US20070283656A1 - Fabric Wall Panel System and Track - Google Patents

Fabric Wall Panel System and Track Download PDF

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Publication number
US20070283656A1
US20070283656A1 US11/423,543 US42354306A US2007283656A1 US 20070283656 A1 US20070283656 A1 US 20070283656A1 US 42354306 A US42354306 A US 42354306A US 2007283656 A1 US2007283656 A1 US 2007283656A1
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United States
Prior art keywords
fabric
web
movable jaw
wall
movable
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Abandoned
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US11/423,543
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Andy W. Anderson
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Individual
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Individual
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Priority to US11/423,543 priority Critical patent/US20070283656A1/en
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/30Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by edge details of the ceiling; e.g. securing to an adjacent wall
    • E04B9/303Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by edge details of the ceiling; e.g. securing to an adjacent wall for flexible tensioned membranes
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/002Coverings or linings, e.g. for walls or ceilings made of webs, e.g. of fabrics, or wallpaper, used as coverings or linings
    • E04F13/005Stretched foil- or web-like elements attached with edge gripping devices
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F19/00Other details of constructional parts for finishing work on buildings
    • E04F19/02Borders; Finishing strips, e.g. beadings; Light coves
    • E04F19/06Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements
    • E04F19/061Borders; Finishing strips, e.g. beadings; Light coves specially designed for securing panels or masking the edges of wall- or floor-covering elements used to finish off an edge or corner of a wall or floor covering area
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/74Removable non-load-bearing partitions; Partitions with a free upper edge
    • E04B2002/7479Details of connection of flexible sheets to frame or posts
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E04B9/04Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
    • E04B2009/0492Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like with fabrics tensioned on frames

Definitions

  • This invention relates to a fabric wall panel system for use in decorating, and more particularly, relates to a fabric wall panel system and track system wherein fabric wall panels can be assembled and then mounted on a wall as a completed panel or the fabric wall panels can be assembled in place on the wall.
  • 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.
  • 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, which 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 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.
  • fabric wall panels can be prefabricated off of the wall.
  • One method for installing prefabricated fabric wall panels employs a cross-nailing system as disclosed by the patent to Anderson, U.S. Pat. No. 4,731,972.
  • the fabric wall panels disclosed in the Anderson patent are prefabricated and then installed by driving two headless pin nails at an angle in a crossed fashion through the frame pieces of the prefabricated panels. The crossed nails penetrate completely through the fabric, partially penetrate the frame, and securely fasten the 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 panels, or remove the panels entirely.
  • 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 fabric wall panel is fabricated and then is affixed to the wall by pressing the slit over the tongue on the hanger.
  • the fabric wall panels can be prefabricated in standard sizes or custom fabricated on site. The fabric wall panels can also be independently replaced or removed entirely by unsnapping the fabric wall panel from the supporting hangers.
  • the present invention satisfies the above-described needs with a fabric wall panel system and method for installing fabric wall panels on a wall.
  • 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.
  • the frame of the fabric panel comprises a plurality of linear frame members.
  • Each linear frame member has a flat spine, a hanger engaging channel, and a fabric clamp.
  • the fabric clamp comprises a fixed jaw and a movable jaw.
  • the fixed jaw includes a back web connected to the spine of the linear frame member, an extending the web connected to the back web, and a fixed jaw lip connected to the extending web.
  • the movable jaw includes a flexible joint connected to the spine of the frame member, a movable web connected to the flexible joint, a return web connected to the movable web, and a movable jaw hook connected to the return web. The movable web pivots about the flexible joint allowing the movable jaw hook to engage and disengaged the fixed jaw lip.
  • the hanger comprises a flat base with two forked tongues extend outwardly from the wall.
  • the base of the hanger is affixed to the wall with an adhesive or other suitable fastening means, and the forked tongues project outward from the wall.
  • Each forked tongue has two forks that diverge from each other as they extend away from the flat base.
  • Each fork has a cam surface and a latch surface.
  • the material of the hanger is resilient so that the forks can be pressed together at their outward ends.
  • the latch surfaces of the forks engage the protrusions within the hollow hanger engaging channel to hold the linear frame member securely to the hanger and thus to the wall.
  • the fabric wall panels can be removed from the hangers by prying the linear frame away from the hanger to disengage the latch surfaces of the forks from the protrusions within the hanger engaging channel of the linear frame member.
  • the fabric wall panel of the present invention can be assembled either on the wall or assembled separately.
  • the completed fabric wall panel can be attached to the wall by engaging the hanger engaging channel on the linear frame member with the forked tongue on the hanger.
  • the fabric can be replaced with the frame of the fabric wall panel still attached to the wall or the fabric wall panel can be removed from wall, and the new fabric installed separately on the fabric wall panel.
  • the fabric wall panels variously have a straight profile, a beveled profile, or a chamfered profile.
  • FIG. 1 is a perspective view of a room having walls covered with a fabric wall panel system in accordance with the present invention.
  • FIG. 2 is a perspective view of a linear frame member and hanger in which the linear frame member includes a fabric clamp with jaws in an open position in accordance with the present invention.
  • FIG. 3 is a perspective view of a linear frame member and hanger in which the linear frame member includes a fabric clamp with jaws in a closed position in accordance with the present invention.
  • FIG. 4 is a side elevation view of a corner joint (separated to illustrate internal detail) between two linear frame members at a corner of a fabric wall panel in accordance with the present invention.
  • FIG. 5 is a cross-section view of a fabric wall panel mounted on a wall by means of a hanger in accordance with an embodiment of the present invention as seen along line 5 - 5 in FIG. 1 .
  • FIG. 6 is a cross-section view of a fabric wall panel, similar to FIG. 5 , in the process of being mounted on a wall by means of a hanger in accordance with an embodiment of the present invention.
  • FIG. 7 is a cross-section view of an alternative embodiment of a linear frame member for creating a beveled profile for a fabric wall panel in accordance with the present invention.
  • FIG. 8 is a cross-section view of an alternative embodiment of a linear frame member for creating a chamfered profile for a fabric wall panel in accordance with the present invention.
