Patent Publication Number: US-8966849-B1

Title: System for mounting wall panels to a wall structure

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to a wall system, and more particularly, to a system for easily mounting wall panels over an existing wall structure. 
     In order to enhance the look of a wall structure, it is known to secure decorative wall panels to the wall structure. However, the securement of wall panels to the wall structure is generally a long and tedious job since it entails using fastening devices such as nails and/or screws to secure the walls panels directly to the wall structure. In addition, the fastening devices are exposed, which can provide an unsightly appearance. 
     A system that overcomes some of these problems is sold by Bamco Inc. of 30 Baekeland Ave., Middlesex, N.J. 08846 under the designation “G500 WALL SYSTEM.” With this system, the wall panels are provided with right angle or bends at their edges. Each planar panel and the right angle bend together form an L-shape. Each bend is secured by screws to a fastening extrusion having the same linear dimension as the wall panel, and the fastening extrusion has a generally rectangular cross-sectional configuration. At each joint area where two panels meet, there are two such fastening extrusions connected together, each secured to a respective wall panel, with an elongated hard silicone gasket between the fastening extrusions. The fastening extrusions are arranged one above the other at each joint area. Thus, the screws are not visible, thereby eliminating the unsightly appearance of previous system. 
     However, because of the L-shape at the bends at the edges of the wall panels, it is necessary to separately secure each bend to a fastening extrusion by screws, in addition to securing the fastening extrusions to the wall structure by screws, further increasing the work required to assemble the wall panels. Also, because the bends in the wall panels extend only in a direction perpendicular to the wall panels, the only structural support is provided by the screws which secure each bend to a fastening extrusion. As a result, it is possible to loosen and/or pull out the wall panels. 
     In addition, in order to secure the fastening extrusions to existing wall structures, one of the connected pair of fastening extrusions is provided with an extension which is separately secured to the existing wall structure. This means that the main bodies of the fastening extrusions are spaced away from the existing wall structure, thereby providing a further weak link in the structure, besides making it more difficult to assemble. 
     U.S. Pat. No. 7,472,521 and U.S. Pat. No. 7,621,084, by the same inventor herein disclose systems for mounting wall panels to an existing wall structure, which includes a plurality of wall panels. There are also a plurality of fastening extrusions. Each fastening extrusion includes a securing section for securing the fastening extrusion to the existing wall structure, and a retaining wall structure at one end of the securing section, the retaining wall structure including a recess which receives one hook wall of the wall panel. 
     The main panel section has a rectangular configuration with four hook walls, and there are four fastening extrusions, with the recess of the retaining wall of each fastening extrusion receiving one hook wall of the wall panel. Each U-shaped cross-sectional profile defines a recess therein, and each fastening extrusion includes at least one stabilizing wall extending from a free end of a respective retaining wall, with the stabilizing wall being received in one recess of a respective U-shaped cross-sectional profile. Each stabilizing wall has an L-shaped cross-sectional profile. Also, the securing section and the retaining wall structure together define a U-shaped cross-sectional profile. 
     A first one of the fastening extrusions includes a tongue and a second one of the fastening extrusions includes a groove for receiving the tongue to connect together the first and second fastening extrusions when the first fastening extrusion is assembled with a first wall panel and the second fastening extrusion is assembled with a second wall panel. In a later embodiment, there is only a single fastening extrusion. 
     There is also at least one channel secured to the securing sections of adjacent fastening extrusions and positioned between adjacent wall panels corresponding thereto. An elongated plug is inserted into each channel for closing off the gap between adjacent wall panels. 
     This arrangement, however, requires the insertion of screws into the fastening extrusions and the channel while supporting the wall panels, which can be burdensome. It also requires the separate channels and plugs in order to close off the gap between adjacent wall panels to provide an aesthetic appearance between the wall panels. If the gap between adjacent panels is varied, this would also require a plurality of different size plugs, which can further add to the cost of the structure. 
     A further system has been sold for more than one year by Creative Metal Contractors Inc. of Toms River, New Jersey, which uses a single fastening extrusion having tongues extending from opposite sides thereof. The single fastening extrusion is secured to the existing wall by screws at a central portion thereof between the tongues. Each wall panel has a main panel section and hook walls at edges of the main panel section, with the main panel section and each hook wall having a U-shaped cross-sectional profile. Fasteners or frame extrusions are secured to the hook walls, with each fastener including walls defining a recess which receives a corresponding tongue of the single fastening extrusion, such that the tongues are spaced away from the hook walls. A compressed joint plug is positioned in overlying relation to the screws and between adjacent hook walls to provide an aesthetic appearance. 
     However, with this latter arrangement, plugs are also required, with the same consequent disadvantages. It may also be difficult to align the recesses over the tongues of the single fastening extrusion. In addition, the single fastening extrusions are secured to the existing wall by screws only through the center of the fastening extrusions, which can result in failure of such securement. Still further, if the gap between adjacent panels is varied, this would also require a plurality of different size plugs, which can further add to the cost of the structure. 
     The invention of U.S. Pat. No. 8,127,507 to the same inventor herein also requires the insertion of screws into the fastening extrusions and the channel while supporting the wall panels, which can be burdensome. It also requires the separate decorated panels in order to close off the gap between adjacent wall panels to provide an aesthetic appearance between the wall panels. 
     U.S. patent application Ser. No. 12/652,879, to the same inventor herein, attempts to cure the aforementioned problems, by providing a wall system which does not require the use of screws to secure the wall panels to the fastening extrusions. Rather, the wall panels have recesses into which the frame extrusions fit, and which also eliminates the use of plugs to cover the gap between adjacent wall panels. This permits easy hanging of the wall panels by providing a male connecting frame extrusion that merely fits within a female connecting wall panel. 
     It is also known from U.S. Pat. No. 4,344,267 to Sukolics, U.S. Pat. No. 4,829,740 to Hutchison and U.S. Pat. No. 5,809,729 to Mitchell, to provide a wall system with L-shaped ends of the panels that include recesses in the bent ends that engage with projections of the extrusions secured by screws to the walls. However, with these patents, there is still a large gap between adjacent bent ends, which is necessary for securing the panels to the extrusions, and which also thereby requires a plug to close this gap. 
