US20070221594A1

US20070221594A1 - Wall system

Info

Publication number: US20070221594A1
Application number: US11/387,742
Authority: US
Inventors: John Pierro
Original assignee: Smartwall Group Inc
Current assignee: Smartwall Group Inc
Priority date: 2006-03-24
Filing date: 2006-03-24
Publication date: 2007-09-27

Abstract

An extruded wall panel system having lateral grooves there across, the rear surfaces of which are adapted to be secured to a vertical wall. A series of hanger units are specially designed to inter engage with the grooves and to be supported thereby in a manner such that various items can be secured to the wall and adjustably mounted at desired vertical and horizontal positions along the entire wall surface. Individual panels are so designed that they can inter engage with each other to provide a seamless, attractive storage wall array.

Description

THE FIELD OF THE INVENTION

The field of invention relates to a wall system wherein various accessories can be mounted on a wall with a great deal of flexibility, strength, attractiveness and movement capability.

BACKGROUND OF THE INVENTION

Grooved wall constructions for use with interengaging hangers to support retail products and goods have been utilized for many years. Retail establishments have used such construction for displaying their goods. These constructions are of oftentimes of wood or particle board and are constructed on site. They usually require skilled carpenters to provide an installation that works well. For appropriate strength such constructions can be expensive and bulky. Wood also requires maintenance to maintain appearance and to maintain support surfaces upon which the hangers are supported. In moist environments, once moisture penetrates wood or particle board the hanger slots deteriorate and cause product failure. Also wood slots are made to carry light weight products. Thus, a principal objective of this invention is to provide a rugged, attractive, extruded moisture resistant panel with designed grooves that can support relatively heavy and bulky items. The panels are so constructed that they can be arrayed across an entire wall and which are exceptionally attractive.
The system is comprised of a series of extruded plastic wall sections adapted to be affixed to the interior walls of a garages, basements, laundry rooms, or the like. The product is especially advantageous in areas or rooms where moisture is likely to be present. The panel sections provide an extremely attractive surface and provide a convenient system for storing a wide variety of products both large and small. The wall is of an extruded plastic with specially designed grooves across the front surface thereof that will accommodate hangers that carry a variety of commonly used household, garden and yard accessories. The wall is extruded from a heavy duty, solid moisture proof PVC where dampness will not penetrate and or be absorbed.
The wall is extruded in a manner that pre-forms specially designed grooves that include back surfaces that are readily attached to a garage wall or the like. The walls can be extruded of convenient lengths, such as 8′, 12′, and 20′ feet lengths and one foot in height. These sections are readily juxtaposed and sized so as to completely cover the desired surface. The heavy duty PVC from which the wall is extruded can be sawed by the installer when formed with PVC thicknesses of approximately ⅝″. The specially designed ball and socket connector creates a water tight seal that locks out moisture and mold. This pivoting connector design also makes installation of the product seamless and self leveling. One foot paneling centered on the existing wall has been found to meet most budget concerns. Also once a single panel is leveled, the remaining panels are self leveling by merely engaging a flange of one panel with a receptor of an adjoining panel.

SUMMARY OF THE INVENTION

An objective of the invention is to provide a wall panel that is exceptionally attractive, rugged and readily affixed to a garage wall or alike.
Another main objective of the invention is to provide a wall panel free from moisture and mold penetration from damp walls of any home or building.
Another objective of the invention is to provide a wall panel that is formed with a series of parallel grooves that receive hanger units that support a wide variety of items for storage in an attractive fashion for ready access.
Another objective of the invention is to provide accessory hangers that slidably inter-engage with the grooves of the wall panels.
A further objective of the invention is to provide hanger/hook units that can carry objects of light to heavy weights with equal efficiency.
A still further objective of the invention is to provide grooves that run laterally of the wall surface to be covered so that the hanger hooks can be moved crossways along the grooves if desired and can be supported at a selected level.
A further objective of the invention is to provide a hanger unit that is adapted to receive support units of varying configuration and capabilities.
Another important objective of this invention is to provide a wall panel having an upper edge formed to receive the lower edge of an adjacent higher wall panel in a manner to provide a groove that is not distinguishable from the pre-formed grooves and, at the same time, provide a groove arrangement of the same dimensions and performance characteristics of the pre-formed grooves.
One of the important main objective of the invention is the ball and socket seal from one panel to the next creating a water tight seal to prevent moisture and mold from getting behind and effecting existing walls.
Another important objective to the invention is the ease of installation where as the ball and socket design is self leveling from panel to panel.
Another objective of the invention is to provide hanging mechanisms that can carry relatively large and heavy accessories and fixtures while permitting same to be stabilized along the assembled wall sections.
One of the main objectives of the invention is to provide a handsome wall panel of substantial strength that can be sized to cover any surface and yet retain a simplicity that provides the average homeowner with a product that can be self-installed if desired.

