US20150191914A1

US20150191914A1 - Method and system for covering surfaces with decorative panels

Info

Publication number: US20150191914A1
Application number: US14/589,323
Authority: US
Inventors: Eran Biterman
Original assignee: Eran Biterman
Current assignee: Palram Applications (1995) Ltd
Priority date: 2014-01-07
Filing date: 2015-01-05
Publication date: 2015-07-09

Abstract

A system and a method for covering of wall or ceiling or any other surfaces of a premise and/or an open space setting. The system has at least two panels, i.e. an outwardly facing, external covering panel, which is provided with at least one decorative element and a back, infrastructure panel provided with an attachment plain and a support plain.

Description

RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Application No. 61/924,263, filed Jan. 7. 2014, the entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to covering of walls (outdoor and indoor) and ceiling of a building and/or creating settings of an open space. It should be appreciated however, that the present invention is not limited merely to covering of internal surfaces of a building. The present invention would be suitable as well for covering surfaces of any other premise, building etc., e.g. outside façade of a building, inside decoration of a vehicle, like a cabin of a yacht, train, airplane, bus, liner etc. and for creating surfaces in open spaces.

BACKGROUND OF THE INVENTION

There are known in the art various systems for covering of surfaces of a premise, e.g. walls, ceiling and roof.
The known in the art systems comprise panels made of shapeable material (plastic, metal etc.) which are secured immediately on the covered surface by virtue of nails or any other suitable fastening means, or are glued or adhered by any other suitable method in partially overlapping relation to each other. An example of such a system is disclosed in US patent publication 2005/0050822, in which is described a panel for installation thereof on a ceiling as a component of a matrix grid of similar panels.
Another example of such a system is disclosed in US publication 2012/0234068, which describes a decorative panel made of a material that can be shaped. The panel is provided with two female mounting portion and two male portions. The female portions have punched holes for fastening the panels directly to surface.
Some drawbacks of systems employing direct adherence of decorative panels are associated with their limited possibility to resist outside loads since they are not supported from inside. The consequence of this limitation is relatively limited ability of the decorative planes to bear decorative pattern. Furthermore due to this limitation it might be not possible to shape the panels with certain decorative patterns having tiny details since thickness of the panels should be sufficient enough for rendering strength to the panel body. One can readily appreciate that this requirement renders such panels relatively expensive.
Still further disadvantage of such panels lies in the fact that they are not suitable for arranging wiring ducts on their inwardly facing surface.
There are also known in the art veneer decorative panels securable on the surface with the aim of a backing connecting systems.
An example of such system can be found in international publication WO 03/095760, describing decorative wall panel interlock system with upward movement. This system comprises a plurality of plastic panels each having a boy portion formed with rows of simulated building elements. The panels are mounted on support surface with a lower marginal edge region of one panel overlying an upper marginal region of a previously mounted panel.
Another example of such a system is disclosed in U.S. Pat. No. 5,809,709, describing surface covering system comprising a covering member and a support structure for supporting the covering member and removable retaining thereof.
These systems allow deployment of ducts for hidden wiring, nevertheless since they employ relatively thick rigid panels the above mentioned deficiency associated with cost and/or limited design remains.
Still further deficiency of systems disclosed in the prior art is associated with the uneven load distribution caused by weight of the covering decorative member on walls and ceilings. This uneven load distribution takes place since the weight of the outside decorative element is concentrated not on the total area of the support structure but merely on the certain locations of the support structure, like edges of the panels or backing lines.