     With all of the above arrangements, it can become difficult to assemble the wall panels with the extrusions, while also ensuring that the extrusions are accurately secured to the wall. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide a wall system that overcomes the aforementioned problems. 
     It is another object of the present invention to provide a wall system in which the wall panels and extrusions are connected together prior to fastening the extrusions to the existing wall. 
     It is a still further object of the present invention to provide a wall system that is easy to assemble with an existing wall structure. 
     It is a yet further object of the present invention to provide a wall system that is easy and economical to manufacture and use. 
     In accordance with an aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel including a main wall panel section, and at least two bent end sections extending at an angle from different edges of the main wall panel section, each bent end section having a wall thickness. A plurality of main fastening extrusions are provided, each main fastening extrusion including a base section adapted to be secured to the existing wall structure, and first and second spaced apart bent end securing walls extending at an angle from the base section, the two bent end securing walls having a spacing therebetween greater than the wall thickness of two bent end sections. A plug member is inserted in the spacing between adjacent bent end securing walls for preventing escape of the adjacent bent end securing walls from the spacing, the plug member held in the spacing by a tape at a lower end of the plug member that secures the plug member to the base section, or at least one wing extending outwardly from a lower end of the plug member and which extends beneath a distal lower end of a respective bent end section. 
     In one embodiment, a recess is provided at a first surface of each bent end section which faces a second surface of a respective bent end securing wall, and a projection at the second surface of each bent end securing wall which is adapted to be received in a respective recess. Alternatively, a recess is provided at the second surface of each bent end securing wall, and a projection at the first surface of each bent end section which is adapted to be received in a respective recess at the second surface. 
     Each projection has a cross-sectional shape of a square shape, a rectangular shape, a triangular shape, a triangular shape with a rounded upper surface, a trapezoidal shape, or a cylindrical shape. 
     Preferably, each recess is formed in the first surface of each bent end section, and each projection is formed at the second surface of each bent end securing wall. 
     Preferably, the plug member includes two wings extending outwardly in opposite directions from a lower end of the plug member and which extend beneath a distal lower end of respective adjacent bent end sections in the spacing. 
     In accordance with another aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel including a main wall panel section, and at least two bent end sections extending at an angle from different edges of the main wall panel section, each bent end section having a wall thickness. There are a plurality of main fastening extrusions, each main fastening extrusion including a base section adapted to be secured to the existing wall structure, and first and second spaced apart bent end securing walls extending at an angle from the base section, the two bent end securing walls having a spacing therebetween greater than the wall thickness of two bent end sections. 
     In one embodiment, a recess is provided at a first surface of each bent end section which faces a second surface of a respective bent end securing wall, and a projection at the second surface of each bent end securing wall which is adapted to be received in a respective recess. Alternatively, a recess is provided at the second surface of each bent end securing wall, and a projection at the first surface of each bent end section which is adapted to be received in a respective recess at the second surface. 
     Each recess and projection form a dovetail joint, with each projection engaged in a respective recess by sliding transversely therein. Thus, each projection and each recess has a trapezoidal cross-sectional shape. 
     Further, an extra gap can be provided between the base section of each main fastening extrusion and distal lower ends of bent end sections, and a plate member provided in the gap for closing off the gap and providing an aesthetic appearance. 
     In accordance with still another aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel including a main wall panel section, and at least two bent end sections extending at an angle from different edges of the main wall panel section, each bent end section having a wall thickness. There are a plurality of main fastening extrusions, each main fastening extrusion including a base section adapted to be secured to the existing wall structure, and first and second spaced apart bent end securing walls extending at an angle from the base section, the two bent end securing walls having a spacing therebetween substantially equal to the wall thickness of one the bent end section 
     In one embodiment, a recess is provided at a first surface of each bent end section which faces a second surface of a respective bent end securing wall, and a projection at the second surface of each bent end securing wall which is adapted to be received in a respective recess. Alternatively, a recess is provided at the second surface of each bent end securing wall, and a projection at the first surface of each bent end section which is adapted to be received in a respective recess at the second surface. 
     In this aspect, each projection has an upper surface with a shape of an inclined surface, or a curved convex surface. Further, each recess has a corresponding to the shape of the respective projection received therein, or a rectangular cross-sectional shape. 
     In accordance with still another aspect of the present invention, a system for mounting wall panels to an existing wall structure, includes a plurality of wall panels, each wall panel including a main wall panel section, and at least two bent end sections extending at an angle from different edges of the main wall panel section, each bent end section having a wall thickness. There are a plurality of main fastening extrusions, each main fastening extrusion including a first main fastening extrusion section and a second main fastening extrusion section. The first main fastening extrusion section includes a first base section adapted to be secured to the existing wall structure, a first bent end securing wall extending at an angle from the first base section, and an L-shaped extension. The L-shaped extension includes a first leg as a lateral connecting wall that extends inwardly from a lower portion of the first bent end securing wall at a position spaced above and parallel to the first base wall so as to form a space therebetween, and a second leg as a first inner wall that extends from a free end of first leg in parallel spaced apart relation to the first bent end securing wall with a spacing substantially equal to the wall thickness of one bent end section which fits therein. The second main fastening extrusion section includes a second base section adapted to be positioned within the space between the first leg and the first base wall, a second bent end securing wall extending at an angle from the second base section, and a second inner wall that extends from the second base section in parallel spaced apart relation to the second bent end securing wall with a spacing substantially equal to the wall thickness of one bent end section which fits therein. 
     In one embodiment, a recess is provided at a first surface of each bent end section which faces a second surface of a respective bent end securing wall, and a projection at the second surface of each bent end securing wall which is adapted to be received in a respective recess. Alternatively, a recess is provided at the second surface of each bent end securing wall, and a projection at the first surface of each bent end section which is adapted to be received in a respective recess at the second surface. 
