Abstract:
An eco-friendly wall panel system may comprise a plurality of panels, horizontal joints and panel clips which are all fabricated from the same sheet of material. For example, the panels may initially be fabricated from the phenolic sheets. After the maximum quantity of panels has been fabricated from any one sheet, the remaining portion of the phenolic sheet may be used to fabricate the horizontal runners and the panel clips which may be smaller than the panels. As such, as much of the phenolic sheet is being used to fabricate the system. Hence, the process and the product are both eco-friendly.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
       [0002]    Not Applicable 
       BACKGROUND 
       [0003]    The embodiments disclosed herein relate to a plurality of wall panels mountable to a wall or ceiling. 
         [0004]    Prior art wall panel systems include a plurality of panels that are arranged in rows and columns. These panels are mounted to a wall or ceiling by connecting panel clips to the backside of the panels and attaching horizontal and vertical runners to the wall. The panel clips engage the horizontal and vertical runners with a tongue and groove connection. 
         [0005]    Unfortunately, the process of manufacturing the panels is not eco-friendly. In particular, the panels are fabricated from a plurality of sheets. In cutting out the plurality of panels from the sheet, the left over portion of the sheet which is too small to cut out any additional panels is discarded. The left over portion is thrown away as waste and fills up our landfills. 
         [0006]    Moreover, the horizontal runners, vertical runners and the panel clips are also not eco friendly. The horizontal and vertical runners and the panel clips are typically extruded aluminum. At the end of the useful life of the prior art wall panel system, the horizontal and vertical runners and the panel clips are removed from the wall and discarded as waste which also fills up our landfills. 
         [0007]    Accordingly, the process of fabricating the panel system and the system itself is not eco-friendly. Hence, there is a need in the art for an eco-friendly wall panel system. 
       BRIEF SUMMARY 
       [0008]    The embodiments disclosed herein address the needs discussed above, discussed below and those that are known in the art. 
         [0009]    A recessed reveal wall panel system which includes a plurality of wall panels that are mounted to a wall or ceiling is disclosed herein. The plurality of panels may be mounted to the wall or ceiling with a plurality of horizontal joints and panel clips. These horizontal joints and panel clips may be fabricated from the same material as the plurality of panels. For example, the plurality of panels may be cut out from sheets of an eco-friendly material (e.g., phenolic). After the panels are cut out from the sheets, the remaining portion of the sheet may be used to fabricate the horizontal runners and the panel clips. In this manner, most of sheet is utilized during the process of fabricating the wall panel system and waste is minimized. Accordingly, the process and product are eco-friendly. 
         [0010]    More particularly, a method of manufacturing a wall panel kit is disclosed. The method may comprise the steps of providing one or more rigid sheets all fabricated from one type of material (e.g., phenolic or other eco friendly material); cutting a plurality of panels and at least one joint or panel clip from the one or more rigid sheets; wherein the panel clip is attachable to the panel and the joint is attachable to a wall for joining the panel to the wall. 
         [0011]    The cutting step may include the step of cutting the one or more sheets into rectangular panels. 
         [0012]    The cutting step may also include the steps of cutting horizontal joints from the one or more sheets, the horizontal joints being longer than the width of the panel and cutting upper and lower grooves in opposed longitudinal surfaces of the horizontal joints; and cutting vertical joints from the one or more sheets, the vertical joints being shorter than a height of the panels. The upper and lower grooves of the horizontal joints may be formed with a shaper. 
         [0013]    The cutting step may also include the steps of cutting horizontal edge joints from the one or more sheets; and cutting a first groove in one of opposed longitudinal surfaces of the horizontal edge joints. 
         [0014]    In the method, the panel clips are attached to the panels. The joints are attached to the wall. 
