Abstract:
A fabric wall panel system includes wall panels mounted on a wall by means of a releasable hanger. Each fabric wall panel comprises a frame and a flat filler insert covered by a fabric. Each frame member has a flat spine, an outside web, an inside web, and a front web. Together the outside web, the inside web, and the front web form a hollow channel along the edge of the frame member with internal protrusions to engage the hanger and hold the fabric wall panel in place on the wall. The hanger comprises a resilient material with a flat base affixed to the wall with two forked tongues extend perpendicularly therefrom. The forked tongues engage the protrusions within the hollow channel to hold the frame member securely to the hanger and thus to the wall. The hanger with its resilient forked tongues assures proper spacing between the adjacent fabric wall panels mounted on the hanger.

Description:
FIELD OF THE INVENTION 
     This invention relates to a fabric wall panel system for use in decorating, and more particularly, relates to a fabric wall panel system having fabric wall panels which are removably mounted to a wall so that the seams between the fabric wall panels are uniform and fit tightly. 
     BACKGROUND OF THE INVENTION 
     Fabric wall panels are used to decorate the interior space in many buildings. Fabric coverings for the panels are available in numerous textures and patterns which can be coordinated with the furnishings and carpets in a room. These fabric wall panels can be customized to meet the decorating needs of various locations and decorating tastes. 
     Besides decorating versatility, fabric wall panels provide other desirable features. Such features include sound and heat insulation. Particularly, in large rooms such as auditoriums and theaters, fabric wall panels may include a layer of acoustical material hidden behind the fabrics which modifies the acoustical character of the room. In addition, heat insulating material may be mounted behind the fabrics to enhance heat transfer properties of a wall. 
     A substantial costs involved in fabric panels is the cost of installation. Moreover, if the fabric becomes worn or the decorating scheme changes, the need may arise to change the fabric panels. Consequently, the method of mounting and/or changing the fabric wall panels becomes an important consideration when fabric wall panels are selected for a building project. 
     Another consideration in the selection and use of fabric wall panels is assuring a quality installation. Particularly, the wall panels should line up uniformly with each other, and the seams between adjacent wall panels should be tight and uniform. With most fabric wall panel systems, quality of installation including alignment and uniformity of seams depends on the skill of the installer. 
     Some prior fabric wall panels are installed in situ. For example, as disclosed in Baslow U.S. Pat. No. 4,018,260, border pieces of a panel are permanently attached to the wall to form a framework for mounting a fabric sheet. The fabric sheet completely covers the wall without being adhered to the wall itself. The linear border pieces include a key way into which the fabric is forced by means of a compressible spline. The linear border pieces also include a storage channel, which allows the border pieces to create a finished look at the edges. The Baslow patent does not disclose a method of fabric wall panel prefabrication or removable attachment. The uniformity of installation depends on the skill of the installer in terms of aligning the framework and forcing the fabric into the key way so that the fabric is uniformly stretched on the framework. 
     In addition, fabric wall panels can be prefabricated. One method for installing prefabricated fabric wall panels employs a cross-nailing system as disclosed by the patent to Anderson, U.S. Pat. No. 4,731,972. The fabric wall panels disclosed in the Anderson patent are prefabricated and then installed by driving two headless pin nails at an angle in a crossed fashion through the frame pieces of the prefabricated panels. The crossed nails penetrate completely through the fabric, partially penetrate the frame, and securely fasten the panel to the wall. A fabric wall panel attached using this cross-nailing method cannot be easily removed from the wall if one should desire to replace panels or remove the panels entirely. 
     One successful removable wall panel system is disclosed in Anderson U.S. Pat. No. 5,715,638. In that patent, the fabric wall panels are mounted on the wall by means of hangers. Each frame member of each wall panel has a spine with an elongated slit, a side edge, and a front edge which together define a groove. A flat filler insert is fitted within the groove of each frame member. Fabric is stretched over the frame and flat filler insert and is bonded to the back of the spine of each frame member to complete the finished fabric wall panel. The hanger has a flat base and a perpendicularly extending tongue with an enlarged head. A number of hangers are affixed on the wall using an adhesive. The slit on the frame of the fabric wall panel is aligned with the tongue of hanger on the wall, and the fabric wall panel is affixed to the wall by pressing the slit over the tongue on the hanger. The fabric wall panels can be prefabricated or installed in situ. The fabric wall panels can also be independently replaced or removed entirely by unsnapping the fabric wall panel from the supporting hangers. 
