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 with the bent end sections being at least in near abutting relation.

Description

BACKGROUND OF THE INVENTION

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 has 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.

U.S. Pat. No. 7,472,521 and U.S. Pat. No. 7,621,084, by the same inventor herein disclose systems for mounting wall panels to an existing wall structure, which includes a plurality of wall panels. There are also a plurality of fastening extrusions. Each fastening extrusion includes a securing section for securing the fastening extrusion to the existing wall structure, and a retaining wall structure at one end of the securing section, the retaining wall structure including a recess which receives one hook wall of the 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 U-shaped cross-sectional profile defines a recess therein, and each fastening extrusion includes at least one stabilizing wall extending from a free end of a respective retaining wall, with the stabilizing wall being received in one recess of a respective U-shaped cross-sectional profile. Each stabilizing wall has an L-shaped cross-sectional profile. Also, the securing section and the retaining wall structure together define a U-shaped cross-sectional profile.

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. In a later embodiment, there is only a single fastening extrusion.

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 gap between adjacent wall panels.

This arrangement, however, requires the insertion of screws into the fastening extrusions and the channel while supporting the wall panels, which can be burdensome. It also requires the separate channels and plugs in order to close off the gap between adjacent wall panels to provide an aesthetic appearance between the wall panels. If the gap between adjacent panels is varied, this would also require a plurality of different size plugs, which can further add to the cost of the structure.

A further system has been sold for more than one year by Creative Metal Contractors Inc. of Toms River, N.J., which uses a single fastening extrusion having tongues extending from opposite sides thereof. The single fastening extrusion is secured to the existing wall by screws at a central portion thereof between the tongues. Each wall panel has 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. Fasteners or frame extrusions are secured to the hook walls, with each fastener including walls defining a recess which receives a corresponding tongue of the single fastening extrusion, such that the tongues are spaced away from the hook walls. A compressed joint plug is positioned in overlying relation to the screws and between adjacent hook walls to provide an aesthetic appearance.

However, with this latter arrangement, plugs are also required, with the same consequent disadvantages. It may also be difficult to align the recesses over the tongues of the single fastening extrusion. In addition, the single fastening extrusions are secured to the existing wall by screws only through the center of the fastening extrusions, which can result in failure of such securement. Still further, if the gap between adjacent panels is varied, this would also require a plurality of different size plugs, which can further add to the cost of the structure.

In addition, in the latter arrangement, the gap between adjacent wall panels is sealed with a silicone sealant and a compressed joint plug. As a result, the air pressure behind the wall panels varies relative to the ambient air pressure in front of the panels. However, architectural requirements require the air pressures to be the same or equalized so as not to reduce the longevity of the wall structure of the building.

The invention of U.S. Pat. No. 8,127,507 to the same inventor herein also requires the insertion of screws into the fastening extrusions and the channel while supporting the wall panels, which can be burdensome. It also requires the separate decorated panels in order to close off the gap between adjacent wall panels to provide an aesthetic appearance between the wall panels.

U.S. patent application Ser. No. 12/652,879, to the same inventor herein, attempts to cure the aforementioned problems, by providing a wall system which does not require the use of screws to secure the wall panels to the fastening extrusions. Rather, the wall panels have recesses into which the frame extrusions fit, and which also eliminates the use of plugs to cover the gap between adjacent wall panels. This permits easy hanging of the wall panels by providing a male connecting frame extrusion that merely fits within a female connecting wall panel.

It is also known from 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, to 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. However, with these patents, there is still a large gap between adjacent bent ends, which is necessary for securing the panels to the extrusions, and which also thereby requires a plug to close this gap.

SUMMARY OF THE INVENTION

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 are merely pressed into place and retained therein by spring-like extrusions secured to the walls.

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 that permits sliding of the walls panels on the extrusions.

