US20140237928A1 - Modular Wall Panel - Google Patents

Modular Wall Panel Download PDF

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Publication number
US20140237928A1
US20140237928A1 US14/192,919 US201414192919A US2014237928A1 US 20140237928 A1 US20140237928 A1 US 20140237928A1 US 201414192919 A US201414192919 A US 201414192919A US 2014237928 A1 US2014237928 A1 US 2014237928A1
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Prior art keywords
layer
wall panel
modular wall
rigid
finishing
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US14/192,919
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Matthew Kiernan
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SUPERWALL BASEMENT FINISHING SYSTEM Inc
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SUPERWALL BASEMENT FINISHING SYSTEM Inc
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Priority to US14/192,919 priority Critical patent/US20140237928A1/en
Assigned to SUPERWALL BASEMENT FINISHING SYSTEM INC. reassignment SUPERWALL BASEMENT FINISHING SYSTEM INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KIERNAN, MATTHEW
Publication of US20140237928A1 publication Critical patent/US20140237928A1/en
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0235—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/08—Closed cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538—Roughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a wall panel, methods, and systems for its installation. More particularly, the present invention relates to a modular wall panel with improved physical characteristics, and methods and systems for its installation.
  • Finished or “club” basements are a common part of residential structures.
  • Conventional wood framing has been widely used to achieve a finished wall surface.
  • Recently the developments of other innovative wall finishing systems have emerged. These systems are comprised of “shape-molded” insulation panels such as: In-So-FastTM; R-RetroTM; Re-FitTM and BuildLockTM.
  • Owens Corning also markets fiberglass softwall systems whose use is common in residential settings.
  • the wall finishing systems typically consist of some type of framework and/or studs into which modular wall panels are fitted.
  • the wall panels used in these finishing systems suffer from several drawbacks however, which make handling, fitting, and installation difficult. Many of the wall panels are too rigid, which makes cutting and handling of them difficult. Cutting the wall material often can damage saws which are used therein. Other wall panels are very light and easy to handle, but are also easily damaged in shipping and handling of the panel. Such panels also do not possess sufficient tensile strength to structurally serve as a wall, and are difficult to hang things thereupon.
  • wall panels are too heavy and are difficult to work with. Some heavier paneling requires specialized framework to accommodate the panels, and may be too heavy to be used in some framing systems. Additionally, most wall panels require a finishing step in order to make the finished wall cosmetically acceptable after installation. Some finishing steps include painting, wallpapering, or other type of procedure in order to make the newly installed wall acceptable in the home or office in which it was installed.
  • the modular wall panel includes a first insulating layer made of an extruded polystyrene foam.
  • the panel further includes a second rigid layer made of a closed cell polyvinylchloride foam board.
  • a third finishing layer is further included in the panel, the third layer made of a cosmetically acceptable material for living conditions.
  • first layer of the modular wall panel is adhered to the second layer, and the second layer is adhered to the third layer in a sandwich configuration where the second layer resides between the first and third layer.
  • layers of the modular wall panel are adhered together by an adhesive selected from any water based contact adhesive.
  • the first insulating layer of the modular wall panel is from about 3 centimeters to about 7 centimeters thick; and the second rigid layer is from about 3 millimeters to about 7 millimeters thick.
  • the first insulating layer is from about 4 centimeters to about 6 centimeters thick; and the second rigid layer is from about 4 millimeters to about 6 millimeters thick.
  • the first insulating layer is about 5 centimeters thick and said second rigid layer is about 5 millimeters thick.
  • the third finishing layer of the modular wall panel is formed of a material selected from the group of vinyl wall fabric coverings, rigid vinyl wall materials, wainscoting, or formica.
  • a system of making or finishing a wall in an edifice includes providing a framework for supporting wall panels. Within the framework is inserted a modular wall panel.
  • the modular wall panel includes a first insulating layer formed of an extruded polystyrene foam; a second rigid layer formed of a closed cell polyvinylchloride foam board; and a third finishing layer comprising a cosmetically acceptable material for living conditions.
  • FIG. 1 shows a blown-up cross section of a modular wall panel of the present invention.
  • FIG. 2 shows a front view of a modular wall panel of the present invention.
  • This structure of the panel of the present invention is comprised of three layers, and they have one dimension (their respective thicknesses) that is smaller than their other two respective dimensions. These plates are essentially planar; but they could be curved into two or three dimensions, developable or non-developable in the mathematical sense.
