Patent Abstract:
Wall systems according to certain embodiments of the present invention provide a means for finishing interior walls such as basement walls. In certain embodiments of the present invention, wall panels offer several options for light switches, plug outlets, cable outlets, communication box outlets and the like. In other embodiments of the present invention, wall panels are provided with a means for eliminating or reducing the need for taping and filling that is used in conventional drywall finishing.

Full Description:
TECHNICAL FIELD 
       [0001]    The invention generally relates to wall panels and systems. 
       BACKGROUND 
       [0002]    A typical basement has perimeter walls of poured concrete or blocks which line a hole or cavity excavated into a ground surface and which acts as a foundation for a home or other structure supported thereby. 
         [0003]    Typical perimeter walls are built with load bearing rather than aesthetic aspects in mind and accordingly tend to be somewhat irregular and are generally uninsulated. In order to finish a basement, the foregoing aspects must be dealt with. 
         [0004]    The typical way to finish a basement is to erect “studs” (vertical wooden members) typically spaced 16 inches apart along the interior face of the perimeter walls. Insulation of some form (e.g. Styrofoam™ or fibreglass) is inserted in the channels defined by the wall and the adjacent studs. A suitable vapour barrier is placed over the insulation if required and “drywall” (gypsum wallboard) sheets are secured to the studs over the insulation and vapour barrier. 
         [0005]    The “finishing” of a typical basement using the prior system is labour and time intensive. Typically upper and lower framing members would be installed adjacent respectively the ceiling joist and a floor. Studs would be mounted between the upper and lower members. The insulation would be cut and installed. The drywall sheets would be cut and secured and finally joints between the drywall sheets would be taped and filled with drywall compound for subsequent sanding and final finishing. 
         [0006]    In addition to the above steps, accommodation must be made for electrical sockets and switches. Such would typically be mounted in boxes secured to the studs and serviced by wiring also secured to the studs. Once the boxes have been installed, a challenge is presented to one installing drywall sheets over the boxes in that the location of the boxes has to be carefully measured and translated to the drywall sheet in order to cut suitable openings to accommodate the boxes. 
       SUMMARY 
       [0007]    In one or more embodiments, the present invention relates to wall systems which provide a means for finishing interior walls; such as basement walls. In certain embodiments of the present invention, wall panels offer several options for light switches, plug outlets, cable outlets and communication box outlets. In other embodiments of the present invention, wall panels are provided with a means for eliminating or reducing the need for taping and filling that is used in conventional drywall finishing. 
         [0008]    Wall systems according to the present invention are modular. 
         [0009]    In one or more embodiments, the present invention relates to a modular wall panel including a sheet of material suitable for forming at least part of an interior wall, the sheet having an outer face and an inner face; a layer of insulation secured to the sheet on the inner face; and connectors for connecting the panel to one or two other panels. In certain embodiments, the panel may further include at least two framing members. In certain embodiments, connectors may be provided in the framing members. Suitable connectors include but are not limited to tongue and groove and click lock connectors. In certain embodiments, one or more conduits for wiring may be provided in the panel. Suitable conduits include tubes such as PVC tubes. In certain embodiments, the conduits may be located in the insulation of the panel. In certain embodiments, the conduits are housed in channels in the insulation. In certain embodiments, channels formed in the insulation may serve as conduits. In certain embodiments, the panel may further comprise an electrical or communications outlet. In certain embodiments, the panel may comprise one or more bevels formed in one or more edges of the panel. In certain embodiments, the panel includes one or more level bubbles in one or more directions. In certain embodiments, the panel may be a door header panel, a light switch panel, an outlet or cable panel or a plain wall panel. In certain embodiments, two or more panels can be connected together to form a interior wall or part thereof. In certain embodiments, two or more panels are connected together to form a modular wall system. 