SUMMARY OF THE INVENTION

In view of the difficulties and drawbacks associated with previous wall covering and ceiling systems it will be advantageous to provide a method and system employing thin decorative panels which solves the previous problems while providing a more efficient system with unlimited design options and an option for hidden wiring and lighting solutions.
It is an objective of the present invention to provide a method and system for decorative covering of walls (interior and exterior) and/or ceiling of a premise and/or setting of an open space by providing partitions delimiting certain area in the open space. In accordance with the present invention the system comprises at least two panels made for example of a plastic material, while one panel is an infrastructure panel and the second panel is an external covering panel. The infrastructure panel comprises a back, or an attachment plain securable immediately on the surface to be covered or on an airy infrastructure partition in open spaces, while the opposite plain of the infrastructure panel being intended for supporting of the second panel. The external, covering panel comprises a face provided with a decorative pattern. The back plain of the infrastructure panel is provided with array of substructures, separated by walls and designed to support and at the same time to removable secure the covering panel on the infrastructure panel. By virtue of this provision the covering panel can be made sufficiently thin so as to shape on it a pattern having tiny details. Furthermore the covering panel can be laminated, if required, by materials, rendering it flexible and it can be designed so as to impart modularity and possibility for continuous changeable facing.
It is an objective of the present invention to form a method and system for decorative cover of walls (interior and exterior) and ceiling and partitions used for delimiting open space settings using at least two panels made of recycled plastic material and hence to allow saving costs of the system and at the same time render it environmentally friendly.
It is still further an objective of the present invention to provide a system for decorative cover of walls of an premise or creating partitions for delimiting settings in open space having at least one infrastructure panel and an external covering panel which is removable securable on infrastructure panel such that location of the covering panel can be changed and by virtue of this provision a face free style design would be possible, where the installer and later on the user can change positions of the covering panels from time to time in order to change the look of the wall or the ceiling and create ever changing ambient.
It is still further objective of the present invention to provide a method and a system for decorative cover of walls of a premise, which allows deployment of hidden wiring or piping therein.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matte regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features and advantages thereof may best be understood by reference to the following detailed description when read with the accompanying drawings in which:

FIGS. 1A 1B and 1C are illustrations of exemplary infrastructure panels according to embodiments of the present invention;

FIG. 2A shows an infrastructure panels partially covered by external panels according to some embodiment of the present invention;

FIGS. 2B, 2C, and 2D are detailed cross section views of the infrastructure panel and external panels illustrated in FIG. 2A;

FIGS. 3A and 3B are schematic illustrations of different types of surfaces partially covered with infrastructure panels and external panels from different vies, according to some embodiments of the present invention;

FIG. 4A is an illustration of a wall or a screen according to an embodiment of the present invention;

FIGS. 4B and 4C are detailed vies of cross sections of elements of the wall or screen illustrated in FIG. 4A;

FIGS. 5A, 5B. 5C, 5D and 5E are different examples of external panels according to embodiments of the present invention; and

FIG. 6 is a flowchart of a method for installing external panels according to embodiments of the present invention.

