Patent Publication Number: US-2009223151-A1

Title: Wall finishing system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     TECHNICAL FIELD OF THE INVENTION 
     The present invention relates generally to wall panels. More specifically, the present invention relates to a system of panels that are mountable to existing masonry walls for finishing and insulating the walls of a building&#39;s basement. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 6,854,218 teaches a system and method of panelized construction for use in construction of a building module, such as a residential housing addition. A plurality of pre-fabricated panels, such as wall panels, roof panels, floor panels, and ceiling panels may be provided to decrease on-site building time. The panels may comprise one or more covering layers pre-installed on a frame. The panels may also comprise pre-installed insulation or other core materials. The panels may further comprise a pre-installed portion of a house system, such as an electrical system. Additionally, the panels may comprise pre-installed windows, doors, or skylights. The panels may be designed to meet the residential building code requirements of one or more jurisdictions to decrease permitting time and inspection delays. The panels and other materials may be included in a building kit for a building module to be constructed by contractors or do-it-yourselfers. 
     U.S. Pat. No. 4,464,873 teaches a wall panel for use as a foundation and upper wall is disclosed. The wall panel comprises a plurality of spaced first framing members having top ends, bottom ends, first edges and second edges. A plurality of spaced second framing members, having top ends, bottom ends, first edges and second edges are provided. The spacing between the first framing members is substantially equal to the spacing between the second framing members. The bottom ends of the second framing members are positioned on top of the top ends of the first framing members. Means for fastening the first framing members to the second framing members are provided. Foundation grade treated sheathing are cooperatively connected to the first edge of the first framing members. External sheathing is cooperatively connected to the first edge of the second framing member. 
     U.S. Pat. No. 4,819,397 discloses a wall panel and wall paneling system which panels include a light weight polystyrene tray having an compartment. Within the compartment is installed a insulative, resilient insert. A fabric facing or web is loosely stretched across the opening of the tray&#39;s compartment to enclose the insert within the compartment, and the fabric is glued to the walls of the tray. When the wall panel is installed, by gluing it to the existing walls, molding strips engage the side walls of the tray to hold adjacent panels together, to stretch the fabric facing more tightly across the opening of the compartment, and to expose the molding strips and side walls as uniformly spaced vertical battens. 
     U.S. Pat. No. 5,564,250 teaches an insulation system for metal buildings, having a roof structure formed by roof panels supported on parallel, relatively narrowly-spaced purlins which are, in turn, supported on parallel, relatively widely-spaced main support beams, comprises a plurality of adjacently positioned strips of insulating material suspended below the roof structure so as to form a relatively flat and continuous surface. The strips of insulating material are supported on a system of insulation support tube strings suspended from and extending in parallel spaced relation to selected purlins. Each insulation support tube string runs the entire length of the building in spaced and transverse relationship to the main support beams. 
     U.S. Pat. No. 4,653,241 teaches an insulation system suitable for rapidly securing insulation to the interior surface of a basement wall, comprising a continuous roll of flexible insulation of a length substantially greater than its width and having an impermeable vapor barrier continuously laminated on one side thereof and in intimate contact therewith, the continuous roll being cut in sections of a length determined by the dimensions of a corresponding section of the interior surface of a basement wall to be covered, each section of insulation being supported tautly against the wall by at least one continuous fastening strip. 
     U.S. Pat. No. 6,918,212 teaches a fabric wall panel system that includes fabric wall panels mounted on a wall of a room by means of a ceiling track with a downwardly open channel mounted adjacent the ceiling and extending the length of the wall and a base track with an upwardly depending support surface mounted adjacent the floor and extending the length of the wall. Each fabric wall panel comprises a fabric cover overlaying a panel insert. Each fabric wall panel is mounted by inserting the top of the fabric wall panel into the downwardly open channel of the ceiling track and supporting the bottom of the fabric wall panel on the upwardly depending support surface of the base track. In one embodiment, the fabric wall panel is fabricated on-site and sized to have a length approximately equal to the length of the wall so that no vertical seams are created. In another embodiment, standard size panels are used with abutting vertical mid-wall seams between adjacent panels. 
