Abstract:
A fabric wall panel includes a number of frame members for attachment to a wall to form a frame. Each frame member has a stationary jaw for attachment to the wall and a movable jaw pivotally attached to the stationary jaw by a flexible and stretchable hinge for rotation between an open position and a close position. Each frame member has an opening lock that locks the movable jaw in the open position to facilitate the insertion of fabric between the movable jaw and the stationary jaw. Each frame member also has one or more closing locks that connect the movable jaw to the stationary jaw to thereby hold the movable jaw in the closed position.

Description:
FIELD OF THE INVENTION 
     This invention relates to a fabric wall panel for use in decorating, and more particularly, relates to a track for a frame for a fabric wall panel with an improved closure and clamping mechanism. 
     BACKGROUND OF THE INVENTION 
     Fabric wall panels are used to decorate the interior space in many buildings. Fabric coverings for the panels are available in numerous textures and patterns that can be coordinated with the furnishings and carpets in a room. These fabric wall panels can be customized to meet the decorating needs of various locations and decorating tastes. 
     Besides decorating versatility, fabric wall panels provide other desirable features. Such features include sound and heat insulation. Particularly, in large rooms such as auditoriums and theaters, fabric wall panels may include a layer of acoustical material hidden behind the fabrics that modifies the acoustical character of the room. In addition, heat-insulating material may be mounted behind the fabrics to enhance heat transfer properties of a wall. 
     A substantial cost involved in using fabric panels is the cost of installation. Moreover, if the fabric becomes worn or the decorating scheme changes, the need may arise to change the fabric panels. Consequently, the method of mounting and/or changing the fabric wall panels becomes an important consideration when fabric wall panels are selected for a building project. 
     Another consideration in the selection and use of fabric wall panels is assuring a quality installation. Particularly, the wall panels should line up uniformly with each other, and the seams between adjacent wall panels should be tight and uniform. With most fabric wall panel systems, quality of installation including alignment and uniformity of seams depends on the skill of the installer. 
     Some prior fabric wall panels are installed in situ. For example, as disclosed in Baslow U.S. Pat. No. 4,018,260, border pieces of a panel are permanently attached to the wall to form a framework for mounting a fabric sheet. The fabric sheet completely covers the wall without being adhered to the wall itself. The linear border pieces include a key way into which the fabric is forced by means of a compressible spline. The linear border pieces also include a storage channel, which allows the border pieces to create a finished look at the edges. The uniformity of installation depends on the skill of the installer in terms of aligning the framework and particularly forcing the fabric into the key way so that the fabric is uniformly stretched on the framework. 
     In addition, fabric wall panels can be prefabricated off of the wall. One method for installing a prefabricated fabric wall panel employs a cross-nailing system as disclosed by the patent to Anderson, U.S. Pat. No. 4,731,972. Each fabric wall panel disclosed in the Anderson patent is prefabricated and then installed by driving two headless pin nails at an angle in a crossed fashion through the frame pieces of the prefabricated wall panel. The crossed nails penetrate completely through the fabric, partially penetrate the frame, and securely fasten the fabric wall panel to the wall. A fabric wall panel attached using this cross-nailing method cannot be easily removed from the wall if one should desire to replace the fabric, replace the panel, or remove the panel entirely. 
     One successful removable wall panel system is disclosed in Anderson U.S. Pat. No. 5,715,638. In that patent, a fabric wall panel is mounted on the wall by means of hangers. Each frame member of each wall panel has a spine with an elongated slit, a side edge, and a front edge that together define a groove. A flat filler insert is fitted within the groove of each frame member. Fabric is stretched over the frame and flat filler insert and is bonded to the back of the spine of each frame member to complete the finished fabric wall panel. The hanger has a flat base and a perpendicularly extending tongue with an enlarged head. A number of hangers are affixed on the wall using an adhesive. The slit on the frame of the fabric wall panel is aligned with the tongue of hanger on the wall, and the prefabricated fabric wall panel is affixed to the wall by pressing the slit over the tongue on the hanger. Each fabric wall panel can be prefabricated in standard sizes or custom fabricated on site. Each fabric wall panel can also be independently replaced or removed entirely by unsnapping the fabric wall panel from the supporting hangers and replacing it with another prefabricated fabric wall panel. 