  • the sandwich structure 10 therefore comprises a first insulating layer 12 made of extruded polystyrene foam, a second rigid layer 14 made of a closed cell PVC foamboard, and a third finishing layer 16 .
  • Insulating layer 12 has a length 18 , and a width 20 , and a thickness 22 .
  • Rigid layer 14 also has a length and width which are identical to insulating layer 12 as the layers form a sandwich structure.
  • Finishing layer 16 also has a length and a width, which may be the same as insulating layer 12 and rigid layer 14 , but may be slightly longer in either dimension as it may be wrapped around a side of the panel if in fabric form.
  • a framework is first established in an edifice in which the modular wall panel will be used.
  • the framework can be placed against a perimeter wall of the edifice or an internal wall, and includes a rigid frame, which may be steel.
  • a rigid frame which may be steel.
  • the modular wall panels may be used with a variety of frames and materials.
  • the size, i.e., length and width, of the modular wall panels may vary greatly depending on how it will be used. They may be used as squares; i.e., length equals width.
  • the framework may be installed by methods well known in the art.
  • a steel frame is first installed, after which our panels are appended thereto, typically with screw fasteners.
  • a PVC molding is optionally installed thereafter, including crown molding, chair rails, and other items.
  • the modular wall panels may be easily replaceable, or updated at a later date.
  • First insulating layer 12 consists of extruded polystyrene foam (XPS), which consists of closed cells, offers improved surface roughness and higher stiffness and reduced thermal conductivity. The density range is about 28-45 kg/m 3 . Extruded polystyrene foam is commonly used as an insulator. Because of the extrusion manufacturing process, XPS does not require facers to maintain its thermal or physical property performance. Thus, it makes a more uniform substitute for corrugated cardboard. Thermal resistivity is usually about 35 m ⁇ K/W (or R-5 per inch in American customary units) but can range between 29 and 39 m ⁇ K/W depending on bearing/density.
  • XPS extruded polystyrene foam
  • Thermal conductivity varies between 0.029 and 0.039 W/(m ⁇ K) depending on bearing strength/density and the average value is ⁇ 0.035 W/(m ⁇ K).
  • Water vapor diffusion resistance ( ⁇ ) of XPS is typically around 80-250. While XPS is the preferred embodiment, it is recognized that other insulative layers may be substituted therefore without varying from the scope of the invention.
  • the second rigid layer 14 is made of closed-cell PVC foamboard.
  • Closed-cell PVC foamboard is a light-weight rigid material used primarily in the manufacture of signs and displays, although its material properties have made it extremely popular among model makers, prop, composite experimental aircraft and yacht builders.
  • closed-cell PVC foamboard is solid and has a very rigid structure. Where it differs is in its closed-cell foam structure, which makes it very light (as little as half the weight of solid PVC), highly resistant to moisture and some chemicals, and very easy to cut and shape. It also has thermoplastic properties, and begins to soften at around 65° C.
  • closed-cell PVC foamboard can be cut as easily as wood, softened and shaped by immersing in boiling water or with a standard heat gun, and painted with standard automobile paints.
  • the third finished layer 16 may be a flexible fabric skin such as a fabric coated with a vinyl.
  • a vinyl material that may be used for such a purpose is manufactured by USCAN, LLC of Merritt Island, Fla.; an example of such vinyl material is marketed under the trade name or identifier US 185-HC.
  • This type of vinyl may be composed of a polyester base fabric with a PVC coating. It may have, for example, a thickness of 0.58 mm, a weight of 630 grams per square meter, and a temperature resistance of ⁇ 30 to +70 degrees Celsius.
  • An adhesive is used to assemble the layers together.
  • Preferred adhesives are water-based contact adhesives, which also benefit from being environmentally acceptable.
  • a preferred adhesive is H2O from Wilson Art International®, which consists principally of polychlorprene, zinc oxide, water, Resin acid, and Rosin acid, in sodium and potassium form.
  • XPS foam board In order to make the modular wall panel, XPS foam board is used, such as Greenguard® type IV cm square edge, 25 psi.
  • the XPS board can have a thickness of 2 inches for foundation walls (with a R value of 10), or a thickness of 1 inch or 1 ⁇ 2 inch (R value of 5 and 2.5 respectively) when used as non-foundation walls.
  • a PVC foamboard of 3 mm thickness from Laird Plastics® is also used in conjunction with vinyl wall coverings from Brewster Wall Coverings (15 oz or 20 oz vinyl).
  • a water based adhesive such as H2O from Wilson Art International®, is applied to one side of the XPS foam and one side of the PVC, then press laminated together.
  • the adhesive is then applied to the PVC side of combined structure, as well as to the backside of vinyl wall covering, and press laminated together, which includes wrapping the vinyl and laminating to side of PVC foamboard. After assembly, the composite is trimmed to a rectangle.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