     U.S. Pat. No. 4,459,790 teaches a laterally spaced apart, vertically disposed studs that are each provided with a pair of latch-receiving slots disposed laterally and rearwardly of a longitudinally extending, panel-separating rib. A wall panel is disposed between each pair of adjacent studs and is provided with a pair of laterally spaced apart latch members. Each latch member is positioned on the panel to be insertable in and removable from one of the latch-receiving slots on each of the adjacent studs with the wall panel in an elevated position. With the wall panel in a lowered position, the latch members cannot escape through the slots and the panel is held against the studs. 
     U.S. Pat. No. 4,973,796 teaches a wall structure for removably positioning panels and brackets is provided with a pair of electrical buses adapted to be contacted by an electrical clip at any one of a plurality of different heights. 
     U.S. Pat. No. 6,601,349 discloses a free-standing panel wall system which includes at least an elongated floor rail and an elongated top rail, each of a generally U-shaped cross section, and first and second sets of upright standards of generally U-shaped cross-section and having respective side wings that project laterally from the standard, there being one set of standards releasably secured at their top and bottom ends on respective ones of the opposite side webs of the floor rail and top rail. At spaced apart locations intermediate the floor and top rails and disposed between the standards of the first and second sets of standards there is provided a plurality of horizontal connectors, each of which is removably secured to respective ones of the standards on the opposite sides of the horizontal connectors. In one embodiment, there is provided one or more wall system sections which extend generally laterally of the plane of the main wall system section. 
     U.S. Pat. No. 5,216,859 teaches an improved horizontal support member for a demountable wall system which decreases the number of pieces which must be cut and folded, and subsequently assembled, to form a frame to which the gypsum board panels of the wall are assembled while increasing the strength and stability of the wall. The support member is formed from an elongate sheet of metal by making a series of longitudinal cuts in the metal and then folding the cut metal edges along lines which are substantially parallel to the longitudinal cuts to form first and second bars. The space between longitudinal cuts acts as a spacer to maintain the first and second bars in spaced, substantially parallel relationship. 
     U.S. Pat. No. 5,440,854 teaches a multi veneer anchor structural assembly for interconnection between the inner wythe and the outer wythe of an edifice. The assembly includes a pair of base members mounted in spanning relationship with at least vertical channels which form the frame of an edifice. A vertical plate is connected between the base members and has formed thereon a plurality of outwardly projecting vertical members each of which is engagable with a wall tie; with the wall ties being connected to an outer wythe. The assembly forms part of a drywall construction system which includes an insulating strip disposed between adjacent ones of the vertical plates, thereby providing a complete insulating layer for the edifice. In an alternate embodiment, the vertical plate is fabricated with a plurality of locally deformed areas which results in a high degree of stiffness of the veneer anchor structural assembly. 
     U.S. Pat. No. 5,791,093 teaches a slatwall panel having a plurality of horizontally-oriented, vertically arrayed extruded slatwall members which define recesses from which standard one-quarter inch offset hardware and display fixtures may be hung. A slidably connected tongue and claw connection is provided for vertically adjacent members. A method of forming a panel of such members on a wall is also described. In one form, the panel is preassembled. In the other, it is assembled in situ. 
     U.S. Pat. No. 4,674,240 teaches a wall panel system comprises units of extruded plastic strips having vertically-spaced, horizontally-extending C-shape channels for receiving prongs or clips of various types of hangers. The channels are connected by lands against which a hanger engages. Along the top and bottom horizontal edges of the units are joint members by which like units are connected. 