  • the present invention is a fabric wall panel system and method for installing and replacing or recovering fabric wall panels on a wall.
  • the fabric wall panel system comprises a fabric wall panel and a hanger.
  • the hanger is attached to wall and releasably engages the fabric wall panel for easy installation and removal of the fabric wall panel.
  • the hanger and fabric wall panels are configured so that when the fabric wall panels are mounted on the wall, the hanger assures that adjacent fabric wall panels are properly aligned and that seams between adjacent wall panels are uniform and tight.
  • a wall includes existing or permanent walls, moveable walls, partitions, and the like.
  • FIG. 1 is a perspective view of a room 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 fabric wall panel 10 is connected to the walls 2 and 4 by means of a series of hangers 50 ( FIGS. 2 and 3 ).
  • 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 21 , and a flat filler insert 22 .
  • Each frame 12 is made up of four linear frame members 14 , 16 , 18 , and 20 .
  • the linear frame members 14 , 16 , 18 , and 20 are extrusions made of high impact premium unplasticized polyvinyldloride #lox, such as PLC27766 sold by Georgia Gulf Corporation of Plaquemine, La. Metal extrusions, including aluminum extrusions, may also be used for the linear frame members 14 , 16 , 18 , and 20 .
  • the linear frame member 18 is shown in perspective and comprises a flat spine 27 , an inside web 32 , a front web 30 , and an intermediate web 31 .
  • the inside web 32 is connected to and extends perpendicularly from the spine 27 .
  • the front web 30 interconnects the inside web 32 and the intermediate web 31 .
  • the inside web 32 , the front web 30 , and the intermediate web 31 form a hollow, hanger engaging channel 41 .
  • the hollow, hanger engaging channel 41 has a hanger engaging opening 40 opposite the front web 30 .
  • Protrusion 25 and 42 extend from inside web 32 into the hollow, hanger engaging channel 41 .
  • protrusion 26 and 43 extend from intermediate web 31 into the hollow, hanger engaging channel 41 .
  • the protrusions 25 , 26 , 42 , and 43 form a slot 24 that accommodates an L-shaped reinforcement bracket 29 at each corner 28 of the frame 12 ( FIG. 4 ). Also, between the corners of the frame 12 where the hangar engaging opening 40 is not obstructed by the L-shaped reinforcement bracket 29 , the protrusions 42 and 43 form part of a hanger locking mechanisms, which hanger locking mechanism holds the fabric wall panel 10 onto the wall 2 .
  • the linear frame member 18 further includes a clamp 33 for clamping the edges of the fabric 21 to the linear frame member 18 (as well as to the linear frame members 14 , 16 , and 20 ).
  • the clamp 33 comprises a fixed jaw 34 and a movable jaw 46 .
  • the fixed jaw 34 comprises a back web 35 , an extending web 36 , and a jaw lip 37 , all integrally formed.
  • the back web 35 is attached to the spine 27 via the intermediate web 31 , the front web 30 , and the inside web 32 of the linear frame member 18 .
  • the back web 35 extends essentially parallel to the back wall 2 .
  • the extending web 36 is attached to the back web 35 and extends perpendicularly away from the back wall 2 .
  • the jaw lip 37 forms one end of the extending web 36 .
  • the movable jaw 46 comprises a flexible joint 45 , a movable web 47 , a return web 48 , and a jaw hook 49 , all integrally formed.
  • the movable web 47 is attached by means of the flexible joint 45 to spine 27 via the front web 30 and the inside web 32 of the linear frame member 18 .
  • the movable web 47 extends essentially parallel to the back wall 2 .
  • the return web 48 is attached to the movable web 47 and extends toward the back wall 2 .
  • the jaw hook 49 forms one end of the return web 48 .
  • the flexible joint 45 is formed from premium plasticized polyvinyldloride #75a lox, such as PLC20675 sold by Georgia Gulf Corporation of Plaquemine, La.
  • That material allows the movable web 47 to pivot with respect to the front web 30 of the linear frame member 18 .
  • the intermediate web 31 , the back web 35 , the extending web 36 , the movable web 47 , and the return web 48 define a fabric housing 38 .
  • a piece of double backed tape or other contact adhesive 44 is installed on the outside surface of the return web 48 to secure the fabric 21 during the fabrication process of the fabric wall panel 10 .
  • FIG. 2 the clamp 33 is open.
  • the movable web 47 of the movable jaw 46 is pivoted about the flexible joint 45 and away from the wall 2 . Consequently, an opening 39 exists between the fixed jaw lip 37 of the fixed jaw 34 and the movable jaw hook 49 of the movable jaw 46 .
  • the fabric 21 is threaded through the opening 39 , and any excess is stored in the fabric housing 38 .
  • FIG. 3 shows the clamp 33 in the closed position with the fabric 21 captured between the fixed jaw lip 37 of the fixed jaw 34 and the movable jaw hook 49 of the movable jaw 46 .
  • the linear frame member 18 is positioned to be connected to the back wall 2 by means of the hanger 50 .
  • the hanger 50 includes a base 52 that is attached to the back wall 2 by means of a suitable adhesive or by mechanical means such as cross nailing or stapling.
  • the base 52 may be flat or slightly concave to assure that the base 52 lies flat against wall 2 once the hanger 50 has been attached to the wall 2 .
  • the hanger 50 includes forked tongues 54 and 55 ( FIGS. 5 and 6 ).
  • the forked tongue 54 comprises outwardly extending forks 56 and 58 .
  • the forks 56 and 58 have cam surfaces 60 and 62 and latching surfaces 64 and 66 .
  • the forks 56 and 58 are flexible so that they can deflect toward each other.
  • the flat base 52 has an index mark 70 in the shape of a V to indicate the midpoint between the forked tongues 54 and 55 .
  • the hanger 50 is an extrusion made of high impact premium unplasticized polyvinylcloride #lox, such as PLC27766 sold by Georgia Gulf Corporation of Plaquemine, La.
  • the insert 22 may consist of any number of materials to provide sound or heat insulation.
  • the insert may be an acoustical insert in the nature of a rigid board such as Owens/Corning 705 Fiberglas insulation board sold by Owens/Corning Fiberglas Corp. of Toledo, Ohio.