     Another successful removable wall panel system is disclosed in Anderson U.S. Pat. No. 6,574,936. That patent discloses a fabric wall panel comprising a frame constructed of frame members or tracks. Wall hangars are affixed to the walls. Each fabric wall panel is separately constructed. The frame members engage the wall hangers to allow easy attachment and removal of the prefabricated fabric wall panel from the walls. 
     Another removable wall panel system is disclosed in Anderson United States Patent Application Publication No. 2007/0283656. The fabric wall panels comprise a frame, a flat filler, and a fabric stretched over the flat filler and held by a clamp around the edges of the frame. The fabric wall panels are removably mounted on the wall by means of a hanger. Because of the fabric is held on the frame by the clamp, the fabric wall panel may be assembled either on the wall or separately from the wall. 
     U.S. Pat. Nos. 4,676,016; 4,805,330; and 6,431,251 all disclose a wall panel system in which the frame members are connected directly to the wall, and the frame members engage the fabric by a hook and snap arrangement. 
     The prior art has thus failed to disclose a fabric wall panel system in which the installer can easily mount and assemble the fabric wall panels in situ on the walls. 
     SUMMARY OF THE INVENTION 
     The present invention satisfies the above-described needs with a fabric wall panel having a frame over which a fabric is stretched and secured. In some embodiments, a flat filler insert is positioned between the wall and the fabric. The frame comprises a plurality of linear frame members or tracks attached to the wall. Each track has closure mechanism comprising a stationary jaw for attachment to the wall, a flexible and stretchable hinge, and a movable jaw that is connected to the stationary jaw by means of the flexible and stretchable hinge. 
     The track has an open position in which the movable jaw pivots away from the fixed jaw by means of the hinge to create an opening for the insertion of fabric into the opening between the open movable jaw and the stationary jaw. In addition, the track has an opening lock to hold the movable jaw in its open position during installation of the fabric. The opening lock consists of a movable lock member on the movable jaw and a matching stationary lock member on the stationary jaw that engage each other to hold the movable jaw in the open position. The flexible and stretchable hinge allows the movable lock member and the stationary lock member to engage and disengage when pressure is exerted on the movable jaw. 
     The track also has a close position in which the movable jaw pivots by means of the flexible and stretchable hinge into engagement with the stationary jaw to secure the fabric to the tracks that form the frame of the fabric wall panel. In order to maintain the movable jaw in the close position and clamp the fabric between the movable jaw and the stationary jaw, the track has a back closing lock and a front closing lock between the movable jaw and the stationary jaw for holding the movable jaw in the close position and engaging the fabric. In order to assure positive clamping of the fabric, the stationary jaw has a stationary front return and the movable jaw has a movable front return, each of which project toward each other, but do not meet, when the movable jaw is in the closed position. The space between the movable front return and the stationary front return provides an access opening for accommodating thick fabric along a line where two adjacent tracks abut each other. Further, the movable front return is offset from the front closing lock in order to ensure that pressure exerted by the tension in the fabric is carried by the movable front return and therefore does not tend to disengage the front closing lock. 
     When the fabric of the fabric wall panel needs replacing, the fabric can be replaced by opening the movable jaw and removing the fabric while the tracks of the fabric wall panel are still attached to the wall. New fabric is inserted into the opening between the movable jaw and the stationary jaw, and the movable jaw is then closed to stretch and clamp the new replacement fabric between the movable jaw and the stationary jaw of the tracks forming the frame. 
     In separate embodiments of the present invention, the movable front return of the movable jaw may have, for example, a straight profile or a beveled profile, depending on the desired aesthetic appearance of the interface between two adjacent, abutting fabric wall panels. 