BRIEF DESCRIPTION OF DRAWINGS

A more complete appreciation of the invention, and many of its intended advantages will be readily obtained as the same becomes better understood by reference to the following description when considered in connection with the accompanied drawings, wherein:
FIG. 1 is a vertical end-view of panel sections attached to an interior wall;
FIG. 2 is a partial perspective of a panel section, which illustrates various aspects of the panel;
FIG. 3 is a front perspective view of a hanger unit;
FIG. 4 is a side view of the hanger unit of FIG. 3;
FIG. 5 is a perspective view of an alternate hanger member;
FIG. 6 is a side view of the wall panel and hanger unit;
FIG. 7 is a front elevation view of a wall panel section disclosing two hanger units slidably received in the grooves thereof;
FIG. 8 is a front elevation of a plurality of panel wall sections assembled in a manner to cover an entire wall;
FIG. 9 is an exploded perspective of a hanger assembly that will support a heavy object; and
FIG. 10 is a side view of the assembled parts of FIG. 9.

A DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to the drawings wherein like numerals indicate like parts, the numeral 10 generally refers to a wall panel section of the present invention. From the cross section of FIG. 2, it can be seen that the panel sections are extruded so as to provide a plurality of identical grooves 12, 14 and 16 laterally there across. FIG. 2 also shows the panels affixed to garage wall 11. The garage ceiling is identified by the numeral 13. Only one of said grooves will be described in detail. Each groove is defined by a lower ledge 20, a wall engaging vertical member 22, a top 24, and a downwardly extending lip 26. The lip 26 has a rounded surface 28, and an inner surface 30. FIG. 2 also shows upper and lower panels connected together at pivot joint J.
At its upper edge, each panel section 10 is formed with an inwardly directed u-shaped receptor 32 with an arcuate bottom. At its lower end the panel is formed with a downward extending flange, 38 having a lower rounded surface. As seen in FIG. 2, flange 38 is adapted to be snugly received by the receptor 32. This forms another groove 18. The groove 18 is identical in size and function to the grooves 12, 14 and 16 of each panel section and is virtually indistinguishable therefrom to a viewer after installation.
Some walls, especially in older garages, are slightly irregular. The wall panels of this invention are quite stiff and sturdy. However, the receptor 32—flange 38 arrangement acts as a hinged joint which facilitates securing multiple panels to walls having such deformation. Also, the matching surfaces of the flange and receptor provide a barrier to moisture penetration.
As seen in FIG. 1, the planar areas between the grooves are identified by the numeral 40. The rear surfaces of the vertical planar wall members are identified by the numeral 42. Surfaces 42 abut against wall 11 and can be affixed thereto by screws or the like.
A hanger unit 50 can best be seen in FIGS. 3, 4, 5 and 6. The hanger body is comprised of a rectangular plate 52 having a pair of cradle support holes 52 and 54 extending therethrough. In the embodiment shown, the holes 52 and 54 are adapted to respectively receive support arms 55 and 57 of support 56. The arms are connected by a base 59.
The hanger component 56 has the outer ends of bars 55 and 57 threaded. This permits the component to receive additional support apparatus. FIG. 5 shows an alternate hanger component 56 a. In this embodiment arms 55 a and 57 a are bent upwardly to provide a cradle support.
The plate 52 at its upper edge is formed with an inwardly directed spacer 59 and an upward locking member 60. At its lower edge the plate 50 is formed with an inwardly directed support flange 62. The locking member 60 is apertured at 64 and the plate 52, as stated above, is apertured at 52 and 54. The aperture 64 can be utilized to secure the plate to the extruded wall section and the garage wall if desired. If the hanger is secure to the wall 11, it cannot be moved. Although an important objective is slidability, in some instances a fixed position may be desired.
FIG. 6 shows a hanger unit 50 received by the wall panel. The locking member 60 is received in groove 12 and the flange 62 is received in the groove 14 immediately below groove 12.
Member 60 is restricted from outward movement by lip 26. The support flange 62 rests on ledge 20. Much of the weight carried by the support arms 55 and 57 will be absorbed on ledge 20.
FIG. 7 shows a typical wall section 40 with a plurality of hangers units; 50 slidably received in grooves. The disclosed hangers are free to move laterally. As described, the wall panels are located and secured to the building wall 11 so that the respective grooves of laterally disposed panels form extensions of one another. This permits full lateral movement from side wall to side wall.
The individual wall panels can be readily sized with hand or power saws, FIG. 8 shows a plurality of panels arranged to cover an entire wall. A single wall panel is encompassed by brackets B1 and B4. A second wall panel of the same size is encompassed by the brackets B2 and B4. A third panel is encompassed by brackets B-1 and B-5 and a fourth panel section is encompassed by the brackets B-2 and B-5. Note that the third and fourth panel sections have been shortened along edges 70 and 72. The first, second, third and fourth panels extend from floor to ceiling. A fifth panel section encompassed by brackets B-3 and B-4 and a sixth panel section defined by brackets B-3 and B-5 permit the system to extend from side wall to side wall. The fifth and sixth panel sections are laterally reduced along cuts 74 and 76. The sixth panel is also cut along the line 78, which engages the floor or cuts 70 and 72.
Note that the panels are assembled and mounted to the wall 11 with their grooves 12 horizontally aligned. This permits the hanger brackets 50 to move from side wall to side wall. Of course, since all of the aligned grooves are spaced from the grooves above and below, the brackets can be vertically adjusted as well. As can be readily understood, a sufficient number of panels are arranged one on top of the other so that a floor to ceiling wall system can be provided.
FIGS. 9 and 10 is an illustration of a hanger assembly 78 that will support large accessories such as cabinets and the like. This hanger assembly 78 is comprised of two basic parts. A slidable unit 80 having its upper end formed with an inwardly directed spacer 82 having an upwardly extending locking member 84 that is received by groove 12 in the same fashion that unit 50 is received. Near its lower end, unit 80 has a plurality of threaded bolts 84 and 86 extending outwardly therefrom.
The hanger assembly 78 has a second component 90 having a planar section 92 with a supporting ledge 94 along its upper edge. The components 80 and 90 are of the same length. Inwardly of its side edges, the component 90 is formed with bolt receiving openings 96 and 98. The assembly 78 is adapted to support a cabinet or the like C. Only the top 100 and rear wall 102 of the cabinet is shown.
As seen best in FIG. 10, the locking member 84 is first inserted in groove 12. It should also be noted that the back 102 of cabinet C is formed with pre-drilled openings spaced from one another the same distance as bolts 84 and 86 are spaced from one another.
The cabinet C is positioned for its openings to receive the bolts 84 and 86. Then, the second component 90 is placed inside the cabinet with its openings also receiving the bolts 85 and 86. Nuts 87 and 89 are then tightened so as to firmly secure the units together. This arrangement permits the wall panels to support large and heavy members such as cabinets, but still retain the advantage of vertical and horizontal positioning.
The elongated components 80 and 90 are normally one or two inches shorter than the interior width of the cabinets. These lengths provide good support and stability to the cabinet.
Numerous modification varieties of the present invention are possible in light of the above description. It is, therefore, to be understood that within the scope of the following claims, the invention may be practiced, otherwise, than as specifically described herein.