         [0010]    In another embodiment, the present invention relates to a template comprising a plate including an opening in the plate for tracing the outline of an opening for a well in a modular wall panel; and a flange at one end of the plate and in a plane perpendicular to the plane of the plate. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0011]    Embodiments of the present invention are described below with reference to the accompanying illustrations in which: 
           [0012]      FIG. 1  is a front view of a panel according to an embodiment of the present invention; 
           [0013]      FIG. 2  is a cross section taken along line A-A of  FIG. 1 ; 
           [0014]      FIG. 3  is a rear view of the panel of  FIG. 1  with insulation not shown; 
           [0015]      FIG. 4  is a cross section taken along line B-B of  FIG. 3 ; 
           [0016]      FIG. 5  is front view of a panel according to another embodiment of the present invention; 
           [0017]      FIG. 6  is a cross section taken along line A-A of  FIG. 5 ; 
           [0018]      FIG. 7  is a rear view of the panel of  FIG. 5  with insulation not shown; 
           [0019]      FIG. 8  is a cross section taken along line B-B of  FIG. 7 ; 
           [0020]      FIG. 9  is front view of a panel according to another embodiment of the present invention; 
           [0021]      FIG. 10  is a cross section taken along line A-A of  FIG. 9 ; 
           [0022]      FIG. 11  is a rear view of the panel of  FIG. 9  with insulation not shown; 
           [0023]      FIG. 12  is a cross section taken along line B-B of  FIG. 11 ; 
           [0024]      FIG. 13  is front view of a panel according to another embodiment of the present invention; 
           [0025]      FIG. 14  is a cross section taken along line A-A of  FIG. 13 ; 
           [0026]      FIG. 15  is a rear view of the panel of  FIG. 13  with insulation not shown; 
           [0027]      FIG. 16  is a cross section taken along line B-B of  FIG. 15 ; 
           [0028]      FIG. 17  is front view of a panel according to another embodiment of the present invention; 
           [0029]      FIG. 18  is a cross section taken along line A-A of  FIG. 17 ; 
           [0030]      FIG. 19  is a rear view of the panel of  FIG. 17  with insulation not shown; 
           [0031]      FIG. 20  is a cross section taken along line B-B of  FIG. 19 ; 
           [0032]      FIG. 21  is front view of a panel according to another embodiment of the present invention; 
           [0033]      FIG. 22  is a cross section taken along line A-A of  FIG. 21 ; 
           [0034]      FIG. 23  is a rear view of the panel of  FIG. 21 ; 
           [0035]      FIG. 24  is a cross section taken along line B-B of  FIG. 23 ; 
           [0036]      FIG. 25  is a side view of a sheet of material suitable for forming an interior wall according to an embodiment of the present invention; 
           [0037]      FIG. 26  is a side view of part of two sheets of wall finishing material according to an embodiment of the present invention jointed together; 
           [0038]      FIG. 27  is a side view of a template according to an embodiment of the present invention; 
           [0039]      FIG. 28  is a top view of the template of  FIG. 27 ; 
           [0040]      FIG. 29  is a front view of a panel according to the present invention showing the template of  FIG. 27  in use; 
           [0041]      FIG. 30  is a front view of a wall installation of panels according to one or more embodiments of the present invention; 
           [0042]      FIG. 31  is a side view of the installation of  FIG. 30 ; 
           [0043]      FIG. 32  is a side view of a panel according to the present invention; 
           [0044]      FIG. 33  is a side view of a panel according to the present invention; 
           [0045]      FIG. 34  is a side view of a panel according to the present invention; and 
           [0046]      FIG. 35  is a top view of a panel according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0047]    A modular wall panel according to one embodiment of the present invention is generally illustrated by reference  2 . 
         [0048]    The panel  2 , also referred to as a “light switch panel” if a light switch installed in the panel, is comprised of a sheet  4  of medium-density fiberboard (“MDF”) having an outer wall finishing surface  6  and an interior surface  8 . The sheet  4  is 14 inches wide and 96 inches high but may be of other dimensions depending upon the application. The sheet  4  may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board and drywall. The wall finishing surface  6  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface  6  may be pre-primed such that once installed, it can be painted without further priming. 
         [0049]    Two framing members  10  and  12  are secured to the panel on the interior surface  8  side of the sheet  4 . The framing members  10  and  12  may be secured to the sheet  4  by suitable adhesives or fasteners. The framing members  10  and  12  are at or near the edges of the sheet  4  but may be located at other locations on the sheet  4  provided that the sheet  4  is provided with a sufficient amount of structural integrity. The framing members  10  and  12  are 2′×3′ wood lumber and extend from the top  26  of the sheet  4  to near the bottom edge  27  of the sheet  4 . Recesses  29  are provided between the end of the framing members  10  and  12  and the bottom edge  27  to receive a cleat when the panel  2  is installed on joists provided with a cleat. Recesses  29  are optional and the framing members  10  and  12  may extend to the bottom edge  27 . The framing members  10  and  12  may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the sheet  4 . The framing member  10  is provided with a groove  14  while the framing member  12  is provided with a tongue  16 . The groove  14  is for receiving a tongue from another panel while the tongue  16  is designed to be received by a groove in another panel when more than one panel  2  is joined together to form an interior wall or part of an interior wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the panel  2  for connecting panel  2  to one or more other panels. 