It will be appreciated that for simplicity and clarity of illustration elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these specific details. In other instances, well known methods, procedures, and components have not been described in detail so as not to obscure the present invention.
Embodiments of the present invention provide an assembly for installing panels on a surface, such as a wall or ceiling. The apparatus may comprise at least one infrastructure panel and at least one external panel.
With reference to FIGS. 1A, 1B. and 1C, infrastructure panel 100 may be formed as an array of substructures 110. According to some embodiments of the present invention, each substructure 110 may have at least one infrastructure attachment plain 112 and at least one support plain 111. Infrastructure attachment plains 112 and support plains 111 may be spaced apart from each other by at least one wall 113. Wall 113 may be substantially perpendicular to infrastructure attachment plains 112. According to some embodiments of the present invention, wall 113 may also be perpendicular to support plain 111. However, it should be appreciated that, according to other embodiments, support plain 111 may not be parallel to infrastructure attachment plain 112.
According to some embodiments, walls 113, infrastructure attachment plains 112, support plains 111 and external panel (500A-500E in FIGS. 5A-5E) may create a plurality of cavities there between. However, since pressure applied to support plains is directed through wall or walls 113 to an attachment surface 105, sufficient pressure resistance is obtained.
According to some embodiments of the present invention, infrastructure panel 100 may be thermoformed from appropriate materials, such as polyvinylchloride (PVC), Polycarbonate, and any other thermoplastic polymers known in art. It should be understood that other forming technics may he used, such as pressing or injection, and that other materials as may appropriate according to the forming process used in order to form infrastructure panel 100. For example panel 100 may be formed by pressing of organic materials, such as wood chips or paper, or by pressing of metal sheets or by metal casting. Alternatively panel 100 may be formed by plastic injection.
According to some embodiments, infrastructure panel 100 may he formed of a film of material have thickness in the range of 0.5-2.0 millimeters (mm), thus allowing cutting, by standard cutting means such as scissors or knife, of infrastructure panel 100 between substructures 110, along niches 120, and even though substructures 110, to fit to any surface 105 dimension, comers and the like. It should be further appreciated that surface 105 may be a wall a ceiling or even an infrastructure panel (400′ in FIG. 4C), placed hack to back with panel 100.
According to some embodiments of the present invention, infrastructure panel 100 and external panel (500A-500E in FIGS. 5A-5E) may be manufactured from non-toxic materials, and may be heat resistant and washable.
According to some embodiments of the present invention, each infrastructure attachment plain 112 may be adapted to allow attaching of infrastructure panel 100 to surface 105. It should be appreciated by those skilled in the art of attaching of infrastructure attachment plain 112 to surface 105 may be by means of adhesives, plaster, screws, rivets and any other attaching means known in the art.
According to some embodiments, each support plain 111 may be adapted to engage a portion of an external panel (500A-500E in FIGS. 5A-5E) and provide the external panel structural support.
According to some embodiments of the present invention, infrastructure panel 100 may be transparent or partially transparent to allow light to path through.
As may be seen in FIG. 2A one or more infrastructure 100 may be covered by one or more external panels 200. Each external panel 200 may have a face 205 and edges 210.
According to some embodiments of the present invention, one or more of edges 210 of external panels 200 may be bent rearwards (i.e., towards the surface to be covered and/or the infrastructure attachment plain). According to some embodiments, when external panel 200 is installed, bent edges 210 may be substantially perpendicular to surface (105 in FIG. 1A) and/or to infrastructure attachment plain (112 in FIG. 1A)
With reference to FIGS. 2B, 2C and 2D, according to some embodiments of the present invention, infrastructure panel 100 may have one or more niches 120 between proximal substructures 110 each of niches 120 may be adapted to receive at least an edge 210 a of one external panel 200 and at least another edge 210 b in FIG. 2B of another external panel 200.
As may be seen in FIG. 2B, 2C and 2D, external panels 200 may have different shapes. According to one embodiment, illustrated in FIG. 2B, external panel face 205 may be flat. According to other embodiments, such as, for example, the embodiment illustrated in FIG. 2C, face 205 may not be flat and may be protruding from support plain 111 of infrastructure panel 100.
As may further seen in FIG. 2C, according to sonic embodiments of the present invention, a mediating panel 230 may be introduced between support plane 111 of infrastructure panel 100 and face 205 of external panel 200. It should be appreciated that mediating panel 230 may serve as an adaptor to fit external panels 200 having special shapes to a universal infrastructure panel 100.
As may further be seen in FIGS. 2A, 2B, 2C and 2D, infrastructure panel 100 may be formed as a matrix or array of substructures 110. For example. infrastructure panel 100 may formed as a matrix or array of substructures 110. It should be appreciated that any other array dimension may be used and other shapes of infrastructure panel 100 may be used. For example, some of substructures 110 in row or column of substructures 110 array may be removed to create an uneven number of substances 110 in different rows or columns.
According to yet another embodiment of the present invention, external panels 200A and 200B may be installed on infrastructure panel 100 by introducing edges 210 into niches 120 between proximal substructures 110. It should he appreciated by those skilled in the art that external panels 200A and 200B may be further fastened to infrastructure panel by any fastening means known in the art, such as by adhesives, plaster and the like.
According to some embodiments of the present invention, each of niches 120 may be adapted to receive and retain at least two edges 210 of proximal external panels 200A and 200B. For example, each of niches 120 may have an opening in the range of 0.1-10.0 mm. According to some embodiments niches 120 may have a depth that substantially equals the distance between support plain 111 and infrastructure attachment plain 112 (i.e., equals the height of wall 113).
According to some embodiments, the depth of the niches 120 may be in the range of 10-30 mm. It should be appreciated that other depths may be used.
According to some embodiments, as illustrated, for example, in FIG. 2D, face 205 of external panel 200 may have cavity 208 to receive a filling such as stone, metal, marble tiles, ceramic tiles carpet or textile material, noise absorbing material and the like. It should be appreciated that a combination of filling materials may be used. It should be appreciated that additional or alternative filling materials may be used.