         [0015]    In another aspect of the wall panel system, a paneled wall is disclosed. The paneled wall may comprise a plurality of wall panels and a plurality of horizontal joints. The plurality of wall panels may be fabricated a wood based material such as phenolic. The wall panels may be arranged in a series of rows and columns on the wall. Each of the wall panels may be disposed parallel to the wall. Each of the wall panels may have an upper panel clip defining an upwardly directed tongue. The upper panel clips may be attached to a back side of the panels at upper edge portions of the panels. Also, a lower panel clip may define a downwardly directed tongue. The lower panel clip may be attached to the back side of the panels at lower edge portions of the panels. 
         [0016]    The plurality of horizontal joints fabricated from the wood based material may each have a length greater than a width of one of the panels. Each horizontal joint may define upper and lower longitudinal surfaces. The upper longitudinal surface may have an upper groove. The lower longitudinal surface may have a lower groove. The horizontal joints may be attached to the wall horizontal to the ground and parallel to the other horizontal joint(s). The tongue of the lower clip may be received into the upper groove of the horizontal joint. The tongue of the upper clip may be received into the lower groove of the horizontal joint. 
         [0017]    The wood based material of the wall panels and the horizontal joints may be phenolic. 
         [0018]    The wall panels, horizontal joints and panel clips may have identical thicknesses. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which: 
           [0020]      FIG. 1  is a plan view of a recessed reveal wall panel system mounted to a wall; 
           [0021]      FIG. 1A  is a cross-sectional view of a horizontal joint of the system shown in  FIG. 1 ; 
           [0022]      FIG. 1B  is a cross-sectional view of a vertical joint of the system shown in  FIG. 1 ; 
           [0023]      FIG. 1C  is a cross-sectional view of a bottom-edge joint of the system shown in  FIG. 1 ; 
           [0024]      FIG. 1D  is a cross-sectional view of a top edge joint of the system shown in  FIG. 1 ; 
           [0025]      FIG. 1E  is a cross-sectional view of a vertical edge joint of the system shown in  FIG. 1 ; 
           [0026]      FIG. 1F  is a cross-sectional view of a mid panel tongue and groove connection of the system shown in  FIG. 1 ; 
           [0027]      FIG. 2  is a perspective view of a first embodiment of an outside corner of the recessed reveal wall panel system; 
           [0028]      FIG. 2A  is top view of the outside corner of the system shown in  FIG. 2 ; 
           [0029]      FIG. 3  is a perspective view of a second embodiment of the outside corner of the recessed reveal wall panel system; 
           [0030]      FIG. 3A  is a top view of the outside corner of the system shown in  FIG. 3 ; 
           [0031]      FIG. 4  is a perspective view of an inside corner of the recessed reveal wall panel system; and 
           [0032]      FIG. 4A  is a top view of the inside corner of the system shown in  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    Referring now to the drawings, a plurality of panels  10  arranged in rows and columns  12 ,  14  are shown. The adjacent edges  16  of adjacent panels  10  have a recessed look which are shown in  FIGS. 1A and 1B . Adjacent panels  10  have a vertical or horizontal gap  18  so that adjacent edges  16  of adjacent panels  10  show an underlining horizontal joint  20  or vertical joint  22 . The horizontal and vertical joints  20 ,  22  may be fabricated from the same material as the panel  10  and also have the same aesthetic qualities as the panels  10 . In this manner, a recessed aesthetic feel is produced when looking at the wall panel system  24  comprised of the plurality of panels  10 . The plurality of panels  10  and the horizontal and vertical joints  20 ,  22  may be fabricated from the same type of material. Preferably, the material is an eco-friendly material such as phenolic (i.e. wood chips hardened in resin). To manufacture a kit of the system  24 , sheets of phenolic may be provided. From these sheets of phenolic, the rectangular panels  10  are cut to size. After the panels  10  are cut, the left over pieces of phenolic which are too small to fabricate additional monolithic panels  10  are used for the horizontal and vertical joints  20 ,  22 . In this manner, use of the phenolic sheets is maximized and waste is minimized. Accordingly, the kit utilizes an eco-friendly material (e.g., phenolic). Also, the method by which the parts of the kit are produced minimizes waste and is also an eco-friendly process. 
