US20040128932A1

US20040128932A1 - Foam wall system

Info

Publication number: US20040128932A1
Application number: US10/337,469
Authority: US
Inventors: Roberto Estape
Original assignee: Individual
Current assignee: Individual
Priority date: 2003-01-07
Filing date: 2003-01-07
Publication date: 2004-07-08

Abstract

A foam panel system which is secured to studs, to conventional drywall, or other support surfaces and an installation kit therefore. The foam panels have a surface that can be prepared to resemble a variety of materials, including brick, stone, wood, artwork, coral, tiles, or even commercial information such as corporate logos, etc. Surface preparation can be accomplished by a computerized laser cutter to cut standard or unique images into the surface of a foam panel. Alternatively, molds can also be prepared with unique patterns or standard designs which are used to create panels by conventional molding techniques. Alternatively, hot dies can be used to impress a variety of surface treatments into a finished or unfinished foam panel. After the surface design is created, it may be dyed or distressed or suit a particular desired design result. Optional precut cable channels can be designed which span one or more foam panel segments to allow cables to be run within a wall with no cutting at the job site. Optional removable panel sections allow portions of panels to be removed for a variety of purposes, including entertainment, education, etc., or to provide access to hidden storage areas. An integrated illumination device allows the foam panel segments to be illuminated from within by small devices such as LEDs, electroluminescent lamps (“EL lamps”), etc., which can be embedded within the foam panel and which can be controlled by a simple off switch, a remote control, or programmed to turn on and off in a predetermined sequence.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to foam wall panels, blocks, cut outs, and surface treatments. In particular, it relates to foam wall panel systems which can be prefabricated at a central manufacturing location and installed at a remote installation site. In addition, the invention relates to foam wall panels systems whose surface appearance can be modified via laser treatment, molding, hot die application, stamping, pouring, cutting equipment of any kind, and/or distressing. It relates to both installation kits and repair kits for the foam panels. The invention further relates to foam wall panels which may have optional internal lamps to illuminate the wall from inside, and/or may have removable segments to conceal equipment or provide concealed storage.

2. Background

There have been innumerable variations in the manner that walls have been constructed. Beginning with simple stone walls in primitive times, to lath and plaster walls in modern times to the most recent introduction of a variety of wall surfacing materials which are applied either directly to the underlying wall studs, or to the surface of a conventional drywall surface. These wall surfacing materials can be either natural material, or synthetic material designed to provide the appearance of natural material.

An advantage of using natural surface materials, such as bricks, stone, marble, tile, wood, coral, etc., is that they provide attractive wall surfaces. Originally, in order to provide a wall fabricated from many natural and man-made materials, the walls were fabricated from complete stones, bricks, etc. While these walls provided an attractive and pleasing appearance, there was also an obvious disadvantage to this type of construction in that the materials used were heavy and difficult to manipulate, they were expensive, they required a fair amount of skill to install, and they required a building structure capable of supporting the substantial weight load which this type of wall structure would create. It would be desirable to be able to create a wall which had the esthetic advantages that these surface materials provide without the foregoing disadvantages.

An attempt to overcome the disadvantages associated with the use of entire stones, bricks, etc., resulted in the creation and use of veneers which give the appearance of being fabricated from relatively heavy and expensive material, but in fact are fabricated from relatively thin and lightweight material having the same appearance as their heavier counterparts. In most cases, a conventional wall fabricated from studs and drywall panels is first constructed. After the drywall panels are in place, natural surface materials are then adhered to the drywall surface. The natural surface materials are typically cut into thin veneer segments which form a surface that appears to the eye as being a wall constructed of much thicker and heavier pieces. These veneer segments can be bricks, natural stone, wood, tile, coral, marble, etc.

There are several advantages associated with this technique. First, the segments of veneer typically are much less expensive than the actual pieces of material they represent. For example, brick veneer costs just fraction of what the number of bricks required to cover an equivalent surface would cost. In addition, a conventional brick wall would require mortar to assemble bricks into a wall and a skilled brick mason to install them. In contrast, a brick veneer wall would only require adhesive to secure the pieces of veneer to the underlying drywall, and a small amount of decorative mortar applied between the brick veneer pieces to give the illusion of a brick wall. In addition to cost advantages, even though skilled labor is still required to install a veneer wall, it's much lighter weight and ease of handling allows the installer to complete installation of the wall in a substantially more rapid and convenient manner. Yet another advantage associated with veneer walls is also associated with their substantially reduced weight. Depending on the height of a particular wall, the weight of the wall fabricated from whole bricks or stone may be so great that structural problems are created in the walls, the floor, or the building itself due to the weight. Those skilled in the art will recognize that the disadvantages associated with, cost, weight, and the requirement for skilled labor would occur with any non-veneer natural material used to fabricate a wall. It would be desirable have a method of fabricating a wall having the appearance of natural materials without the disadvantages associated with them.