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

Description

    FIELD OF THE INVENTION
  • The present application claims priority U.S. Provisional Application Ser. No. 61/770,587, filed Feb. 28, 2013, herein incorporated by reference in its entirety.
  • The present invention relates to a wall panel, methods, and systems for its installation. More particularly, the present invention relates to a modular wall panel with improved physical characteristics, and methods and systems for its installation.
    • BACKGROUND
  • Finished or “club” basements are a common part of residential structures. Conventional wood framing has been widely used to achieve a finished wall surface. Recently the developments of other innovative wall finishing systems have emerged. These systems are comprised of “shape-molded” insulation panels such as: In-So-Fast™; R-Retro™; Re-Fit™ and BuildLock™. Owens Corning also markets fiberglass softwall systems whose use is common in residential settings. The wall finishing systems typically consist of some type of framework and/or studs into which modular wall panels are fitted.
  • The wall panels used in these finishing systems suffer from several drawbacks however, which make handling, fitting, and installation difficult. Many of the wall panels are too rigid, which makes cutting and handling of them difficult. Cutting the wall material often can damage saws which are used therein. Other wall panels are very light and easy to handle, but are also easily damaged in shipping and handling of the panel. Such panels also do not possess sufficient tensile strength to structurally serve as a wall, and are difficult to hang things thereupon.
  • Other wall panels are too heavy and are difficult to work with. Some heavier paneling requires specialized framework to accommodate the panels, and may be too heavy to be used in some framing systems. Additionally, most wall panels require a finishing step in order to make the finished wall cosmetically acceptable after installation. Some finishing steps include painting, wallpapering, or other type of procedure in order to make the newly installed wall acceptable in the home or office in which it was installed.
  • It is therefore desirable to provide a modular wall panel, and installation systems and methods which are easier to handle and install, are more environmentally friendly, and are more cosmetically acceptable.
    • SUMMARY
  • Provided therefore herein is a modular wall panel, and a system for installing and method of making thereof. The modular wall panel includes a first insulating layer made of an extruded polystyrene foam. The panel further includes a second rigid layer made of a closed cell polyvinylchloride foam board. A third finishing layer is further included in the panel, the third layer made of a cosmetically acceptable material for living conditions.
  • In an embodiment, the first layer of the modular wall panel is adhered to the second layer, and the second layer is adhered to the third layer in a sandwich configuration where the second layer resides between the first and third layer. In another embodiment, layers of the modular wall panel are adhered together by an adhesive selected from any water based contact adhesive.
  • In another embodiment, the first insulating layer of the modular wall panel is from about 3 centimeters to about 7 centimeters thick; and the second rigid layer is from about 3 millimeters to about 7 millimeters thick. In another embodiment, the first insulating layer is from about 4 centimeters to about 6 centimeters thick; and the second rigid layer is from about 4 millimeters to about 6 millimeters thick. In a preferred embodiment, the first insulating layer is about 5 centimeters thick and said second rigid layer is about 5 millimeters thick.
  • In yet another embodiment, the third finishing layer of the modular wall panel is formed of a material selected from the group of vinyl wall fabric coverings, rigid vinyl wall materials, wainscoting, or formica.
  • In yet another embodiment, a system of making or finishing a wall in an edifice is provided herein. The system includes providing a framework for supporting wall panels. Within the framework is inserted a modular wall panel. The modular wall panel includes a first insulating layer formed of an extruded polystyrene foam; a second rigid layer formed of a closed cell polyvinylchloride foam board; and a third finishing layer comprising a cosmetically acceptable material for living conditions.
    • DETAILED DESCRIPTION
  • FIG. 1 shows a blown-up cross section of a modular wall panel of the present invention.
  • FIG. 2 shows a front view of a modular wall panel of the present invention.
    •
  • This structure of the panel of the present invention is comprised of three layers, and they have one dimension (their respective thicknesses) that is smaller than their other two respective dimensions. These plates are essentially planar; but they could be curved into two or three dimensions, developable or non-developable in the mathematical sense.
