The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall structure.
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 using fastening devices such as nails and/or screws to secure the walls panels directly to the wall structure. In addition, the fastening devices are exposed, which can provide an unsightly appearance.
A system that overcomes some of these problems is sold by Bamco Inc. of 30 Baekeland Ave., Middlesex, N.J. 08846 under the designation “G500 WALL SYSTEM.” With this system, the wall panels are provided with right angle or bends at their edges. Each planar panel and the right angle bend together form an L-shape. Each bend is secured by screws to a fastening extrusion having the same linear dimension as the wall panel, and the fastening extrusion having a generally rectangular cross-sectional configuration. At each joint area where two panels meet, there are two such fastening extrusions connected together, each secured to a respective wall panel, with an elongated hard silicone gasket between the fastening extrusions. The fastening extrusions are arranged one above the other at each joint area. Thus, the screws are not visible, thereby eliminating the unsightly appearance of previous system.
However, because of the L-shape at the bends at the edges of the wall panels, it is necessary to separately secure each bend to a fastening extrusion by screws, in addition to securing the fastening extrusions to the wall structure by screws, further increasing the work required to assemble the wall panels. Also, because the bends in the wall panels extend only in a direction perpendicular to the wall panels, the only structural support is provided by the screws which secure each bend to a fastening extrusion. As a result, it is possible to loosen and/or pull out the wall panels.
In addition, in order to secure the fastening extrusions to existing wall structures, one of the connected pair of fastening extrusions is provided with an extension which is separately secured to the existing wall structure. This means that the main bodies of the fastening extrusions are spaced away from the existing wall structure, thereby providing a further weak link in the structure, besides making it more difficult to assemble.
Accordingly, it is an object of the present invention to provide a wall system that overcomes the aforementioned problems.
It is another object of the present invention to provide a wall system which does not require the use of screws to secure the wall panels to the fastening extrusions.
It is still another object of the present invention to provide a wall system in which the wall panels have U-shaped hooks at their edges which are securely held at the fastening extrusions without any screws or other fastening devices.
It is yet another object of the present invention to provide a wall system that is easy to assemble with an existing wall structure.
It is a further object of the present invention to provide a wall system in which the fastening extrusions are secured flush against the existing wall structure by fastening devices, thereby increasing the structural integrity thereof.
It is a still further object of the present invention to provide a wall system that is easy and economical to manufacture and use.
In accordance with an aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel having a main panel section and hook walls at edges of the main panel section, with the main panel section and each hook wall having a U-shaped cross-sectional profile. There are also a plurality of fastening extrusions, each fastening extrusion including a securing section for securing the fastening extrusion to the existing wall structure, a first retaining wall structure near one end of the fastening extrusion and adjacent the securing section, the first retaining wall structure including a recess which receives one hook wall of the wall panel, and a second retaining wall structure near another end of the fastening extrusion, the second retaining wall structure including a recess which receives one hook wall of another wall panel.
The main panel section has a rectangular configuration with four hook walls, and there are four fastening extrusions, with the recess of the retaining wall of each fastening extrusion receiving one hook wall of the wall panel.
Each fastening extrusion includes a planar section having a length, with the first retaining wall structure and the second retaining wall structure extend from a same side of the planar section. The first retaining wall structure is spaced from the one end of the fastening extrusion, and the securing section includes a tail section of the planar section which extends between the one edge and the first retaining wall. Preferably, each retaining wall structure has an L-shaped cross-sectional profile which faces the L-shaped cross-sectional profile of the other retaining wall structure. Also, at least one of the L-shaped cross-sectional profiles can be angled away from the planar section by a small angle. Thus, the planar section and each retaining wall structure together define a U-shaped cross-sectional profile that defines the respective recess.
A corner fastening extrusion is provided for starting assembly at a corner wall. The corner fastening extrusion includes a planar wall section for securing the fastening extrusion to the existing wall structure, and a first retaining wall structure near one end of the planar wall section, the first retaining wall structure including a recess which receives one hook wall of a wall panel. The corner fastening extrusion is used at edges of a respective wall panel corresponding to corners between a side wall and floor, two side walls, and a side wall and a ceiling.
There is also at least one channel secured to the securing sections of adjacent fastening extrusions and positioned between adjacent wall panels corresponding thereto. An elongated plug is inserted into each channel for closing off the channel.