     Further, there is a spacing between the first and second inner walls, and surfaces of the first and second inner walls that face each other have barbs thereon for receiving a plug. 
     The above and other features of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevational view of a plurality of wall panels mounted to an existing wall structure; 
         FIG. 2  is a perspective view, partly in section, of a main fastening extrusion having a wall panel secured thereto by plugs, according to the present invention; 
         FIG. 2A  is a perspective view, partly in section, of a modified main fastening extrusion having a modified wall panel secured thereto by modified plugs, according to the present invention; 
         FIG. 3  is a bottom plan view of a blank for forming the wall panel of  FIG. 2 ; 
         FIG. 4  is a cross-sectional view of the blank of  FIG. 3 , taken along lie  4 - 4  thereof; 
         FIG. 5  is a perspective view, partly in section, of a first corner fastening extrusion having a wall panel secured thereto, according to the present invention; 
         FIG. 6  is a perspective view, partly in section, of a second corner fastening extrusion having a wall panel secured thereto, according to the present invention; 
         FIG. 7  is a perspective view, partly in section, of the main fastening extrusion of  FIG. 2  connected with two wall panels, and with a channel and plug between the wall panels; 
         FIG. 8  is a perspective view, partly in section, of the main fastening extrusion of  FIG. 2  connected with two wall panels, and with an elongated member between the wall panels; 
         FIG. 8A  is a perspective view, partly in section, of a the main fastening extrusion of  FIG. 8  connected with two wall panels, and with a modified elongated member between the wall panels; 
         FIG. 8B  is a perspective view, partly in section, of a modification of the main fastening extrusion of  FIG. 8A  connected with two wall panels; 
         FIG. 9  is a cross-sectional view of a first modified corner fastening extrusion according to the present invention; 
         FIG. 10  is a cross-sectional view of a second modified corner fastening extrusion according to the present invention; 
         FIG. 11  is a cross-sectional view of a further modified main fastening extrusion and corner fastening extrusions according to the present invention; 
         FIG. 12  is a cross-sectional view of a still further modified main fastening extrusion according to the present invention; 
         FIG. 12A  is a cross-sectional view of a modified main fastening extrusion of  FIG. 12 ; 
         FIG. 12B  is a perspective view of a further modified main fastening extrusion of  FIG. 12 ; 
         FIG. 13  is a cross-sectional view of a yet further modified main fastening extrusion according to the present invention; 
         FIG. 14  is a perspective view of a wall panel according to another embodiment of the present invention; 
         FIG. 15  is a bottom perspective view of a portion of the wall panel of  FIG. 14 , with only one bent end section bent at a right angle to the main panel section thereof; 
         FIG. 16  is a bottom plan view of a portion of the wall panel of  FIG. 14 ; 
         FIG. 17  is a perspective view, partly in section, of the wall panel of  FIG. 14 ; 
         FIG. 18  is a perspective view of a fastening extrusion segment for use with the wall panel of  FIG. 14 ; 
         FIG. 19  is a perspective view, partly in section, of a modification of the wall panel of  FIG. 14 ; 
         FIG. 20  is a perspective view of a modified fastening extrusion segment for use with the wall panel of  FIG. 19 ; 
         FIG. 21  is a perspective view, partly in section, of a further modification of the wall panel of  FIG. 14 ; 
         FIG. 22  is a perspective view of a further modified fastening extrusion segment for use with the wall panel of  FIG. 21 ; 
         FIG. 23  is a perspective view, partly in section, of a still further modification of the wall panel of  FIG. 14 ; and 
         FIG. 24  is a perspective view of a still further modified fastening extrusion segment for use with the wall panel of  FIG. 23 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings in detail, and initially to  FIGS. 1-5  thereof, there is shown a system  10  according to the present invention for easily mounting wall panels  12  over an existing wall structure  14 . Wall structure  14  preferably includes any planar wall. Each panel  12  includes a rectangular shaped, planar main panel section  16  and at least two bent end sections  18  bent at a right angle in the same direction at edges of main panel section  16 . Main panel  16 , however, need not be planar, and in fact, can have different shapes, such as a wave shape, etc. to provide different aesthetic appearances. Preferably, there are four bent end sections  18  at each edge of main panel section  16  which form an L-shaped cross-sectional shape thereat. However, the invention is not limited thereby and wall panels  12  can be formed with two, three or four bent end sections  18 . Wall panels  12  are formed preferably by, but not limited to, a polyethylene core  20  with a thin aluminum wall  22  covering opposite sides thereof, as shown in  FIG. 4 . However, for the sake of simplicity in the drawings, all of the drawings except for  FIG. 4  show wall panels  12  formed of only a single material. 
     In addition, each bent end section  18  includes a cut-out recess  24  at the inner surface  26  thereof, spaced slightly away from main panel section  16  and extending in the lengthwise direction thereof parallel to main panel section  16 . Each cut-out recess  24  preferably has a square or rectangular configuration in cross-section, although the present invention is not limited thereby. As a result, cut-out recess  24  effectively forms a notch in the inner surface  26  of bent end section  18 . Cut-out recess  24  preferably extends along the entire length of the bent end section  18 , although the present invention is not so limited, that is, cut-out recess  24  can extend along only a part of the length of bent end section  18 , or there may be a plurality of spaced apart cut-out recess  24 . 
     As shown in  FIG. 2 , main fastening extrusions  28  are provided for securing each wall panel  12  to existing wall structure  14 . Each main fastening extrusion  28  is preferably formed as a single, one-piece, unitary member that includes a base section  30  secured to existing wall structure  14  and a supporting section  32  that connects to a side edge of each panel  12 . As with each panel  12 , each main fastening extrusion  28  is formed preferably by, but not limited to, a polyethylene core  20  with a thin aluminum wall  22  covering opposite sides thereof. Alternatively, each main fastening extrusion  12  can be formed from polyvinyl chloride (PVC), aluminum or any other suitable material. 
