Patent Document

CROSS-REFERENCE TO RELATED PROVISIONAL APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 60/071,308 filed on Jan. 13, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention is directed generally to a wall panel mounting system and method and, in particular, to a mounting system used to support preformed wall panels on a wall surface using a novel construction, system and method. 
     Various systems for covering walls are known. In addition to regular wallpaper applied with adhesive application, various types of fabric wall coverings are also known as wall fabrics and are directly adhered either to the wall surface or on brackets or clips applied to the wall. It is also known to provide upholstered wall panels which attach to the walls by various means such as screws, bolts or clips, for example, Z-clips. Typical wall panel systems are described, for example, in U.S. Pat. Nos. 4,449,346 to Tremblay, and 2,182,523 to Markowski. 
     While such wall panel systems provide a decorative and pleasing wall appearance, it has proven difficult to both attach the panels to the wall surface, and to remove the panels after installation for cleaning, replacement or the like. Accordingly, the present invention has been developed to improve over such prior art systems while allowing for neat fabrication, easy installation, and appropriate easy removal of the wall panels after installation. 
     SUMMARY OF THE INVENTION 
     Generally speaking, in accordance with the present invention, a wall panel mounting system for releasably securing a preformed wall panel to a wall, is provided. The system includes a bracket including a base portion adapted to be attached to the wall having at least one leg extending outwardly from the base portion. The wall panel includes a frame having a front surface supporting a fabric thereon. The frame includes a rear wall having a recessed slot therein adapted to receive the at least one leg therein. The recessed slot is defined by opposing walls. The at least one leg and opposing walls have an interfering engagement to releasably hold the wall panel in place on the wall. 
     In a preferred embodiment, the frame is rectangular and a suitable wall panel fabric is stretched therearound. The bracket is elongated and attached to the wall in a vertical direction, with the recessed slot in the frame extending in a vertical direction to mate with the at least one leg. 
     Accordingly, it is an object of the present invention to provide an improved wall panel mounting system and method. 
     Another object of the present invention is to provide a wall panel mounting system and method which allows easy installation and appropriate easy removal of the wall panels after installation. 
     A still further object of the present invention is to provide a wall panel mounting system and method which provides a neat and clean appearance to walls on which the system and method of the present invention are used to install wall panels. 
     Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification. 
     The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the system embodying features of construction, combination of elements and arrangement of parts which are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which: 
     FIG. 1 is a perspective view of a wall showing adjacent wall panels mounted thereon using the system and method of the present invention; 
     FIG. 2 is an enlarged sectional view taken along line  2 — 2  of FIG. 1; 
     FIG. 3 is an enlarged sectional view taken along the sectional line  3  depicted in FIG. 1 showing the manner in which corners of the wall panel frame are joined together; and 
     FIG. 4 is an enlarged sectional view taken along line  4 — 4  of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Generally speaking, the present invention includes, as described in more detail below and depicted in the accompanying figures, a U-shaped fastener formed preferably from a thermoplastic material which is attached to a wall surface using an appropriate adhesive such as glue, or screws or other such fastening means. Each wall panel assembly includes a frame with slots which receive the legs of the U-shaped fastener to hold the wall panels on the wall. 
     FIG. 1 of the drawings depicts two wall panels  10  and  50  shown edge to edge supported on a wall  12 . Looking more particularly at FIG. 2, it is noted that wall panels  10  and  50  are similarly constructed, so only wall panel  10  will be described in detail. 
     Wall panel  10  is formed from four lengths of an extruded aluminum material to form a frame  20 . The four lengths of extruded aluminum of frame  20  are each an elongated strip of aluminum formed with the cross-section shown in FIG.  2 . Frame  20  includes a front surface  22  having a raised flange or projection  24  on the outer edge thereof. Frame  20  also includes a side wall  26  and a rear wall  28 . A generally square opening  30  is provided in frame  20  which is adapted to receive a panel rail connector  70  (FIG. 3) as will be described below in further detail. 
     An opposing wall  34  of frame  20  includes two extending fingers  36  and  38  which define a channel  37  for receiving a fill material  54  as will be described below. Frame  20  also includes a recessed slot  40  having opposing walls  40   a  and  40   b  with a high friction surface or other attaching means such as serrations, grooves or the like therealong. 
     A U-shaped wall bracket  80  is preferably formed from a thermoplastic material and includes a base  82  having two upstanding legs  84  and  86 . The opposing surfaces of legs  84  and  86  have a softer plastic or rubber-like material formed or applied thereon, preferably through co-extrusion or the like. Accordingly, the opposing surfaces of each of legs  84  and  86  will be strongly but releasably captured in slot  40 . 