     Further objects, features and advantages will become apparent upon consideration of the following detailed description of the invention when taken in conjunction with the drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a room having walls covered with a plurality of fabric wall panels constructed in accordance with the present invention. 
         FIG. 2  is a perspective view of a frame member or track for the fabric wall panel in an open position in accordance with a first embodiment of the present invention. 
         FIG. 3  is a perspective view of the track of  FIG. 2  in a closed position in accordance with the first embodiment of the present invention. 
         FIG. 4  is a cross-section view of the tracks of two adjacent fabric wall panels in accordance with the first embodiment of the present invention as seen along line  4 - 4  in  FIG. 1  with the track in the open position. 
         FIG. 5  is a cross-section view of the tracks of two adjacent fabric wall panels in accordance with the first embodiment of the present invention as seen along line  4 - 4  in  FIG. 1  with the track in the closed position. 
         FIG. 6  is a perspective view of a frame member or track for a fabric wall panel in an open position in accordance with a second embodiment of the present invention. 
         FIG. 7  is a perspective view of the track of  FIG. 6  in a closed position in accordance with the second embodiment of the present invention. 
         FIG. 8  is a cross-section view of the tracks of two adjacent fabric wall panels in accordance with the second embodiment of the present invention as seen along line  4 - 4  in  FIG. 1  with the track in the open position. 
         FIG. 9  is a cross-section view of the tracks of two adjacent fabric wall panels in accordance with the second embodiment of the present invention as seen along line  4 - 4  in  FIG. 1  with the track in the closed position. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is a fabric wall panel system, with an improved linear frame member or track and a method for installing a fabric wall panel on a wall and replacing the fabric on the fabric wall panel. The fabric wall panel system comprises a plurality of fabric wall panels mounted on the wall of a room. For the purposes of the present invention, a wall includes existing or permanent walls, moveable walls, partitions, and the like. Although the present invention will be generally described in the context of a room with walls of sheet rock, those skilled in the art will recognize that the present invention is not limited to that environment. Referring now to the drawings, in which like numerals represent like elements throughout the several figures, the present invention will be described. 
     Turning to the figures,  FIG. 1  is a perspective view of a room  1  with a back wall  2  and a side wall  4  covered with fabric wall panels  10 , including fabric wall panels  10   a  and  10   b , in accordance with the present invention. The room also has a ceiling  6  and a floor  7 . The back wall  2  and the side wall  4  converge at a corner  8 . 
     Each of the fabric wall panels  10  in  FIG. 1  is similarly constructed. The fabric wall panel  10  comprises a rectangular frame  12 , a fabric  22 , and a flat filler insert  24 . Each frame  12  is made up of four linear frame members or tracks  14 ,  16 ,  18 , and  20 . The tracks  14 ,  16 ,  18 , and  20  are extrusions made of high impact premium unplasticized polyvinylcloride, such as PLC27766 sold by Georgia Gulf Corporation of Atlanta, Ga. and of a melt processable rubber, such as Alcryn®4070 NC sold by Ferro Corporation of Cleveland, Ohio. 
     The linear frame member or track  18  is shown in perspective in  FIGS. 2 and 3 . Adjacent tracks  14  and  18  are shown in cross-section in  FIGS. 4 and 5 . Each of the tracks  14  and  18 , for example, comprises a stationary jaw  26  and a movable jaw  30  connected by a flexible and stretchable hinge  28 . The flexible and stretchable hinge  28  is formed of melt processable rubber identified above, and the rest of the track is formed of the high impact polyvinyl chloride identified above.  FIGS. 2 and 4  show the tracks  14  and  18  with the movable jaw  30  in an open position with the movable jaw  30  pivoted away from the stationary jaw  26 .  FIGS. 3 and 5  show the tracks  14  and  18  with the movable jaw  30  in a closed position with the movable jaw  30  pivoted into engagement with the stationary jaw  26 . In the open position, the movable jaw  30  is held open by an opening lock  46 . In the closed position, the movable jaw  30  is held closed by a back closing lock  48  and a front closing lock  50 . While the embodiment shown in  FIGS. 2-5  shows a back closing lock  48  and a front closing lock  50 , the back closing lock  48  could be eliminated leaving only the front closing lock  50 . 