     Base section  30  includes a central planar wall  34  that seats flush against existing wall structure  14 , and which has a plurality of linearly aligned openings  36  extending therealong and through which screws (not shown) can be inserted to secure central wall panel  34  to existing wall structure  14 . Two, parallel, spaced apart, bent end securing walls  38  extend outwardly at right angles from central planar wall  34  for securing bent end sections  18  of two adjacent wall panels  12  thereto, with the distance between bent end securing walls  38  being greater than the thickness of two bent end sections  18 . Bent end securing walls  38  are spaced inwardly from edges of central planar wall  34  so as to divide central planar wall  34  into a central section  40  between bent end securing walls  38 , and two wing sections  42  and  43  to the outside of bent end securing walls  38 . Openings  36  are provided along wing sections  42  and  43 . Openings (not shown) can also be provided along central section  40 . 
     Each bent end securing wall  38  includes an inwardly directed projection  44  at the inner surface  46  of the respective bent end securing wall  38 , with each projection  44  having a square or rectangular configuration in cross-section, which corresponds in shape and dimensions to square or rectangular cut-out recess  24 , although the present invention is not limited thereby. For example, each cut-out recess  24  and projection  44  can have a triangular nose-shape in cross-section as shown in applicant&#39;s copending U.S. patent application Ser. No. 13/868,574, the entire disclosure of which is incorporated herein by reference, or any other suitable configuration. Projection  44  preferably extends along the entire length of the bent end securing wall  38 , although the present invention is not so limited, that is, projection  44  can extend along only a part of the length of bent end securing wall  38 , or there may be a plurality of spaced apart projections  44 . However, in such case, cut-out recesses  24  would be likewise configured. 
     The upper free end of each bent end securing wall  38  includes an outwardly extending stub wall  39  that is perpendicular to the respective bent end securing wall  38  and parallel to and immediately adjacent to or abutting with main panel section  16  when assembled with wall panel  12 . 
     As shown in  FIG. 3 , each wall panel  12  is preferably formed from a planar blank  48 , which can be stamped from or cut from a larger sheet of the respective material. Specifically, each planar blank  48  is formed by planar main panel section  16  which is preferably, but not limited to, a square shape with all sides being equal. There are four bent end sections  18 , each formed as one unitary piece at a respective side edge of planar main panel section  16 , and coplanar therewith. A V-shaped cut-out  50  extends through one thin aluminum wall  22  and polyethylene core  20  at the connecting edge of each bend end section  18  to the side edge of planar main panel section  16 , as best shown in  FIG. 4 . This permits each bent end section  18  to be bent along its respective V-shaped cut-out  50  at a right angle to planar main panel section  16  in the manner shown, for example, in  FIG. 2 . Each bent end section  18  further includes cut-out recess  24  at the inner surface  26  thereof and spaced slightly away from main panel section  16 . For ease of explanation hereafter, and for conformity, reference will be made to a top bent end section  18   a , a left side bent end section  18   b , a right side bent end section  18   c  and a bottom bent end section  18   d , although this is only for explanation purposes and does not limit the invention. 
     As discussed above, in practice, it can be difficult to assemble extrusions  28  to an existing wall structure while also holding wall panels  12 . 
     Therefore, in accordance with the present invention, as shown in  FIG. 2 , snap-in clips or plugs  52  are removably provided for temporarily securing wall panels  12  to main fastening extrusions  38 , in order to provide ease of assembly. Snap-in plugs  52  are of a much small length than bent sections  18  of wall panels  12 , and for example, may be approximately 2 cm long. Also, snap-in plugs  52  are made of a flexible, resilient material, preferably plastic, but not limited thereto. For example, plugs  52  can be made of any suitable material, such as a metal, a composite or the like. 
     Specifically, each snap-in plug  52  includes a holding wall  54  of a generally square or rectangular configuration, a biasing wall  56  and a connecting wall  58  which connects together holding wall  54  and biasing wall  56  in generally parallel, spaced apart relation. Biasing wall  56  includes a U-shaped projection engaging wall section  60  for receiving a projection  44  of a bent end securing wall  38 , an entry engaging wall section  62  connected to a distal end of projection engaging wall section  60 , and a connecting wall section  64  connected to the opposite end of projection engaging wall section  60 . A gap  61  is defined between holding wall  54  and biasing wall  56 . U-shaped projection engaging wall section  60  includes a central leg wall section  66  in parallel, spaced relation to biasing wall  56  and two outer leg wall sections  68  and  70  extending outwardly at right angles in the same direction from opposite edges of central leg wall section  66  so as to define a recess  72  for receiving a projection  44 . Entry engaging wall section  62  is connected to the free end of outer leg wall section  68 . Entry engaging wall section  62  has a beveled or inclined surface  74  at the outer facing surface thereof. Connecting wall section  64  is connected in parallel, spaced relation to holding wall  54  and has opposite ends thereof connected to the free end of outer leg wall section  70  and one edge of connecting wall  58 , respectively. The opposite edge of connecting wall  58  is connected with one edge of holding wall  54 , such that holding wall  54 , connecting wall  58  and biasing wall  56  effectively have a U-shaped configuration, which is perpendicular to the U-shaped configuration of U-shaped projection engaging wall section  60 . 
     With this arrangement, a wall panel  12  can be temporarily secured to a bent end securing wall  38 . Specifically, as shown in  FIG. 2 , wall panel  12  is assembled with bent end securing wall  38  such that cut-out recess  24  receives projection  44  and the respective surfaces of bent end section  18  and bent end securing wall  38  are in abutting, or near abutting, relation, that is in juxtaposition next to each other. Then, plugs  52  are inserted in the gap between the assembled bent end section  18  and the other bent end securing wall  38 . To accomplish this, plug  52  are merely pressed down into this gap, such that beveled surface  74  of biasing wall  56  engages with and rides along the upper free edge of the projection  44  of the other bent end securing wall  38 , which causes biasing wall  56  to be biased in a direction toward holding wall  54  until plug  52  is pressed sufficiently into this gap that the projection  44  of the other bent end securing wall  38  engages in recess  72 . Since biasing wall  56  is no longer constrained, and due to the resilient nature thereof, biasing wall  56  returns to its original position shown in  FIG. 2 , whereupon the projection  44  seats entirely in recess  72 , thereby locking plug  52  in the gap. In this position, the outer face of holding wall  54  presses against the outer face of bent end section  18  to hold it in place and prevent escape thereof. This operation is repeated for a plurality of plugs  52 . In order to later remove plugs  52 , each plug can be pulled up with holding wall  54  being pulled up first, thereby angling the plug and releasing projection  44  from recess  72 . This can be accomplished by hand, or if necessary, by a simple tool, such as a screwdriver shaft inserted into gap  61 . 