         [0034]    More particularly, referring now to  FIG. 1 , the panels  10  are attached to the wall  26  by way of a plurality of horizontal joints  20 . The horizontal joints  20  are spaced apart and are parallel to each other and generally horizontal to the ground  28 . Upper and lower horizontal clips  32 ,  34  may be attached to the backside  30  of each of the panels  10  that engage the horizontal joints  20  in a tongue and groove fashion to mount the panels  10  to the wall  26  (see  FIG. 1A ). 
         [0035]    To begin mounting the wall panel system  24  to the wall  26 , referring to  FIG. 1C , a bottom horizontal edge joint  36  is attached to the wall  26  with one or more screws  38  along the length of the joint  36 . The bottom horizontal edge joint  36  preferably is horizontal to the ground  28  and extends the full length of the row of panels  10  as shown in  FIG. 1 . The bottom horizontal edge joint  36  may have a single groove  40  formed on the upper side that extends along the entire length of the bottom horizontal edge joint  36 . The groove  40  of the bottom horizontal edge joint  36  may receive a tongue  42  of a lower horizontal clip  34 . The groove  40  of the bottom horizontal edge joint  36  may be formed in the upper longitudinal surface  44  of the bottom horizontal edge joint  36 . The bottom horizontal edge joint  36  may also have a plurality of countersink holes  46  along the length of the bottom horizontal edge joint  36 . One or more screws  38  are fitted within the countersink holes  46  and attached to the wall  26  to attach the bottom horizontal edge joint  36  to the wall  26 . A gap  18  reveals the underlying bottom edge joint  36 . The components can be adjusted so that the gap  18  is between 1/16″ to 12″. 
         [0036]    Referring back to  FIG. 1 , the bottom most row  12  of panels  10  are laid adjacent to the ground  28  on the bottom horizontal edge joint  36 . Referring back to  FIG. 1C , the panels  10  may have one or more lower horizontal clips  34  attached to the backside  30  of the panels  10 . The lower horizontal clip  34  may extend across the entire width of the panel  10  or may be only a few inches long. When short panel clips  34  are used, two lower horizontal clips  34  may be attached to the backside  30  of the panels  10  on the left and right sides of the panel  10 , to provide stability when the clips  34  engage the bottom horizontal edge joint  36 . The lower horizontal clip  34  may have a base  48  with a channel  50  extending along the length of the lower horizontal clip  34 . One or more holes  52  may be formed in the lower horizontal clip  34  at the position of the channel  50  through which screws  38  are inserted and used to attach the clip  34  to the panel  10 . After the lower horizontal clips  34  are attached to the panels  10 , the tongue  42  of the lower horizontal clip  34  is pushed into the groove  40  of the bottom horizontal edge joint  36 . The various components are sized and configured so as to form a gap  18 , which is preferably the same size as the gaps  18  shown in  FIGS. 1A and 1B . The sizes of the panels  10 , vertical joint  22  and the horizontal joint  20  may be enlarged or reduced to adjust the size of the gap  18  which may be between 1/16″ to 12″. 
         [0037]    Referring now to  FIG. 1A , each of the panels  10  in the bottom most row  12  panels  10  may have one or more upper horizontal clips  32 . The upper horizontal clip  32  may be identical to the lower horizontal clip  34  except that they  32  are positioned at the top of the panel  10  and the tongue  42  of the upper horizontal clip  32  is oriented upwardly instead of downwardly as in the case of the lower horizontal clip  34 . With the upper horizontal clip  32  attached to the panel  10  in the same manner as the lower horizontal clip  34  is attached to the panel  10 , the horizontal joint  20  is engaged to the upper horizontal clip  32  and secured to the wall  26  as shown in  FIG. 1A . More particularly, the horizontal joint  20  may define upper and lower longitudinal surfaces  54 ,  56 . Each of the upper and lower longitudinal surfaces  54 ,  56 , may respectively have an upper groove  58  and a lower groove  60 . The grooves  58 ,  60  may be formed with a shaping machine. The horizontal joint  20  may additionally have a plurality of countersink holes  46  along the length of the horizontal joint  20  which receives screws  38  to attach the joint  20  to the wall  26 . 