         [0050]    In order to provide electrical or communications service to the panel  2 , a box  18  is provided for housing an electrical or communications outlet (not shown). The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, internet jack, and the like. An opening  20  in the sheet  4  provides access to the box  18 . The box  18  is located in the panel  2  such that upon installation of the panel  2 , the box  18  is at approximately the standard height from the floor that is typical for that type of box. The box  18 , in other embodiments, may be located elsewhere in the panel  2  such that when panel  2  is installed, the box  18  is located at a non-standard height above the floor. In other embodiments the horizontal position of the box  18  in the panel  2  may vary. A tube conduit  22  extends from an opening  24  in the box  18  to the top edge  26  of the panel  2 . The conduit  22  allows for the installation of wiring for wiring an electrical or communications outlet housed in the box  18 . The conduit  22  can be made of PVC or other suitable material. 
         [0051]    Insulation can be placed in the area between the framing members  10  and  12  and around the box  18  and conduit  22  and secured to the sheet  4  and/or the members  10  and  12  by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction to insulate. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet  4  and/or to the members  10  and  12  and/or retained in place by other suitable means such as by a sheet of plastic vapour barrier material, (not shown) or other suitable material secured to the back side of the panel. 
         [0052]    In another embodiment, in the panel  2 , the box  18  and the conduit  22  can be housed in sheet foam insulation  30 .  FIG. 2  is a cross section taken along line A-A of  FIG. 1  of another embodiment (with insulation  30 ) of the panel  2  of  FIG. 1  (panel  2  in  FIGS. 1 ,  3  and  4  is shown without insulation). The insulation  30  may cover all or part of the area of the sheet  4 . In such an embodiment, a well (not shown) is provided in the sheet insulation to house the box  18 . A channel (not shown) is provided in the foam insulation to house the conduit  22 . In a further embodiment, the tube conduit  22  can be omitted and a channel in the insulation  30  can serve as a conduit for wiring. In a still further embodiment, the well in the sheet of insulation is omitted. In such an embodiment, an opening in the sheet  4  and a well in the insulation  30  may be cut such that the cut well is in communication with the conduit  22 . An electrical or communications box may then be inserted into the well. In a still further embodiment, the sheet  4  may be omitted 
         [0053]    The incorporation of an electrical outlet box  18  with an electrical conduit  22  in panel  2  facilitates the installation of electrical or communication services in a finishing operation such as in a basement. Previously, electrical outlet and cable would have been secured to studs prior to placement of drywall over the studs. This proved challenging in guessing with any degree of accuracy where to place a hole in the overlying drywall sheet so as to correspond with the electrical or communications outlet. 
         [0054]    A wall panel according to another embodiment of the present invention is illustrated by reference  40 . The panel  40  is also referred to as an “outlet or cable panel” if an outlet or cable box is installed in the panel. The panel  40  is comprised of a sheet  44  of MDF having an outer wall finishing surface  46  and an interior surface  48 . The sheet  44  is 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheet  44  may be made of other material suitable for forming an interior wall, such as gypsum but not limited to wallboard, shiplap, HDF, OSB, fibre cement board and drywall. The wall finishing surface  46  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface  46  may be pre-primed such that once installed, it can be painted without further priming. 
         [0055]    Two framing members  50  and  52  are secured to the panel on the interior surface  8 . The framing members  50  and  52  may be secured to the sheet  40  by suitable adhesives or fasteners. The framing members  50  and  52  are at or near the edges of the sheet  44  but may be located at other locations on the sheet  44  provided that the sheet  44  is provided with a sufficient amount of structural integrity. The framing members  50  and  52  are 2′×3′ wood lumber and extend from the top  53  of the sheet  44  to near the bottom edge  55  of the sheet  44 . Recesses  57  are provided between the end of the framing members  50  and  52  and the bottom edge  55  to receive a cleat when the panel  40  is installed on joists provided with a cleat. Recesses  57  are optional and the framing members  50  and  52  may extend to the bottom edge  55 . The framing members  50  and  52  may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel  40 . The framing member  50  is provided with a groove  54  while the framing member  52  is provided with a tongue  56 . The groove  54  is for receiving a tongue from another panel while the tongue  56  is designed to be received by a groove in another panel when more than one panel  40  is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members  50  and  52  for connecting panel  40  to one or more other panels. 