     U.S. Pat. No. 4,809,479 teaches a slat wall section includes a plurality of front horizontal members spaced from each other in a front plane. The front members having first and second horizontal edges, both of which have a rearwardly extending lip. Rear horizontal members having first and second horizontal borders are disposed in a rear plane, which is substantially parallel to the front plane. Each section includes first and second ends, with one rear member extending to the first end and one front member extending to the second end. Substantially parallel transverse connecting members extend between, and are generally perpendicular to, the front and rear members. At least one connecting member extends from each of the front members to a rear member. The connecting members are spaced from the first and second horizontal edges of the front members. A first connector defines the first end of the section, and includes a flange extending toward the front plane. 
     U.S. Pat. No. 5,018,323 teaches a system of interconnecting wall panels, which in normal use provide horizontal parallel recesses along the length of the wall, into which shelf brackets can be fitted, the converse face of the recesses providing detents by which the panels can be attached to a supporting structure on the wall behind. 
     U.S. Pat. No. 6,883,288 teaches a J-channel is provided with a retainer which biases an inserted siding panel against a cantilevered end of an outer face of the J-channel. The retainer has an engagement tab biased from a wall member which is preferably connected to an inner face of the J-channel member. An engagement tab and an inwardly directed lip at the cantilevered end of the outer face preferably retained an inserted panel therebetween. 
     U.S. Pat. No. 6,425,219 discloses a modular partition system based upon a panel frame structure formed of vertical members of substantially lesser thickness than the panels to be formed, which may be joined end-to-end in a modular manner, and side-by-side to join vertical ends of adjacent panels, and horizontal C-section rails secured to opposite sides of the vertical rails with mouths of the C-sections facing outwardly. Cladding panels are secured by vertically-spaced sets of spring clips engaging respectively upper and lower surfaces of vertically-spaced horizontal rails, and panels and other furnishings are secured to brackets engaged within the C-section of horizontal rails. The relationship of the horizontal and vertical members allows for easy cabling, and the use of the clamps permits panels and furnishings to be located without substantial regard to the horizontal modularity of the system. The basic paneling system requires a minimum number of different modular parts. 
     U.S. Pat. No. 5,535,556 discloses a basement wall that is formed by a series of vertical metal studs supported at their lower ends on a metal sill extending along the upper face of a concrete footing. An insulating sheathing is mounted on the metal studs to form the wall outer surface. The sheathing is formed by two panel layers of rigid foam core insulator material. Edges of the inner panels are offset from the edges of the outer panels to form labyrinth seals preventing migration of ground water through the sheathing. 
     U.S. Pat. No. 5,617,686 teaches an insulating foamed polymer wall panel comprising a sheet of foamed polymer having sizable dimensions to form a substantial part of a wall when assembled. Adjacent wall panels are coupled using splines, which together with the side edges of the panels, form the sidewalls of a cement channel between the panels. The panel has connecting slots for receiving the splines and a plurality of edges, each top and side edge having a longitudinally extending groove to accommodate the fill of cement therein. The grooves provide tongue-and-groove connections between the cement post and adjacent wall panels once the cement has set, thus locking the latter into place. 
     U.S. Pat. No. 5,377,470 teaches a modular insulating wall panel system comprising a monolithic insulating panel incorporated within frame construction, and a method for constructing same. The frame skeleton comprises columns, studs, a sole plate and a top plate. The panel, having a plurality of edges, each with a recess therein, is inserted within the frame skeleton so that each recess receives an adjacent structural member. 
     U.S. Pat. No. 5,848,512 discloses a structural member for use in securing a wallboard to an existing wall. The structural member is constructed a single piece of extruded plastic formed into an I-beam shape with a hollow center. The hollow center eases passage of a fastener mechanism, yet provides structural rigidity with the reinforcement by the fastener. Passage of water pipes and electrical wires transversely is possible by use of predefined spacer wall openings. 
     U.S. Pat. No. 6,460,305 teachers a highly moisture resistant basement wall system which facilitates quick construction includes a plurality of spaced apart metal studs extending vertically upwardly from a sill, and metal decking secured to the plurality of studs. The resulting basement is drier and more comfortable, and warmer in the winter than conventional basements defined by concrete walls. 