It is a 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 and a plurality of main fastening extrusions. Each wall panel includes a main wall panel, and at least two bent end sections extending at an angle from different edges of the main wall panel, each bent end section having a wall thickness. Each fastening extrusion includes at least one base section adapted to be secured to the existing wall structure, and two spaced apart flexible and resilient bent end securing walls extending at an angle from the at least one base section, the two bent end securing walls having a spacing therebetween corresponding substantially to the wall thickness of two bent end sections. A cut-out section is formed at either a first surface of each bent end section which faces a respective bent end securing wall, or a second surface of each bent end securing wall which faces the first surface. A projection is formed at the other of the first surface of each bent end section, and the second surface of each bent end securing wall. Pressing of the bent end sections into the spacing between the bent end securing walls causes at least one bent end securing wall to be biased away from the other bent end securing wall until the projections engage in respective cut-out sections to permit the bent end securing walls to spring back to lock the bent end sections in the spacing in a manner that outer walls of the bent end sections are at least in near abutting relation with each other.

Each cut-out section has a cut-out holding surface that is substantially parallel to the main wall panel, or at least extends at an angle away from the main wall panel, and each projection has a projection holding surface for engaging with a respective cut-out holding surface. The bent securing walls are dimensioned such that, when each projection engages in a respective cut-out section, a free end of each bent end securing wall engages an undersurface of the respective main panel section, so as to lock the bent end section in the spacing in a tight fitting manner. Preferably, each projection has an inclined surface which terminates in the projection holding surface thereof, and each cut-out has an inclined surface which terminates in the cut-out holding surface thereof.

In one embodiment, each bent end section has a lower end with a beveled surface for engaging with the inclined surface of the respective projection when the bent end section is pressed into the spacing between the bent end securing walls to cause the respective bent end securing wall to be biased away from the other bent end securing wall until the projection engages in the respective cut-out section.

Preferably, the cut-out sections are provided on inner surfaces of the bent end sections, and the projections on the bent end securing walls face each other, with the two projections having a spacing therebetween which is less than the wall thickness of two bent end sections in an unbiased position of the bent end securing walls.

In another embodiment, each bent end securing wall is formed in an arcuate configuration, with the projection formed as a free end of the respective bent end securing wall.

In still another embodiment, each projection and respective cut-out section are shaped and dimensioned such that each projection force fits into a respective cut-out section in a snapping manner to lock the walls panels to the extrusions. Preferably, in this embodiment, each cut-out section has a part cylindrical shape extending over an angle greater than 180 degrees, and each projection has a part cylindrical shape extending over an angle greater than 180 degrees and corresponding in diameter to the diameter of the cut-out section so as to snap fit therein.

In one embodiment, each fastening extrusion is formed as a one-piece, unitary construction. In another embodiment, 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 the base sections. There are also a plurality of corner fastening extrusions. Each corner fastening extrusion includes 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 the base section, each corner bent end securing wall including a projection at one surface thereof facing another adjacent corner wall of the existing wall structure when the base section is secured to the one corner wall. The corner base section has dimensions to space the flexible and resilient corner bent end securing wall from the adjacent corner wall with a spacing corresponding substantially to the wall thickness of one bent end section. Thus, pressing of a bent end section into the spacing between the corner bent end securing wall and the adjacent corner wall causes the corner bent end securing wall to be biased away from the adjacent corner wall until the projection engages in a respective cut-out section to lock the bent end section in the spacing in a manner that an outer wall of the bent end section is least in near abutting relation with the adjacent corner wall.

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 including a main wall panel, and at least two bent end sections extending at an angle from different edges of the main wall panel, each bent end section having a wall thickness. A plurality of main fastening extrusions are provided, each fastening extrusion including at least one base section adapted to be secured to the existing wall structure, and two spaced apart flexible and resilient bent end securing walls extending at an angle from the at least one base section, the two bent end securing walls having a first spacing therebetween substantially greater than the wall thickness of two bent end sections. There is at least one further wall positioned between the spaced apart bent end securing walls, with a second spacing between the at least one further wall and each bent end securing wall being substantially equal to the wall thickness of one bend end section. A cut-out section is formed at either a first surface of each bent end section which faces a respective bent end securing wall, or a second surface of each bent end securing wall which faces the first surface. A projection is formed at the other of the first surface of each bent end section, and the second surface of each bent end securing wall. Pressing of each bent end section into a respective second spacing between one bent end securing wall and the at least one further wall causes the bent end securing wall to be biased away from the at least one further wall until the respective projection engages in a respective cut-out section to permit the bent end securing wall to spring back to lock the bent end section in the second spacing.