     While the disclosed fabric wall panel system has been successful, several improvements are needed. First, because the spacing between panels depends on the thickness of the fabric replacing a thick fabric with a thinner fabric can result in open mid-wall seams between panels. Second, the underlying frame of the fabric panels sometimes show through under the stretched fabric. Third, gluing the fabric to the frame can make removal of the fabric difficult when the fabric on the panel is changed. 
     The prior art has thus failed to disclose a removable fabric wall panel system in which the mid-wall seams are uniform and tightly fitting, the underlying frame for the wall panels does not show through the fabric, and the fabric attachment to the panel frame does not depend entirely on glue. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies the above-described needs with a fabric wall panel system and method for installing fabric wall panels on a wall. The fabric wall panels comprise a frame, a flat filler, and a fabric stretched over the flat filler and around the edges of the frame. The fabric wall panels are removably mounted on the wall by means of a hanger. 
     The frame of the fabric panel comprises a plurality of linear frame members. Each frame member has a flat spine, an outside web, an inside web, and a front web. Together the outside web, the inside web, and the front web form a hollow channel along the edge of the frame member. The hollow channel has an opening opposite the front web of the frame member which offers access to the inside of the hollow channel. The outside web and the inside web of the frame member each have a protrusion that extends into the channel to engage the hanger and hold the fabric wall panel in place on the wall. 
     The hanger comprises a flat base with two forked tongues extend perpendicularly therefrom. The base of the hanger is affixed to the wall with an adhesive or other suitable fastening means, and the forked tongues project outward from the wall. Each forked tongue has two forks that diverge from each other as they extend away from the flat base. Each fork has of cam surface and a latch surface. The material of the hanger is resilient so that the forks at their outward ends can be pressed together. The forked tongues of the hanger are aligned with and forced into the opening of the hollow channel of the frame member. The cam surfaces of the forks engage the protrusions within the hollow channel, and the forks are thereby forced together. When the frame member is fully seated onto the flat base of the hanger, the latch surfaces of the forks engage the protrusions within the hollow channel to hold the frame member securely to the hanger and thus to the wall. The fabric wall panels can be removed from the hangers by prying the frame away from the hanger to disengage the latch surfaces of the forks from the protrusions within the hollow channel of the frame members. 
     When the fabric is wrapped around the frame, the excess fabric is inserted into the opening of the hollow channel. Consequently, when the frame is pressed onto the hangers, the forks within the hollow channel engage the fabric and lock it between the latch surface of the fork and the protrusion within the hollow channel. Consequently, in some applications, the necessity of gluing the fabric to frame is eliminated. 
     The hanger of the present invention with its forked tongues assures proper spacing between the adjacent fabric wall panels mounted on the hanger. Consequently, frame members of adjacent wall panels are secured together to reduce the visibility of the seam between the adjacent wall panels and to ensure a uniform width for the seam between adjacent wall panels. In that regard, the outside web of the frame member has an angled portion near its front edge. The angled portion extends toward the adjacent wall panel thereby assuring that the adjacent panels are held tightly together in order to disguise the presence of the seam between them. 
     The hanger also has an index mark on the spine. The index mark is centered between the two tongues and runs the length of the hanger. The index mark serves as a guide for cutting the hanger in half along its length. Once the hanger has been cut in half along its length, the resulting half hanger has a single tongue and used for installation of the fabric wall panels adjacent a corner next to an adjoining wall. 
     In one embodiment of the present invention, the inside web of the frame member is shorter than the outside web of the frame member so that the front web of the frame member slopes inwardly and toward the base. Such a construction is used so that the edge between the front web and the inside web of the frame member does not show through on the front of the fabric wall panel. 
     In other embodiments of present invention, the front web of the frame member variously has a radius profile, a beveled profile, and a chamfered profile. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a room having walls covered with a fabric wall panel system in accordance with the present invention. 
     FIG. 2 is a perspective view of a linear frame member and hanger in accordance with the present invention. 
     FIG. 3 is a cross-section view of a fabric wall panel mounted on a wall by means of a hanger in accordance with an embodiment of the present invention as seen along line  3 — 3  in FIG.  1 . 