In accordance with another aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel having a main panel section and hook walls at edges of the main panel section, with the main panel section and each hook wall having a U-shaped cross-sectional profile. A plurality of first fastening extrusion assemblies are provided. Each fastening extrusion assembly includes a securing section for securing the fastening extrusion assembly to the existing wall structure, a first retaining wall structure near one end of the fastening extrusion assembly and adjacent the securing section, the first retaining wall structure including a first recess which receives one hook wall of the wall panel and a second recess, and a second retaining wall structure near another end of the fastening extrusion assembly, the second retaining wall structure including a third recess which receives one hook wall of another wall panel and a fourth recess. A second fastening extrusion assembly is also provided, each second fastening extrusion assembly including a securing section for securing the second fastening extrusion assembly to the existing wall structure, and a first L-shaped retaining wall structure near one end of the fastening extrusion, the first L-shaped retaining wall structure extending into one of the second and fourth recess.
Each of the first fastening extrusion assemblies includes a first fastening extrusion and a second fastening extrusion. A first one of the fastening extrusions includes a tongue and a second one of the fastening extrusions includes a groove for receiving the tongue to connect together the first and second fastening extrusions when the first fastening extrusion is assembled with a first wall panel and the second fastening extrusion is assembled with a second wall panel. A depth of each tongue is greater than a depth of each groove such that each tongue does not fit entirely in the respective groove.
There is also at least one channel secured to the first and second fastening extrusion assemblies and positioned between adjacent wall panels corresponding thereto. An elongated plug is inserted into each channel for closing off the channel.
The main panel section has a rectangular configuration with four hook walls, and there are four first and second fastening extrusion assemblies associated with each main panel section, with the first and third recesses of the first and second retaining walls receiving one hook wall of the wall panel.
There is also a starter extrusion for starting assembly at a corner wall, including a securing section for securing the starter extrusion to the existing wall structure, and a first retaining wall structure connected with the securing section of the starter extrusion and including a fifth recess which receives one hook wall of another wall panel and a sixth recess. There is also a corner fastening extrusion for starting assembly at a corner wall, the corner fastening extrusion including a planar wall section for securing the corner fastening extrusion to the existing wall structure, and a first retaining wall structure at one end of the planar wall sectioni the first retaining wall structure including an L-shaped retaining wall structure extending into the sixth recess. The starter extrusion and corner fastening extrusion are used at edges of a respective the wall panel corresponding to corners between a side wall and floor, two side walls, and a side wall and a ceiling.
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
Main fastening extrusions 26 are provided for securing each wall panel 12 to existing wall structure 14. Each main fastening extrusion 22 includes a first fastening extrusion 28 and a second fastening extrusion 30 secured to first half fastening extrusion 28.
As shown best in
A U-shaped retaining wall 38 is formed at the opposite side edge of elongated planar section 32, immediately below recess 36. Specifically U-shaped retaining wall 38 is defined by planar section 32, a first right angle retaining wall section 40 at the opposite side edge of elongated planar section 32 and extending at a right angle away from planar section 32, and a second right angle retaining wall section 42 at the outer free side edge of first right angle retaining wall section 40 and extending at a right angle thereto, such that second right angle retaining wall section 42 is positioned in front of elongated planar section 32 and in spaced, parallel relation thereto. U-shaped retaining wall 32 thereby defines an inwardly directed recess 44 therein for receiving second right angle panel section 24 of hook structure 20 of a respective wall panel 12.
An L-shaped stabilizing wall 46 is secured to the free side edge of second right angle retaining wall section 42. L-shaped stabilizing wall 46 includes a first stabilizing wall section 48 secured to the free side edge of second right angle retaining wall section 42 and extending outwardly at a right angle therefrom, and a second stabilizing wall section 50 secured to the free side edge of first stabilizing wall section 48 and extending outwardly at a right angle therefrom, such that each second stabilizing wall section 50 is positioned in parallel, spaced apart relation to second right angle retaining wall section 42.
In like manner, as shown best in
A U-shaped retaining wall 58 is formed at the opposite side edge of elongated planar section 52, immediately below recess 56. Specifically U-shaped retaining wall 58 is defined by planar section 52, a first right angle retaining wall section 60 at the opposite side edge of elongated planar section 52 and extending at a right angle away from planar section 52, and a second right angle retaining wall section 62 at the outer free side edge of first right angle retaining wall section 60 and extending at a right angle thereto, such that second right angle retaining wall section 62 is positioned in front of elongated planar section 52 and in spaced, parallel relation thereto. U-shaped retaining wall 58 thereby defines an inwardly directed recess 64 therein for receiving second right angle panel section 24 of hook structure 20 of a respective wall panel 12.