         [0038]    The horizontal joint  20  is laid against the wall  26  and the tongues  42  of the upper horizontal clips  32  of the panels  10  are received in the lower groove  60  of the horizontal joint  20  to lock the bottom most panel  10  in place vertically. Screws  38  are placed in the countersink holes  46  and used to attach the horizontal joint  22  to the wall  26  which locks the bottom most row of panels  10  to the wall  26 . The screws  38  are off center and may be positioned behind the panels  10  to hide the screws  38  from plain view. 
         [0039]    Referring now to  FIG. 1B , behind laterally adjacent vertical edges  16  of adjacent panels  10 , a vertical joint  22  may be secured to the wall  26 . The vertical joint  22  may have the same cross-sectional configuration as the horizontal joint  20  shown in  FIG. 1A . Opposed distal ends of the vertical joint  22  may abut the horizontal joint  20  or the bottom horizontal edge joint  36  or the top horizontal edge joint  62  as shown in  FIG. 1 . The vertical joint  22  may be fabricated (i.e., cut) from the horizontal joint  20  to save material and manufacturing time as will be discussed further below. The vertical joint  22  does not contact or attach to the panel  10 . Rather, the vertical joint  22  provides aesthetic uniformity between the horizontal gap  18  shown in  FIG. 1A  and the vertical gap  18  shown in  FIG. 1B . People view the same material through the gaps  18  in both the horizontal and vertical orientations (see  FIGS. 1A and 1B ). Screws  38  may be used to attach the vertical joint  22  to the wall  26 . The screws  38  may be positioned behind the panel  10  to hide the screws  38  from plain view. The panels  10  may be shifted left or right since the tongues  42  move within the grooves  60 . The panels  10  may be adjusted so that the vertical gap  18  (see  FIG. 1B ) between laterally adjacent panels  10  is equal to the horizontal gap  18  between upper and lower panels  10  (see  FIG. 1A ). Other configuration are also contemplated. The upper and lower horizontal clips  32 ,  34  preferably do not extend across the entire width of the panel  10 . Rather, one or more upper and lower horizontal clips  32 ,  34  are attached to each of the panels  10 . This allows air to flow to the space between the wall  26  and the panel  10  between two horizontal clips  32  as shown by airflow line  64  (see  FIG. 1A ). Air is also allowed to flow through the vertical gap  18  and behind the panel  10  shown in  FIG. 1B  as shown by airflow line  64 . This free flow of air equalizes humidity between the front side  66  and the backside  30  of the panel  10  to mitigate warping of the panels  10 . There may be at least a 1/16″ space to allow for air flow. 
         [0040]    The left and right most panels  10  may also have a vertical edge joint  68  as shown in  FIG. 1E . The vertical edge joint  68  may have the same configuration as the bottom horizontal edge joint  36  except that the vertical edge joint  68  is shorter. Also, the vertical edge joint  68  is not attached to the panel  10 . The vertical edge joint  68  may extend between and abut horizontal joint  20 , bottom edge horizontal edge joint  36  or top horizontal edge joint  62  as shown in  FIG. 1 . The vertical edge joint  68  may be secured to the left side or right side (as shown) of panel  10  with screws  38  along its length. The screws  38  are hidden behind panels  10 . The vertical edge joint  68  may be overlapped by panel  10  to complete the recessed aesthetic look of the wall panel system  24 . The revealed size of the vertical joint  68  may be adjusted between 1/16″ to 12″. 