The veneer material, discussed above, was developed primarily to overcome the disadvantages associated with using larger and heavier non-veneer materials such as brick, stone, wood, coral, rock, etc. Unfortunately, veneer materials are not a perfect solution for all of the problems associated with non-veneer materials. In particular, veneer walls still require skilled labor for proper installation. This greatly increases the total installation cost. Likewise, certain types of veneer material, such as those fabricated from natural stone, may be expensive and difficult to obtain due to variances in natural coloration and patterns inherent in a particular piece of stone. While obtaining proper color pattern or particular type of wall covering may be difficult, the ability to obtain an adequate supply of any type of a particular material may sometimes be difficult. It would be desirable to have a veneer wall surface which is inexpensive manufacture, which can be fabricated with a consistent appearance, and which can be supplied in any desired quantity.

The recent development of synthetic foam wall panels, blocks, segments, etc., which are fabricated from a variety of foam materials has provided a solution to some of the foregoing problems. However, these foam wall panels typically are manufactured in large segments, are unwieldy to install, and are not suitable for all applications. In addition, they typically are available in only a few sizes and shapes and cannot be easily customized at the manufacturing site or the installation site. It would be desirable to have foam wall panels which can be provided in any desired shape or pattern requested by a customer, which are small enough to manipulate by a single person, and which require a minimal level of skill to install, and which can be modified or customized at the installation site by an unskilled installer.

Prior art foam wall panels also do not provide for the integration of other technologies such that the wall panels can be used as part of a prefabricated wall system. For example, while wall panels can be manually cut by a workman to run a crude cable trough during the installation process, prior art foam wall panels do not provide a fully integrated cable channel system which allows wiring to be easily concealed within it. Likewise, prior art wall panels do not provide for the integration of other functions within them, such as integrated lamps to illuminate the wall itself, or removable segments for use as entertainment devices, and/or provide secure concealed storage locations.

While the prior art has solved many of the foregoing problems associated with wall construction, it has failed to provide a multi-functional foam wall panel system which is lightweight and easy to install by a unskilled workman, which can be custom fabricated in a variety of designs including unique designs provided by a customer, which can include integrated and concealed cable channels, which can include other integrated devices, such as illumination devices, and which can have removable segments that can be used for entertainment purposes, or which can be used to conceal storage compartments or equipment panels. Likewise, the prior art has failed to provide an installation kit designed to allow an unskilled installer to install a foam panel system, and/or a repair kit which would allow an unskilled user to repair a previously installed foam panel system.

SUMMARY OF THE INVENTION

The present invention provides an installation and/or repair kit which is used in conjunction with a foam panel system which is adhered to, or replaces, a wall, a ceiling, or a floor. The foam panels used by the system are sized to allow easy manipulation by a single installer and have edges which are designed to join with corresponding adjacent panels such that when installed they form a large segment of wall, ceiling, or floor. The foam panels are prepared with a surface that can resemble any type of material, from simple brick, rock, tile, stone, coral, wood, complex artwork, photographic images, or even commercial information such as corporate logos, etc.

Several methods of surface preparation are available. A preferred embodiment uses a computerized laser cutter to cut standard or one-of-a-kind images, including photographic images, into the surface of a foam panel. Alternatively, molds can also be prepared with unique patterns or standard designs. Foam panels can then be molded using conventional molding or pouring techniques. Another alternative preferred embodiment uses hot dies to impress a variety of surface treatments into a foam panel at the fabrication and/or the installation site. After the surface design is completed, the surface can be dyed or distressed or suit a particular desired design result.

Alternative embodiments provide for cable channels which are free cut into multiple foam wall panel segments to allow cables to be run inside one or more panels within a wall. In addition, the invention provides for unique cut panel sections which allow portions of panels to be removable for a variety of purposes, including entertainment, education, etc. In addition, the movable panels can be used to provide access to hidden storage areas or to concealed equipment panels.