     Alternatively, plugs  52  can be slid into the same engagement from the side. 
     It will be appreciated that this operation can be performed in the shop so that this assembly of wall panel  12 , extrusion  28  and plugs  52  can be assembled as a unitary assembly to the job site. This operation is preferably performed in the shop for three sides of wall panel  12 , that is, with respect to three bent end sections  18  of a wall panel  12  that have been turned at right angles to main panel section  16  about V-shaped cut-outs  50 , with the fourth bent end section  18  remaining coplanar with main panel section  16 , the reason for which will be understood from the description hereafter. This can occur with the three bent end securing walls by bending bent end sections  18  at right angles to main wall panel  16  and then securing a main fastening extrusion  28  to each bent end section  18  by plugs  52 . Alternatively, with bent end sections  18  coplanar to main wall panel  16 , prior to bending thereof, a main fastening extrusion  28  can be secured to each bent end section  18  by plugs  52 , with bent end sections  18  then being bent at right angles to main panel section  16 . In the latter arrangement, as will be understood from the description hereafter, main fastening extrusions  28  can be slide along bent end sections  18  prior to bending thereof. This is advantageous where the profiles of cut-out recesses  24  and projections only allow for this type of assembly. 
     When assembling the main fastening extrusion  28  with the fourth bent end section  18 , it may be necessary to assembly main fastening extrusion  28  with the fourth bent end section  18  while this bent end section  18  is coplanar with main wall panel  16 , and then to bend this bent end section  18  at right angles to main wall panel  16 . 
     It will be appreciated that, while recesses  24  and recesses  72  have been shown in bent end sections  18  and plugs  52 , respectively, and projections  44  have been shown at bent end securing walls  38 , the reverse may be true, as shown in  FIG. 2A , in which recesses  24  and  72  in bent end sections  18  and plugs  52  have been replaced with projections  124  and  172 , and projections  44  at bent end securing walls  38  have been replaced with recesses  144 . In such case, plugs  152  are required to be slid into position from the side. 
     In order to start a wall at a corner of existing wall structure  14 , as shown in  FIG. 5 , left side corner fastening extrusions  76  are provided. Each corner fastening extrusion  76  includes a base section  78  formed by a planar wall  80  that lies flush against an existing wall  14 . A first bent end securing wall  82  extends outwardly at a right angle from planar wall  80  for securing a bent end section  18  of a wall panel  12  thereto. Bent end securing wall  82  includes a projection  84  at the inner surface  86  thereof, with projection  84  having a parallelepiped configuration, that is, a square or rectangular configuration in cross-section, which corresponds in shape and dimensions to square or rectangular cut-out recess  24 , although the present invention is not limited thereby. For example, each cut-out recess  24  and projection  84  can have a nose-shape in cross-section as shown in applicant&#39;s copending U.S. patent application Ser. No. 13/868,574, the entire disclosure of which is incorporated herein by reference, or any other suitable configuration. Projection  84  preferably extends along the entire length of the bent end securing wall  82 , although the present invention is not so limited, that is, projection  84  can extend along only a part of the length of bent end securing wall  82 , or there may be a plurality of spaced apart projections  84 . However, in such case, cut-out recesses  24  would be likewise configured. Further, recess  24  and projection  84  can be reversed in the same manner as shown in  FIG. 2A . 
     The upper free end of bent end securing wall  82  includes an outwardly extending stub wall  88  that is perpendicular to the respective bent end securing wall  82  and parallel to and immediately adjacent to or abutting with main panel section  16  when assembled with wall panel  12 . 
     A second bent end securing wall  90  extends outwardly from planar wall  80  in parallel, spaced apart relation to bent end securing wall  82 , with the spacing between bent end securing walls  82  and  90  being substantially equal to the thickness of one bent end section  18 . Projection  84  faces in a direction toward bent end securing wall  90  as to be positioned in the gap between bent end securing wall  82  and second wall  90 . The opposite side of bent end securing wall  90  is provided with barbs  92  that are angled toward planar wall  80 . Planar wall  80  is thereby divided into a central section  94  between bent end securing walls  82  and  90 , and two wing sections  96  and  98  to the outside of bent end securing wall  82  and bent end securing wall  90 , respectively, with wing section  98  having a plurality of linearly aligned openings  100  extending therealong and through which screws (not shown) can be inserted to secure planar wall  80  to existing wall structure  14 . 
     For mounting wall panels  12 , a left side bent end section  18   b  of a first wall panel  12  is slid into the gap between bent end securing walls  82  and  90  of a corner fastening extrusion  76 , with projection  84  received in cut-out recess  24  of the first wall panel  12 . This can be performed after bent end section  18   b  is bent at a right angle, or alternatively, before bent end section  18   b  is bent at a right angle to main panel section  16  and then bent with respect thereto. In like manner, a corner fastening extrusion  76  is assembled with top bent end section  18   a.    
     Then, a main fastening extrusion  28  is assembled with right side bent end section  18   c  of the first wall panel  12 , and a main fastening extrusion  28  is assembled with bottom side bent end section  18   d  of the first wall panel  12  in the same manner. This can be performed after bent end sections  18   c  and  18   d  are bent at right angles, or alternatively, before bent end sections  18   a  are bent at right angles to main panel section  16  and then bent with respect thereto. However, in accordance with the present invention, because of the larger gap between bent end securing walls  38  of this main fastening extrusion  28 , plugs  52  are pressed down into this gap for each main fastening extrusion  28  in order to hold bent end sections  18   c  and  18   d  thereto. 