         [0056]    In order to provide electrical or communications service to the panel  40 , a box  58  is provided for housing an electrical or communications outlet (not shown). The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, Internet jack, and the like. An opening  60  in the sheet  50  provides access to the box  58 . The box  58  is located in the panel  40  such that upon installation of the panel  40 , the box  58  is at approximately the standard height from the floor that is typical for that type of box. The box  58  in other embodiments may be located elsewhere in the panel  40  such that when the panel  40  is installed, the box  58  is located at a non-standard height above the floor. In other embodiments, the horizontal position of the box  58  in the panel  40  may vary. A tube conduit  62  extends from an opening  64  in the box  58  to the top  66  of the panel  40 . A second conduit  63  extends horizontally from the box  58  and through the member  50 . A third conduit  65  extends horizontally from the box  28  and through the member  52 . The conduits  62 ,  63  and  65  allow for the installation of wiring for wiring an electrical or communications outlet housed in the box  58 . The conduits  62 ,  63  and  65  may be made of PVC or other suitable material. 
         [0057]    Insulation can be placed in the area between the framing members  50  and  52  and around the box  58  and conduits  62 ,  63  and  65  and secured to the sheet  40  and/or the members  50  and  52  by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet  44  and/or to the members  50  and  52  and/or retained in place by other suitable means such as a sheet of plastic vapour barrier material secured to the back side of the panel  40 . 
         [0058]    In another embodiment, in the panel  40 , the box  58  and the conduits  62 ,  63  and  65  can be housed in a sheet of foam insulation  66 .  FIG. 6  is a cross section taken along line A-A of  FIG. 5  but with insulation  66  included. Panel  40  is shown in  FIGS. 5 ,  7  and  8  without insulation  66 . The insulation  66  may cover all or part of the area of the sheet  44 . In such an embodiment, a well (not shown) is provided in the sheet insulation  66  to house the box  18 . Channels are provided in the sheet insulation  66  to house conduits  62 ,  63  and  65 . In a further embodiment, the conduits  62 ,  63  and  65  can be omitted and the channels themselves can serve as the conduits for wiring. In a still further embodiment, the well in the sheet of insulation  66  is omitted. In such an embodiment, an opening in the sheet  44  and a well in the insulation  66  may be cut such that the cut well is in communication with one or more of the conduits  62 ,  63  and  65 . An electrical or communications box may then be inserted into the well. In a still further embodiment, the sheet  44  may be omitted. 
         [0059]    A modular wall panel according to another embodiment of the present invention is generally illustrated by reference  80 . The panel  80  is also referred to as a “plain wall panel”. The panel  80  is comprised of a sheet MDF having an outer wall finishing surface  86  and an interior surface  88 . The sheet  84  is 14 inches wide and 96 inches high but may be of other dimensions depending upon the application. The sheet  84  may be made of other suitable material for forming an interior wall such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. The wall finishing surface  86  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface  86  may be pre-primed such that once installed, it can be painted without further priming. 
         [0060]    Two framing members  90  and  92  are secured to the panel on the interior surface  88 . The framing members  90  and  92  are secured to the panel  40  on the interior surface  88  side of sheet  84  by suitable adhesives or fasteners. The framing members  90  and  92  are at or near the edges of the sheet  84  but may be located at other locations on the sheet  84  provided that the sheet  84  is provided with sufficient amount of structural integrity. The framing members  90  and  92  are 2′×3′ wood lumber and extend from the top  91  of the sheet  84  to near the bottom  93  of the sheet  84 . Recesses  95  are provided between the end of the framing members  90  and  92  and the bottom edge  93  to receive a cleat when the panel  80  is installed on joists provided with a cleat. Recesses  95  are optional and the framing members  90  and  92  may extend to the bottom edge  93 . The framing members may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel  80 . The framing member  90  is provided with a groove  94  while the framing member  92  is provided with a tongue  96 . The groove  94  is for receiving a tongue from another panel while the tongue  96  is designed to be received by a groove in another panel when more than one panel  80  is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors., such as a click-lock system, may be provided in the framing members  80  and  82  for connecting panel  80  to one or more other panels. 
         [0061]    In order to allow wiring to pass through the panel, the panel  80  is provided with a conduit tube  98  which extends through the members  90  and  92 . The conduit  98  can be made of PVC or other suitable material. 