     U.S. Pat. No. 5,974,753 teaches a wall covering system that includes prefabricated T-shaped (in cross section) horizontal supporting strips, L-shaped horizontal supporting strips, L-shaped end-locking strips and decorative panels. The end-locking strips interact with the horizontal strips and the decorative panels, provide an aesthetic appearance to the finished system when assembled on a wall and provide safety by covering the exposed ends of the T-shaped horizontal strips. In use, the wall paneling system disclosed herein may be easily and conveniently installed onto existing walls by a user without professional assistance and may be just as easily and conveniently removed from the wall whenever it is desired to inspect behind the panels, change the decor, or to remove the panels for installation at another location. 
     U.S. Pat. No. 6,018,919 teaches a wall finishing system that is a sheet material designed to cover an entire wall, requiring minimal seams. The wall material has the characteristic of shrinking after application causing surface irregularities to pull out to a smooth plane. The sheet material can be applied to various substrates including finished or unfinished drywall, paneling, cement block, etc. 
     Published U.S. Patent Application 2006-0236653 discloses a basement wall insulating and finishing system for finishing a basement to increase the amount of livable space in a home. The basement finishing system comprises a plurality of connectable panels. An insulation layer is secured to the rear surface of the panels. The insulation layer has a generally flat front surface that is secured to the rear surface of the panels. The insulation layer also provides an uneven rear surface that is positioned adjacent to the existing basement foundation wall, and a pair of uneven side surfaces. The uneven rear and side surfaces of the insulation layer provide a plurality of grooves or dimples that allow moisture and air to move freely between the basement wall and the insulation layer. The panels and insulation layer are mounted to the existing basement walls by mounting brackets. 
     Published U.S. Patent Application 2006-0026917 discloses a prefabricated wall panel and method are disclosed. A panel including a sheet rock layer and a laminated in-situ foam layer within a frame is attached to a pre-existing masonry wall, such as a basement wall. 
     Published U.S. Patent Application 2003-0150183 discloses a prefabricated wall panel and method are disclosed. A panel including a sheet rock layer and a laminated in-situ foam layer within a frame is attached to a pre-existing masonry wall, such as a basement wall. 
     Published U.S. Patent Application 2004-0219853 discloses a finished faced insulation system for use where a reduced thickness is desired for interior basement applications for walls not requiring thermal insulation (non-thermal gradient walls) and for the interior of basement walls where thermal insulation is required (thermal gradient walls). The insulation system of the present invention is also suitable for use on masonry walls, frame construction walls, and combined construction walls (knee-walls). The insulations system provides an insulative core having a first surface and a second surface, said first surface being suitable for exposure to an interior of a room, said second surface being suitable for being placed adjacent a wall; a decorative facer adhered to said first surface; and a structural facer adhered to said second surface. 
     Traditional finishing methods as those previously discussed above and known in the prior art suffer from many shortcomings. Typically, most systems are labor intensive to install and result in disruptions to household activities for weeks while construction is completed. Therefore what is needed is a system that can be installed quickly, efficiently, and with a reduction in necessary labor. 
     Foundation problems and rewiring become additional time- and labor-intensive projects and typically there is no access without demolition to the structure, which greatly increases the cost refinishing. What is needed is a basement refinishing system that eliminates the need for access to wiring, can be installed over imperfect foundations, and is economical to install. 
     Many of the system disclosed in the prior art use panels that are easily dented, damaged and punctured. Therefore what is needed is needed is a system that does not use panels made from materials that are susceptible to damage during transport, installation, and use. 
     Additionally, many of the systems disclosed in the prior art require separate insulation and acoustic control. What is needed is a wall system that uses panels that have integrated insulation and acoustic control. 
     Finally, many of the systems disclosed in the prior art are susceptible to mold, mildew, warping, rotting and water damage are not designed, applicable, nor intended for use in basements. Therefore what is needed is a wall finishing system that utilizes panels and components that are not susceptible to and are designed to resists mold, mildew, warping, rotting and other water damage. 