     It will be appreciated that, because bottom bent end section  18   d  is already bent at a right angle to main panel section  16 , bent end section  18   b  cannot slide out from corner fastening extrusion  76 . 
     It will be appreciated that, in place of main fastening extrusion  28 , a plurality of spaced apart main fastening extrusions of a shorter length can be provided. The same applies to corner fastening extrusions  76 . 
     When brought to a job site, and assuming that the first panel  12  is to be secured at position A in  FIG. 1 , where there is a top wall  14  corresponding to bent end section  18   a , it is only necessary to first secure corner fastening extrusions  76  assembled with top bent end section  18   a  and left side bent end section  18   b  at position A in  FIG. 1  by screws (not shown) inserted into openings  100 . Because main fastening extrusions  28  are held by plugs  52  to bent end sections  18   c  and  18   d , they need not be separately held during installation. Screws (not shown) secure these main fastening extrusions  28  to the existing wall through openings  36  in wing sections  43  and/or central section  40 . There is thus no need to hold main fastening extrusions  28  in place. Alternatively and/or in addition thereto, openings  36  can be provided in central section  40  to secure main fastening extrusions  28  to the existing wall  14 . Thereafter, plugs  52  are removed, since they are no longer necessary. 
     Then, moving down in  FIG. 1  to position B, a second wall panel  12  which has been previously assembled with a corner fastening extrusion  76  at left side bent end section  18   b  and with main fastening extrusions  28  at right side bent end section  18   c  and bottom bent end section  18   d , is assembled in the same manner. No main fastening extrusion  76  is assembled with top bent end section  18   a . Rather, top bent end section  18   a  at position B is inserted in the gap of the main fastening extrusion  28  secured with bottom bent end section  18   d  of wall panel  12  at position A. Thus, top bent end section  18   a  of the wall panel at position B is inserted into this other main fastening extrusion  28  such that cut-out recess  24  of this top bent end section  18   a  at position B receives the projection  44  of the other bent end securing wall  38  of the main fastening extrusion  28  already assembled with the wall panel  12  at position A. In this manner, the wall panel  12  at position B merely hangs down from this main fastening extrusion  28  already screwed into the wall. 
     In this position, screws (not shown) are inserted through openings  100  of corner fastening extrusion  76  at position B, and through openings  36  in wing sections  43  of main fastening extrusions  28  pre-assembled with left side bent end section  18   c  and bottom bent end section  18   d  at position B so as to secure wall panel  12  at position B. 
     This operation continues for wall panels at positions C and D in  FIG. 1 , with the only exception being that a corner fastening extrusion  76  is assembled with bottom bent end section  18   d  of the wall panel  12  at position D. 
     Thereafter, the assembling operation can proceed to position E in  FIG. 1 . For this position, a corner fastening extrusion  76  is first assembled with wall panel  12  at top bent end section  18   a , and main fastening extrusions  18   c  and  18   d  are assembled with the same wall panel at right end bent end section  18   c  and bottom bent end section  18   d . With this pre-assembly, left side bent end section  18   b  is assembled with the other bent end securing wall  38  of the main fastening extrusion  28  assembled with right side bent end section  18   c  at position A such that cut-out recess  24  of this left side bent end section  18   b  at position E is assembled with the projection  44  at the other bent end securing wall  38  of the main fastening extrusion  28  assembled with right side bent end section  18   c  at position A. Screws (not shown) are then inserted into openings  100  of corner fastening extrusion  76  assembled with wall panel  12  at top bent end section  18   a , and into openings  36  of main fastening extrusions  18   c  and  18   d  assembled with the same wall panel at right end bent end section  18   c  and bottom bent end section  18   d , in order to secure the wall panel  12  at position E. Plugs  52  can then be removed. 
     At position F in  FIG. 1 , main fastening extrusions  28  are only pre-assembled with bent end sections  18   c  and  18   d . In such case, the left bent end section  18   b  is assembled with the main fastening extrusion  28  already assembled with the right side bend end section  18   c  at position B, and the top bent end section  18   a  is assembled with the main fastening extrusion  28  already assembled with the bottom side bend end section  18   d  at position E. Thereafter, the main fastening extrusions  28  pre-assembled with right side bent end section  18   c  and bottom bent end section  18   d  at position F are screwed into the wall through openings  36 . 
     This operation continues for wall panels at positions G and H in  FIG. 1 , with the only exception being that a corner fastening extrusion  76  is assembled with bottom bent end section  18   d  of the wall panel  12  at position H. The operation of wall panels at positions E-H continues in the direction to the right in  FIG. 1  until the last panel positions I-L are reached. 
     At positions I-L in  FIG. 1 , the same operation occurs as with wall panels  12  at position E-H, except that a right side corner fastening extrusion  176  ( FIG. 6 ) is assembled with right side bent end section  18   c  of the wall panel  12  at these positions, in which right side corner fastening extrusion  176  is a mirror image of left side corner fastening extrusion  76 . 
     When plugs  52  are removed and walls panels  12  are installed, it is preferable to fill the gaps between bent end sections  18  of adjacent wall panels  12 , that is, in the space previously occupied by plugs  52 . In this regard, as shown in  FIG. 7 , an elongated U-shaped channel  102  is inserted in the gap between adjacent bent end sections of adjacent wall panels  12 . Preferably, the inner facing surfaces of U-shaped channel  102  has barbs  104  for capturing a rubber or plastic plug  106  inserted therein to provide an aesthetic appearance. 
     Alternatively, as shown in  FIG. 8 , at least one elongated plug member  108  having a rectangular cross-section can be inserted into this gap to provide an aesthetic appearance, and secured therein by structural caulking or tape  109 , which can be a double side adhesive tape sold by The 3M Company. 