An L-shaped stabilizing wall 66 is secured to the free side edge of second right angle retaining wall section 62. L-shaped stabilizing wall 66 includes a first stabilizing wall section 68 secured to the free side edge of second right angle retaining wall section 62 and extending outwardly at a right angle therefrom, and a second stabilizing wall section 70 secured to the free side edge of first stabilizing wall section 68 and extending outwardly at a right angle therefrom, such that each second stabilizing wall section 70 is positioned in parallel, spaced apart relation to second right angle retaining wall section 62.
With this arrangement, panels 12 and extrusions 28 and 30 are first assembled in a shop such that two first fastening extrusions 28 and two second fastening extrusions 30 are first secured to each wall panel 12. Specifically, as shown in
In order to retain extrusions 28a, 28b, 30a and 30b assembled with panel 12, triangular corner plates 71 are inserted in recesses 36 and 56 of adjacent extrusions 28a, 28b; 28b, 30a; 30a, 30b; and 30b, 28a. A fastening device, such as a screw (not shown) is then screwed through extrusions 28, 28b, 30a and 30b, and through corner plates 71, thereby holding the assembly together. It will be appreciated that this is not required for the structural integrity of the system, but is merely provided to enable the panels 12 and extrusions 28 and 30 to be assembled off premises and then transported and assembled at a premises.
In order to start the assembling process, a starter extrusion 72 is provided, as shown in
As shown in
It will be appreciated that the lowermost panel 12a of
Then, as shown in
The same operation occurs at the adjacent sides of each wall panel 16. This operation continues until the wall panels 12 reach the ceiling (not shown), and the same operation is performed, as was performed at floor 14b, by using starter extrusion 72.
It will therefore be appreciated that a novel system 10 for easily mounting wall panels 12 over an existing wall structure 14 has been described which does not require the use of fastening devices to secure wall panels 12 to main fastening extrusions 26 or starter extrusions 72, and specifically, in which each wall panel 12 has a U-shaped hooked structure 20 at its ends which are securely held at extrusions 26 and 72 without any fastening devices, such as screws or the like. This arrangement prevents wall panels 12 from being pulled out away from existing wall structure 14. Further, wall system 10 is easy to assemble with an existing wall structure 14 and in which extrusions 14 by fastening devices, thereby increasing the structural integrity thereof. Also, extrusions 28, 30 and 72 are assembled flush against an existing wall, thereby adding to the structural integrity.
It will be appreciated that various modifications can be made to the present invention within the scope of the claims. For example, second stabilizing wall sections 50 and 70 can be eliminated. As another alternative, channels 94 can be eliminated, and rubber plugs 96 merely inserted in the gap between adjacent wall panels 12.
With the above arrangement, however, screws 96 must be screwed through connecting walls 94c, and elongated planar sections 32 and 52, including tongues 34, into side wall 14a. In practice, this may be time-consuming and burdensome. Further, in practice, it may become difficult to perfectly align all of the panels together with the fastening extrusions 28 and 30.
Therefore, referring now to
Specifically, first fastening extrusion 128 is modified from first fastening extrusion 28 by deleting first stabilizing wall section 48 and second stabilizing wall section 50.
The elongated side edge of planar section 132 of first fastening extrusion 128 opposite tongue 134 includes a recess 136 therein. Recess 136 can extend the entire length of planar section 132, or alternatively, can be formed only at the ends of planar section 132. A shallow channel 137 is formed in the outer surface of planar section 132 in alignment with recess 136.
A U-shaped retaining wall 138 is formed at the same side edge of elongated planar section 132 as recess 136. Specifically U-shaped retaining wall 138 is defined by planar section 132, a first right angle retaining wall section 140 at the opposite side edge of elongated planar section 132 and extending at a right angle away from planar section 132, and a second right angle retaining wall section 142 at the outer free side edge of first right angle retaining wall section 140 and extending at a right angle thereto, such that second right angle retaining wall section 142 is positioned in front of elongated planar section 132 and in spaced, parallel relation thereto. U-shaped retaining wall 138 thereby defines an inwardly directed recess 144 therein for receiving second right angle panel section 24 of hook structure 20 of a respective wall panel 12.
Second fastening extrusion 130 is modified from first fastening extrusion 30 by deleting first stabilizing wall section 68 and second stabilizing wall section 70, and by shortening elongated planar section 152, thereby reducing the depth dimension of groove 154 therein. In this regard, only a distal portion of tongue 134 of first fastening extrusion 128 extends into groove 154. As a result of this construction, and as shown in
As with the first embodiment, the opposite elongated side edge of planar section 152 includes a recess 156 therein. Recess 156 can extend the entire length of planar section 152, or alternatively, can be formed only at the ends of planar section 152. A shallow channel 157 is formed in the outer surface of planar section 152 in alignment with recess 156.