Another alternative embodiment provides for an integrated illumination device which allows the foam panel segments to be illuminated from within. As a result, portions of, or even the entire wall, can be illuminated for a variety of aesthetic purposes. The illumination can be provided by small devices such as LEDs, or by alternative devices such as electroluminescent lamps (“EL lamps”) which are embedded within the foam panel and which can be controlled by a simple on/off switch, or programmed to be activated in a specified or programmable sequence.

BRIEF DESCRIPTION OF THE DRAWINGS

In FIG. 1, a preferred embodiment of a blank foam wall panel is shown, prior to creation of a surface pattern or addition of optional features. [0016]
FIG. 2 illustrates a preferred embodiment of the invention illustrating the application of surface detail via a laser cutter. [0017]
FIG. 3 illustrates a preferred embodiment of the invention illustrating the application of surface detail via a molding process. [0018]
FIG. 4 shows a preferred embodiment of the invention which uses a hot die to apply surface detail to a foam wall panel. [0019]
In FIG. 5, an alternative preferred embodiment is shown in which removable segments are incorporated into the foam wall panel. [0020]
FIG. 6 illustrates an alternative preferred embodiment in which cable troughs are precut into one or more segments of foam wall panel. [0021]
FIG. 7 illustrates another alternative embodiment of the invention in which illumination panels have been embedded into the foam wall panel. [0022]
FIG. 8A illustrates an exploded prospective view of yet another alternative preferred embodiment in which foam panels resembling segments of a wood panel are shown being assembled form complete wood panel. [0023]
FIG. 8B illustrates the embodiment of FIG. 8B after the segments have been assembled into a complete panel.[0024]

