Abstract:
Provided herein is a modular wall panel, and a system for installing and method of making thereof. The modular wall panel includes a first insulating layer made of extruded polystyrene foam. The panel further includes a second rigid layer made of a closed cell polyvinylchloride foam board. A third finishing layer is further included in the panel, the third layer made of a cosmetically acceptable material for living conditions.

Description:
FIELD OF THE INVENTION 
       [0001]    The present application claims priority U.S. Provisional Application Ser. No. 61/770,587, filed Feb. 28, 2013, herein incorporated by reference in its entirety. 
         [0002]    The present invention relates to a wall panel, methods, and systems for its installation. More particularly, the present invention relates to a modular wall panel with improved physical characteristics, and methods and systems for its installation. 
     
    
     BACKGROUND 
       [0003]    Finished or “club” basements are a common part of residential structures. Conventional wood framing has been widely used to achieve a finished wall surface. Recently the developments of other innovative wall finishing systems have emerged. These systems are comprised of “shape-molded” insulation panels such as: In-So-Fast™; R-Retro™; Re-Fit™ and BuildLock™. Owens Corning also markets fiberglass softwall systems whose use is common in residential settings. The wall finishing systems typically consist of some type of framework and/or studs into which modular wall panels are fitted. 
         [0004]    The wall panels used in these finishing systems suffer from several drawbacks however, which make handling, fitting, and installation difficult. Many of the wall panels are too rigid, which makes cutting and handling of them difficult. Cutting the wall material often can damage saws which are used therein. Other wall panels are very light and easy to handle, but are also easily damaged in shipping and handling of the panel. Such panels also do not possess sufficient tensile strength to structurally serve as a wall, and are difficult to hang things thereupon. 
         [0005]    Other wall panels are too heavy and are difficult to work with. Some heavier paneling requires specialized framework to accommodate the panels, and may be too heavy to be used in some framing systems. Additionally, most wall panels require a finishing step in order to make the finished wall cosmetically acceptable after installation. Some finishing steps include painting, wallpapering, or other type of procedure in order to make the newly installed wall acceptable in the home or office in which it was installed. 
         [0006]    It is therefore desirable to provide a modular wall panel, and installation systems and methods which are easier to handle and install, are more environmentally friendly, and are more cosmetically acceptable. 
       SUMMARY 
       [0007]    Provided therefore herein is a modular wall panel, and a system for installing and method of making thereof. The modular wall panel includes a first insulating layer made of an extruded polystyrene foam. The panel further includes a second rigid layer made of a closed cell polyvinylchloride foam board. A third finishing layer is further included in the panel, the third layer made of a cosmetically acceptable material for living conditions. 
         [0008]    In an embodiment, the first layer of the modular wall panel is adhered to the second layer, and the second layer is adhered to the third layer in a sandwich configuration where the second layer resides between the first and third layer. In another embodiment, layers of the modular wall panel are adhered together by an adhesive selected from any water based contact adhesive. 
         [0009]    In another embodiment, the first insulating layer of the modular wall panel is from about 3 centimeters to about 7 centimeters thick; and the second rigid layer is from about 3 millimeters to about 7 millimeters thick. In another embodiment, the first insulating layer is from about 4 centimeters to about 6 centimeters thick; and the second rigid layer is from about 4 millimeters to about 6 millimeters thick. In a preferred embodiment, the first insulating layer is about 5 centimeters thick and said second rigid layer is about 5 millimeters thick. 
         [0010]    In yet another embodiment, the third finishing layer of the modular wall panel is formed of a material selected from the group of vinyl wall fabric coverings, rigid vinyl wall materials, wainscoting, or formica. 
         [0011]    In yet another embodiment, a system of making or finishing a wall in an edifice is provided herein. The system includes providing a framework for supporting wall panels. Within the framework is inserted a modular wall panel. The modular wall panel includes a first insulating layer formed of an extruded polystyrene foam; a second rigid layer formed of a closed cell polyvinylchloride foam board; and a third finishing layer comprising a cosmetically acceptable material for living conditions. 
     
    
     
       DETAILED DESCRIPTION 
         [0012]      FIG. 1  shows a blown-up cross section of a modular wall panel of the present invention. 
           [0013]      FIG. 2  shows a front view of a modular wall panel of the present invention. 
       
