IP Library Granted Patent US 7,805,899
Granted Patent B2
US 7,805,899 · App. 12/422,943 · Granted Oct 5, 2010

High impact, moisture resistant wall panel system

Assignee: Environmental Interiors, Inc.
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Quick Facts
Patent No.
US 7,805,899
App. No.
12/422,943
Granted
Oct 5, 2010
Kind
B2
Abstract

A high impact, moisture resistant, wall panel system and methods for mounting a high impact, moisture resistant wall panel to an existing structure are disclosed herein. A high impact, moisture resistant wall panel includes an inert substrate composed of a high density inorganic material, wherein the substrate is dimensionally stable, a laminate composed of a substantially rigid polymeric material, and an adhesive for engaging the laminate to the substrate.

Claims (54)

1. A wall comprising:

a structure including a first mounting, the first mounting having a base secured to the structure and a hook;

a plurality of high impact panels, the plurality of panels including a first panel adjacent to second, third and fourth panels on three respective sides, each panel including:

an inert substrate composed of a high density, dimensionally stable inorganic material;

a laminate composed of substantially rigid polymeric material, wherein the laminate provides a finished surface and wherein the laminate encapsulates a plurality of side surfaces of the substrate;

an adhesive to secure the laminate to the substrate, and

a second mounting for mating with the first mounting, the second mounting having a base secured to the substrate and a hook for removably engaging with the hook of the first mounting secured to the structure; and

a space between side surfaces of the first, second, third and fourth adjacent panels to form a reveal between adjacent panels, and wherein each panel may be individually mounted and individually removed without moving the second, third and fourth adjacent panels;

wherein disengaging the second mounting from the first mounting permits each of the plurality of panels to be individually removed without removing adjacent panels;

wherein engaging the second mounting to the first mounting permits each of the plurality of panels to be individually replaced without removing adjacent panels; and

wherein the plurality of panels are securely mounted adjacent to each other in a horizontal and vertical relationship on the structure thereby to form a wall with the finished surface exposed.

2. The wall of claim 1 wherein each panel is removable by disengaging the hook of the first mounting from the hook of the second mounting.

3. The wall of claim 1 wherein the structure further includes a third mounting, the third mounting having a base secured to the structure and a hook; and wherein each panel further includes a fourth mounting for mating with the third mounting, the fourth mounting having a base secured to the substrate and a hook for removably engaging with the hook of the third mounting secured to the structure; and wherein the base of the second mounting is secured towards a top of each panel and wherein the base of the fourth mounting is secured towards a bottom of each panel.

4. The wall of claim 3 wherein each panel is solely mounted to the structure by the engagement of the hook of the first mounting with the hook of the second mounting and the engagement of the hook of the third mounting with the hook of the fourth mounting and wherein the structure is without external framing elements about an edge of each panel.

5. The wall of claim 1 wherein the panel is fire resistant without requiring at least one fire retardant.

6. The wall of claim 1 wherein the panel is moisture resistant without requiring an additional protective coating, layer or vapor barrier.

7. The wall of claim 1 wherein each panel further includes:

a side edge of the laminate, wherein the side edge is substantially perpendicular to a front face of the laminate; and

a beveled interface between the side edge and the front face, wherein the beveled interface includes a beveled edge of the substrate that underlies a beveled edge of the laminate and wherein the laminate encapsulates all side surfaces of the substrate.

8. The wall of claim 1 wherein the laminate seamlessly and contiguously covers and bonds with a front face and a plurality of side edges of the substrate.

9. The wall of claim 1 wherein the substrate is moisture resistant, fire resistant and is dimensionally stable in response to changes in temperature and humidity.

10. A wall comprising:

a structure including a first mounting, the first mounting having a base secured to the structure and a hook;

a plurality of high impact panels, the plurality of panels including a first panel adjacent to second, third and fourth panels on three respective sides, each panel including:

an inert substrate composed of a high density inorganic material, wherein the inorganic material is moisture resistant without requiring an additional protective coating, layer or vapor barrier, is fire resistant and is dimensionally stable in response to changes in temperature and humidity;

a laminate composed of substantially rigid polymeric material, wherein the laminate provides a finished surface and wherein the laminate encapsulates a plurality of side surfaces of the substrate;

an adhesive to secure the laminate to the substrate, and

a second mounting for mating with the first mounting, the second mounting having a base secured to the substrate and a hook for removably engaging with the hook of the first mounting secured to the structure; and

