Abstract:
A seamless wall finishing system has a plurality of wall panels which are spaced apart from an exterior wall. The spacing creates an air gap which provides an airflow passage between the exterior wall and the second surface of the wall panels. The wall panels have a mold resistant non-organic thread or yarn wall covering which is adhered to a central portion of a first surface of each of the wall panels. The wall panels define a pair of uncovered areas on opposite sides of each of the plurality of wall panels. A vertically extending seam is created between adjacent wall panels which is filled with a seam tape made from the mold resistant nylon yarn wall covering. An air circulation system is provided for circulating air behind the wall panels. A method of assembling the modular basement wall finishing system is also provided.

Description:
FIELD 
     The present disclosure relates to modular wall finishing systems. More particularly to a modular basement wall finishing system having a seamless wall structure. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     Commercial wall systems are used for finishing many types of interior spaces. Typically these wall systems are installed between a floor and a ceiling surface using a large quantity of framing members. Additionally, when the wall system is installed, insulation is often used to increase thermal efficiency. The framing members and insulation create a complex installation process, increase cost, and inhibit removal for future use of the wall system in a different space or location. 
     Typically these systems are used in buildings having porous block or poured concrete walls that can retain unwanted moisture and wick the moisture into the living space. This unwanted moisture is often trapped in a confined space between the exterior walls and the interior walls which creates harmful mold. The mold and moisture eventually cause permanent damage to the interior walls, framing members, and insulation which prevents reuse and requires replacement of these components. 
     Therefore, there has been and continues to be a need for a modular wall system that has little complexity and provides moisture and mold resistant qualities as well as improving thermal efficiency. 
     SUMMARY 
     The present disclosure is directed to a seamless wall finishing system, having a series of wall panels which are spaced apart from the exterior walls. The spacing creates an air gap between the wall panels and the exterior walls to provide an airflow passage between the exterior wall and the backside of the wall panels. 
     In another embodiment of the present disclosure, a mold resistant non-organic thread or yarn wall covering that can include nylon, fiberglass, polyester, etc. is adhered to a central portion of a first surface of each of a plurality of wall panels. A perimeter of the first surface of each of the plurality of wall panels has an uncovered area such that when a first of the plurality of wall panels is mounted adjacent a second of the plurality of wall panels a vertically extending seam is defined. A mold resistant non-organic thread or yarn seam tape is then adhered to the vertically extending seam. 
     A method of assembling a modular basement wall finishing system is also provided. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
         FIG. 1  is a partial cross-sectional view of the modular basement finishing system according to the present disclosure; 
         FIG. 2  is a schematic view of the modular basement finishing system illustrating an air gap and ventilation system according to the principles of the present disclosure; 
         FIG. 3  is a partial cross-sectional view of the modular basement finishing system further illustrating the air gap and ventilation system depicted in  FIG. 2 ; 
         FIG. 4  is a schematic view of the modular basement finishing system illustrating an alternative air gap and ventilation system; 
         FIG. 5  is a plan view of a series of adjoining wall panels illustrating the “H-Clip” attachment method; and 
         FIG. 6  is a fragmentary side elevation view of a portion of the modular basement finishing system showing the application of the seam tape into a vertically extending seam created by adjoining sheets of mold resistant non-organic thread or yarn wall coverings. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
     With reference to  FIG. 1 , a modular basement finishing system is depicted generally by reference number  10 . As will be discussed, the modular basement finishing system  10  is designed to be erected and detachably secured between a floor structure  20  and a ceiling structure  22 . The modular basement finishing system  10  may be spaced away from the basement foundation wall  12  which may allow air to flow through an airflow passage  24  between the basement foundation wall  12  and the modular basement wall finishing system  10 . It is understood that the modular basement finishing system  10  may be spaced away from the basement foundation wall  12  at an appropriate interval to achieve a desired airflow. In a preferred embodiment, an elongated floor railing  18  may be detachably secured to the floor structure  20  using fasteners  17 . The elongated floor railing  18  is typically constructed of metal or any other suitable materials. An elongated ceiling railing  16  may be detachably secured to a ceiling structure  22  using fasteners  17 . The elongated ceiling railing  16  is typically constructed of metal or any other suitable material. The ceiling structure  22  may include joists, rafters, or any other suitable structure for retaining fasteners  17 . The elongated ceiling railing  18  is typically constructed of metal angle iron or any other suitable material. A wall panel  14  is vertically positioned adjacent the elongated floor railing  18  and the elongated ceiling railing  16 . The wall panel  14  may be detachably secured to the elongated ceiling railing  16  using fasteners  17 . Additionally, the wall panel  14  may be detachably secured to the elongated floor railing  18  using fasteners  17 . It is understood that the wall panel  14  may also be detachably secured to the elongated floor railing  18  and the elongated ceiling railing  16  using any method of detachably securing wall panels  14  known in the art. 