Claims

1. An extruded planar wall panel having a back surface to be secured to a vertical wall and a front surface:

first and second sides defining the lateral width of said panel;

top and bottom edges defining the vertical height of said panel;

a first groove formed in said front surface and extending between said first and second sides;

a second groove formed in said front surface, parallel to and spaced from said first groove and extending between said first and second sides;

said grooves defined by a rear surface that is part of said back surface, and a base parallel to said bottom edge and spaced from said rear surface.

2. The panel of claim 1 wherein a downwardly extending lip defined by said front surface and an interior surface of said back surface define a locking reception space.

3. The panel of claim 2 used in combination with a hanger comprising:

a plate having an upper edge and a lower edge;

a first locking member formed along said upper edge for reception in said first groove; and

a second locking member formed along said lower edge for reception in said second groove.

4. The invention of claim 3 wherein said plate has a pair of openings to receive a pair of support arms that extend outwardly from said plate.

5. The invention of claim 1 wherein a receptor channel is formed along said top edge; and

a downwardly extending ridge is formed along said bottom edge that is dimensioned to be pivotally received by said receptor.

6. The invention of claim 1 comprising a second wall panel having the same dimensions and structure of said extruded wall panel wherein the ridge of one of said panels is snugly received by the receptor of the other of said panels.

7. A panel array comprising:

multiple panels each having equally spaced grooves formed in the front surface thereof;

inter-engaging means between the said panels that form a groove parallel to said equally spaced grooves; and

said panels when arranged in a side-by-side relationship, will have their respective grooves co-extensive with grooves of other panels at the same level.

8. The invention of claim 7 comprising:

means to secure all of said panels to a wall; and

hanger units having locking members slidably received by said grooves.

9. A wall panel system comprising:

a first elongated extruded plastic member having an upper edge and a bottom edge;

an arcuate receptor channel formed at said upper edge;

a flange extending downwardly from said bottom edge;

a second elongated plastic member having a second upper edge and a second bottom edge;

a second flange extending downwardly from said second bottom edge; and

a said second flange having a rounded surface that closely engages the interior surface of said arcuate receptor when said first and second members are juxtaposed adjacent to each other.

10. The insertion of claim 9 wherein said first member has a back surface to be second to another wall and a front surface:

first and second sides defining the lateral width of said member;

top and bottom edges defining the vertical height of said panel;

said grooves defined by a rear surface that is part of said back surface; and

a base parallel to said bottom edge and spaced from said rear surface.

11. The wall system of claim 10 used in combination with a hanger comprising:

a plate having an upper edge and a lower edge;

12. The invention of claim 11 wherein said plate has a pair of openings to receive a pair of support arms that extend outwardly from said plate.

13. The invention of claim 9 wherein a receptor channel is formed along said top edge; and

a downwardly extending flange is formed along said bottom edge.

14. The invention of claim 1 comprising a second wall panel having the same dimensions and structure of said extruded wall panel wherein the flange of one of said panels is snugly received by the receptor of the other of said panels.