     SUMMARY OF THE INVENTION 
     The present invention is a Basement Finishing System that consists of an Acoustic Suspended Ceiling; Vinyl Laminated Outside Corners; Vinyl Laminated Inside Corners; Extruded Polystyrene Insulation; Vinyl Laminated Substrate; Baseboard Molding; Crown Molding; Pre-Wired Electrical Chases for Outlets and Switches; Laminate Flooring; and Recessed Lighting. 
     In the Basement Finishing System of the present invention, the walls composition is made from a “sandwich panel” that measures 4×8′ by 4″. The wall is made of a ½ inch sheet of Aquaboard brand Fiberock from USG on the front side which is laminated with a vinyl finish followed by a 2″ layer of extruded polystyrene insulation placed between another sheet of ½ inch Aquaboard. The wall component is then held in place with a wall suspension system that enables quick installation by affixing an upper channel to the ceiling rafters which then connect to a bracket on the back of the wall and which then rests in a floor track. 
     The primary advantage of the present invention is that the system provides a quick, clean installation that results in a new living space in about one week. 
     Another advantage of the present invention is that the system allows one to remove wall panels for easy access to foundation and wiring whenever necessary and then quickly and easily replace them once the need for access ends. 
     Yet another advantage of the present invention is that the panels of the system are constructed from durable, dent-resistant materials that allow the wall to stand up to kids, pets, and other common household residents and events that commonly cause wall damage. 
     Still another advantage of the present invention is that the panels of the system are constructed with built-in acoustic and thermal insulation. 
     A final advantage of the present invention is that the installation and panel components of the system are designed specifically for basement conditions and are construction from materials that are specifically resistant to moisture, mold, mildew, and other type of damage caused by water. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. 
         FIG. 1  is a perspective view of a wall finishing system according to the present invention; 
         FIG. 2  is a side cross-section view of a wall panel for the wall finishing system according to the present invention; 
         FIG. 3  is a side cross-section view of a wall panel for the wall finishing system installed according to the present invention; 
         FIGS. 4   a  is a top view of the connector bar for the wall finishing system installed according to the present invention; 
         FIG. 4   b  is a perspective view of the connector bar for the wall finishing system installed according to the present invention; 
         FIG. 5  is a side view of the connector bar bracket for the wall finishing system installed according to the present invention; 
         FIG. 6  is a side view of the floor track for the wall finishing system installed according to the present invention; 
         FIG. 7  is a top view of the floor track mount for the wall finishing system installed according to the present invention; 
         FIG. 8  is a perspective view of the top bar for the wall finishing system installed according to the present invention; and 
         FIG. 9  is a perspective view of the top bar bracket for the wall finishing system installed according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description of the invention of exemplary embodiments of the invention, reference is made to the accompanying drawings (where like numbers represent like elements), which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, but other embodiments may be utilized and logical, mechanical, electrical, and other changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims. 
     In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known structures and techniques known to one of ordinary skill in the art have not been shown in detail in order not to obscure the invention. 
     Referring to the figures, it is possible to see the various major elements constituting the apparatus of the present invention. The present invention is a Basement Wall Finishing System. Now referring to  FIG. 1 , a perspective view of a basement wall finishing system installed according to the present invention is shown. The key components of the wall finishing system include: an Acoustic Suspended Ceiling  1  with Vinyl Laminated Outside Corners  2  and Vinyl Laminated Inside Corners  3 . Extruded Polystyrene Insulation  4  is used to cover the walls and attaches to a Vinyl Laminated Substrate  5 . Finishing wall trim includes Baseboard Molding  6  and Crown Molding  7 . The Extruded Polystyrene Insulation  4  used to cover the walls includes Pre-Wired Electrical Chases  16  for Outlets and Switches  8 . Finishing off the installation off a basement wall finishing system, Laminate Flooring  9  is used as well as recessed lighting  10  in the Acoustic Suspended Ceiling  1 . 