  • With reference to the Figures, the sandwich structure 10 therefore comprises a first insulating layer 12 made of extruded polystyrene foam, a second rigid layer 14 made of a closed cell PVC foamboard, and a third finishing layer 16. Insulating layer 12 has a length 18, and a width 20, and a thickness 22. Rigid layer 14 also has a length and width which are identical to insulating layer 12 as the layers form a sandwich structure. Finishing layer 16 also has a length and a width, which may be the same as insulating layer 12 and rigid layer 14, but may be slightly longer in either dimension as it may be wrapped around a side of the panel if in fabric form.
  • In order to assemble, a framework is first established in an edifice in which the modular wall panel will be used. The framework can be placed against a perimeter wall of the edifice or an internal wall, and includes a rigid frame, which may be steel. It is an advantage of the present invention that the modular wall panels may be used with a variety of frames and materials. The size, i.e., length and width, of the modular wall panels may vary greatly depending on how it will be used. They may be used as squares; i.e., length equals width.
  • The framework may be installed by methods well known in the art. A steel frame is first installed, after which our panels are appended thereto, typically with screw fasteners. A PVC molding is optionally installed thereafter, including crown molding, chair rails, and other items. The modular wall panels may be easily replaceable, or updated at a later date.
  • First insulating layer 12 consists of extruded polystyrene foam (XPS), which consists of closed cells, offers improved surface roughness and higher stiffness and reduced thermal conductivity. The density range is about 28-45 kg/m3. Extruded polystyrene foam is commonly used as an insulator. Because of the extrusion manufacturing process, XPS does not require facers to maintain its thermal or physical property performance. Thus, it makes a more uniform substitute for corrugated cardboard. Thermal resistivity is usually about 35 m·K/W (or R-5 per inch in American customary units) but can range between 29 and 39 m·K/W depending on bearing/density. Thermal conductivity varies between 0.029 and 0.039 W/(m·K) depending on bearing strength/density and the average value is ˜0.035 W/(m·K). Water vapor diffusion resistance (μ) of XPS is typically around 80-250. While XPS is the preferred embodiment, it is recognized that other insulative layers may be substituted therefore without varying from the scope of the invention.
  • The second rigid layer 14 is made of closed-cell PVC foamboard. Closed-cell PVC foamboard is a light-weight rigid material used primarily in the manufacture of signs and displays, although its material properties have made it extremely popular among model makers, prop, composite experimental aircraft and yacht builders. Like PVC, closed-cell PVC foamboard is solid and has a very rigid structure. Where it differs is in its closed-cell foam structure, which makes it very light (as little as half the weight of solid PVC), highly resistant to moisture and some chemicals, and very easy to cut and shape. It also has thermoplastic properties, and begins to soften at around 65° C. Typically, closed-cell PVC foamboard can be cut as easily as wood, softened and shaped by immersing in boiling water or with a standard heat gun, and painted with standard automobile paints.
  • The third finished layer 16 may be a flexible fabric skin such as a fabric coated with a vinyl. A vinyl material that may be used for such a purpose is manufactured by USCAN, LLC of Merritt Island, Fla.; an example of such vinyl material is marketed under the trade name or identifier US 185-HC. This type of vinyl may be composed of a polyester base fabric with a PVC coating. It may have, for example, a thickness of 0.58 mm, a weight of 630 grams per square meter, and a temperature resistance of −30 to +70 degrees Celsius.
  • An adhesive is used to assemble the layers together. Preferred adhesives are water-based contact adhesives, which also benefit from being environmentally acceptable. A preferred adhesive is H2O from Wilson Art International®, which consists principally of polychlorprene, zinc oxide, water, Resin acid, and Rosin acid, in sodium and potassium form.
    • EXAMPLES
  • Example 1
  • In order to make the modular wall panel, XPS foam board is used, such as Greenguard® type IV cm square edge, 25 psi. The XPS board can have a thickness of 2 inches for foundation walls (with a R value of 10), or a thickness of 1 inch or ½ inch (R value of 5 and 2.5 respectively) when used as non-foundation walls. A PVC foamboard of 3 mm thickness from Laird Plastics® is also used in conjunction with vinyl wall coverings from Brewster Wall Coverings (15 oz or 20 oz vinyl).
  • In order to assemble the layer components, a water based adhesive, such as H2O from Wilson Art International®, is applied to one side of the XPS foam and one side of the PVC, then press laminated together. The adhesive is then applied to the PVC side of combined structure, as well as to the backside of vinyl wall covering, and press laminated together, which includes wrapping the vinyl and laminating to side of PVC foamboard. After assembly, the composite is trimmed to a rectangle.
  • It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims (8)