  • the insert may be a mineral fiber board insert such as Micore board sold by USG Acoustical Products Company of Chicago, Ill.
  • the thickness of the insert 22 is such that the insert 22 serves as a backing for the fabric 21 as shown in FIGS. 5 and FIG. 6 .
  • FIG. 4 shows details of the corner 28 formed between the linear frame members 18 and 20 .
  • the corner 28 is open to show the internal detail.
  • An L-shaped reinforcement bracket 29 engages the slot 24 formed by protrusions 25 , 26 , 42 , and 43 .
  • the L-shaped reinforcement bracket 29 and the linear frame members 18 and 20 are joined in conventional fashion, such as by gluing, by fasteners, or by welding.
  • the L-shaped reinforcement bracket 29 serves to stabilize the corner 28 after the frame 12 has been assembled off of the wall 2 and during subsequent handling and attachment of the completed frame 12 to the back wall 2 .
  • the filler insert 22 is seated against the spine 27 of the linear frame members 14 and 18 of the frame 12 .
  • the insert 22 not only provides sound or heat insulation, but it also provides rigidity to the frame 12 .
  • the prefabricated fabric wall panel 10 is completed by stretching fabric 21 over the insert 22 and frame 12 , around the movable web 47 , over the double backed tape 44 on the return web 48 , through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49 , and into the fabric housing 38 .
  • the fabric is then clamped to the linear frame members 14 , 16 , 18 , and 20 by closing the clamped 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engaged each other and securely clamped the fabric 21 .
  • the double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21 between the fixed jaw lip 37 and the movable jaw hook 49 .
  • the hanger 50 which is one of a several hangers, is mounted to the back wall 2 by means of gluing, cross nailing, or stapling.
  • a separate contact adhesive on the back of the hanger 50 may be used to secure the hanger 50 to the back wall 2 until the separately applied adhesive has fully cured.
  • each hanger 50 is positioned on the wall 2 so that the forked tongue 54 aligns with the hanger engaging opening 40 of the hollow, hanger engaging channel 41 of the linear frame member 18 of the fabric wall panel 10 a .
  • the forked tongue 55 aligns with the hanger engaging opening 40 of the hollow, hanger engaging channel 41 of the linear frame member 14 of fabric wall panel 10 b . Because the forked tongues 54 and 55 are mounted to a single hanger base 52 , their spacing is fixed. Once the hanger engaging openings 40 of the fabric wall panels 10 a and 10 b are aligned with the forked tongues 54 and 55 , the fabric wall panels 10 a and 10 b are moved toward the wall 2 .
  • the cam surfaces 60 and 62 engage the protrusions 42 and 43 inside the hollow, hanger engaging channel 41 .
  • the forks 56 and 58 are forced toward each other.
  • the cam surfaces 60 and 62 pass by the protrusions 42 and 43 so that the forks 56 and 58 spring back and the latching surfaces 64 and 66 engage the protrusions 42 and 43 as shown in FIG. 5 .
  • the latching surfaces 64 and 66 engage the protrusions 42 and 43 to hold the linear frame members 14 and 18 and thus the frame 12 and the fabric wall panel 10 in place.
  • the resilient forks 58 and 56 adjacent the marker index 70 urge the fabric wall panels 10 a and 10 b toward each other so that any spacing, at seam 87 between the fabric panels 10 a and 10 b , is minimized.
  • the return webs 48 FIG. 5
  • the flexibility of the forks 58 and 59 allow the fabric wall panel system to accommodate fabrics of different thickness and still assure that the seam 87 remains closed.
  • the index mark 70 on the hanger 50 indicates a point at which the hanger can be cut into two parts for installation of the fabric wall panel 10 next to a corner, such as corner 8 .
  • the flexible fork 58 urges the fabric panel 10 a toward the index mark 70 and thus toward and adjacent wall.
  • the fabric wall panels 10 can be fabricated directly on the wall 2 .
  • the on-the-wall installation process begins by first attaching the hangars 50 to the wall 2 in a predetermined arrangement for the fabric wall panels 10 that are to be installed. Once the hangers 50 are attached to the wall 2 , the linear frame members 14 , 16 , 18 , and 20 are attached to the hangers 50 by means of the fork tongues 54 and 55 engaging the hanger engaging openings 40 of the hollow, hanger engaging channel 41 . The attachment of the linear frame members 14 , 16 , 18 , and 20 forms frames 12 on the wall 2 . Next, the flat filler insert 22 is placed within each frame 12 and temporarily secured in place either by friction or a suitable adhesive.
  • the fabric 21 is then applied to each of the frames 12 of the fabric wall panels 10 .
  • the fabric wall panel 10 is completed by stretching the fabric 21 over the insert 22 and the frame 12 , around the movable web 47 , over the double backed tape 44 on the return web 48 , through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49 , and into the fabric housing 38 .
  • the fabric 21 is then clamped to the linear frame members 14 , 16 , 18 , and 20 by closing the clamped 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engage each other and securely clamp the fabric 21 .
  • the double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21 . Once the fabric 21 has been secured within the clamp 33 , the installation of the fabric wall panels 10 is complete.
  • the fabric wall panels 10 of the present invention offered two options. First, the fabric 21 can be replaced with the fabric wall panels 10 in place on the wall 2 . Alternatively, the fabric wall panels 10 can be removed from the wall 2 , and the fabric 21 can be replaced off of the wall 2 . In order to replace the fabric 21 while the fabric wall panels 10 are in place on a wall 2 , the movable jaw hook 49 of the movable jaw 46 is manually disengaged from the fixed jaw lip 37 of the fixed jaw 34 to thereby release of the fabric 21 from the linear frame members 14 , 16 , 18 , and 20 . The new fabric 21 is then reinstalled on the frame 12 in place on the wall 2 as previously described.
  • the fabric 21 can be replaced by a removing of the entire fabric wall panel 10 from the wall 2 .
  • Each fabric wall panel 10 is pulled off of the underlying hanger 50 .