DESCRIPTION OF THE PREFERRED EMBODIMENT

Prior to a detailed discussion of the figures, a general overview of the system will be presented. The invention provides a foam panel system which allows decorative foam panels to be installed on a wall by an unskilled workman, such as a do-it-yourselfer. The system provides an installation kit and/or a repair kit which is designed to allow an unskilled installer to install small prefabricated segments of foam panels that are easily manipulated by a single person, and which can be assembled at the job site to create a finished wall, ceiling, and/or floor. The system is also designed to allow a wide variety of designs and patterns to be applied to the foam panels either at the fabrication site or at the installation site. The system allows a single individual to install a custom foam surface on a ceiling, on wall, or floor. In addition, a wide variety of surface treatments can be pre-applied were applied at the installation site. The repair kit allows the single individual to repair a damaged foam panel after installation through the use of a foam applicator which fills in gouges or cuts in the foam which are then sanded and colored to match the rest of the foam surface. Those skilled in the art will recognize that the installation kit and the repair kit can be substantially the same with the exception that the installation kit would come with a suitable number of foam panels to complete a given surface area. Alternatively, the installation kit and repair kit would contain the same items and the foam panel segments would be obtained separately. [0025]
The foam panels are fabricated preferably from a foam polymer and can be fabricated in a variety of thicknesses, strengths, and densities. For ease of discussion, the foam panels used herein may be referred to as surface treatments, panels, wall panels, foam panels, foam blocks, or foam wall panels. However, these panels can be placed in any suitable location, such as walls, ceilings, or even floors. The density and strength of the foam selected would be governed by its intended use. Panels used in a ceiling can be fairly thin and have a low density since they do not normally sustain physical contact. Likewise, panels used on walls would preferably be stronger and more dense than foam panels used on a ceiling because walls are more apt to sustain physical impacts in the normal course of a day's activity. Of course, the foam selected for use on a floor's surface must have sufficient density and strength to accommodate the heavy use and impact which normally occurs on floors. One method of increasing the strength of foam panels used to incorporate layers of mesh material, which can be fabricated from fiberglass, nylon, wire mesh, or any other suitable mesh material. The mesh material can be used as backing, or can be fabricated within the panel. In addition, the external surfaces of the wall panels can be covered with an acrylic latex, or other any other suitable material, in order to form a hardened surface. The hardened surface not only increases the strength of the wall panel, it also inhibits the growth of mold, etc. by preventing penetration of the foam panel by mold spores and moisture. [0026]
There are a variety of commercially available foam materials which can be used to implement this invention. These materials can be precast, poured, molded, laser cut, stamped, or hand carved with any suitable tool. In addition, the invention provides for any number of surface treatments to suit various design goals. In fact, providing the wall panels are fabricated with suitable levels of strength, the foam panels can also be used on the external walls of a building. [0027]
The foam panels can be installed in a variety of ways. The preferred embodiment envisions an installation kit having a preselected number of foam panel segments sufficient to cover a preselected amount of surface area. In addition to the panels themselves, the kit also the includes attachment materials to secure the foam panels to a support surface. The attachment materials can be adhesive, nails, tacks, tapcons, staples, or any other suitable attachment material. An optional cutting tool can also be included in the kit to allow segments of panels to be cut to fit a particular installation site. In addition, the cutting tool can also be used to repair damage, or to cut cable troughs in the rear of the panels to allow wiring to be run underneath the panels. The cutting tool can be a hot knife, or a conventional cutting device such as a blade, a grinding tool, etc. Finally, cosmetic treatments such as paints, dyes, etc. are also included to allow the installer to create a desired aesthetic effect. Optionally, special equipment such as hot dies having decorative designs may also be supplied to allow designs to be engraved in the surface of selected panels at the installation site. [0028]
A repair kit is also envisioned for use with the foam wall panel system. The repair kit is a modified version of the installation kit. It differs from the installation kit in that it would typically contain only a small number of replacement panels or no panels at all. It would preferably have items required to secure or re-secure a panel to a support surface, a supply of foam which can be applied to restore damaged panel sections, tools to shape and sand the applied foam, and cosmetic treatments such as paints, dyes, etc. to properly color the newly applied foam. In addition, just as extra ceramic, marble, or stone tiles are often kept or repair of conventional floors, those skilled in the art recognize that it would be prudent to have one or more replacement foam panels in the event that an entire panel would have to be replaced. [0029]