FIGS. 3A and 3B are schematic illustrations of different types of surfaces partially covered embodiments of the present invention. As seen in FIGS. 3A and 3B, surface 305 may be a wall or a ceiling. Surface 305 may be continues, as seen in FIGS. 3A or recessed surface 305 as illustrated in FIG. 3B. It should be appreciated that other surfaces 305 may be covered according to embodiments of the present invention, channels 306 for wiring, pipes and the like may be passed between surface 305 and infrastructure panels 300. According to other embodiments, channels 306 may be passed between neighboring infrastructure panels 300.
As seen in FIGS. 4A, 4B and 4C, a structure 402 such as a wall or a screen may be created by connecting a plurality of infrastructure panels 400 and a plurality of infrastructure panels 400′ to each other so that infrastructure attachment plains 412 and 412′ of panels 400 and 400′ are facing one towards the other. It should be appreciated that structure 402 may be connected to the ceiling or the floor by connecting means such as strings 404 or pillars (not shown). Other connecting means may be used as known in the art. According to some embodiments, structure 402 may not be connected to the floor or the ceiling and may have a base element (not shown) to allow structure 402 to stand autonomously, thus allowing structure 402 to be portable, and placed in changing positions.
Reference is now made of FIGS. 5A, 5B, 5C, 5D and 5E, which provide exemplary external panels 500A-500E according to embodiments of the present invention, each external panel 500A-500E may have a face 505, and edges 510.
According to some embodiments of the present invention, one or more of edges 510 of external panels 500A-500E may be bent rearwards (i.e., towards the surface to be covered). According to some embodiments, when external panel 500A-500E is installed, bent edges 510 may be substantially perpendicular to surface (105 in FIG. 1A).
According to some embodiments, external panels 500A-500E may be made of a film of polyvinyl chloride (PVC), ABS, Polycarbonate (PC), Polypropylene (PP), and any other thermoplastic material. It should be appreciated that thermoset materials may also be used, when forming external panels by casting.
According to other embodiments of the present invention, external panels 500 may be made from organic materials such as paper or wood chips, in pressing process.
According to some embodiments of the present invention, the film may have a thickness in the range of 0.5-10 millimeters (mm).
As may be seen in FIGS. 5A-5E, external panels 500A-500E may have a non-flat face 505. It should be appreciated however, that external panels may have a flat face (i.e., when external panel is installed in place, face 505 is substantially parallel to infrastructure attachment plain 112 in FIGS. 1A, 1B and 1C).
As seen in FIGS. 5A-5E, according to some embodiments, external panels 500B and 500C may have a non-flat face 505 (e.g., a curved face, a bulgy face and the like). It should be appreciated by those skilled in the art that other dimensions, shapes, face and edges structure and texture designs and colors of external panels 500A-500E may be used.
According to some embodiments of the present invention, external panels 500A-500E may be made fully or partially transparent to allow light to path therethrough. It should be appreciated that, when using non opaque infrastructure panels and external panels, a light source may be placed between surface (105 in FIG. 1A) and infrastructure panel (100 in FIG. 1) and may serve as an in wall light.
Reference is now made to FIG. 6, which is a flowchart of a method for applying surface cover panels to a surface, according to some embodiments of the present invention. As seen in block 610 the method may comprise attaching a first infrastructure panel to a surface by attaching a plurality of infrastructure attachment plains to the first infrastructure panel to the surface to be covered. It should be appreciated that the surface may be a wall, a ceiling, another infrastructure panel and any other surface. As seen in block 620, after attaching a first infrastructure panel, additional infrastructure panels may be attached proximal to the previously installed panel, to create an array of infrastructure panels to cover the entire surface. It should be appreciated that the surface, according to some embodiments of the present invention, mat be a wall or a ceiling a or a portion thereof or, as illustrated in FIGS. 4A, 4B and 4C, may be another infrastructure panels array facing in an opposite direction. It should be further appreciated that attaching of infrastructure panels to a surface may be by means of adhesives, by mean of plaster, by mean of screws or nails or by other attaching means known in the art.
According to some embodiments, proximal infrastructure panels may he installed so that niches crossing one infrastructure panel in one direction may be aligned with niches of a first proximal infrastructure panel crossing the first proximal infrastructure panel in a first direction and niches crossing one infrastructure panel in a second direction may be aligned with niches of second proximal infrastructure panel crossing the second proximal infrastructure panel in a second direction. It should be appreciated by those skilled in the art that other arrangements of infrastructure panels may be applied.
According to some embodiments of the present invention, after installing an array of infrastructure panels on the surface to be covered uncovered margins may remain. With reference to block 630. it is seen that in order to cover the uncovered margins, one or more additional infrastructure panels may he cut along one or more niches of each additional infrastructure panel to fit to cover the uncovered margins of the surface.
After the entire surface is covered with infrastructure panels and/or portions cut to shape thereof, external panels may be installed (block 640). The installation of external panels, according to some embodiments of the present invention, may be done by placing a first external panel so that all of the external panel's edges are retained within a niche in at least one infrastructure panel.
According to some embodiments, when required a mediating panel may be placed between infrastructure panels and external panels, as seen in dashed block 633.
According to dome embodiments, prior to covering some or all of the infrastructure panels with external panels an adhesive may be applied to some or all of the support plains or to the internal face (i.e., the face of the external panel facing the infrastructure panel when installed) of external panels (block 635)
Alternatively or additionally, after installing some of the external panels on the infrastructure panels, a filling material may be applied to fill the gaps between proximal external panels and to retail external panels in place (block 645)
It would be appreciated that, prior to infrastructure panels being attached, channels may be placed to run wiring, pipes and the like, to be covered by the infrastructure panels.
While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents will now occur to those of ordinary skill in the art, It is therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