  • the exertion of the outward force on the fabric wall panels 10 causes the latching surfaces 64 and 66 ( FIGS. 5 and 6 ) to disengage the protrusions 42 and 43 thereby releasing the fabric wall panels 10 from the wall 2 .
  • the old fabric 21 is removed from the fabric wall panel 10 by opening the clamp 33 and pulling the fabric 21 from the fabric housing 38 and through the opening 39 .
  • the old fabric 21 then is replaced on the fabric wall panel 10 by stretching the new fabric 21 over the insert 22 and frame 12 , around the movable web 47 , over the double backed tape 44 on the return web 48 , through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49 , and into the fabric housing 38 .
  • the fabric 21 is then clamped to the linear frame members 14 , 16 , 18 , and 20 by closing the clamp 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engaged each other and securely clamp the fabric 21 .
  • the double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21 .
  • the hanging process is repeated using the same hangers that were previously installed.
  • the system allows for the replacement of a thin fabric with a thick fabric and vice versa because of the flexible forks 58 and 59 urge the fabric panels 10 a and 10 b together at seam 87 .
  • FIGS. 7 and 8 disclose additional profiles for the linear frame members 14 , 16 , 18 , and 20 .
  • FIG. 7 shows a profile in which the extending web 36 is shortened so that the movable web 47 , in the closed position, is angled toward the wall 2 as compared to the orientation of the movable 47 in FIG. 5 where, in the closed position, the movable web is angled away from the wall 2 .
  • the orientation of the movable web 47 in FIG. 7 produces a fabric wall panel with beveled edges as compared to the square profile for the fabric wall panels shown in FIG. 5 .
  • FIG. 8 shows a movable web 47 with straight segments 102 and 106 connected by an angled segment 104 .
  • the movable web 47 produces a fabric wall panel with a chamfered profile.
  • the forked tongues 54 and 55 serve the same function to assure that the seams remain substantially closed, Consequently, the fabric wall panels 10 can accommodate fabrics of differing thicknesses.
  • the present invention provides an improved fabric wall panel system for installing fabric wall panels employing a snap hanger and clamping jaw to hold the fabric.
  • the removal and replacement process is less complicated. Therefore, the preferred embodiment of the present invention allows for easy installation and removal of fabric wall panels.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Finishing Walls (AREA)

Abstract

A fabric wall panel system includes wall panels mounted on a wall by means of a releasable hanger. Each fabric wall panel comprises a frame and a flat filler insert covered by a fabric. Each frame member has hanger engaging channel and a fabric clamp. The hanger has a flat base affixed to the wall with two forked tongues extend perpendicularly therefrom. The forked tongues engage the hanger engaging channels to hold the fabric wall panel to the wall. The fabric clamp allows the fabric to be installed or removed with the frame mounted on the wall.

Description

    FIELD OF THE INVENTION
  • This invention relates to a fabric wall panel system for use in decorating, and more particularly, relates to a fabric wall panel system and track system wherein fabric wall panels can be assembled and then mounted on a wall as a completed panel or the fabric wall panels can be assembled in place on the wall.
  • 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, which 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 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 Baslow patent does not disclose a method of fabric wall panel off wall prefabrication or removable attachment. The uniformity of installation depends on the skill of the installer in terms of aligning the framework and 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 prefabricated fabric wall panels employs a cross-nailing system as disclosed by the patent to Anderson, U.S. Pat. No. 4,731,972. The fabric wall panels disclosed in the Anderson patent are prefabricated and then installed by driving two headless pin nails at an angle in a crossed fashion through the frame pieces of the prefabricated panels. The crossed nails penetrate completely through the fabric, partially penetrate the frame, and securely fasten the 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 panels, or remove the panels entirely.
  • One successful removable wall panel system is disclosed in Anderson U.S. Pat. No. 5,715,638. In that patent, the fabric wall panels are 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 fabric wall panel is fabricated and then is affixed to the wall by pressing the slit over the tongue on the hanger. The fabric wall panels can be prefabricated in standard sizes or custom fabricated on site. The fabric wall panels can also be independently replaced or removed entirely by unsnapping the fabric wall panel from the supporting hangers.
  • Another successful removable wall panel system is disclosed in Anderson U.S. Pat. No. 6,574,936. That patent discloses fabric wall panels comprising a frame constructed of frame members. Wall hangars are affixed to the walls. The fabric wall panels are separately constructed. The frame members engage the wall hangers to allow easy attachment and removal of the completed fabric wall panels from the walls.
  • 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. Consequently, the panels are assembled on the wall.
  • The prior art has thus failed to disclose a fabric wall panel system in which the installer has the option of assembling the fabric wall panels separately or assembling the fabric wall panels on the walls.
  • SUMMARY OF THE INVENTION
  • The present invention satisfies the above-described needs with a fabric wall panel system and method for installing fabric wall panels on a wall. 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.
  • The frame of the fabric panel comprises a plurality of linear frame members. Each linear frame member has a flat spine, a hanger engaging channel, and a fabric clamp. The fabric clamp comprises a fixed jaw and a movable jaw. The fixed jaw includes a back web connected to the spine of the linear frame member, an extending the web connected to the back web, and a fixed jaw lip connected to the extending web. The movable jaw includes a flexible joint connected to the spine of the frame member, a movable web connected to the flexible joint, a return web connected to the movable web, and a movable jaw hook connected to the return web. The movable web pivots about the flexible joint allowing the movable jaw hook to engage and disengaged the fixed jaw lip.
  • The hanger comprises a flat base with two forked tongues extend outwardly from the wall. The base of the hanger is affixed to the wall with an adhesive or other suitable fastening means, and the forked tongues project outward from the wall. Each forked tongue has two forks that diverge from each other as they extend away from the flat base. Each fork has a cam surface and a latch surface. The material of the hanger is resilient so that the forks can be pressed together at their outward ends. When the fabric wall panel is mounted to the wall, the forked tongues of the hanger are aligned with and forced into the opening of the hollow, hanger engaging channel of the linear frame member. The cam surfaces of the forks engage the protrusions within the hanger engaging channel of the frame members. When the linear frame member is fully seated onto the flat base of the hanger, the latch surfaces of the forks engage the protrusions within the hollow hanger engaging channel to hold the linear frame member securely to the hanger and thus to the wall. The fabric wall panels can be removed from the hangers by prying the linear frame away from the hanger to disengage the latch surfaces of the forks from the protrusions within the hanger engaging channel of the linear frame member.