When redecorating an existing room with drywall construction, the foam panels can be attached or otherwise secured directly to the drywall. Likewise, in the case of new construction, they can be secured to drywall, or preferably, replace the drywall. Substitution of the foam panels for drywall is particularly useful during construction since it can substantially reduce costs associated with construction of the interior walls. When used to fabricate walls, the foam panels would be selected with a suitable thickness of and density to provide proper physical strength and wear characteristics for that purpose. In addition, it would also be coated with a proper surface hardener, such as acrylic latex, acrylic plaster, or other suitable hardeners or finishing compounds to provide adequate strength and hardness as well as a surface resistant to moisture, mold, etc. In addition, the foam panel can also be further strengthened through the use of a backing, surface coating, or interior layer of reinforcing material (e.g. fiberglass, fiber mesh, fiber cloth/hair, metal rods or tubing, or any other suitable reinforcing material). Typically, foam wall panels can be fabricated in a variety of thicknesses to suit particular intended use. The preferred embodiment envisions a variety of base thicknesses which may range from approximately 0.5, 0.625, 0.875 inches plus the required thickness needed to provide the surface decor have been found to be suitable as drywall replacement. The total thickness is not critical and can vary widely based on the intended use and home and nature of the surface treatment. The foam panels may have increased thickness over conventional drywall to accommodate the carving of decorative patterns on the surface of the foam. The type of engraving or surface treatment on the wall panel will also have a direct effect on what the appropriate thickness should be. [0030]
In the preferred embodiment, the installer will permanently attach a foam panel to a drywall surface, or to studs if there is no drywall. In the event that the foam panel is attached to the surface of drywall, then the thickness of the foam panel can be reduced because the drywall contributes to the structural strength of the wall and provides additional support for the foam wall panels. The wall and ceiling panels are preferably connected together with a foam/glue expandable adhesive. Those skilled in the art will recognize that any other suitable permanent adhesive may also be used providing it is suitable for use with both foam panels and their associated support structures. The adjacent panels can be fabricated with or without interlocking side wedges and bonded to any existing external wall, internal wall, ceiling, or soffit. A variety of methods can be used to secure the panels to support services. For example, adhesive material, hook and loop material, screws, nails, tacks, tapcons, staples etc., can all be used depending on the individual installation. [0031]
During normal installation, the installer would select a foam panel and secure it to a support surface, such as a wall, using any at the attachment methods described above. The small segments used by the invention are sized such that they can be easily manipulated by an individual even when standing on a ladder. The individual installing the foam panels would then select additional panels which are placed adjacent to corresponding panels and secured to the support surface until the entire selected area is completed. Of course, those skilled in the art will recognize that the attachment method selected will vary based on the nature of the support surface. [0032]
While the foam panels would normally be secured permanently to the wall, there are situations where it would be desirable to have removable panels. In addition to the foregoing attachment methods, it is also possible to attach removable foam wall panels to a wall such that one or more panels may be selectively removed and reattached. Any suitable attachment means can be used so long as a particular wall panel can be detached and reattached. For example, hook and loop material can be used, magnetic attachment points can be provided, adhesive material can be used, snap on connectors can be used, etc. Several advantages are provided by detachable wall panels. They can be used to conceal a variety of unsightly devices (e.g., fuse boxes, telephone equipment panels, etc.) such that they can be easily accessed when needed, yet out of sight when not needed. They can be used to conceal storage devices (e.g., safes containing valuables, etc.) from public view. Alternatively, rather than being used to conceal items, the removable segments of foam panels can be designed for entertainment or education. For example, a child's room may have foam or other decorations that can be attached to locations on the wall of a child's room. These detachable items may be pieces of a game (e.g., chess or checker pieces, etc.), letters of the alphabet, etc. [0033]
An advantage of using foam to construct the panels is that the foam can be cut with channels (i.e., also referred to as cable troughs or conduits) that allow cabling to be run inside of it. This provides a substantial advantage during the construction process because workman such as electricians, plumbers, cable installers, etc., can easily cut channels due to changes in construction plans, etc. These channels allow wiring to be hidden inside of wall panels such that they are protected from damage, and also are prevented from creating an unsightly appearance. While foam panels can be easily cut using proper tools (e.g., a hot knife), they can also be precut with any suitable cutting device during the fabrication process. Preferably, a standard set of troughs are provided which align with troughs in adjacent panels to allow wiring to be run across substantial sections of a wall without requiring any significant cutting at the job site. When creating these cable troughs at the manufacturing facility, hot knives can be used, laser cutters can be used, hot dies can be used, mechanical cutters can be used, etc. An advantage provided by the use of cable troughs within foam wall panels is that, since the foam wall panels rests on the surface of the support structure, there is no need for holes to be cut in studs, etc. This reduces the total amount of effort on the part of someone such as an electrician to install wiring. The cable trough can be cut in the rear of the panel so that it is not in view once the panel is installed. Alternatively, the cable channel can be cut in front of the panel and provided with a cover. And advantage of creating the cable troughs at the manufacturing facility is that a cover fabricated from foam can be cut which encloses the cable trough which is precisely cut. When cables are installed into the foam panel at the installation site, the cover can conceal the cable trough so that wires can be hidden from view and protected from damage. In addition, the wires can be easily accessed if necessary by removing the cover. [0034]