Claims

1. A system for decorative covering of various surfaces of a premise, a building, or transportation vehicles and/or for delimiting open space settings e.g. walls and/or ceiling and/or partitions said system comprising at least a first and a second panel, while the first panel being a back infrastructure panel and the second panel being an external covering panel provided with a decorative pattern, said second panel being removable attachable to the first panel, said first panel is defined by an attachment plain securable immediately on the surface to be covered or securable on partitions of an airy infrastructure for delimiting open space settings, and by an opposite support plain configured and dimensioned to support the second panel upon attaching the second panel to the first panel.

2. A system for decorative covering as defined in claim 1, in which the support plain of the first panel is provided with an array of substructures which are designed and dimensioned to provide support to the second panel after it is attached to the first panel.

3. A system for decorative covering as defined in claim 2, in which said attachment plain and said support plain of the first panel are spaced apart from each other by at least one separation wall.

4. A system for decorative covering as defined in claim 1, in which at least the first panel is made of a thermoplastic polymeric material.

5. A system for decorative covering as defined in claim 4, in which said first panel has a thickness of 0.5-3 mm.

6. A system for decorative covering as defined in claim 1, in which at least the first panel is made of a non-toxic, washable thermoplastic polymeric material.

7. A system for decorative covering as defined in claim 1, in which the first panel is securable on the surface to be covered by an adhesive or by a mechanical means,

8. A system for decorative covering as defined in claim 2, in which each support plain of the first panel is configured and dimensioned to engage a portion of the second panel to provide structural support thereto.

9. A system for decorative covering as defined in claim 1, in which at least the first panel is made of at least partially transparent material to allow light to pass there through.