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

In another embodiment, the at least one further wall includes two inner walls, each connected to one bent end securing wall, or the at least one base section. Each inner wall is connected in parallel, spaced relation inwardly of a respective bent end securing wall by a distance substantially equal to the wall thickness of one bent end section. Each bent end section has dimensions such that pressing of the bent end section into the second spacing between a bent end securing wall and an inner wall causes the respective bent end securing wall to be biased away from the other bent end securing wall until the projection engages in the respective cut-out section, so as to lock the bent end section in the spacing. A closure member is provided for closing a space between the inner walls.

In one embodiment, each inner wall is connected by a lateral connecting wall to a respective bent end securing wall with a third spacing between each lateral connecting wall and the at least one base section, and the closure member extends in the third spacing. In another embodiment, each inner wall is connected to the 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 the at least one base section, and the closure member includes a plug inserted between the inner walls and engaged by the barbs.

In accordance with still 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 including a main wall panel, and at least two adjacent bent end sections extending at an angle from different edges of the main wall panel, with at least two bent end sections meeting at at least one corner, each bent end section including a cut-out section at an inner wall surface thereof, each bent end section having a wall thickness, each cut-out section having a panel holding surface. There are a plurality of main fastening extrusions, each fastening extrusion including at least one base section adapted to be secured to the existing wall structure, and two spaced apart flexible and resilient bent end securing walls extending at an angle from the at least one base section, each bent end securing wall including a projection at one surface thereof facing the other bent end securing wall, each projection having an extrusion holding surface for engaging with a respective panel holding surface. Each corner has a corner opening that permits sliding of each wall panel on the extrusion when the panel holding surface is engaged with the extrusion holding surface. Preferably, each corner opening is formed by a cut-away section at an end edge of at least one bent end 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.

BRIEF DESCRIPTION OF THE DRAWINGS

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

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

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

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

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

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

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

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

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;

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

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

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

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

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

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

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

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

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

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;

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

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

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

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;

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

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;

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

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

DETAILED DESCRIPTION

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.

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.

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.

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. However, for the sake of simplicity in the drawings, FIGS. 2 and 4 show main fastening extrusions 38 formed of only a single material.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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 j, projection 52 would have a similar slope.

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.

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.

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.

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.

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.

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.

It will be appreciated that, with the above embodiments, the respect ive 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.

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.

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.

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.

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 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.

FIG. 19 shows another embodiment similar to that of FIG. 18, in which second legs 90 extend 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.

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.

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

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.

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.

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.

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.

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.

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.

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.

Claims

1. A system for mounting wall panels to an existing wall structure, comprising: a plurality of wall panels, each wall panel formed from a material including a core sandwiched between two thin metal layers and each wall panel including: a main wall panel, andat least two bent end sections extending at a right angle from different edges of said main wall panel, each bent end section having a wall thickness; anda plurality of main fastening extrusions, each fastening extrusion including: at least one base section adapted to be secured to the existing wall structure,an arrangement for securing said at least one base section to the existing wall structure, andtwo spaced apart bent end securing walls extending at a right angle from said at least one base section, the two bent end securing walls having a spacing therebetween measured at positions where the bent end securing walls extend from said at least one base section, and at least one of the bent end securing walls being flexible and resilient;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;wherein the spacing is dimensioned to be substantially equal to the wall thickness of two said bent end sections such that pressing of said bent end sections into said spacing between said bent end securing walls causes at least one said bent end securing wall to be biased away from the other bent end securing wall until said projections engage in respective said cut-out recesses to permit said at least one said bent end securing wall to spring back to an original unbiased position thereof to lock said bent end sections in said spacing in a manner that outer walls of said bent end sections are parallel to each other and at least in near abutting relation with each other along entire lengths thereof;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; anda 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 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 with a spacing corresponding substantially to 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 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 at least in near abutting relation with the adjacent corner wall.

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, andextending 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, andsaid bent securing walls are dimensioned such that, when each projection engages in a respective said cut-out recess, a free end of each said bent end securing wall engages an undersurface of the respective said main wall panel, so as to lock said bent end section in said spacing in a tight fitting manner.

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 recess 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 said projections on said bent end securing walls face each other, andthe two projections have a spacing therebetween which is less than the wall thickness of two said bent end sections in an unbiased position of said bent end securing walls.

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

7. 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; andat least two said spaced apart flexible and resilient bent end securing walls extending from each base section, each extending at an angle from one of said base sections.