    
    
       [0014]    This structure of the panel of the present invention is comprised of three layers, and they have one dimension (their respective thicknesses) that is smaller than their other two respective dimensions. These plates are essentially planar; but they could be curved into two or three dimensions, developable or non-developable in the mathematical sense. 
         [0015]    With reference to the Figures, the sandwich structure  10  therefore comprises a first insulating layer  12  made of extruded polystyrene foam, a second rigid layer  14  made of a closed cell PVC foamboard, and a third finishing layer  16 . Insulating layer  12  has a length  18 , and a width  20 , and a thickness  22 . Rigid layer  14  also has a length and width which are identical to insulating layer  12  as the layers form a sandwich structure. Finishing layer  16  also has a length and a width, which may be the same as insulating layer  12  and rigid layer  14 , but may be slightly longer in either dimension as it may be wrapped around a side of the panel if in fabric form. 
         [0016]    In order to assemble, a framework is first established in an edifice in which the modular wall panel will be used. The framework can be placed against a perimeter wall of the edifice or an internal wall, and includes a rigid frame, which may be steel. It is an advantage of the present invention that the modular wall panels may be used with a variety of frames and materials. The size, i.e., length and width, of the modular wall panels may vary greatly depending on how it will be used. They may be used as squares; i.e., length equals width. 
         [0017]    The framework may be installed by methods well known in the art. A steel frame is first installed, after which our panels are appended thereto, typically with screw fasteners. A PVC molding is optionally installed thereafter, including crown molding, chair rails, and other items. The modular wall panels may be easily replaceable, or updated at a later date. 
         [0018]    First insulating layer  12  consists of extruded polystyrene foam (XPS), which consists of closed cells, offers improved surface roughness and higher stiffness and reduced thermal conductivity. The density range is about 28-45 kg/m 3 . Extruded polystyrene foam is commonly used as an insulator. Because of the extrusion manufacturing process, XPS does not require facers to maintain its thermal or physical property performance. Thus, it makes a more uniform substitute for corrugated cardboard. Thermal resistivity is usually about 35 m·K/W (or R-5 per inch in American customary units) but can range between 29 and 39 m·K/W depending on bearing/density. Thermal conductivity varies between 0.029 and 0.039 W/(m·K) depending on bearing strength/density and the average value is ˜0.035 W/(m·K). Water vapor diffusion resistance (μ) of XPS is typically around 80-250. While XPS is the preferred embodiment, it is recognized that other insulative layers may be substituted therefore without varying from the scope of the invention. 
         [0019]    The second rigid layer  14  is made of closed-cell PVC foamboard. Closed-cell PVC foamboard is a light-weight rigid material used primarily in the manufacture of signs and displays, although its material properties have made it extremely popular among model makers, prop, composite experimental aircraft and yacht builders. Like PVC, closed-cell PVC foamboard is solid and has a very rigid structure. Where it differs is in its closed-cell foam structure, which makes it very light (as little as half the weight of solid PVC), highly resistant to moisture and some chemicals, and very easy to cut and shape. It also has thermoplastic properties, and begins to soften at around 65° C. Typically, closed-cell PVC foamboard can be cut as easily as wood, softened and shaped by immersing in boiling water or with a standard heat gun, and painted with standard automobile paints. 
         [0020]    The third finished layer  16  may be a flexible fabric skin such as a fabric coated with a vinyl. A vinyl material that may be used for such a purpose is manufactured by USCAN, LLC of Merritt Island, Fla.; an example of such vinyl material is marketed under the trade name or identifier US 185-HC. This type of vinyl may be composed of a polyester base fabric with a PVC coating. It may have, for example, a thickness of 0.58 mm, a weight of 630 grams per square meter, and a temperature resistance of −30 to +70 degrees Celsius. 
         [0021]    An adhesive is used to assemble the layers together. Preferred adhesives are water-based contact adhesives, which also benefit from being environmentally acceptable. A preferred adhesive is H2O from Wilson Art International®, which consists principally of polychlorprene, zinc oxide, water, Resin acid, and Rosin acid, in sodium and potassium form. 
       EXAMPLES  
       [0022]    Example 1 
         [0023]    In order to make the modular wall panel, XPS foam board is used, such as Greenguard® type IV cm square edge, 25 psi. The XPS board can have a thickness of 2 inches for foundation walls (with a R value of 10), or a thickness of 1 inch or ½ inch (R value of 5 and 2.5 respectively) when used as non-foundation walls. A PVC foamboard of 3 mm thickness from Laird Plastics® is also used in conjunction with vinyl wall coverings from Brewster Wall Coverings (15 oz or 20 oz vinyl). 
         [0024]    In order to assemble the layer components, a water based adhesive, such as H2O from Wilson Art International®, is applied to one side of the XPS foam and one side of the PVC, then press laminated together. The adhesive is then applied to the PVC side of combined structure, as well as to the backside of vinyl wall covering, and press laminated together, which includes wrapping the vinyl and laminating to side of PVC foamboard. After assembly, the composite is trimmed to a rectangle. 
         [0025]    It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.