  • Because the linear frame member has the fabric clamp, the fabric wall panel of the present invention can be assembled either on the wall or assembled separately. When assembled separately, the completed fabric wall panel can be attached to the wall by engaging the hanger engaging channel on the linear frame member with the forked tongue on the hanger. Similarly, when the fabric needs replacing, the fabric can be replaced with the frame of the fabric wall panel still attached to the wall or the fabric wall panel can be removed from wall, and the new fabric installed separately on the fabric wall panel.
  • In the several embodiments of present invention, the fabric wall panels variously have a straight profile, a beveled profile, or a chamfered profile.
  • 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 fabric wall panel system in accordance with the present invention.
  • FIG. 2 is a perspective view of a linear frame member and hanger in which the linear frame member includes a fabric clamp with jaws in an open position in accordance with the present invention.
  • FIG. 3 is a perspective view of a linear frame member and hanger in which the linear frame member includes a fabric clamp with jaws in a closed position in accordance with the present invention.
  • FIG. 4 is a side elevation view of a corner joint (separated to illustrate internal detail) between two linear frame members at a corner of a fabric wall panel in accordance with the present invention.
  • FIG. 5 is a cross-section view of a fabric wall panel mounted on a wall by means of a hanger in accordance with an embodiment of the present invention as seen along line 5-5 in FIG. 1.
  • FIG. 6 is a cross-section view of a fabric wall panel, similar to FIG. 5, in the process of being mounted on a wall by means of a hanger in accordance with an embodiment of the present invention.
  • FIG. 7 is a cross-section view of an alternative embodiment of a linear frame member for creating a beveled profile for a fabric wall panel in accordance with the present invention.
  • FIG. 8 is a cross-section view of an alternative embodiment of a linear frame member for creating a chamfered profile for a fabric wall panel in accordance with the present invention.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
  • The present invention is a fabric wall panel system and method for installing and replacing or recovering fabric wall panels on a wall. The fabric wall panel system comprises a fabric wall panel and a hanger. The hanger is attached to wall and releasably engages the fabric wall panel for easy installation and removal of the fabric wall panel. The hanger and fabric wall panels are configured so that when the fabric wall panels are mounted on the wall, the hanger assures that adjacent fabric wall panels are properly aligned and that seams between adjacent wall panels are uniform and tight.
  • 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 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 fabric wall panel 10 is connected to the walls 2 and 4 by means of a series of hangers 50 (FIGS. 2 and 3).
  • 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 21, and a flat filler insert 22. Each frame 12 is made up of four linear frame members 14, 16, 18, and 20. The linear frame members 14, 16, 18, and 20 are extrusions made of high impact premium unplasticized polyvinyldloride #lox, such as PLC27766 sold by Georgia Gulf Corporation of Plaquemine, La. Metal extrusions, including aluminum extrusions, may also be used for the linear frame members 14, 16, 18, and 20.
  • Referring now to FIGS. 2 and 3, the linear frame member 18 is shown in perspective and comprises a flat spine 27, an inside web 32, a front web 30, and an intermediate web 31. The inside web 32 is connected to and extends perpendicularly from the spine 27. The front web 30 interconnects the inside web 32 and the intermediate web 31. The inside web 32, the front web 30, and the intermediate web 31 form a hollow, hanger engaging channel 41. The hollow, hanger engaging channel 41 has a hanger engaging opening 40 opposite the front web 30. Protrusion 25 and 42 extend from inside web 32 into the hollow, hanger engaging channel 41. Likewise, protrusion 26 and 43 extend from intermediate web 31 into the hollow, hanger engaging channel 41. As will be described in greater detail, the protrusions 25, 26, 42, and 43 form a slot 24 that accommodates an L-shaped reinforcement bracket 29 at each corner 28 of the frame 12 (FIG. 4). Also, between the corners of the frame 12 where the hangar engaging opening 40 is not obstructed by the L-shaped reinforcement bracket 29, the protrusions 42 and 43 form part of a hanger locking mechanisms, which hanger locking mechanism holds the fabric wall panel 10 onto the wall 2.
  • With continuing reference to FIGS. 2 and 3, the linear frame member 18 further includes a clamp 33 for clamping the edges of the fabric 21 to the linear frame member 18 (as well as to the linear frame members 14, 16, and 20). The clamp 33 comprises a fixed jaw 34 and a movable jaw 46. The fixed jaw 34 comprises a back web 35, an extending web 36, and a jaw lip 37, all integrally formed. The back web 35 is attached to the spine 27 via the intermediate web 31, the front web 30, and the inside web 32 of the linear frame member 18. The back web 35 extends essentially parallel to the back wall 2. The extending web 36 is attached to the back web 35 and extends perpendicularly away from the back wall 2. The jaw lip 37 forms one end of the extending web 36.
  • The movable jaw 46 comprises a flexible joint 45, a movable web 47, a return web 48, and a jaw hook 49, all integrally formed. The movable web 47 is attached by means of the flexible joint 45 to spine 27 via the front web 30 and the inside web 32 of the linear frame member 18. The movable web 47 extends essentially parallel to the back wall 2. The return web 48 is attached to the movable web 47 and extends toward the back wall 2. The jaw hook 49 forms one end of the return web 48. The flexible joint 45 is formed from premium plasticized polyvinyldloride #75a lox, such as PLC20675 sold by Georgia Gulf Corporation of Plaquemine, La. That material allows the movable web 47 to pivot with respect to the front web 30 of the linear frame member 18. The intermediate web 31, the back web 35, the extending web 36, the movable web 47, and the return web 48 define a fabric housing 38. A piece of double backed tape or other contact adhesive 44 is installed on the outside surface of the return web 48 to secure the fabric 21 during the fabrication process of the fabric wall panel 10.