     With continuing reference to  FIGS. 2-5 , the stationary jaw  26  comprises a stationary flat spine  32 , a stationary back return  34  with a stationary back return hook  35 , and a stationary front return  37 . The stationary back return hook  35  forms one half of the opening lock  46 . The stationary jaw  26  also includes a stationary hinge connector  36  protruding outwardly from the stationary flat spine  32  for attachment to the flexible and stretchable hinge  28 . The stationary jaw  26  further includes a stationary back lock stub  38  protruding outwardly from the stationary flat spine  32  and having a stationary back lock stub hook  39 . The stationary back lock stub hook  39  forms one half of the back closing lock  48 . In addition, the stationary jaw  26  has a stationary front lock stub  40  protruding outwardly from the stationary flat spine  32  and having a stationary front lock stub hook  41 . The stationary front lock stub hook  41  forms one half of the front closing lock  50 . As best shown in  FIGS. 4 and 5 , the stationary flat spine  32  of the stationary jaw  26  is attached to the back wall  2  by any suitable means including adhesive, cross nailing, screws, or other suitable fastening means. 
     With continuing reference to  FIGS. 2-5 , the movable jaw  30  comprises a movable flat spine  52 , a movable back end  54  with a movable back end hook  55 , and a movable front return  56 . The movable back end hook  55  forms one half of the opening lock  46 . The movable jaw  30  also includes a movable hinge connector  62  protruding outwardly from the movable flat spine  52  for attachment to the flexible and stretchable hinge  28 . The movable jaw  30  further includes a movable back lock stub  58  protruding outwardly from the movable flat spine  52  and having a movable back lock stub hook  59 . The movable back lock stub hook  59  forms one half of the back closing lock  48 . In addition, the movable jaw  30  has a movable front lock stub  60  protruding outwardly from the movable flat spine  52  and having a movable front lock stub hook  61 . The movable front lock stub hook  61  forms one half of the front closing lock  50 . A strip of double-sided tape  57  is attached to the outside of the movable front return  56  along its length. 
     The stationary back return hook  35  and the movable back end hook  55  together form the opening lock  46 , which, as shown in  FIGS. 2 and 4 , holds the movable jaw  30  in the open position. The stationary back lock stub hook  39  and the movable back lock stub hook  59  together form the back closing lock  48 , which, as shown in  FIGS. 3 and 5 , holds the movable jaw  30  in the closed position. The stationary front lock stub hook  41  and the movable front lock stub hook  61  together form the front closing lock  50 , which, as shown in  FIGS. 3 and 5 , also holds the movable jaw  30  in the closed position. 
     As previously noted, the tracks  14 ,  16 ,  18 , and  20  are formed by extruding the high impact premium unplasticized polyvinylcloride and the melt processable rubber. During the elevated temperature extrusion process, the flexible and stretchable hinge  28 , formed of melt processable rubber identified above, is extruded in contact with the stationary hinge connector  36  and the movable hinge connector  62 , formed of the high impact premium unplasticized polyvinylcloride. As the flexible and stretchable hinge  28  and the hinge connectors  36  and  62  cool, a bond is formed thereby creating the flexible and stretchable hinge  28  between the movable jaw  30  and the stationary jaw  26 . Not only is the flexible and stretchable hinge  28  flexible in terms of allowing the stationary jaw  26  and the movable jaw  30  to pivot with respect to each other, the flexible and stretchable hinge  28  also allows for stretching to enable the stationary back return hook  35  and the movable back end hook  55  to engage to lock the movable jaw  30  in the open position and disengage to unlock the movable jaw  30  in order for the movable jaw to pivot to the closed position. 