Another advantage of the foam panel construction method disclosed herein is that it allows a number of artistic surface treatments to be made. For example, any type of landscape such as caves, mountains, ocean scenes, etc. can be carved into the panel. Likewise, other themes such as sporting events, children's themes, historical themes, scientific themes, etc. can be engraved on the surface of foam panels. The panel can also be carved to resemble natural materials such as coral, bricks, stone, wood, tile, etc. As a practical matter, there is no limit to the type and variety of artwork which may be applied to a foam panel via a device such as a computer controlled laser cutter, by standing, by hand carving, etc. In addition, because these foam panels can be precision cut under computer control, they can be fabricated such that an individual can supply a particular image which the computer can use to control the engraving of a unique panel which may be based on a photograph or other form of digital artwork. This is a significant advantage over prior art panel fabrication techniques in that it allows unique, individualized artwork to be engraved on the foam panels. [0035]
In the case where hot dies are used to engraved an image on a foam panel, the preferred embodiment conditions an installation and/or repair kit which contains multiple dies which attached to a hand-held die power source. This allows the installer to select from a number of different die designs, attach the die to the power source, and engrave the selected image on to the surface of the foam panel. As a result of this technique, the installer can selectively apply variety of designs onto a wall even after the wall has been installed on support surface. [0036]
The invention disclosed herein also provides another unique advantage over prior art panel systems in that the removable panels also allow otherwise unsightly features on a wall (e.g., circuit breaker panels, telephone equipment panels, cables, etc.) to be temporarily covered when access to them is not needed. As a result of using these removable panels, the esthetic appeal of particular wall may be greatly improved. [0037]
Another feature which prior art wall systems do not provide is a wall system in which the wall panels themselves can be illuminated. Foam panels provide an additional advantage in that illumination devices can be inserted within them during their fabrication process. In a preferred embodiment, small low-power illumination devices such as LEDs to (“light admitting diodes”) or EL lamps (“electroluminescent lamps”) are embedded inside the foam while the foam panel is being cast. At the same time, wiring is run inside the panel from the illumination devices to the panel's edge. Once the wall is completed, the illumination devices can be activated. When the illumination devices are activated, light will emanate directly from the wall to create an interesting and unusual effect. The use of the smaller panel segments also allows the installer to have more precise control over the sections of wall or other surface area will be illuminated. [0038]
An advantage of EL lamps is that they can cover surface large areas while using minimum amounts of energy, creating minimum amounts of heat, and occupying a minimum amount of volume. In addition, EL lamps can be cut into any desired pattern, such as text characters, figures, corporate logos, etc. This allows selected characters, or other symbols (e.g., corporate logos, etc.) to be embedded within the wall panels and independently and selectively illuminated. On the other hand, devices such as LEDs can be embedded within a foam panel after it is fabricated. This allows a standard base panel to be fabricated for a wide variety of uses, but also allows that same base panel to be customized to suit a particular purpose. EL lamps and LEDs are well known in the art and their operation will not be described in greater detail here. [0039]
Those skilled in the art will recognize that strength and density differences in particular foams will result in foam panels of different thicknesses having similar strength characteristics. Of course, foam panels used for ceilings may have reduced thicknesses and strength because their lack of contact with individuals alleviates concerns regarding physical impact in the course of daily use. In practice it has been found that panels having a thickness of ⅝ inches or less is suitable for ceiling panels, but this can also vary based on the decorative patterns engraved on their surface. Likewise, foam panels used for floors would necessarily require higher strength, and perhaps greater thickness/density than foam panels used for walls for the same reason. While the intended location and use of a particular foam panel is a factor when considering characteristics such as its thickness and density, the exact density and thickness of the foam panel can very and is not critical. [0040]
The foam wall panel system has numerous advantages over the prior art. For example: [0041]
1. Foam can be fabricated with water resistant surfaces on both the front, rear and sides. This is a substantial advantage over drywall systems which are easily damaged by water. [0042]
2. Foam is mold and mildew resistant when sealed or treated properly. This is a valuable feature because mold contamination has become a serious health hazard problem in many areas of the country. [0043]
3. Foam wall panels have superior sound insulation properties as compared with drywall construction. This provides greater privacy and greater consideration for neighbors in high-density buildings such as apartments. [0044]
4. Foam panels are fire retardant when properly treated with commercially available treatments such as acrylic hardeners or UL rated chemicals. This is a substantial safety improvement over drywall systems whose paper sheathing is often combustible. [0045]