         [0062]    Insulation can be placed in the area between the framing members  90  and  92  and around the conduit  98  and secured to the sheet  84  and/or the members  90  and  92  by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet  84  and/or to the members  90  and  92  and/or retained in place by a sheet of plastic vapour barrior material or other suitable material secured to the back side of the panel. 
         [0063]    In another embodiment, in the panel  80 , the conduit  98  can be housed in a sheet of foam insulation  100 .  FIG. 10  is a cross section taken along line A-A of  FIG. 9  but with insulation  100  included. Panel  80  is shown in  FIGS. 9 ,  11  and  12  without insulation  100 . The insulation  100  may cover all or part of the area of the sheet  84 . In such an embodiment, a channel is provided in the foam insulation to house the conduit  98 . In a further embodiment, the conduit  98  can be omitted and a channel in the insulation  100  may serve as a conduit for wiring. 
         [0064]    The incorporation of a conduit  98  in panel  80  facilitates the installation of electrical or communication services in a finishing operation such as in a basement. 
         [0065]    A modular wall panel according to another embodiment of the present invention is generally illustrated by reference  120 . 
         [0066]    The panel  120  is comprised of a sheet  124  of MDF having an outer wall finishing surface  126  and an interior surface  128 . The sheet  124  is  24  inches wide and  96  inches high but may be of other dimensions depending upon the application. The sheet  124  may be made of other suitable material for forming an interior wall such as such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. gypsum wallboard and drywall. The wall finishing surface  126  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface  126  may be pre-primed such that once installed, it can be painted without further priming. 
         [0067]    Two framing members  130  and  132  are secured to the panel on the interior surface  128  side of the sheet  124 . The framing members  130  and  132  may be secured to the sheet  124  by suitable adhesives or fasteners. The framing members  130  and  132  are at or near the edges of the sheet  124  but may be located at other locations on the sheet  124  provided that the sheet  124  is provided with sufficient amount of structural integrity. The framing members  130  and  132  are 2′×3′ wood lumber and extend from the top edge  125  of the sheet  124  to near the bottom edge  127 . Recesses  129  are provided between the framing members  130  and  132  and the bottom edge  127  to receive a cleat when the panel  120  is installed on joists provided with a cleat. Recesses  129  are optional and framing members  130  and  132  may extend to the bottom edge  127 . The framing members  130  and  132  may be of other dimensions and may be made from other suitable materials such as wood-plastic composite materials, metals, alloys and plastics that provide sufficient structural integrity to the panel  120 . The framing member  130  is provided with a groove  134  while the framing member  132  is provided with a tongue  136 . The groove  134  is for receiving a tongue from another panel while the tongue  136  is designed to be received by a groove in another panel when one or more panel  120  (or other panels according to the present invention) is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members  130  and  132  for connecting panel  120  to one or more other panels. 
         [0068]    In order to provide electrical or communications service to or through the panel  122 , two horizontal conduits  142  and  144  and two vertical conduits  146  and  148  are provided. The conduits  146  and  148  are PVC tubes but may be made of other suitable materials. 
         [0069]    Insulation can be placed in the area between the framing members  130  and  132  and around the conduits  146  and  148  and secured to the sheet  124  and/or the members  130  and  132  by suitable means such as adhesives and fasteners. The insulation can be any insulation suitable for residential or commercial construction. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet  124  and/or to the members  130  and  132  and/or retained in place by a sheet of plastic vapour barrier material or other suitable material secured to the back side of the panel. 
         [0070]    In another embodiment, in the panel  120 , the conduits  142 ,  144 ,  146 , and  148  are housed in a sheet of foam insulation  150 .  FIG. 14  is a cross section taken along line A-A of  FIG. 13  but with insulation  150  included. Panel  120  is shown in  FIGS. 13 ,  15  and  16  without insulation  150 . The insulation  150  may cover all or part of the area of sheet  124 . In a further embodiment, the conduits  142 ,  144 ,  146  and  148  can be omitted and the channels formed in the insulation  150  can themselves serve as conduits. 