     FIG. 4 is a cross-section view of a fabric wall panel, similar to FIG. 3, in the process of being mounted on a wall by means of a hanger in accordance with an embodiment of the present invention. 
     FIG. 5 is a cross-section view of a frame member having a front web with a radius profile. 
     FIG. 6 is a cross-section view of a frame member having a front web with a beveled profile. 
     FIG. 7 is a cross-section view of a frame member having a front web with a chamfered profile. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is a fabric wall panel system and method for installing fabric wall panels on a wall. The fabric wall panel system comprises a fabric wall panel and a hanger. The hanger is attached to wall and releasably engages the fabric wall panel for easy installation and removal without damaging the wall. The hanger and fabric wall panels are configured so that when the fabric wall panels are mounted on the wall, the hanger assures that adjacent fabric wall panels are properly aligned and that seams between adjacent wall panels are uniform and tight. 
     For the purposes of the present invention, a wall includes existing or permanent walls, moveable walls, partitions, and the like. Although the present invention will be generally described in the context of a room with walls of sheet rock, those skilled in the art will recognize that the present invention is not limited to that environment. Referring now to the drawings, in which like numerals represent like elements throughout the several figures, the present invention will be described. 
     Turning to the figures, FIG. 1 is a perspective view of a room with a back wall  2  and a side wall  4  covered with fabric wall panels  10 , including  10   a  and  10   b , in accordance with the present invention. The room also has a ceiling  6  and a floor  7 . The back wall  2  and side wall  4  converge at a corner  8 . Each fabric wall panel  10  is connected to the walls  2  and  4  by means of a series of hanger hangers  50  (FIG.  2 ). 
     Each of the fabric wall panels  10  in FIG. 1 is similarly constructed. The following discussion focuses oh the two adjacent fabric wall panels  10   a  and  10   b . Fabric wall panel  10   a  comprises a rectangular frame  12   a , a fabric  21   a , and a flat filler insert  22   a . Likewise, the fabric wall panel  10   b  comprises a rectangular frame  12   b , a fabric  21   b , and a flat filler insert  22   b . Each frame  12   a  and  12   b  is made up of four linear frame members  14   a ,  16   a ,  18   a , and  20   a  and tour linear frame members  14   b ,  16   b ,  18   b , and  20   b , respectively. The linear frame members  14 ,  16 ,  18 , and  20  are extrusions made of polyvinyl chloride (PVC). A PVC designated 7045 White 08 PVC sold by Georgia Gulf Corporation of Plaquemine, La., is useful in connection with the present invention. Metal extrusions including aluminum extrusions may also be used for the linear frame members  14 ,  16 ,  18 , and  20 . 
     Referring now to FIGS. 1 and 2, the linear frame member  14   a  is shown in perspective and comprises a flat spine  27 , an inside web  32 , a front web  30 , and an outside web  31 . The inside web  32  is connected to and extends from the spine  27 . The front web  30  interconnects the inside web  32  and the outside web  31 . Together the inside web  32 , the front web  30 , and the outside web  31  form a hollow channel  41 . The hollow channel  41  has an opening  40  opposite the front web  30 . A protrusion  42  extends from inside web  32  into the hollow channel  41 . Likewise, a protrusion  43  extends from outside web  31  into the hollow channel  41 . As will be described in greater detail, the protrusions  42  and  43  form part of a locking mechanisms that holds the fabric wall panel  10  onto the wall  2 . 
     As shown in FIG. 2, the linear frame member  14   a  is connected to the back wall  2  by means of the hanger  50 . The hanger  50  includes a base  52  which is attached to the back wall  2  by means of a suitable adhesive or by mechanical means such as cross nailing or stapling. The base  52  may be flat or slightly concave to assure that it lies flat against wall  2  once it has been installed. The hanger  50  includes forked tongues  54  and  55  (FIG.  3 ). As shown in FIG. 2, forked tongue  54  comprises outwardly extending forks  56  and  58 . Likewise, forked tongue  55  comprises outwardly extending forks  57  and  59  (FIG.  4 ). The forks  56  and  58  have cam surfaces  60  and  62  and latching surfaces  64  and  66 . The forks  56  and  58  are flexible so that they can deflect toward each other. The flat base  52  has an index mark  70  in the shape of a V to indicate the midpoint between the forked tongues  54  and  55 . The hanger  50  is an extrusion made of polyvinyl chloride (PVC). A PVC designated 7045 White 08 PVC sold by Georgia Gulf Corporation of Plaquemine, La., is useful in connection with the present invention. 