10. A system for decorative covering as defined in claim 2, in which to one or more first panels are attached one or more second panels.

11. A system for decorative covering as defined in claim 2, in which each second panel is provided with a face bearing the decorative pattern and said second panel is provided with edges directed towards the first panel being substantially perpendicular to the attachment plain of the first panel.

12. A system for decorative covering as defined in claim 2, in which said first panel is provided with at least one niche situated between adjacent substructures, wherein said at least one niche is configured and dimensioned to receive and accommodate therein edges of the adjacent second panels.

13. A system for decorative covering as defined in claim 12, comprising an array of second panels attached to the array of substructures of the first panel.

14. A system for decorative covering as defined in claim 13, comprising an array of second panels configured with dissimilar shape.

15. A system for decorative covering as defined in claim 11, in which said face is flat.

16. A system for decorative covering as defined in claim 11, in which said face is not flat.

17. A system as defined in claim 11, comprising a mediating panel, situated between the first and the second panel and adapted to support face of the second panel.

18. A system for decorative covering as defined in claim 2, in which said array of substructures of the first panel is configured as a matrix.

19. A system for decorative covering as defined in 18, in which said array is 8×8 matrix.

20. A system for decorative covering as defined in claim 12, in which upon attachment of the second panel to the first panel the edges of the adjacent second panels are received within the niche provided between adjacent substructures of the first panel.

21. A system for decorative covering as defined in claim 20, in which said niche is defined by a depth, which is equal to a distance between support plain of the first panel and attachment plain of the first panel.

22. A system for decorative covering as defined in claim 11, in which said face is provided with at least one depression, which receives and accommodate therein a filling material.

23. A system for decorative covering as defined in claim 1, in which at least one channel is provided between the surface to be covered and the first panel, said channel is adapted to accommodate a wiring, pipes or any other required items.

24. A system for decorative covering as defined in claim 1, comprising a base element to allow the system to stand autonomously and be portable.

25. A system for decorative covering as defined in claim 1, for covering an airy infrastructure made for example from metal chassis.

26. A system for decorative covering as defined in claim 1, comprising a double sided first back panels coverable from both sides by second and third face panels

27. A method for decorative covering of various surfaces of a premise or a building, or a transportation vehicles e.g. and/or of an open space settings e.g. walls and/or ceiling and/or partitions comprising

a) providing at least a first and a second panel, while the first panel being a back infrastructure panel and the second panel being an external covering panel provided with a decorative pattern, said first panel is defined by an attachment plain and by an opposite support plain configured and dimensioned to support the second panel upon attaching the second panel to the first panel.

b) securing the first infrastructure panel to the surface to be covered;

c) securing additional first infrastructure panels proximal to the previously attached first infrastructure panels;

d) attaching the second external covering panels to the support plains of the first panels.

28. A method for decorative covering, as defined in claim 25, in which said first panels are secured on the surface to be covered by an adhesive, by a plaster or by a suitable mechanical means.

29. A method for decorative covering, as defined in claim 26, in which second panels are secured on the support plains of the first panel by an adhesive or by a plaster.

30. A method for decorative covering, as defined in claim 25, comprising deployment of a mediating panel between the first panel and the second panel.

31. A method for decorative covering as defined in claim 25, comprising arranging channels on the surface to be covered, said channels being configured and dimensioned to run wiring pipes or other items, said channels are arranged on the surface to be covered before attaching the first panel thereto.

32. A method for decorative covering as defined in claim 25, comprising cutting the first panels upon securing thereof on the surface to be covered in order to cover uncovered margins, wherein said cutting is carried out before attaching the second panels to the first panels.

33. A method for decorative settings as defined in claim 25 comprising a stand-alone infrastructure to which the first panel can he attached.

34. A method for creating decorative partitions as defined in claim 25 comprising a double side first panel where the second surface panels can be attached to both sides of the first back panel

35. A method for creating decorative partitions for delimiting a space, as defined in claim 25 comprising two first back panels attached back to back where the second surface panels can be attached to each side of the back panels.