  • As shown in FIG. 2, the clamp 33 is open. The movable web 47 of the movable jaw 46 is pivoted about the flexible joint 45 and away from the wall 2. Consequently, an opening 39 exists between the fixed jaw lip 37 of the fixed jaw 34 and the movable jaw hook 49 of the movable jaw 46. The fabric 21 is threaded through the opening 39, and any excess is stored in the fabric housing 38. FIG. 3 shows the clamp 33 in the closed position with the fabric 21 captured between the fixed jaw lip 37 of the fixed jaw 34 and the movable jaw hook 49 of the movable jaw 46.
  • As shown in FIGS. 2 and 3, the linear frame member 18 is positioned to be connected to the back wall 2 by means of the hanger 50. The hanger 50 includes a base 52 that is attached to the back wall 2 by means of a suitable adhesive or by mechanical means such as cross nailing or stapling. The base 52 may be flat or slightly concave to assure that the base 52 lies flat against wall 2 once the hanger 50 has been attached to the wall 2. The hanger 50 includes forked tongues 54 and 55 (FIGS. 5 and 6). As shown in FIGS. 2 and 3 the forked tongue 54 comprises outwardly extending forks 56 and 58. The forks 56 and 58 have cam surfaces 60 and 62 and latching surfaces 64 and 66. The forks 56 and 58 are flexible so that they can deflect toward each other. With reference to FIGS. 5 and 6, the flat base 52 has an index mark 70 in the shape of a V to indicate the midpoint between the forked tongues 54 and 55. The hanger 50 is an extrusion made of high impact premium unplasticized polyvinylcloride #lox, such as PLC27766 sold by Georgia Gulf Corporation of Plaquemine, La.
  • The insert 22 may consist of any number of materials to provide sound or heat insulation. The insert may be an acoustical insert in the nature of a rigid board such as Owens/Corning 705 Fiberglas insulation board sold by Owens/Corning Fiberglas Corp. of Toledo, Ohio. Alternatively, the insert may be a mineral fiber board insert such as Micore board sold by USG Acoustical Products Company of Chicago, Ill. The thickness of the insert 22 is such that the insert 22 serves as a backing for the fabric 21 as shown in FIGS. 5 and FIG. 6.
  • When the fabric wall panel 10 is prefabricated off the wall, for example, the linear frame members 14, 16, 18, and 20 are miter-cut and connected at their corners. FIG. 4 shows details of the corner 28 formed between the linear frame members 18 and 20. The corner 28 is open to show the internal detail. An L-shaped reinforcement bracket 29 engages the slot 24 formed by protrusions 25, 26, 42, and 43. The L-shaped reinforcement bracket 29 and the linear frame members 18 and 20 (FIG. 4) are joined in conventional fashion, such as by gluing, by fasteners, or by welding. The L-shaped reinforcement bracket 29 serves to stabilize the corner 28 after the frame 12 has been assembled off of the wall 2 and during subsequent handling and attachment of the completed frame 12 to the back wall 2. As shown in FIGS. 5 and 6, the filler insert 22 is seated against the spine 27 of the linear frame members 14 and 18 of the frame 12. As previously stated, the insert 22 not only provides sound or heat insulation, but it also provides rigidity to the frame 12. The prefabricated fabric wall panel 10 is completed by stretching fabric 21 over the insert 22 and frame 12, around the movable web 47, over the double backed tape 44 on the return web 48, through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49, and into the fabric housing 38. The fabric is then clamped to the linear frame members 14, 16, 18, and 20 by closing the clamped 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engaged each other and securely clamped the fabric 21. The double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21 between the fixed jaw lip 37 and the movable jaw hook 49. Once the fabric wall panel 10 has been prefabricated off of the wall 2, the completed fabric wall panel 10 is attached to the wall using hangers 50.
  • With reference to FIGS. 5 and 6, the installation of the completed fabric wall panels 10 a and 10 b onto the back wall 2 is illustrated. The hanger 50, which is one of a several hangers, is mounted to the back wall 2 by means of gluing, cross nailing, or stapling. A separate contact adhesive on the back of the hanger 50 may be used to secure the hanger 50 to the back wall 2 until the separately applied adhesive has fully cured.
  • With continuing reference to FIGS. 5 and 6, each hanger 50 is positioned on the wall 2 so that the forked tongue 54 aligns with the hanger engaging opening 40 of the hollow, hanger engaging channel 41 of the linear frame member 18 of the fabric wall panel 10 a. Similarly, the forked tongue 55 aligns with the hanger engaging opening 40 of the hollow, hanger engaging channel 41 of the linear frame member 14 of fabric wall panel 10 b. Because the forked tongues 54 and 55 are mounted to a single hanger base 52, their spacing is fixed. Once the hanger engaging openings 40 of the fabric wall panels 10 a and 10 b are aligned with the forked tongues 54 and 55, the fabric wall panels 10 a and 10 b are moved toward the wall 2. As the forked tongue 54 enters into the hanger engaging opening 40 of the linear frame member 18, the cam surfaces 60 and 62 engage the protrusions 42 and 43 inside the hollow, hanger engaging channel 41. As result of the engagement of the cam surfaces 60 and 62 and the protrusions 42 and 43, the forks 56 and 58 are forced toward each other. As the linear frame members 14 and 18 are moved toward the base 52 of the hanger 50, the cam surfaces 60 and 62 pass by the protrusions 42 and 43 so that the forks 56 and 58 spring back and the latching surfaces 64 and 66 engage the protrusions 42 and 43 as shown in FIG. 5. With the frame members 14 and 18 seated against the base 52 of the hanger 50, the latching surfaces 64 and 66 engage the protrusions 42 and 43 to hold the linear frame members 14 and 18 and thus the frame 12 and the fabric wall panel 10 in place.
  • Once both fabric wall panels 10 a and 10 b are seated at shown in FIG. 5, the resilient forks 58 and 56 adjacent the marker index 70 urge the fabric wall panels 10 a and 10 b toward each other so that any spacing, at seam 87 between the fabric panels 10 a and 10 b, is minimized. In addition, the return webs 48 (FIG. 5) are angled toward each other in order to keep the seam 87 closed. The flexibility of the forks 58 and 59 allow the fabric wall panel system to accommodate fabrics of different thickness and still assure that the seam 87 remains closed.