5. Foam panels are washable when sealed and treated properly. This is a substantial convenience improvement over drywall systems which are not typically washable. [0046]
6. Foam panels are durable when properly treated or finished (i.e., coated, sprayed, laminated with fiberglass or mesh material, etc.). Due to their inherent strength and resistance to physical damage, foam panels provide an improved reliability over drywall systems. [0047]
7. Foam panels are easier to install than drywall. They do not require a skilled worker to tape and finish the wall as would be required for drywall insulation. In contrast, foam panels require minimum wall preparation and adhere to substantially any surface, including interior, exterior, ceiling, floor, and soffit surfaces. They also do not require a skilled workman to install them. [0048]
8. Foam panels provide a greater variety of potential surface finishes. As a practical matter, drywall systems are limited to a handful of surface finishes. Likewise, veneer systems have a limited number of selectable designs. In contrast, the manufacturing process used to create foam wall panels provides an unlimited number of potential surface designs. Numerous texture and thickness variations are possible, such as pre-surfaced knocked down, orange peel or numerous other artistic stone, wood and coral designs. [0049]
9. Foam panels can be fabricated with a wide range of colors and patterns. In addition, the foam can be dyed such that if inadvertently chipped, there would be no difference in color shown by the underlined material exposed by the chip. [0050]
10. Foam panels are easily repairable. Damaged panels can easily be prepared for the application of expandable foam. After the expandable foam is applied, it can be properly formed using hot knife cutting, sanding and coloring. This is particularly important, because the decorative surface of the foam panel is more detailed and complex than the flat surface of a drywall system, and the ability to repair it without replacement will greatly reduce the convenience and cost of repair. [0051]
11. Foam panels can be installed with a wide variety of corner angles. For example, panels ranging from 30 to 160 degrees are easily formed. [0052]
12. Foam panel walls can be installed much more rapidly than drywall. For example, an unskilled do-it-yourself worker can install a foam wall in hours, while a drywall installation may require an entire day's work, or more, by a skilled worker. [0053]
13. Foam panel walls are substantially less expensive than walls fabricated from actual stone, wood, coral, etc. In addition, foam walls can be installed with only a fraction of the mess and debris created by the installation of other wall systems. [0054]
14. Foam panel walls are much lighter than stone, wood, or coral walls. As a result, there is substantially less compression and damage to floors and/or flex fractures to walls or other support surfaces than there would be with a stone, wood, or coral wall having a substantially identical appearance. [0055]
15. Foam panel-walls provide accessories not possible with other wall types. For example, foam panel walls can contain integral and low voltage panels, they can contain integral picture hanging tracks, they can contain puzzle or game patterns, they can contain artwork in the form of stamped carvings, they can be used to provide designs and etchings for a variety of unusual shaped segments. In addition, they can contain unique features such as illuminated walls which would be impossible with walls fabricated from stone, etc. Other features possible with foam panels are the formation of integral ledges which can be used to hang objects such as pictures, artwork, etc., or even extended ledges which may support objects in the manner of a mantle. In fact, the foam panels themselves can provide an almost unlimited variety of artistic designs. In addition to aesthetic designs, the foam wall panels can also be fabricated such that they provide functional features such as air or water tracks within the wall panels or associated moldings. [0056]
In the preferred embodiment, it is envisioned that the individual panels will have suitable sizes and weights such that they can be easily manipulated by an individual installer. Those skilled in the art recognize that individual panels within a group of panels used to fabricate a wall can vary from one another in both size and appearance to create a particular esthetic look. Having discussed the features and advantages of the invention in general, we turn now to a more detailed discussion of the figures. [0057]
In FIG. 1, a preferred embodiment of a blank [0058] foam wall panel 1 is shown, prior to creation of a surface pattern or addition of optional features. For ease of discussion, a simple generally rectangular wall panel 1 is shown. However, those skilled in the art will recognize that the wall panel can take any particular shape. This wall panel 1 shows a front surface 2 which will eventually be engraved with a surface treatment of some kind. Side edges 4, 5 and top and bottom edges 6, 7 are also shown. These side edges 4, 5 and top and bottom edges 6, 7 will abut adjacent wall panels when the wall is completed. Rear surface 3 will be secured to the wall studs or to underlying drywall, or other wall structure, when the wall panel 1 is installed.
FIG. 2 illustrates a preferred embodiment of the [0059] foam wall panel 1 illustrating the application of ornamental detail to the front surface 2 via a laser cutter 8. In this example, the ornamental design is intended to resemble a brick wall. A computer controlled laser cutter 8 controls the laser beam 9 which engraves grooves 10 into the front surface 2 of foam wall panel 1. The computer controlled laser cutter 8 controls the engraving of grooves 10 such that they resemble the mortar pattern between bricks in a brick wall. Once a brick pattern has been cut, the surface can be stained to resemble any color brick, and the grooves and can be colored to resemble mortar. Of course, the foam can be pre-dyed to resemble the proper color for mortar or brick, and only one color would then need to be added to complete the wall panel coloration.