         [0071]    An electrical or communications box can be located at points along any of the conduits  142 ,  144 ,  146  and  148 . In order to locate a box, a suitably sized and shaped opening  160  is cut in the sheet  124  and a suitably sized and shaped well (not shown) is cut in the sheet insulation  150  to house box  162 . The conduits passing through the well are also cut. For example, if box  162  is located at intersection  156 , conduit  142  is severed to form two conduits  164  and  166  and conduit  148  is severed to form two conduits  168  and  170 . Conduit  164  extends from an opening  172  in the box  162  to the top  174  of the panel  120 . Conduit  166  extends from an opening  174  in the box  162  to near the bottom  176  of the sheet  124 . Conduit  168  extends from an opening  178  in the box  162  and through the framing member  130 . A conduit  170  extends from an opening  180  in the box  162  and through the faming member  132 . 
         [0072]    Once the well is cut, an electrical or communications box may then be inserted into the well. The electrical or communications outlet includes an electrical outlet, electrical switch, cable box, telephone jack, internet jack, and the like. 
         [0073]    The conduits  164 ,  166 ,  168 , and  170  allow for the installation of wiring for wiring an electrical or communications outlet housed in the box  162 . 
         [0074]    A modular wall panel according to another embodiment of the present invention is generally illustrated by reference  180 . The wall panel  180  is referred to as a “door header panel” when the panel is installed above a door in an interior wall. The panel  180  comprises a sheet  182  of MDF having an outer wall finishing surface  186  and an interior surface  188 . The sheet  184  is 38 inches wide and 16 inches tall but may be of other dimensions depending upon the application. The sheet  184  may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. gypsum wallboard and drywall. The wall finishing surface  186  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface  186  may be pre-primed such that once installed, it can be painted without further priming. 
         [0075]    Two framing members  190  and  192  are secured to the panel  180  on the interior surface  188  side of the sheet  182 . The framing members  190  and  192  may be secured to the sheet  182  by suitable adhesives and fasteners. The framing member  190  is at one end of the sheet  182 . The framing member  192  is located at an interior location of the sheet  182  but may be placed at another location where it can impart sufficient structural integrity to the sheet  182 . The framing members  190  and  192  are 2′×3′ wood lumber and extend from the width of the sheet  182 . The framing members in certain embodiments can extend less than the width of the sheet  182 . The faming members  190  and  192  may be made from other materials such as metals, alloys, composites and plastics that provide sufficient structural integrity to the panel  180 . The framing member  190  is provided with a groove  194  while the framing member  192  is optionally provided with a tongue  196 . The groove  194  is for receiving a tongue from another panel while the tongue  196  is designed to be received by a groove in another panel when more than one panel according to the present invention is joined together to form a wall or part of a wall. Instead of tongue and groove, other suitable connectors, such as a click-lock system, may be provided in the framing members  190  and  192  for connecting panel  180  to one or more other panels. 
         [0076]    A third framing member  198  is provided. The third member  198  is not initially attached to the sheet  182  and may be provided with the sheet  182  as a kit. If the full width of the panel  180  is to be used, the third member  198  is affixed at the end of the sheet  182  opposite to the end where framing member  190  is located. If the panel  180  is to be less than the full width of the sheet  182 , (for example a width less than full 38″ width in the embodiment shown in  FIGS. 22 and 24 ), the third member  198  is affixed at a location on the sheet  182  closer to the member  190 . Cut lines  200  may be provided on the interior surface  188 , such as at 26″, 28″, 30″ and 32″ along the width of the sheet  182  (as measured from the end of the sheet  182  where the framing member  190  is located). The sheet  182  can be cut along one of the cut lines  200  according to the width of the panel desired. The third member  198  is then affixed along the cut line where the sheet  182  has been cut. The member  198  is provided with a tongue  202  designed to be received by a groove in another panel when the panel  180  is to be joined to another panel on the end where third member  198  is located. 
         [0077]    The panel  180  may be provided with insulation  204 . The insulation can be any insulation suitable for residential or commercial construction to insulate. Examples of insulation which can be used include sheet foam insulation (for example be of Styrofoam™) and fibre glass insulation (for example Fiberglass Pink™). In certain embodiments, the insulation may be secured to the sheet  182  and/or to the members  190  and  192  and/or retained in place by other suitable means such as by a sheet of plastic vapour barrier material or other suitable material secured to the back of the panel  180 . 
         [0078]    Insulation can be omitted from modular wall panels according to certain embodiments of the present invention. 
         [0079]    Framing members can be omitted from modular wall panels according to certain embodiments of the invention if the sheet used in the panel has sufficient structural integrity to be installed without the need for framing members to provide additional structural integrity. In such embodiments, the modular wall panels have connector means associated with the panels that are attached to the sheets by means other than framing members. 