     In order to form a full wall panel, such as rectangular wall panels  10  or  50  depicted in FIG. 1, four appropriate lengths (two vertical and two horizontal) of extruded aluminum to form frame  20  are provided. Each end of each of the four frame sections are cut at a 45° angle to allow the frame pieces to be joined edge to edge to form a rectangular frame, much like the edges of a picture frame are joined. The L-shaped panel rail connector  70  shown in FIG. 3 is used to join adjacent frame sections  20  and  20   a  together. Legs  70   a  and  70   b  of panel rail connector  70  are received respectively in a corresponding opening  30  in adjacent frame sections  20  and  20   a . The corners of frames  20  and  20   a  can then be staked to hold the frame edges together. 
     Because panel rail connector  70  and opening  30  are generally square in cross-section, the panel rail connector can be inserted in various orientations to allow for inside and outside comers, irregular surfaces and shapes, and the like. 
     Frame  20  is preferably formed around a relatively rigid fill material  54  such as duct board with a foil backing  55  which is properly cut to size. Fill material  54  can also form a tackable surface such as the Micore® product from U.S. Gypsum (non-hydroscopic), or wood or wood grounds can be placed in strategic locations on the panels to allow pictures or the like to be supported on the wall panels. Alternatively, the fill can be customized for particular client needs involving acoustics, hanging of various items, or the like. It is preferred that the fill material be essentially impervious to air transmission to prevent air from circulating through the panels to dirty or soil the fabric. 
     After the four frame sections are joined together using the panel rail connectors  70  and fill material is encased thereby, a desired fabric or other material  60  is glued or otherwise adhered thereon in the manner indicated by stretching over the front surface  22  of frame  20 , along the side  26  and partially around the back  28  using glue, other adhesive or the like to hold the fabric thereon. Flange or projection  24  raises fabric  60  off of the surface of fill material  54  and front surface  22  of bracket  20  to give a neat, clean appearance and to hide imperfections. Any type of fabric or other material suitable for wall coverings may be used. As used herein, fabric refers to any suitable material supported on the front surface of the frame. 
     Installation of the wall panels usually starts at the edge of the wall, either at an inside or outside corner or edge. FIG. 4 of the drawings shows such an outside corner installation, for example. Starting at the edge  102  of wall  100 , one leg  186  of a bracket  180  is utilized. In this regard, U-shaped plastic bracket  80  can be pre-scored along the backwall thereof to allow the component to be broken into two separate L-shaped components when desired for use, for example, as depicted in FIG.  4 . 
     Leg  182  of bracket  180  is secured to wall  100  using appropriate fastening means such as an adhesive, glue, screws or the like. Bracket  180  is supported on wall  100  in a vertical fashion so that the panel ( 10  or  50 ) can be properly adjusted vertically with respect to the ceiling and floor. Horizontal brackets are not needed or desirable. Slot  40  of frame  20  is positioned over leg  186  and is then pressed thereon. Serrations on the inside walls forming slot  40  interfere with serrations formed on leg  186  to interlock the panel thereon to hold the panel in the desired orientation and alignment on the wall. 
     Next, a U-shaped bracket  80  is supported vertically on the wall in alignment with the vertical slot on the other side of the wall panel, and the second leg of the U-shaped bracket can be used to hold one edge of the next panel tightly adjacent thereto as best depicted in FIG.  2 . In this regard, it is noted that side wall  26  of each frame section includes about a 1° to 1 ½° relief to cause the outer edges of the panels to abut against one another as depicted. This feature is also provided to allow for imperfections on the wall surface or for manufacturing tolerances. 
     Installation continues as described above until the entire wall surface or room is appropriately covered with wall panels. The system, construction and method of the present invention allows for quick and efficient field installation. 
     While the combined bracket and panel system of the present invention provides a tight hold of the panels to the wall, the system also allows removal of the panels for any desired reason or purpose. The top or bottom of the panel can be appropriately grabbed by hand or a pry tool used to pull the panel away from the wall thereby releasing the interfering serrations or other gripping means of the bracket legs and slot walls. In this fashion, panels can be replaced, repaired, cleaned or the like. 
     It is noted that the serrations in the slot should preferably not match the serrations on the bracket. Thus, for example, in slot  40 , there might be six (6) serrations per inch, while on bracket leg  84  there might be five (5) serrations per inch. The bracket itself is preferably co-extruded from plastic material having two different durometers. The base portion of the bracket is preferably formed from hard plastic material such as PVC having a durometer of 100, whereas the opposing inner and outer surfaces of the legs of the U-shaped bracket are co-extruded with a PVC material having a durometer of 75 to 80 for example. The plastic formation of the bracket gives it the rigid flexibility and resiliency to help abut the front edges of adjacent panels together. 
     The corner braces or rail panel connectors  70  are preferably formed of a high tension polymer such as ABS. 
     The present construction, using, for example, a fill with foil backing, essentially prevents air from flowing through the panels, thereby cutting down on dirt or dust flow therethrough. In addition, because the bracket covers air flow through the seams between panels, an essentially total barrier is provided. 
     The detailed description herein is not meant to be limited to the specific embodiments or figures described. There are many appropriate variations that will accomplish the intent of the invention and be within the spirit and scope of the invention as will be recognized by those skilled in the art. 
     It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above method and in the system set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense 
     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Technology Category: e