     The insert  22  may consist of any number of materials to provide sound or heat insulation. The insert may be an acoustical insert in the nature of a rigid board such as Owens/Corning 705 Fiberglas insulation board sold by Owens/Corning Fiberglas Corp. of Toledo, Ohio. Alternatively, the insert may be a mineral fiber board insert such as Micore board sold by USG Acoustical Products Company of Chicago, Ill. The thickness of the insert  22 , such as insert  22   a  (FIG.  3  and FIG.  4 ), generally equals the height of the outside web  31  so that the surface of the insert  22   b  is generally coplanar with the front web  30  of the frame member  14   a . The insert  22 , such as insert  22   a , thus serves as a backing for the fabric  21 , such as fabric  21   a , shown in FIG.  3  and FIG.  4 . 
     When the fabric wall panel  10   a  is prefabricated, for example, the linear frame members  14   a ,  16   a ,  18   a , and  20   a  are miter-cut and connected at their corners in conventional fashion, such as by gluing, fasteners, or welding. The filler insert  22   a  is seated against the spine  27  of the frame  12   a . As previously stated, the insert  22   a  not only provides sound or heat insulation, but it also provides rigidity to the frame  12   a . The fabric wall panel  10   a  is completed by stretching fabric  21   a  over the insert  22   a  and frame  12   a , around the front web  30  and the outside web  31 , and gluing the fabric  21   a  to the back of the spine  27 . SM high-strength adhesive  90  sold by 3M Company of St. Paul, Minn., has been found to be suitable for gluing a large number of fabrics to the PVC material of the frame  12   a . The fabric  21   a  may be attached in any other suitable fashion such as by stapling. Any excess fabric  72  (FIGS. 1 and 4) may be inserted into the hollow channel  41  through opening  40 . As will be explained in greater detail below, the excess fabric  72  is locked within the hollow channel  41  thereby assuring a taut fit. Once the fabric wall panel  10   a  has been prefabricated, it is attached to the wall using hangers  50 . 
     With reference to FIGS. 3 and 4, the installation of the wall panels  10   a  and  10   b  onto the back wall  2  is illustrated. The hanger  50 , which is one of a several hangers, is mounted to the back wall  2  by means of gluing, cross nailing, or stapling. A separate contact adhesive on the back of the hanger  50  may be used to secure the hanger  50  to the back wall  2  until the separately applied adhesive has fully cured. 
     With continuing reference to FIGS. 3 and 4, each hanger  50  is positioned on the wall so that the forked tongue  54  aligns with the opening  40  of hollow channel  41  for frame member  14   a  of fabric panel  10   a . Similarly, the forked tongue  55  aligns with opening  80  of hollow channel  81  for frame member  14   b  of fabric panel  10   b . Because the forked tongues  54  and  55  are mounted to a single hanger base  52 , their spacing is fixed. Once the openings  40  and  80  of the fabric panels  10   a  and  10   b  are aligned with the forked tongues  54  and  55 , the fabric panels  10   a  and  10   b  are moved toward the wall  2 . As the forked tongue  54  enters into the opening  40  of the frame member  14   a , the cam surfaces  60  and  62  engage the protrusions  42  and  43  inside the hollow channel  41 . As result of the engagement of the cam surfaces  60  and  62  and protrusions  42  and  43 , the forks  56  and  58  are forced toward each other. As the frame member  14   a  is moved toward the base  52  of the hanger  50 , the cam surfaces  60  and  62  pass by the protrusions  42  and  43  so that forks  56  and  58  spring back and the latching surfaces  64  and  66  engage the protrusions  42  and  43  as shown in FIG.  3 . With the frame member  14   a  seated against the base  52  of the hanger  50 , the latching surfaces  64  and  66  engage the protrusions  42  and  43  to hold the frame member  14   b  in place. 