         [0041]    Referring now to  FIG. 1F , at the middle of one or more of the panels  10 , a wall clip  70  and a panel clip  72  may be engage to each other to further reinforce the panel  10 . The wall clip  70  and the panel clip  72  may also be fabricated from the same sheet of material that the panels  10 , edge joints  36 ,  62 , horizontal joints  20 , vertical joints  22  are fabricated so that most of the wall panel system  24  is fabricated from an eco friendly material and also by an eco friendly process. The wall clip  70  may be the same part as the bottom and top edge joints  36 ,  62  except shorter. The wall clip  70  may be attached to the wall  26  horizontally from the ground  28 . The wall clip  70  may only be a short length and not run across the entire length of the panel  10 . Likewise, the panel clip  72  may only be a short length. The wall clip  70  and panel clip  72  may be attached to the wall  26  and the panel  10 , respectively, with one or more screws  38 . A tongue  78  of the panel clip  72  is inserted into a groove  80  of he wall clip  70 . Preferably, the wall and panel clips  70 ,  72  are oriented in the horizontal direction as shown. However, it is also contemplated that they  70 ,  72  may b oriented in the vertical direction or upside down. The panel clip  72  may have a cross sectional configuration as shown in  FIG. 1F . However, the panel clip  72  may be replaced with the panel clip  32 ,  34 . 
         [0042]    The wall panel system  24  may also be installed on an outside corner shown in  FIGS. 2 and 2A . The edge joint  74  may be physically joined to edge joint  76  on the adjacent wall  26 . The edge joint  74 ,  76  may be attached to the wall  26  by way of screws  38  received in countersink holes  46  formed in the edge joint  74 ,  76 . The panels  10  are mounted to the wall  26  as discussed above. The edges of the adjacent panels  10  do not contact or abut each other. This reveals the underlying edge joint  74 ,  76  to provide a consistent aesthetic look between the front face of the wall  26  and the outside corner. The various components can be adjusted so that more or less of the edge joints  74 ,  76  are revealed. 
         [0043]    Referring now to  FIGS. 3 and 3A  a second embodiment of an outside corner is shown. This second embodiment of the outside has an identical configuration as that shown in  FIGS. 2 and 2A  except that the adjacent panels  10  interlock with each other. No recess is revealed. 
         [0044]    Referring now to  FIGS. 4 and 4A , an inside corner of the wall panel system  24  is shown. The panel  10  that forms the inside corner is attached to the wall  26  in the same manner as discussed above. The inside corner may be fabricated additionally with two vertical joints  22  which may be attached to the wall  26  as discussed above and arranged in the format shown in  FIG. 4A . The adjacent panels  10  may have a gap  18  which is the same size as the vertical and horizontal gaps  18  shown in  FIGS. 1A and 1B . The underlying vertical joint  22  is revealed through the gap  18 . The screws  38  are hidden behind the panels  10 . The components may be adjusted so that the gap  18  may be 1/16″ to 12″. 
         [0045]    Additional rows  12  of panels  10  may be stacked upon each other as shown in  FIG. 1  until the desired height is reached. The top edge of the wall panel  50 ,  54  may be finished with a top horizontal edge joint  62  shown in  FIG. 1D . The top horizontal edge joint  62  is attached to the wall  26  and engages the upper horizontal clip  32  attached to the panel  10 . This locks the panels  10  in place. The top horizontal edge joint  62  is the same as the bottom edge joint  36  except it  62  is upside down compared to joint  36 . The top edge joint  62  is revealed. The size of the joint  62  can be adjusted so that the amount that the joint  62  is revealed can be 1/16″ to 12″. 
         [0046]    One or more shims may be placed between the wall  26  and the bottom and top edge joints  36 ,  62 , and the horizontal joint  20  to even out the exterior visible face of the plurality of panels  10 . The shims may be held by the screws  38 . Additionally or alternatively, one or more shims may be placed between the panels  10  and the horizontal clips  32 ,  34  to even out the exterior visible face of the plurality of panels  10 . 