     Now referring to  FIG. 2 , a side cross-section view of a wall panel for the wall finishing system according to the present invention is shown. In the Basement Wall Finishing System of the present invention, the walls composition is made from a “sandwich panel” that measures 4×8′ by 3″. The wall is made of a ½ inch sheet of Aquaboard brand Fiberock from USG on the front side  11  which is laminated with a vinyl finish followed by a 2″ layer of extruded polystyrene insulation  12  placed between another sheet of ½ inch Aquaboard  13 . In an alternative embodiment and unfinished panel is provided that may be painted as desired. 
     The wall component or panel  14  is then held in place with a wall suspension system that enables quick installation by affixing an upper or top channel  48  to the ceiling rafters which then connect to a top bar  52  on the back of the wall and which then rests in a floor track  32 . 
       FIG. 3  illustrates a side cross-section view of a “sandwich panel” wall panel for the wall finishing system installed according to the present invention. The wall is made of a sheet of Aquaboard brand Fiberock from USG on the front side  14  which is laminated with a vinyl finish followed by a 2″ layer of extruded polystyrene insulation  15  placed between another sheet of Aquaboard  18 . The connectable panels are further comprised of Pre-Wired Electrical Chases  16  &amp;  17  for Outlets and Switches. 
     A connector bar  20  is used for securing the panels to a building structures wall as illustrated in  FIGS. 4   a ,  4   b , and  5 . The connector bar  20  consists of a first steel plate  24  with a plurality of elongated holes  23  that has a second steel plate  22  mounted to the one side of first steel plates  24  top surface. The second steel plate  22  further consists of a slot  25  that runs the length of the second steel plate  22  and is perpendicular to the first steel plate  24 . The connector bar  27  is used to secure the connector bar to the wall panel and the building&#39;s wall or structure. From a side view, the connector bar is “F” shaped and clearly illustrates the first steel plate  24 , second steel plate  22 , and slot  25 . 
     Now referring to  FIGS. 6 and 7  the floor track  32  for securing the wall panel to the building&#39;s wall and floor is shown. The floor track  32  is a flat piece of metal that is secured to an existing floor surface via glue, screws, nails, or other known construction means. The floor track  32  consists of a flat metal bar  34  that has a raised tab portion  36  running perpendicular to the flat metal bar and extending outward. The floor track  32  has first section  41  that consists of a first top side  44  for engagement with a wall panel and a second bottom side  40  for engagement with a buildings floor surface. The floor track also uses a post  39  that extends into the interior of the wall panel that retains the panel in a fixed position and resists movement. 
       FIGS. 8 and 9  are views of the top bar  48  for the wall finishing system installed according to the present invention. The top bar  48  is a is a u shaped clamp  52  that is designed to mount to a building&#39;s existing wall or structure and then secure the panel to the building wall or structure by restricting movement of the panel upward and to and from the building&#39;s wall or structure. The top bar  48  consists of a first portion  56  that is mounted to a building&#39;s wall or structure. Extending from the back portion  56  is a top portion  58  that has both a top surface  59  and a bottom surface  55 . The back portion  56  engages a rear surface of a wall panel to secure it in place and restrict movement toward the building&#39;s wall or structure. The bottom surface  55  engages a top surface of a wall panel to secure it in place and restrict upward movement. Finally, the top portion  58  bends  54  to into a parallel plane and position with respect to the back portion  56  to form a front portion  57  that has both an exterior surface  62  and an interior surface  61 . The interior surface  61  engages a front surface of a wall panel to secure it in place and restrict movement away from the building&#39;s wall or structure. 
     Thus, it is appreciated that the optimum dimensional relationships for the parts of the invention, to include variation in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one of ordinary skill in the art, and all equivalent relationships to those illustrated in the drawings and described in the above description are intended to be encompassed by the present invention. 
     Furthermore, other areas of art may benefit from this method and adjustments to the design are anticipated. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.