     With reference to  FIGS. 2 and 3 , the modular basement finishing system may include an air inlet aperture  26  in communication with the airflow passage  24  that is provided between the foundation wall  12  and wall panels  14 . Although the air inlet aperture  26  may be located in an exterior wall  12  as depicted in  FIG. 2 , the air inlet aperture  26  may also be located in a wall panel  14 , the ceiling structure  22  or any other suitable area for locating an air inlet aperture  26  to allow communication with the airflow passage  24 . The modular basement finishing system  10  may further include an air outlet aperture  28  in communication with the airflow passage  24 . Although the air outlet aperture  28  may be located in an exterior wall  12  as depicted in  FIG. 2 , the air outlet aperture  26  may also be located in a wall panel  14 , the ceiling structure  22  or any other suitable area for locating an air outlet aperture  26  to allow communication with the airflow passage  24 . 
     The modular basement finishing system  10  may further include a dehumidifier  32  which may be in communication with the airflow passage  24 . The dehumidifier  32  may reduce the moisture from the airflow entering the airflow passage  24 . It is understood that a dehumidifier  32  may be any device suitable for removing moisture from the air. Although the dehumidifier  32  is shown on the outside of an exterior wall  12 , the dehumidifier  32  may be installed on either side of the wall panels  14  including within the airflow passage  24 . The dehumidifier  32  may also be installed anywhere suitable for maintaining communication with the air inlet aperture  26 .  FIG. 2  further illustrates a blower  30  in communication with the airflow passage  24  and the dehumidifier  32 . The blower  30  may provide air to the dehumidifier  32 . The blower  30  may also be attached between the air inlet aperture  26  and the dehumidifier  32 . In this configuration the blower  30  may draw dehumidified air from the dehumidifier  32  or may force air through the dehumidifier  32 . Alternatively, the blower  30  may be integral to the air inlet aperture  26  or the dehumidifier  32  or connected to the dehumidifier  32  by any means known in the art. Additionally,  FIG. 2  illustrates an exhaust blower  34  in communication with the airflow passage  24 . The exhaust blower  34  may be attached to the air outlet aperture  28 . Alternatively, the exhaust blower  34  may be integral to the air outlet aperture  28  or connected to the air outlet aperture  28  by any means known in the art. 
     With reference to  FIG. 4 , another embodiment of the modular basement finishing system  10  is provided wherein the air inlet aperture  26  and the air outlet aperture  28  are located adjacently. A vertically extending baffle  15  may be installed between the exterior wall  12  and a wall panel  14 . The vertically extending baffle  15  may be positioned substantially between the air inlet aperture  26  and the air outlet aperture  28  and may provide an airflow barrier there between. The vertically extending baffle  15  may begin at the floor structure  20  and continue to the ceiling structure  22 , shown in  FIG. 3 . The vertically extending baffle  15  may be made of any suitable material known in the art. The vertically extending baffle  15  may adhere to the wall panel  14  and the exterior wall  12 . Alternatively, the vertically extending baffle  15  may be fastened or sealed to the wall panel  14  and the exterior wall  12 . The vertically extending baffle  15  may provide uni-directional airflow through the airflow passage  24 . The vertically extending baffle  15  may also be formed integrally to the wall panel  14 . The vertically extending baffle  15  may also attach to the elongated ceiling railing  16  and the elongated floor railing  18 . 
     Additionally,  FIG. 4  illustrates an elbow connector  36  attached to the air outlet aperture  28  and the dehumidifier  32 . The elbow connector  36  may provide a closed loop connection to allow the dehumidifier  32  to reuse the air exiting the air outlet aperture  28  where it is desirable to reduce the workload of the dehumidifier  32  in high humidity conditions. Although the air exiting the air outlet aperture  28  may have a greater moisture content than the air entering the air inlet aperture  26 , it may be a lower moisture content than atmospheric air and thus reduce the workload and energy consumption of the dehumidifier  32  and the blower  30  where an open loop system is used. It should be understood that the closed loop configuration may allow the dehumidifier  32  and the blower  30  to be configured in any orientation between the air inlet aperture  26  and the air outlet aperture  28 . Additionally, where the air inlet aperture  26  and the air outlet aperture  28  are formed, for example in one of the wall panels  14 , the dehumidifier  32 , blower  30 , elbow connector  36 , and exhaust blower  34  can be also be located inside of the interior space created by the wall panels  14 . The dehumidifier  32 , blower  30 , elbow connector  36 , and exhaust blower  34  can be located anywhere that is suitable for communicating with the airflow passage  24 , for example in a utility closet or a mechanical room. 