     Referring to  FIG. 8A , there is shown a modification of the  FIG. 8  embodiment in which elongated plug member  108  is replaced by an elongated, inverted U-shaped plug member  108   a , that is, basically, the same as elongated member  108  having its lower wall removed. In addition, there are lower outwardly extending wings  109   a  extending outwardly from the lower edges of inverted U-shaped member  108   a , which extend beneath the distal lower ends of bent end sections  18 . Inverted U-shaped member  108   a  can be slid in from the side after bent end sections  18  are assembled in position. Bent end sections  18  can be placed in the position shown in  FIG. 8  by merely inserting them in the gap between the bent end securing walls, or alternatively, can be slid in from the side. 
       FIG. 8B  shows a modification of the  FIG. 8A  embodiment in which the cut-out recess  124   b  and inwardly directed projection  144   b  each have complementary triangular shapes in cross-section. 
     As discussed above, inwardly directed projection  44  at the inner surface  46  of the respective bent end securing wall  38  corresponds in shape and dimensions to square or rectangular cut-out recess  24 , although the present invention is not limited thereby. For example, each cut-out-section  32  and projection  44  can have a nose-shape in cross-section as shown in applicant&#39;s copending U.S. patent application Ser. No. 13/868,574, the entire disclosure of which is incorporated herein by reference, or any other suitable configuration. The same applies to projection  84  of each corner fastening extrusion  76 ,  176 , for example, as shown in  FIG. 9 , in which each projection  84   a  and cut-out recess  24   a  has a nose-shaped cross-section. As also shown, barbs  92  are eliminated from second wall  90   a . Further, because of the nose-shaped cross-section of projection  84 , outwardly extending stub wall  88  is replaced by an inclined wall  88   a  that extends from projection  84   a  with the free end thereof immediately adjacent to or abutting with main panel section  16  when assembled with wall panel  12 . 
     As another alternative, as shown in  FIG. 10 , projection  84   b  has a triangular nose-shaped configuration in cross-section with a rounded upper surface that engages in cut-out recess  24  of a square or rectangular cross-section. In this case, outwardly extending stub wall  88  is replaced by an arcuate wall  88   b  that extends from projection  84   b . As also shown, barbs  92  are eliminated from second wall  90   b.    
     As another alternative, as shown in  FIG. 11 , the projections  44 ,  84  of square or rectangular cross-section and cut-out recesses  24 , are replaced with a dovetail joint, that is, with projections  44   c ,  84   c  being of a trapezoidal cross-section and cut-out recesses  24   c  being of a complementary trapezoidal cross-section. In this case, for corner fastening extrusions  76   c ,  176   c , the second bent end securing wall is eliminated. However, to assemble wall panels  12  with main fastening extrusions  28   c  and corner fastening extrusions  76   c ,  176   c , it is necessary to slide projections  44   c ,  84   c  lengthwise into cut-out recesses  24   c  prior to bending bent end sections  18  at right angles to main panel sections  16 . 
       FIG. 12  shows a slight modification to the embodiment of  FIG. 11 , whereby bent end securing walls  38  terminate at projections  44   d  of main fastening extrusion  44   d  and thereby are not positioned adjacent main panel section  16  when assembled therewith. 
       FIG. 12A  shows a slight modification to the embodiment of  FIG. 12 , whereby an extra gap is provided between outer steps  45   e  of main fastening extrusion  28   e  and the distal lower ends of bent end sections  18  in order to slide a rectangular parallelepiped member  93  in the gap for closing off the gap and providing an aesthetic appearance. Rectangular parallelepiped member  93  also covers any screws used to secure main fastening extrusion  28   e . In this embodiment, trapezoidal projections  44   e  in cross-section are also formed. 
       FIG. 12B  shows a slight modification to the embodiment of  FIG. 12 , whereby ends of each cut-out recess  24   c  are open at one end but closed at an opposite end  25   c , which permits projections  44   c  to slide therein but not to fall out the other end. This is particularly advantageous if cut-out recesses  24   c  are oriented vertically. 
       FIG. 13  shows a further modification of a main fastening extrusion  128  which is comprised of two extrusion parts  128   a  and  128   b  assembled together. One extrusion part  128   a  includes a base wall  130   a  and a bent end securing wall  138   a  extending upwardly from one edge thereof, with a projection  144   a  at an inner surface of bent end securing wall  138   a . An upwardly extending L-shaped extension  139   a  includes a first leg  141   a  as a lateral connecting wall that extends inwardly from a lower portion of bent end securing wall  138   a  at a position spaced above and parallel to base wall  130   a , and a second leg  143   a  as an inner wall that extends upwardly from the free end of first leg  141   a  and in parallel spaced apart relation to the respective securing wall  138   a  with a spacing substantially equal to the thickness of a bent end section  18  which fits therein. The outer surface of second wall  143   a  includes downwardly extending barbs  145   a . In this manner, bent end sections  18  are slidably inserted in the gap between a bent end securing wall  138   a  and the respective second leg  143   a , and then bent at right angles to main panel section  16 . 
     With this arrangement, there is a space  147   a  between base wall  130   a  and first leg  141   a . Further, base section  130   a  includes openings  136  for securing base wall  130   a  to a wall  14 . 
     The other extrusion part  128   b  includes a base section  130   b  and a bent end securing wall  138   b  extending upwardly from one edge thereof. An upwardly extending second leg  143   b  as an inner wall extends upwardly from base section  130   b  in parallel spaced apart relation to the respective securing wall  138   b  with a spacing substantially equal to the thickness of a bent end section  18  which fits therein. The outer surface of second wall  143   b  includes downwardly extending barbs  145   b . In this manner, bent end sections  18  are slidably inserted in the gap between a bent end securing wall  138   b  and the respective second leg  143   b , and then bent at right angles to main panel section  16 . 
     During assembly, extrusion part  128   a  with a wall panel  12   a  secured thereto is secured to a wall  14  with screws (not shown) extending through openings  136 . Then, extrusion part  128   b  having a wall panel  12   b  secured thereto has its base section  130   b  inserted into space  147   a , and screws (not shown) are inserted into openings  136  in a different extrusion part  128   a  at the opposite side of wall panel  12   b . As a result, the panels  12   a  and  12   b  are secured relative to each other, with the barbs  145   a  and  145   b  facing each other in order to receive a plug for aesthetic appearances. 