Second fastening extrusion 130 also includes, as with the first embodiment, a U-shaped retaining wall 158 formed at the same side edge of elongated planar section 152 as recess 156. Specifically U-shaped retaining wall 158 is defined by planar section 152, a first right angle retaining wall section 160 at the opposite side edge of elongated planar section 152 and extending at a right angle away from planar section 152, and a second right angle retaining wall section 162 at the outer free side edge of first right angle retaining wall section 160 and extending at a right angle thereto, such that second right angle retaining wall section 162 is positioned in front of elongated planar section 152 and in spaced, parallel relation thereto. U-shaped retaining wall 158 thereby defines an inwardly directed recess 164 therein for receiving second right angle panel section 24 of hook structure 20 of a respective wall panel 12.
In order to further increase stability while making assembly of the panels 12 easier, and in accordance with another aspect of the present invention, a third fastening extrusion 131, as shown best in
In addition, a fourth corner fastening extrusion 151, as shown best in
In order to assemble the panels 12, a person starts from the floor 14b and works up side wall 14a, as shown in
The U-shaped hook structure 20 at the opposite upper side of wall panel 12c has been preassembled with first fastening extrusion 128 and third fastening extrusion 131, with second wall section 139b being inserted into recess 136 and with U-shaped hook structure 20 being inserted into inwardly directed recess 144. Screws (not shown) which extend through recess 133b, shallow channel 137 of first fastening extrusion 128 and U-shaped hook structure 20, hold these elements together. In this position, the free end of the pre-assembled third fastening extrusion 131, in channel 133a thereof, is screwed into side wall 14a by screws 199 along the entire length thereof. Then, second fastening extrusion 130, which is pre-assembled with the lower U-shaped hook structure 20 of another wall panel 12b by screws (not shown) extending through shallow channel 157, is assembled with first fastening extrusion 128 by tongue 134 and groove 154. The U-shaped hook structure 20 at the opposite upper side of wall panel 12b has been preassembled with a first fastening extrusion 128 and third fastening extrusion 131 in the manner described above with panel 12c. In this position, the free end of the pre-assembled third fastening extrusion 131, in channel 133a thereof, is screwed into side wall 14a by screws 199 along the entire length thereof. Then, a U-shaped channel 94 is held between the adjacent hook structures 20 of panels 12b and 12c by screws 98 which are screwed through tongue 134, recess 133c of planar section 133 of third fastening extrusion 131 and then into wall 14a. An elongated rubber plug 96 is then inserted into each channel 94 to provide an aesthetic appearance.
This assembly process continues until the top of wall 14a is reached, wherein another starter extrusion 172 is assembled thereat. This process also continues in the same way in a sidewards direction of each panel 12 until the entire wall structure is assembled.
It will be appreciated that first fastening extrusion 128 and second fastening extrusion 130 of the second embodiment can be eliminated at each juncture of panels 12, as shown by the modified third embodiment of the present invention of
As shown in
In this regard, as shown in
The U-shaped hook structure 20 at the opposite lower side of the wall panel 12d has been preassembled with L-shaped engagement wall 135 of a third fastening extrusion 131. Therefore, when this panel 12 is hung from fourth corner fastening extrusion 151, tail section 147 of the pre-assembled third fastening extrusion 131 is screwed into side wall 14a by screws 199 along the entire length thereof. Then, U-shaped hook structure 20 of another wall panel 12e is inserted into the inwardly directed recess defined by second inwardly directed L-shaped engagement wall 141 of third fastening extrusion 131. To assist in such insertion, a portion 145a of second wall section 145 thereof can be angled slightly away from planar section 133, as shown best in
Of course, it will be appreciated that triangular corner plates 71 are still used with the second and third embodiments in the same manner as the first embodiment.
It will be appreciated that various modifications can be made to the present invention within the scope of the claims. For example, fourth corner fastening extrusion 151 can be formed from third fastening extrusion 131 by forming the latter with a weakened line therealong to be effectively snapped or cut in half, leaving a portion of planar section 133 and first inwardly directed L-shaped engagement wall 135 forming fourth corner fastening extrusion 151.
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.
The present application is a Continuation-In-Part of copending U.S. patent application Ser. No. 11/615,979, filed Dec. 24, 2006 by the same inventor herein and entitled SYSTEM FOR MOUNTING WALL PANELS TO A WALL STRUCTURE.
Number | Date | Country | |
---|---|---|---|
Parent | 11615979 | Dec 2006 | US |
Child | 11691579 | US |