         [0047]    The wall panel system  24  described herein is an eco friendly system. The wall panel system comprises a plurality of panels  10 , bottom and top edge joints  36 ,  62 , vertical edge joints  68  and upper and lower horizontal panel clips  32 ,  34 . With these basic components and screws, the panels  10  may be mounted to the wall  26 . These basic components may be fabricated from different materials, etc. However, preferably, these basic components are fabricated from the same material (e.g., solid phenolic, medium density fibreboard, particle board, solid wood, bamboo, plastic laminate or a different eco friendly material) to minimize waste and more preferably from the same sheets. Initially, the wall to be covered with the wall panel system  24  is measured. In particular, at least the wall&#39;s width and height is measured. To fabricate these components, sheets of material (e.g., phenolic sheets) are initially provided. The sheets may be provided in any thickness (e.g., 5/16″ thick to 1½| thick). From these sheets, the panels  10  are initially cut out from the sheets since the panel  10  is typically the larger component in comparison to the bottom and top edge joints  36 ,  62 , vertical edge joints  68  and the clips  32 ,  34 . After the panels  10  are cut out of the sheets, the bottom and top edge joints  36 ,  62  and the vertical edge joints  68  may be cut out of the left over sheet. In the prior art, the left over sheet is thrown away or discarded. However, the wall panel system  24  utilizes as much of the sheet as possible to minimize waste so as to be an eco friendly process. The grooves  60 ,  58 ,  40 , the channel  50  and countersink holes  46  and holes  52  may be cut with various processes. By way of example, the grooves  60 ,  58  and  40  and channel  50  may be formed with a shaper machine. 
         [0048]    The wall panel system  24  described herein is also customizable. In particular,  FIG. 1  illustrates the wall panel system  24  with the panels  10  being taller than the bottom and top edge joints  36 ,  62 , joints  22 ,  20  and vertical edge joints  68 . However, it is also contemplated that the height and width of the bottom and top edge joints  36 ,  62 , joints  20 ,  22  and vertical edge joints  68  may be adjusted. By way of example and not limitation, the height of the bottom and top edge joints  36 ,  62 , joints  20 ,  22  and/or the vertical edge joints  68  may be enlarged so that the gap  18  between the panels  10  may be enlarged. It may be that more of the sheet can be utilized by cutting the bottom and top edge joints  36 ,  62  and/or the vertical edge joints  68  out of the sheets first before cutting the panels  10 . Accordingly, the process of fabricating the kit may be adjusted to yield the maximum amount of pieces to reduce waste. 
         [0049]    The panels  10  are shown and described as being square or rectangular. However, other shapes are also contemplated (e.g., circular, pentagonal, etc.) so long as the upper and lower clips  32 ,  34  can be mounted to the backside of the panels  10  in a parallel manner to each other. The panels  10  can also be cut to any size. For example, the width of the panel may be 1″ to 14′ wide. The height of the panel may be 1″ to 12′ high. It is also contemplated that the components of the wall panel system  24  may be fabricated from different materials. Different materials can be used to impart a unique aesthetic look to the system  24 . Even when different materials are used for different components of the system  24 , the sheets are optimized to minimize waste. 
         [0050]    The wall panel system  24  describes various tongue and groove connections. The reverse is also contemplated. By way of example and not limitation, the bottom and top edge joints  36 ,  62  and the horizontal joint  20  may be fabricated with tongues and the horizontal clips  32 ,  34  may be fabricated with grooves which mate with the tongues. 
         [0051]    The wall panel system  24  may utilize the same component at different areas of the system  24 . By doing so, waste and the number of process steps may be minimized. By way of example and not limitation, the horizontal joint  20  may also be used as the vertical joint  22 . Also, the bottom edge joint  36  may be used as the top edge joint  62 . 
         [0052]    In the system  24 , the horizontal joint  20 , bottom edge joint  36  and the top edge joint  62  have been described and shown as extending across the entire row of panels  10 . The vertical joints  22  and the vertical edge joints  68  extend between and abut these components  20 ,  36 ,  62 . However, the reverse is also contemplated. The vertical joints  22  and the vertical edge joints  68  may extend from the bottom most panel  10  to the top most panel  10 . The horizontal joint  20 , bottom edge joint and the top edge joint  62  may extend between and abut these components  22 ,  68 . 
         [0053]    The system  24  described herein was shown and described as being mounted to a vertical wall. However, it is also contemplated that the system  24  described herein may be mounted to other surfaces other than vertical such as skewed or horizontal (i.e., ceiling). 
         [0054]    The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of cutting and shaping the components of the kit. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.