     With reference to  FIG. 5 , each wall panel  14  may have an inner foam structure  64  which may provide each wall panel  14  with an insulation value which may increase the temperature and comfort level of a basement or any other suitable type of building. The inner foam structure  64  can be made from material such as closed cell foam or any other suitable material known in the art. The inner foam structure  64  may have mechanical properties capable of loading the wall panel  14  with additional structure, for example, shelving and audio/video equipment. The inner foam structure  64  may have apertures  62  formed therein which may receive an electrical conduit which may supply electricity to outlets and switches in each of the wall panels  50 . Each wall panel  14  may have an aperture  62  formed in substantially the same location so that electrical conduit can be received by the aperture  62  formed in each wall panel  14 . The aperture  62  may be suitable to receive other mechanical or electrical hardware as desired. For example, plumbing conduit may also be installed in the aperture  62 . 
     The inner foam structure  64  may have a first mineral board  58  applied to a first surface of the inner foam structure  64 . The inner foam structure  64  may also have a second mineral board  60  applied to a second surface of the inner foam structure  64 . The first mineral board  58  and the second mineral board  60  may be made of any suitable materials known in the art. The first mineral board  58  and the second mineral board  60  may be adhered to the inner foam structure  64 , attached with fasteners or secured using any other suitable means known in the art. The first mineral board  58  and the second mineral board  60  may be structurally reinforced with a fiberglass mesh or any other suitable reinforcement material. 
     A panel biscuit or H-clip  56  may be used to secure adjacent wall panels  14 . The H-clip  56  allows the adjoining wall panels  14  to be rigidly attached and may eliminate the need for reinforcing frame members. The H-clip  56  may be made from metal, plastic, composite or any other suitable material. The H-clip  56  may be configured in any orientation that may secure adjoining wall panels  14 . A first pocket  52  in the wall panel  14  may be formed by sliding a knife in between the inner foam structure  64  and the back side of the first mineral board  58 . Next, a second pocket  54  may be formed in the wall panel  14  by sliding a knife in between the inner foam structure  64  and the back side of the second mineral board  60  at substantially the same vertical position as the first pocket  52 . The first end  57  of the H-clip  56  may be installed in the first pocket  52  and the second pocket  54 . Next, a first pocket  52  and a second pocket  54  of an adjacent panel are formed to receive a second end  59  of the H-clip  56 . The adjoining wall panels  14  are then abutted such that the second end  59  of the H-clip  56  is inserted into the first pocket  52  and the second pocket  54  of the adjacent wall panel  14 . The wall panels  14  are detachably secured to the elongated floor railing  18  and the elongated ceiling railing  16  using fasteners  17 . The wall panels  14  can be detached by removing the fasteners  17  and separating the adjoining wall panels  17 . A single H-clip  56  may also be pre-installed on one side of each wall panel  14  before the wall panels are shipped to the work site to reduce the quantity of on-site installation steps. 
     With reference to  FIG. 6 , each wall panel  14  may have a pre-applied mold resistant nylon yarn wall covering  38  (wall covering). The wall covering may begin at the ceiling structure  22  and terminate at any desired location such as a chair rail trim or base molding trim (not shown). The wall covering  38  may have an anti-microbial film or may have an anti-microbial paint. The wall covering  38  may also use any suitable material for reducing moisture build up and mold formation known in the art. The wall covering  38  may have a grain pattern and a gloss level that may be designed to be aesthetically pleasing and functional. The grain pattern and the gloss level may provide functionality by hiding scuff marks, for example. Further, the seam tape  40  may have similar or substantially the same grain pattern and gloss level as the wall covering  38 . The seam tape  40  may provide a seamless appearance when adhered between adjacent wall coverings  38  and  42  or patching a damaged area by cutting and removing the damaged area, then creating a patch and adhering it to the wall panel  14 . The wall covering  38  may have a series of non-organic thread or yarn strands embedded therein. The series of non-organic thread or yarn strands may also be disposed on the first surface of the wall covering  38 . The non-organic thread or yarn strands may form or impart a grain pattern on the wall covering  38  and the seam tape  40 . The grain pattern may aid the installer in joining the terminal edges of the seam tape  40  to the terminal edges of the wall covering  38 . The non-organic thread or yarn strands may also provide a uniform vertical line if trimming of the wall covering  38  or the seam tape  40  becomes necessary, for example, where a partial wall panel  14  is installed adjacent a full wall panel  14 , the wall covering  38  will need to be removed from one side of the partial wall panel  14  to create a first uncovered area  44 . The seam tape  40  may be applied over the joint  48  created by adjoining wall panels  14  and to the first uncovered areas  44  and  46 . The seam tape  40  may be any width suitable to cover the first uncovered areas  44  and  46 . The seam tape  40  may have an anti-microbial film or may have an anti-microbial paint. The seam tape  40  may contain any suitable material for reducing moisture build up and mold formation known in the art. The seam tape  40  adhesive may be heat and pressure sensitive or self-adhering.