a space between side surfaces of the first, second, third and fourth adjacent panels to form a reveal between adjacent panels, and wherein each panel may be individually mounted and individually removed without moving the second, third and fourth adjacent panels;

wherein disengaging the second mounting from the first mounting permits each of the plurality of panels to be individually removed without removing adjacent panels;

wherein engaging the second mounting to the first mounting permits each of the plurality of panels to be individually replaced without removing adjacent panels; and

wherein a wall with the finished surface exposed is assembled by securely mounting the plurality of panels adjacent to each other in a horizontal and vertical relationship on the structure and wherein the wall can be disassembled by removing at least one panel of the plurality of panels from the structure.

11. The wall of claim 10 wherein each panel can be disassembled by disengaging the hook of the first mounting from the hook of the second mounting.

12. The wall of claim 10 wherein each panel further includes:

a side edge of the laminate, wherein the side edge is substantially perpendicular to a front face of the laminate; and

a beveled interface between the side edge and the front face, wherein the beveled interface includes a beveled edge of the substrate that underlies a beveled edge of the laminate and wherein the laminate encapsulates all side surfaces of the substrate.

13. The wall of claim 10 wherein the structure further includes a third mounting, the third mounting having a base secured to the structure and a hook; and wherein each panel further includes a fourth mounting, for mating with the third mounting, the fourth mounting having a base secured to the substrate and a hook for removably engaging with the hook of the third mounting secured to the structure; and wherein the base of the second mounting is secured towards a top of each panel and wherein the base of the fourth mounting is secured towards a bottom of each panel.

14. The wall of claim 13 wherein each panel is solely mounted to the structure by the engagement of the hook of the first mounting with the hook of the second mounting, and the engagement of the hook of the third mounting with the hook of the fourth mounting.

15. The wall of claim 1 wherein a vacuum forming process is used to bond the laminate to the substrate.

16. The wall of claim 10 wherein a vacuum forming process is used to bond the laminate to the substrate.

17. A wall comprising:

a structure including a first mounting, the first mounting having a base secured to the structure and a hook;

a plurality of high impact panels, the plurality of panels including a first panel between a second and third panel, the first, second and third panels being vertically aligned, each panel including:

an inert substrate composed of a high density, dimensionally stable inorganic material;

a laminate composed of substantially rigid polymeric material, wherein the laminate provides a finished surface and wherein the laminate encapsulates a plurality of side surfaces of the substrate;

an adhesive to secure the laminate to the substrate, and

a second mounting for mating with the first mounting, the second mounting having a base secured to the substrate and a hook for removably engaging with the hook of the first mounting secured to the structure; and

a space between side surfaces of the first, second, third and fourth adjacent panels to form a reveal between adjacent panels, and wherein each panel may be individually mounted and individually removed without moving the second, third and fourth adjacent panels; and

wherein disengaging the second mounting from the first mounting permits each of the plurality of panels to be individually removed without removing adjacent panels;

wherein engaging the second mounting to the first mounting permits each of the plurality of panels to be individually replaced without removing adjacent panels; and

wherein the plurality of panels are securely mounted adjacent to each other in a horizontal and vertical relationship on the structure thereby to form a wall with the finished surface exposed.

18. The wall of claim 1 further comprising a reveal behind each space between panels and wherein the reveal extends across each space such that the reveal blocks view of the structure.

19. The wall of claim 10 further comprising a reveal behind each space between panels and wherein the reveal extends across each space such that the reveal blocks view of the structure.

20. The wall of claim 17 further comprising a reveal behind each space between panels and wherein the reveal extends across each space such that the reveal blocks view of the structure.

Assignments (4)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 10, 2016
From: ENVIRONMENTAL INTERIORS, INC.
To: G.C. SAGE, INC.
Reel/Frame 039978/0506 →
MERGER Recorded Oct 10, 2016
From: G.C. SAGE, INC.
To: CH HOLDINGS USA, INC.
Reel/Frame 039978/0556 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 10, 2016
From: CH HOLDINGS USA, INC.
To: ENCLOS CORPORATION
Reel/Frame 039978/0602 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 25, 2009
From: MONTGOMERY, JOHN C.
To: ENVIRONMENTAL INTERIORS, INC.
Reel/Frame 022595/0955 →
Continuity (2)
Continuation 1214495500 · Jun 24, 2008
Related Publication 20090313932A1 · Dec 24, 2009