  • The index mark 70 on the hanger 50 indicates a point at which the hanger can be cut into two parts for installation of the fabric wall panel 10 next to a corner, such as corner 8. Again, the flexible fork 58 urges the fabric panel 10 a toward the index mark 70 and thus toward and adjacent wall.
  • Alternatively, the fabric wall panels 10 can be fabricated directly on the wall 2. The on-the-wall installation process begins by first attaching the hangars 50 to the wall 2 in a predetermined arrangement for the fabric wall panels 10 that are to be installed. Once the hangers 50 are attached to the wall 2, the linear frame members 14, 16, 18, and 20 are attached to the hangers 50 by means of the fork tongues 54 and 55 engaging the hanger engaging openings 40 of the hollow, hanger engaging channel 41. The attachment of the linear frame members 14, 16, 18, and 20 forms frames 12 on the wall 2. Next, the flat filler insert 22 is placed within each frame 12 and temporarily secured in place either by friction or a suitable adhesive. The fabric 21 is then applied to each of the frames 12 of the fabric wall panels 10. The fabric wall panel 10 is completed by stretching the fabric 21 over the insert 22 and the frame 12, around the movable web 47, over the double backed tape 44 on the return web 48, through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49, and into the fabric housing 38. The fabric 21 is then clamped to the linear frame members 14, 16, 18, and 20 by closing the clamped 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engage each other and securely clamp the fabric 21. The double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21. Once the fabric 21 has been secured within the clamp 33, the installation of the fabric wall panels 10 is complete.
  • When the fabric 21 of the fabric wall panels 10 needs replacement, the fabric wall panels 10 of the present invention offered two options. First, the fabric 21 can be replaced with the fabric wall panels 10 in place on the wall 2. Alternatively, the fabric wall panels 10 can be removed from the wall 2, and the fabric 21 can be replaced off of the wall 2. In order to replace the fabric 21 while the fabric wall panels 10 are in place on a wall 2, the movable jaw hook 49 of the movable jaw 46 is manually disengaged from the fixed jaw lip 37 of the fixed jaw 34 to thereby release of the fabric 21 from the linear frame members 14, 16, 18, and 20. The new fabric 21 is then reinstalled on the frame 12 in place on the wall 2 as previously described.
  • Alternatively, the fabric 21 can be replaced by a removing of the entire fabric wall panel 10 from the wall 2. Each fabric wall panel 10 is pulled off of the underlying hanger 50. The exertion of the outward force on the fabric wall panels 10 causes the latching surfaces 64 and 66 (FIGS. 5 and 6) to disengage the protrusions 42 and 43 thereby releasing the fabric wall panels 10 from the wall 2. The old fabric 21 is removed from the fabric wall panel 10 by opening the clamp 33 and pulling the fabric 21 from the fabric housing 38 and through the opening 39. The old fabric 21 then is replaced on the fabric wall panel 10 by stretching the new fabric 21 over the insert 22 and frame 12, around the movable web 47, over the double backed tape 44 on the return web 48, through the opening 39 between the fixed jaw lip 37 and the movable jaw hook 49, and into the fabric housing 38. The fabric 21 is then clamped to the linear frame members 14, 16, 18, and 20 by closing the clamp 33 so that the fixed jaw lip 37 and the movable jaw hook 49 engaged each other and securely clamp the fabric 21. The double backed tape 44 is used to temporarily hold the fabric 21 in place until the fixed jaw 34 and the movable jaw 46 can be closed to secure the fabric 21. Once the new fabric 21 has been secured the fabric wall panel 10, the hanging process is repeated using the same hangers that were previously installed. Particularly, the system allows for the replacement of a thin fabric with a thick fabric and vice versa because of the flexible forks 58 and 59 urge the fabric panels 10 a and 10 b together at seam 87.
  • FIGS. 7 and 8 disclose additional profiles for the linear frame members 14, 16, 18, and 20. Particularly, FIG. 7 shows a profile in which the extending web 36 is shortened so that the movable web 47, in the closed position, is angled toward the wall 2 as compared to the orientation of the movable 47 in FIG. 5 where, in the closed position, the movable web is angled away from the wall 2. The orientation of the movable web 47 in FIG. 7 produces a fabric wall panel with beveled edges as compared to the square profile for the fabric wall panels shown in FIG. 5.
  • FIG. 8 shows a movable web 47 with straight segments 102 and 106 connected by an angled segment 104. The movable web 47 produces a fabric wall panel with a chamfered profile. In each of the alternative profiles, the forked tongues 54 and 55 serve the same function to assure that the seams remain substantially closed, Consequently, the fabric wall panels 10 can accommodate fabrics of differing thicknesses.
  • In summary, the present invention provides an improved fabric wall panel system for installing fabric wall panels employing a snap hanger and clamping jaw to hold the fabric. By utilizing the disclosed method for installing fabric wall panels, the removal and replacement process is less complicated. Therefore, the preferred embodiment of the present invention allows for easy installation and removal of fabric wall panels.
  • 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.

Claims (20)

1. A fabric wall panel system for a wall comprising:
a. a fabric wall panel comprising:
i. a frame comprising a plurality of frame members connected together to form the frame, each frame member comprising:
(a) a flat spine;
(b) a hanger engaging channel; and
(c) a fabric clamp,
ii. a fabric stretched over and around the frame and secured to each of the frame members by the fabric clamp; and
b. a hanger comprising:
i. a base for attachment to the wall; and
ii. an elongated flexible tongue extending from the base and for insertion into the hanger engaging channel for releaseably engaging the frame members.
2. The fabric wall panel system of claim 1, wherein the fabric clamp comprises a fixed jaw including a fixed jaw lip and a movable jaw including a movable jaw hook and wherein the movable jaw is movable from an open position in which the fabric can be inserted between the fixed jaw lip and the movable jaw hook to a closed position in which the fixed jaw lip and the movable jaw hook engage each other and the fabric is secured to the frame member between the fixed jaw lip and the movable jaw hook.