     In order to install the fabric panels  10  on the back wall  2 , for example, the installer first creates the square frame  12  by cutting each of the tracks  14 ,  16 ,  18 , and  20  to the desired length, by mitering the ends of the tracks  14 ,  16 ,  18 , and  20 , and by attaching the tracks  14 ,  16 ,  18 , and  20  to the back wall  2 . Particularly, the installer attaches the stationary flat spine  32  of each of the tracks  14 ,  16 ,  18 , and  20  to the back wall  2  by nailing, screws, adhesive, or other suitable attachment means. The tracks  14 ,  16 ,  18 , and  20  are oriented so that the opening  44  ( FIG. 5 ) of each of the tracks faces outwardly from the center of the frame  12 . Consequently, for adjacent fabric panels  10   a  and  10   b , the opening of the track  14  of fabric panel  10   b  and the opening of the track  18  of fabric panel  10   a  are oriented as shown in  FIGS. 4 and 5 . 
     Once each of the tracks are attached to the back wall  2 , the movable jaw  30  is locked in the open position by means of the opening lock  46 . After the movable jaw  30  is locked in the open position, the covering of the double-sided tape  57  is removed, and the fabric  22  is positioned over the double-sided tape  57  of the movable front return  56  of the movable jaw  30  as shown in  FIG. 4 . As of the movable jaw  30  pivots about the hinge  28  to the close position shown in  FIG. 5 , the double-sided tape  57  grips the fabric  22  and stretches the fabric  22 . Once movable jaw  30  is moved to the closed position, the back closing lock  48  and the front closing lock  50  engage the fabric  22  and simultaneously grip the fabric  22  and lock the movable jaw  30  in the closed position. As previously stated, the movable front return  56  and the stationary front return  37  are dimensioned so that the fabric access opening  44  is created to allow for thick fabric. Further, the movable front return  56  is flexible and offset from the front closing lock  50  so that the movable front return  56  can flex in response to the tension in the fabric  22  without compromising the security of the front closing lock  50 . 
     In order to replace the fabric  22  in the fabric panel  10 , the movable jaw  30  is disengaged from the stationary jaw  26  by prying the movable jaw  30  away from the stationary jaw  26  so that the front closing lock  50  and the back closing lock  48  disengage. Once the movable jaw  30  has pivoted away from the stationary jaw  26 , the movable jaw  30  is locked in the open position by means of the opening lock  46 . The old fabric  22  is removed and new fabric  22  is installed as previously described. 
     A second embodiment of the present invention is shown in  FIGS. 6-9 . The linear frame member or track  118  is shown in perspective  FIGS. 6 and 7 . Adjacent tracks  114  and  118  are shown in cross-section in  FIGS. 8 and 9 . Each of the tracks  114  and  118 , for example, comprises a stationary jaw  126  and a movable jaw  130  connected by a flexible and stretchable hinge  128 . The flexible and stretchable hinge  128  is formed of the melt processable rubber identified above, and the rest of the track is formed of the high impact polyvinyl chloride identified above.  FIGS. 6 and 8  show the tracks  114  and  118  with the movable jaw  130  in an open position, and  FIGS. 7 and 9  show the tracks  114  and  118  with the movable jaw  130  in a closed position. In the open position, the movable jaw  130  is held open by an opening lock  146 . In the closed position, the movable jaw  130  is held closed by a back closing lock  148  and a front closing lock  150 . While the embodiment shown in  FIGS. 6-9  shows a back closing lock  148  and a front closing lock  150 , the back closing lock  148  could be eliminated leaving only the front closing lock  150 . 
