includes a cover 616 formed by an elongated L-shaped outer cover wall 618 having a first planar wall 618a in overlying, spaced apart relation to first planar wall 604a, and a second planar wall 618b connected to first planar wall 618a at a right angle, and in overlying, spaced apart relation to second planar wall 604b. Cover 616 includes inwardly extending barbs 620 which engage barbs 614 to secure cover 616 on corner connecting base 602.
With this arrangement, corner connecting base 602 is secured to existing wall 12 by screws 606. The ends of adjacent wall panels 14 meet at the corner, and cover 616 is snapped onto corner connecting base 602 to engage and cover the ends of adjacent wall panels beneath first and second planar walls 618a and 618b. Thus, outer corner connecting member 600 covers the gap between the side edges of wall panels 14 that meet at the corner, while also helping to secure wall panels 14 in position on existing wall 12.
As shown in
Specifically, inner corner connecting member 700 includes a corner connecting base 702 having an L-shaped base wall 704 secured to the inside corner of existing wall 12. L-shaped base wall 704 includes a first planar wall 704a and a second planar wall 704b connected to first planar wall 704a at a right angle, with both planar walls 704a and 704b connected to existing wall 12 by screws 706. Corner connecting base 702 includes an inner diagonal wall 707 extending inwardly from the juncture of first and second planar walls 704a and 704b, with an elongated fork wall 708 connected to the free end of inner diagonal wall 707 and extending inwardly therefrom. Elongated fork wall 708 includes a first planar wall 708a, and a second planar wall 708b connected to first planar wall 708a at a right angle, and in overlying, spaced relation to first and second planar walls 704a and 704b, respectively.
With this arrangement, inner corner connecting base 702 is secured to existing wall 12 by screws 706. The ends of adjacent wall panels 14 which meet at the corner extend beneath first and second planar walls 708a and 708b. Thus, inner corner connecting member 700 covers the gap between the side edges of wall panels 14 that meet at the corner, while also helping to secure wall panels 14 in position on existing wall 12.
Wall panel arrangement 310 differs from wall panel arrangement 10 by eliminating lip 34 and tail section 36. Because tail section 36 is eliminated, wall panel arrangement 310 includes clips 352 for engaging with and securing fourth walls 32 to existing wall 12.
As shown, each clip 352 includes a base wall 354 that seats flush against existing wall 12, and which is secured thereto by spaced apart screws 38 extending therethrough. Base wall 354 further includes a bent trapezoidal shaped section 356 at the end thereof which is opposite to the portion at which screws 38 are inserted. In this manner, the rear surface of fourth wall 32 seats upon the smaller side 356a of trapezoidal shaped section 356.
Clip 352 further includes an L-shaped securement wall 358 extending outwardly therefrom. Specifically, L-shaped securement wall 358 includes a first wall 360 extending outwardly in a transverse manner from the exposed surface of base wall 354 at a position which substantially bisects base wall 354, and a second wall 362 which extends at an angle, preferably a right angle, from the free end of first wall 360 in a direction toward trapezoidal shaped section 356, and in parallel, spaced relation to base wall 354, so as to define a U-shaped channel 364 between base wall 354, first wall 360 and second wall 362.
With this arrangement, fourth wall 32 of a wall panel 14 is captured within U-shaped channel 364.
Wall panel arrangement 810 differs from wall panel arrangement 110 by eliminating lip 34 and tail section 36. Because tail section 36 is eliminated, wall panel arrangement 810 includes clips 352, which are the same as clips 352 in
It will be appreciated that, with wall panel arrangements 310 and 810, intermediary support walls 48 and 148 are spaced from existing wall 12. However, intermediary support walls 48 and 148 can be extended to contact existing wall 12 in the manner shown in
Wall panel arrangement 910 differs from wall panel arrangement 210 by eliminating lip 34 and tail section 36. Because tail section 36 is eliminated, wall panel arrangement 910 includes clips 352, which are the same as clips 352 in
As discussed above with respect to
Further, as shown in
in addition, although the wall panels have been described as being assembled from a lowermost wall panel 14a to an uppermost wall panel 14u in a vertical direction, the present invention is not limited thereby. For example, the wall panels 14 can be assembled in interlocking relation in a left to right, or right to left, direction, that is, 90° from the arrangements shown in the drawings.
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.
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