3. The fabric wall panel system of claim 2, wherein the movable jaw further includes a flexible joint that connects the movable jaw to the frame member and allows the movable jaw to pivot between the open position and the closed position.
4. The fabric wall panel system of claim 2, wherein the movable jaw further includes an adhesive located on the movable jaw.
5. The fabric wall panel system of claim 2, wherein the movable jaw further includes a flexible joint connected to the frame member, a return web connected to the movable jaw hook, and a movable web between the flexible joint and the return web, and wherein the fixed jaw further includes a back web connected to the frame member and an extending the web connected between the back web and the fixed jaw lip, wherein the back web, the extending web, the movable web, and the return web, defined a fabric housing in which any excess of the fabric is contained.
6. The fabric wall panel system of claim 2, wherein the movable jaw further includes a flexible joint connected to the frame member, a return web connected to the movable jaw hook, and a movable web between the flexible joint and the return web, and wherein the fixed jaw further includes a back web connected to the frame member and an extending the web connected between the back web and the fixed jaw lip, and wherein the extending web is dimensioned so that the movable web angles away from the wall from the flexible joint to the return web when the clamp is in the closed position.
7. The fabric wall panel system of claim 2, wherein the movable jaw further includes a flexible joint connected to the frame member, a return web connected to the movable jaw hook, and a movable web between the flexible joint and the return web, and wherein the fixed jaw further includes a back web connected to the frame member and an extending the web connected between the back web and the fixed jaw lip, and wherein the extending web is dimensioned so that the movable web angles toward the wall from the flexible joint to the return web when the clamp is in the closed position.
8. The fabric wall panel system of claim 2, wherein the movable jaw further includes a flexible joint connected to the frame member, a return web connected to the movable jaw hook, and a movable web between the flexible joint and the return web, and wherein the fixed jaw further includes a back web connected to the frame member and an extending the web connected between the back web and the fixed jaw lip, and wherein the movable web has a chamfered portion.
9. The fabric wall panel system of claim 1, wherein the hanger engaging channel has internal protrusions and wherein the flexible tongue of the hanger includes two forks each with a cam surface and a latching surface to engage the protrusions in the hanger engaging channel.
10. The fabric wall panel system of claim 9, wherein the base of the hanger has two flexible tongues positioned side by side to engage two frames.
11. An in place method for installing a fabric wall panel in place on a wall, comprising the steps of:
a. affixing a plurality of hangers to the wall in a predetermined relationship, each hanger comprising:
i. a base for attachment to the wall; and
ii. an elongated flexible tongue extending from the base;
b. attaching a plurality of frame members to the plurality of hangers to form one or more frames on the wall, each frame member comprising:
i. a flat spine;
ii. a hanger engaging channel and for receiving the elongated tongue for releaseably engaging the hanger; and
iii. a fabric clamp attached to the frame member;
c. stretching a fabric over and around the frame and securing the fabric to each frame member of each frame by the fabric clamp.
12. The in place method of claim 11, wherein securing the fabric to the frame member includes opening the fabric clamp to an open position, which fabric clamp comprises a fixed jaw including a fixed jaw lip and a movable jaw including a movable jaw hook, threading the fabric into the fabric clamp between the fixed jaw lip and the movable jaw hook, and closing the clamp by moving the movable jaw from the open position in which the fabric can be inserted between the fixed jaw lip and the movable jaw hook to a closed position in which the fixed jaw lip and the movable jaw hook engage each other and the fabric is secured to the frame member between the fixed jaw lip and the movable jaw hook.
13. The in place method of claim 12, wherein closing the clamp causes the movable jaw to pivot about a flexible joint that connects the movable jaw to the frame member so that the movable jaw pivots between the open position and the closed position.
14. The in place method of claim 12, wherein the stretching step further includes temporarily attaching the fabric to the movable jaw by means of an adhesive located on the movable jaw.
15. The in place method of claim 12, wherein the stretching step further includes inserting any excess of the fabric into a fabric housing of the frame member.
16. A method for separately fabricating and installing a completed fabric wall panel on a wall, comprising the steps of:
a. Separately assembling a fabric wall panel by:
i. assembling a frame comprising a plurality of frame members connected together to form the frame, each frame member comprising:
(a) a flat spine;
(b) a hanger engaging channel; and
(c) a fabric clamp attached to the frame member,
ii. stretching a fabric over and around the frame and securing the fabric to each of the frame members by the fabric clamp to complete the fabric wall panel;
b. affixing a hanger to the wall, the hanger comprising:
i. a base for attachment to the wall; and
ii. an elongated flexible tongue extending from the base and for insertion into the hanger engaging channel for releaseably engaging the frame members; and
c. mounting the completed fabric wall panel on the wall by engaging the elongated flexible tongue of the hanger with the hanger engaging channel of the frame members.
17. The method for separately fabricating and installing a completed fabric wall panel on a wall of claim 16, wherein securing the fabric to the frame member includes opening the fabric clamp to an open position, which fabric clamp comprises a fixed jaw including a fixed jaw lip and a movable jaw including a movable jaw hook, threading the fabric into the fabric clamp between the fixed jaw lip and the movable jaw hook, and closing the clamp by moving the movable jaw from the open position in which the fabric can be inserted between the fixed jaw lip and the movable jaw hook to a closed position in which the fixed jaw lip and the movable jaw hook engage each other and the fabric is secured to the frame member between the fixed jaw lip and the movable jaw hook.
18. The method for separately fabricating and installing a completed fabric wall panel on a wall of claim 17, wherein closing the clamp causes the movable jaw to pivot about a flexible joint that connects the movable jaw to the frame member so that the movable jaw pivots between the open position and the closed position.
19. The method for separately fabricating and installing a completed fabric wall panel on a wall of claim 17, wherein the stretching step further includes temporarily attaching the fabric to the movable jaw by means of an adhesive located on the movable jaw.
20. The method for separately fabricating and installing a completed fabric wall panel on a wall of claim 17, wherein the stretching step further includes inserting any excess of the fabric into a fabric housing of the frame member but.
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