     With all of the above embodiments, except for  FIGS. 2 ,  2 A,  7  and  8 , the bent end sections must be slid in from the side. 
     Referring now to  FIGS. 14-17 , there is shown a system according to another embodiment of the present invention for easily mounting wall panels  212  over an existing wall structure. The wall structure preferably includes any planar wall. Each wall panel  212  includes a rectangular shaped, planar main panel section  216  and at least two bent end sections  218  bent at a right angle in the same direction at edges of main panel section  216 . Main panel  216 , however, need not be planar, and in fact, can have different shapes, such as a wave shape, etc. to provide different aesthetic appearances. Preferably, there are four bent end sections  218  at each edge of main panel section  216  which form an L-shaped cross-sectional shape thereat. However, the invention is not limited thereby and wall panels  212  can be formed with two, three or four bent end sections  218 . Wall panels  212  are formed preferably by, but not limited to, a polyethylene core  20  with a thin aluminum wall  22  covering opposite sides thereof, as shown in  FIG. 4 . However, for the sake of simplicity in the drawings, all of the drawings except for  FIG. 4  show wall panels  212  formed of only a single material. 
     In addition, each bent end section  218  includes a first cut-out recess  224  at the inner surface  226  thereof and spaced slightly away from main panel section  216 . Each cut-out recess  224  preferably has a square or rectangular configuration in cross-section, although the present invention is not limited thereby. As a result, cut-out recess  224  effectively forms a notch in the inner surface  226  of bent end section  218 . Cut-out recess  224  preferably extends along the entire length of the bent end section  218 , although the present invention is not so limited, that is, cut-out recess  224  can extend along only a part of the length of bent end section  218 , or there may be a plurality of spaced apart cut-out recesses  224 . 
     In addition, the inner surfaces  226  of bent end sections  218  further include at least one, and preferably, plurality of, second cut-out recesses  225 , each of which forms a notch in the inner surface  226  of bent end section  218 . Each cut-out recess  225  extends in a direction perpendicular to the lengthwise direction of the bent end section  218 , starting from the free distal end  227  of the bent end section and extending in a direction toward main panel section  216 , terminating at first cut-out recess  224  and in open communication therewith. 
     With this embodiment, rather than providing a main fastening extrusion  28  or corner fastening extrusion  76  that extends the entire length of a bent end section  18 , a plurality of fastening extrusion segments  276  ( FIG. 18 ) which are identical in construction to corner fastening extrusions  76  are provided, but which extend for only a fraction of the length of corner fastening extrusions  76 . 
     Thus, each fastening extrusion segment  276  includes a base section  278  formed by a planar wall  280  that is adapted to lie flush against an existing wall  14 . A first bent end securing wall  282  extends outwardly at a right angle from planar wall  280  for securing a bent end section  218  of a wall panel  212  thereto. Bent end securing wall  282  includes a projection  284  at the inner surface  286  thereof, with projection  284  having a parallelepiped configuration, which corresponds in shape and dimensions to square or rectangular cut-out recess  224 , although the present invention is not limited thereby and can have any other suitable configuration. Projection  284  extends entirely across the bent end securing wall  282 . 
     The upper free end of bent end securing wall  282  includes an outwardly extending stub wall  288  that is perpendicular to the respective bent end securing wall  282  and parallel to and immediately adjacent to or abutting with main panel section  216  when assembled with wall panel  212 . 
     A bent end securing wall  290  extends outwardly from planar wall  280  in parallel, spaced apart relation to first bent end securing wall  282 , with the spacing between bent end securing walls  282  and  290  being substantially equal to the thickness of one bent end section  218 . Projection  284  faces in a direction toward bent end securing wall  290  as to be positioned in the gap between bent end securing walls  282  and  290 . The opposite side of second wall  290  is provided with barbs  292  that are angled toward planar wall  280 . Planar wall  280  is thereby divided into a central section  294  between bent end securing walls  282  and  290 , and two wing sections  296  and  298  to the outside of bent end securing wall  282  and second wall  290 , respectively, with wing section  298  having an opening  300  extending therealong and through which a screw (not shown) can be inserted to secure planar wall  280  to existing wall structure  14 . 
     With this embodiment, each fastening extrusion segment  276  is connected with a bent end section  218  by passing projection  284  up through a second cut-out recess  225  until the projection  284  reaches first cut-out recess  224 , where it can then be slid along first cut-out recess  224  to removably hold the fastening extrusion segment  276  to the respective bent end section  218 . The fastening extrusion segment  276  can be secured to an existing wall structure by screws (not shown) extending through opening  300  therein. In this way, wall panels  212  can be secured to an existing wall structure in the same way as described with the first embodiment. In other words, fastening extrusion segments  276  can be pre-assembled with wall panels  212  and then brought to a job site, saving time and energy, and enabling easier mounting of wall panels  212 . 
       FIGS. 19 and 20  show a fastening extrusion segment  276   a  which differs from fastening extrusion segment  276  of  FIG. 18  by modifying parallelepiped projection  284  to form fastening extrusion segment  276   a  with a projection  284   a  having a cylindrical configuration at the same height, and with bent end securing wall  282   a  terminating at cylindrical projection  284   a . In such case, cut-out recess  224   a  of bent end section  218   a  of wall panel  212   a  has a semi-circular configuration in cross-section to correspond thereto. In such case, second cut-out recesses  225  would remain the same. 
     Other configurations can be provided as well, such as fastening extrusion segments  276   b  and  276   c  and the corresponding wall panels  212   b  and  212   c  shown in  FIGS. 21-24 , and which correspond essentially to fractions of the same shown in  FIGS. 9 and 10 , but with the addition of barbs. 
     It will therefore be appreciated that, by using the present invention, the fastening extrusions can be assembled with the wall panels at a shop, prior to bringing the same to a job site, thereby saving time and energy. 
     Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to those precise embodiments and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.