     Once both fabric wall panels  10   a  and  10   b  are seated at shown in FIG. 3, the forks  58  and  59  adjacent the marker index  70  urge to the fabric wall panels  10   a  and  10   b  toward each other so that any spacing, at seam  87  between the fabric panels  10   a  and  10   b , is minimized. In addition, the outside webs  31  and  86  (FIG. 3) have portions  90  and  92  which angle outwardly from the plane of the outside webs  31  and  86 . The outward angle portions  90  and  92  further assure that seam  87  remains closed. The flexibility of the forks  58  and  59  allow the fabric wall panel system to accommodate fabrics of different thickness and still assure that the seam  87  remains closed. 
     The flexible forks  58  and  59  of the flexible tongues  54  and  55  also serve to capture the excess fabric  72  at the point where, for example, the latching surface  66  engaged protrusion  43 . The engagement of the excess fabric  72  at protrusion  43  assured that the fabric is additionally stretched as the tongues  54  and  55  enter the hollow channels  41  and  81 . 
     The index mark  70  on the hanger  50  indicates a point at which the hanger can be cut into two parts when installation next to a corner, such as corner  8 , is required. Again, the flexible forks  58  urges the fabric panel  10   a  toward the index mark  70  and thus toward and adjacent wall. 
     When the fabric panels  10  need replacement, the process is reversed and each fabric panel is pulled off of the underlying hanger  50 . The exertion of the outward force on the fabric panels  10  causes the latching surfaces, e.g.  64  and  66  (FIG. 4) to disengage the protrusions  42  and  43  thereby releasing the panel can be from the wall  2 . Once the new fabric has been stretched around the frame  12  of the fabric panel  10 , the hanging process is repeated using the same hangers that were previously installed. Particularly, the system allows for the replacement of a thin fabric with a thick fabric and vice versa because of the flexible forks  58  and  59  urge the fabric panels  10   a  and  10   b  together at seam  87 . 
     With respect to the profile of the frame member  14   a , the front web  30  slopes toward the spine  27  from the outside web  31  toward the inside web  32 . For that particular profile, the slope of wall  30  assures that the front surface of the insert  22   a  does not contact fabric  21   a  and therefore show through on the front of the fabric panel  10   b.    
     FIG. 5, FIG. 6, and FIG. 7 disclose additional profiles for the frame members. Particularly, FIG. 5 shows a radius profile  100  for the frame member  14   b . FIG. 6 shows a beveled profile  102  for the frame member  14   b . FIG. 7 shows a chamfered profile  104  for the frame member  14   b . In each of the alternative profiles, the flexible forks serve the same function to a sure that the seams at  105 ,  106 , and  107  remained substantially closed and can accommodate fabrics of different thickness. 
     On-site customization of fabric wall panels  10  is a simple process. The linear frame members  14 ,  16 ,  18 , and  20  are first cut to the exact size of the space required, and the ends are mitered to accommodate the exact angles of the wall space. Once cut and mitered, the linear frame members  14 ,  16 ,  18 , and  20  are then temporarily attached to the wall to assure accuracy of the cuts. The flat filler insert  22  is then cut according to the measurements of the temporarily attached frame members  14 ,  16 ,  18 , and  20  so that the insert  22  fits within the frame  12 . The fabric  21  is attached by stretching it over the frame  12  and gluing it to the back of the spine  27  of the linear frame members  14 ,  16 ,  18 , and  20  and inserting the excess fabric  72  into the hollow channels of the frame members. With the fabric  21  attached, the fabric wall panel  10  is reinstalled on the wall using hangers  50 , as previously described. 
     Once fabric wall panels  10  have been installed according to the above-described system, removal and replacement of the fabric wall panels  10  is a simpler process. Any fabric wall panel  10  can be independently removed by unsnapping the fabric wall panel  10  from the supporting hangers  35 . Another panel may be installed in the other panel&#39;s place by simply snapping the new panel onto the existing hangers. If one desires to remove the panels entirely, all of the panels can be removed by unsnapping each panel from the supporting hanger and removing the hangers from the wall. 
     In summary, the present invention provides an improved and simplified fabric wall panel system for installing fabric wall panels employing a snap hanger. By utilizing the disclosed method for installing fabric wall panels, the removal and replacement process is less complicated. Therefore, the preferred embodiment of the present invention allows for easy installation and removal of fabric wall panels, whereby the procedure does not damage the wall. 
     Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description.