What is claimed is:
1. A modular wall panel comprising:
a first insulating layer comprising an extruded polystyrene foam;
a second rigid layer comprising a closed cell polyvinylchloride foam board; and
a third finishing layer comprising a cosmetically acceptable material for living conditions.
2. The modular wall panel according to claim 1 wherein said first layer is adhered to said second layer, and said second layer is adhered to said third layer in a sandwich configuration where said second layer resides between said first and third layer.
3. The modular wall panel according to claim 2 wherein said layers are adhered together by an adhesive selected from any water based contact adhesive.
4. The modular wall panel according to claim 1 wherein said first insulating layer is from about 3 centimeters to about 7 centimeters thick; and said second rigid layer is from about 3 millimeters to about 7 millimeters thick.
5. The modular wall panel according to claim 1 wherein said first insulating layer is from about 4 centimeters to about 6 centimeters thick; and said second rigid layer is from about 4 millimeters to about 6 millimeters thick.
6. The modular wall panel according to claim 1 wherein said first insulating layer is about 5 centimeters thick and said second rigid layer is about 5 millimeters thick.
7. The modular wall panel according to claim 1 wherein said third finishing layer is formed of a material selected from the group of vinyl fabric wall coverings, rigid vinyl wall materials, wainscoting, or formica.
8. A system for making or finishing a wall in an edifice comprising providing a framework for supporting wall panels and a modular wall panel comprising:
a first insulating layer comprising an extruded polystyrene foam;
a second rigid layer comprising a closed cell polyvinylchloride foam board; and
a third finishing layer comprising a cosmetically acceptable material for living conditions.
US14/192,919 2013-02-28 2014-02-28 Modular Wall Panel Abandoned US20140237928A1 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016153578A1 (en) * 2015-03-20 2016-09-29 Pero Michael A Iii System for manufacture of foam sheets rigidized with polymer infiltration
CN109610689A (en) * 2018-12-27 2019-04-12 湖南省富民乐建材科技发展有限公司 A kind of blind hole foams integrated lightweight wall plate and production technology and system

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EP1275809A2 (en) * 2001-07-10 2003-01-15 esco Metallbaubeschlag-Handel GmbH Exchangeable frame for metal windows, doors or facades

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Publication number Priority date Publication date Assignee Title
DE10006579A1 (en) * 2000-02-14 2001-08-16 Nielsendesign Gmbh & Co Kg Interchangeable frame for assembling articles from panels comprises outer profile and inner profile with grooves at top and bottom, leaf spring fitting into this and curve of spring fitting into recess in outer profile
EP1275809A2 (en) * 2001-07-10 2003-01-15 esco Metallbaubeschlag-Handel GmbH Exchangeable frame for metal windows, doors or facades

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016153578A1 (en) * 2015-03-20 2016-09-29 Pero Michael A Iii System for manufacture of foam sheets rigidized with polymer infiltration
US9694897B2 (en) 2015-03-20 2017-07-04 Michael A. Pero, Iii System for manufacture of foam sheets rigidized with polymer infiltration
CN107429065A (en) * 2015-03-20 2017-12-01 迈克尔·A·佩罗三世 The system of the foam sheet of hardening is penetrated into polymer for manufacture
US10053206B2 (en) 2015-03-20 2018-08-21 Michael A. Pero, Iii System for manufacture of foam sheet rigidized with polymer infiltration
CN109610689A (en) * 2018-12-27 2019-04-12 湖南省富民乐建材科技发展有限公司 A kind of blind hole foams integrated lightweight wall plate and production technology and system

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