     With continuing reference to  FIGS. 6-9 , the stationary jaw  126  comprises a stationary flat spine  132 , a stationary back return  134  with a stationary back return hook  135 , and a stationary front return  137 . The stationary back return hook  135  forms one half of the opening lock  146 . The stationary jaw  126  also includes a stationary hinge connector  136  protruding outwardly from the stationary flat spine  132  for attachment to the flexible and stretchable hinge  128 . The stationary jaw  126  further includes a stationary back lock stub  138  protruding outwardly from the stationary flat spine  132  and having a stationary back lock stub hook  139 . The stationary back lock stub hook  139  forms one half of the back closing lock  148 . In addition, stationary jaw  126  has a stationary front lock stub  140  protruding outwardly from the stationary flat spine  132  and having a stationary front lock stub hook  141 . The stationary front lock stub hook  141  forms one half of the front closing lock  150 . As best shown in  FIGS. 8 and 9 , the stationary flat spine  132  of the stationary jaw  126  is attached to the back wall  2  by any suitable means including adhesive, cross nailing, screws, or other suitable fastening means. 
     With continuing reference to  FIGS. 6-9 , the movable jaw  130  comprises a movable flat spine  152 , a movable back end  154  with a movable back end hook  155 , and a movable front return  156  comprising a first segment  164  and a second segment  166 . The movable back end hook  155  forms one half of the opening lock  146 . The movable jaw  130  also includes a movable hinge connector  162  protruding outwardly from the movable flat spine  152  for attachment to the flexible and stretchable hinge  128 . The movable jaw  130  further includes a movable back lock stub  158  protruding outwardly from the movable flat spine  152  and having a movable back lock stub hook  159 . The movable back lock stub hook  159  forms one half of the back closing lock  148 . In addition, the movable jaw  130  has a movable front lock stub  160  protruding outwardly from the movable flat spine  152  and having a movable front lock stub hook  161 . The movable front lock stub hook  161  forms one half of the front closing lock  150 . A strip of double-sided tape  157  is attached to the outside of the second segment  166  of movable front return  156  along its length. 
     The stationary back return hook  135  and the movable back end hook  155  together form the opening lock  146 , which, as shown in  FIGS. 6 and 8 , holds the movable jaw  130  in the open position. The stationary back lock stub hook  139  and the movable back lock stub hook  159  together form the back closing lock  148 , which, as shown in  FIGS. 7 and 9 , holds the movable jaw  130  in the closed position. The stationary front lock stub hook  141  and the movable front lock stub hook  161  together form the front closing lock  150 , which, as shown in  FIGS. 7 and 9 , also holds the movable jaw  130  in the closed position. 
     As previously noted, the tracks  114 ,  116 ,  118 , and  120  are formed by extruding the high impact premium unplasticized polyvinylcloride and the melt processable rubber. During the elevated temperature extrusion process, the flexible and stretchable hinge  128 , formed of melt processable rubber identified above, is extruded in contact with the stationary hinge connector  136  and the movable hinge connector  162 , formed of the high impact premium unplasticized polyvinylcloride. As the flexible and stretchable hinge  128  and the hinge connectors  136  and  162  cool, a bond is formed thereby creating the flexible and stretchable hinge  128  between the movable jaw  130  and the stationary jaw  126 . Not only is the flexible and stretchable hinge  128  flexible in terms of allowing the stationary jaw  126  and the movable jaw  30  to pivot with respect to each other, the flexible and stretchable hinge  128  also allows for stretching to enable the stationary back return hook  135  and the movable back end hook  155  to engage to lock the movable jaw  130  in the open position and disengage to unlock the movable jaw  30  in order for the movable jaw  30  to pivot to the closed position. 
     As is apparent from the description above, the only difference between the first embodiment and the second embodiment is the construction of the movable front return  156  of the second embodiment. As described above, the movable front return  156  comprises a first segment  164  that attaches to the movable flat spine  152  at an obtuse angle. The second segment  166  is connected to the opposite end of the first segment  164  at an obtuse angle so that the angle between an extension of the second segment  166  and an extension of the movable flat spine  152  forms an acute angle. Consequently, the movable front return  156  still provides the flexibility and offset from the front closing lock  150  necessary to ensure the integrity of the front closing lock  150  when tension is applied to the movable front return  156  by the fabric  22 . 
     While this invention has been described with reference to preferred embodiments thereof, it is to be understood that variations and modifications can be affected within the spirit and scope of the invention as described herein and as described in the appended claims.