         [0080]    Sheets of wall finishing material according to certain embodiments of the present invention may optionally have a bevel on one or both side edges of the sheet. A sheet  210  of material suitable for forming an interior wall  210  is 3 mm in thickness and 24″ in width and 96 inches in height. A first bevel  212  is located at an edge of the sheet  210  of the outer wall finishing surface  214 . The bevel is formed at a  45  degree angle but bevels at other suitable angles are possible. A second bevel  216  is located at the edge of the sheet  210  opposite the edge in which the bevel  212  is formed. Once sheets  210  are joined together to connect the two sheets (such as for installation), the small groove  218  created by two abutting bevelled edges can be caulked with silicone, or similar type of paintable caulking, and then troweled smooth as an alternative to the taping, filling and sanding of seems between panels of traditional gypsum wall sheet installations. 
         [0081]    Panels according to certain embodiments of the present invention may include one or more level bubbles. One level bubble may be located in a side edge of the panel for vertical positioning (see for example  219  in  FIG. 1 ). A level bubble may be located on the front face of the panel for horizontal positioning (see for example  221  in  FIG. 1 ). Level bubbles may be embedded in the panel as long as they are still visible for reading. 
         [0082]    As discussed above, wall panels according to certain embodiments of the present invention, have conduits pre-installed but do not have a well for an electrical or communications box. In order to cut an opening in sheets of wall material, a template may be used such as the template indicate by reference  220 . The template  220  is made of a material that is resistant to wear from a saw blade running inside or along side the template. The template has a plate  222  and a flange  224  at right angles to the plate  222 . The plate  222  includes an H-shaped opening  226  which is dimensioned to correspond to size of an opening for a standard electrical or communications box. The template  222  and the opening  226  may be of other shapes and sizes depending upon the application. 
         [0083]    In use, in order to cut an opening in a sheet of material suitable for forming an interior wall  228 , having conduit  230 , the template  222  is positioned such that the flange  224  abuts the side  232  of the sheet  228 . A saw such as a jig saw is used to cut out an opening in the sheet  228  by cutting along the inside edges of the H-shaped opening  226 . 
         [0084]    A series of wall panels according to certain embodiments of the present invention may be joined together to form an interior wall of a basement. The interior wall could equally be in another area of a dwelling or commercial building. The panels are installed against 2×3 cleats  250  and  260  that are fastened to the bottom of floor joists  270  at the top of the wall and to a subfloor system  265  of the basement. The top cleat  250  may be installed first against floor joists  270  and the bottom cleat  260  is then installed offset from the top cleat to accommodate the notch  280  at the bottom of each floor panel. Once the cleats  250  and  260  are installed, one determines which type of panel is required and where, and installation can proceed beginning in a corner of the basement. For walls that require plumbing installation as well, the cavity  272  created behind the wall  273  formed by the panel system and the exterior wall  274  of a dwelling or commercial building, allows for the pre-installation of all plumbing required. Once the plumbing is installed, the wall panels  290 ,  300 ,  310 ,  320  and  330  may be installed. The wall panels  290 ,  300 ,  310 ,  320  and  330  are preferably installed before the ceiling is installed enabling electrical installation to be completed after installation of the wall panels but prior to the installation of the ceiling. 
         [0085]    Typically the wall panels  290 ,  300 ,  310 ,  320  and  330  would be installed before the ceiling enabling electrical installation to be completed after installation of the wall panels and before the ceiling. 
         [0086]    Wall panel  290  is a light switch panel with light switch  291  installed, panel  300  is a door header panel, panel  310  is an outlet or cable panel with outlet  311  installed, panel  320  is a plain wall panel and panel  330  is a second outlet panel with outlet  331  installed, all according to certain embodiments of the present invention. The panels  290 ,  200 ,  310 ,  320  and  330  are joined together using the tongues and grooves (not shown) provided with the panels  290 ,  200 ,  310 ,  320  and  330 . 
         [0087]    Panels according to embodiments of the present invention can also be configured to be installed with and to accept vertical cleats. 
         [0088]    In further embodiments, panels according to the present invention may include rigid foam with channels and optionally conduits. 
         [0089]    In other embodiments, in place of a rigid or solid foam, such as used for foam sheets  30 ,  66 ,  100 ,  150 ,  204 , can be replaced with a non-solid structure such as a corrugated structure, a honeycomb structure and the like, or a combination of such structures. An exemplary embodiment of such a structure is shown in  FIG. 32  which depicts a panel indicated generally at  400  which includes a first sheet of outer wall finishing material  410  having an outer finishing surface  412  and an inner surface  414  and a second sheet of outer wall finishing material  416  having an outer finishing surface  418  and an inner surface  420 . The sheets  410  and  416  may be made of wall board, but may be made of other material suitable for forming an interior wall, such as but not limited to gypsum wallboard, shiplap, HDF, OSB, fibre cement board or drywall. The interior of the panel  400  includes a corrugated structure  430 . The corrugated structure  430  is secured to the sheets  410  and  416 . A channel  440  is located in the panel  400  and passes through the corrugated structure  430 . Additional channels can be included in the panel  400 . The channel  440  can be lined with a conduit (not shown). The panel  400  includes tongue  450  and groove  460  connectors but other connectors may be substituted therefore or the connectors omitted altogether. Such a wall panel may be used for example as an inner interior wall panel, i.e one which is not used for finishing the inside of an exterior wall. 
         [0090]    In panels according to certain embodiments of the present invention, the framing members can be omitted. The tongue and groove or other type of connectors can be integrated into the foam sheet of the panel. For example a wall panel according to another embodiment of the present invention is illustrated by reference to  FIG. 33 . The panel indicated generally at  500  includes a first sheet  510  of MDF having an outer wall finishing surface  512  and an interior surface  514  and a second sheet  516  of MDF having an outer wall finishing surface  518  and an interior surface  520 . The sheets  510  and  516  are 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheets  510  and  516  may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surfaces  512  and  518  are ones which are suitable for accepting wall finishes such as wallpaper and paint. The surfaces  512  and  518  may be pre-primed such that once installed, it can be painted without further priming. Between the sheets  510  and  516  is sheet foam  580  or other suitable material. 
         [0091]    The panel  500  includes tongue  550  and groove  560  connectors but other connectors may be substituted therefore or the connectors omitted altogether. A channel  570  may be included in the panel  500 . Such a wall panel may be used for example as an inner interior wall panel, i.e one which is not used for finishing the inside of an exterior wall. 
         [0092]    In other embodiments, sheet foam material used in certain embodiments of the present invention can have a dimpled outer surface. For example a wall panel according to another embodiment of the present invention is illustrated by reference to  FIG. 34 . The panel indicated by reference  600  includes a sheet  610  of MDF having an outer wall finishing surface  612  and an interior surface  614 . The sheet is 24″ wide and 96″ high but may be of other dimensions depending upon the application. The sheet  610  may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surface  612  is one which is suitable for accepting wall finishes such as wallpaper and paint. The surface may be pre-primed such that once installed, it can be painted without further priming. A rigid foam  630  is attached to the interior surface  614  and includes dimples  616 . 
         [0093]    In other embodiments of the present invention, the position of channels or conduits as the case may be in the panels may be marked on finishing surfaces according to the present invention by for example chalk lines, such as dashed lines. Chalk is preferred because it can be easily erased or painted over. Alternatively, the lines may be sprayed on or applied as a peel coat. 
         [0094]    A panel according to another embodiment of the present invention may be used as a corner piece in a wall. For example, a wall panel indicated by reference numeral  700  according to another embodiment of the present invention is illustrated by reference to  FIG. 35 . The panel  700  includes outer sheets  702  and  704  of MDF having an outer wall finishing surfaces  706  and  708  and interior surfaces  710  and  712 . The sheets  702  and  704  may be made of other material suitable for forming an interior wall, such as gypsum, wallboard, shiplap, HDF, OSB, fibre cement and drywall. The wall finishing surfaces  706  and  708  are suitable for accepting wall finishes such as wallpaper and paint. The surface may be pre-primed such that once installed, it can be painted without further priming. Groove  714  is formed in the sheet  716  of foam material or the like attached to the sheets  702  and  704  and tongue  718  is formed of the sheet  716 . Alternatively, a member with a groove and a member with a tongue way be recessed within the sheet  716 . One or more channels (not shown) may be formed in the sheet. The channels may be lined with conduits. 
         [0095]    The above invention is described in an illustrative rather than a restrictive sense. Deviation from the exact arrangements and dimensions described may be apparent to persons skilled in the art in adapting the above invention to specific applications. Accordingly, the scope of the invention is defined by the claims set out below.

Technology Classification (CPC): 4