Those skilled in the art will recognize that while a brick pattern was used in FIG. 2, any type of surface treatment can be engraved onto the [0060] front surface 2 of foam wall panel 1. In addition to a brick pattern, it can also be made to appear to be stone, rock, wood, tile, coral (coquina), carvings, stamps, etchings, murals, puzzles, engraved photographic images, landscapes, sand finishes, flat finishes, knock down finishes, popcorn finishes, pebble finishes, and/or moldings of any size and shape. Due to the precision of commercially available lasers, laser cutter 8 can be used to produce an extraordinarily wide range of surface finishes and types of images which may be engraved on the front surface 2 of foam wall panel 1. Of course, the brick pattern illustrated in this figure can also be created by alternative processes, such as molding, hot stamps, and even hand carving. However, the laser cutter 8 has an advantage in that it can create any surface treatment with a high degree of precision.
FIG. 3 illustrates another preferred embodiment of the invention illustrating the application of a rock surface detail to the [0061] front surface 2 of the foam wall panel 1 via a mold 11. The mold 11 is shown being detached from foam wall panel 1. The mold 11 contains a pattern which is used to form raised surfaces resembling rocks 12 and mortar grooves 10 on the front surface 2 of the foam wall panel 1. As previously discussed, the rocks 12 and mortar grooves 10 are used for ease of discussion, however those skilled in the art will recognize that any pattern can be engraved onto the front surface 2 of the foam wall panel 1. Likewise, the mold 11 can take any desired shape rather than the rectangular shape used herein for illustrative purposes. A disadvantage associated with molding is that molding is only done at the fabrication plant, while other surface treatment and finishing techniques have the advantage of being capable of use at the installation site. Molding techniques are well-known in the art and will not be discussed further herein.
FIG. 4 illustrates another preferred embodiment of the invention in which an engraved surface detail is added to the [0062] front surface 2 of the foam wall panel 1 via a hot die 13. In this figure, instead of the stone or brick patterns shown above, a decorative figure of a tiger 19 is engraved onto the foam wall panel 1. The decorative tiger image illustrated in this figure is representative of the fact that any type of design can be engraved on the front surface 2 of foam wall panel 1 using a hot die 13. The hot die 13 has sufficient temperature to heat the foam wall panel 1 such that the front surface 2 of foam wall panel 1 will conform to the shape of the hot die 13. Once the hot die 13 is removed, the front surface 2 cools and preserves the shape of the hot die 13. It should be noted that this and the preceding embodiments illustrates the wide variety of surface treatments which can be applied to a foam panel 1. As was the case with a laser cutter 8 and the mold 11, it is understood that the hot die 13 can take the form of any complex pattern, and can in fact cover the entire front surface 2.
Having discussed several methods of engraving an image onto the [0063] front surface 2 of the foam wall panel 1, the preferred embodiment envisions the use of software controlled laser cutters 8 to cut the foam wall panels 1. The laser cutters 8 will cut any pattern under control of the computer. In addition to laser cutting, foam wall panels 1 can also be engraved using artistic and/or patterned hot stamps (i.e., hot dies) to imprint designs onto the front surface 2. In the case where many foam wall panels 1 bearing the same design are to be produced, it is envisioned that foam will be poured into precast molds for mass production of particular designs.
Once the [0064] foam wall panel 1 has been engraved, its surface will be finished to preserve the design and to add additional properties. For example, the foam wall panel 1 will be coated with a hardener such as latex or acrylic. The hardener provides a durable protective surface for the foam, and may provide selectable coloration. At this point, the foam wall panel 1 will typically provide an R19 insulating factor. In addition, the materials used to fabricate the foam wall panel 1 preferably use a UL rated fire retardant to provide an additional measure of safety in the event of a fire. Once the foam wall panel 1 has been coated, it can also be covered with any type of washable or non-washable paint with or without granular deposits (e.g., popcorn ceiling finishes, rough surface finishes, smooth surface finishes, etc.).
The [0065] foam wall panels 1 can be secured to any commercially available framing structure. The framing structures can be steel, metal, aluminum, wood, concrete, and/or plastic. Each foam wall panel 1 can be secured to its respective framing structure by a variety of methods. They can be secured by nails, screws, tapcon washers, adhesives, hook and loop material, staples, foam adhesive, etc. In addition, they can also be interlocked via male/female grooves, thermal joints, etc.
In FIG. 5, an alternative preferred embodiment is shown in which [0066] removable segments 14 are incorporated into the foam wall panel 1. As was the case above, foam wall panel 1 can take any convenient shape. In addition, the removable segment 14 can also take any convenient shape. For example, in addition to the brick pattern illustrated in this figure, it can also be formed in a variety of other shapes, such as the shape of a game piece, a cartoon character, an alphabet character, etc., for use in a child's room. Of course, the removable segment 14 can have a different surface finish, or even a different color. In the preferred embodiment, the removable segment 14 has a thickness which is less than the thickness of the foam wall panel 1. This allows the removable segment 14 to be removed without exposing the support wall behind the foam wall panel 1. It also allows formation of the storage compartment behind the surface of the foam wall panel 1 which may be used to conceal valuables, etc. Alternatively, at least portion of the removable segment 14 can extend entirely through the foam wall panel 1 while being secured around its peripheral edge. By providing a method of accessing the support wall behind foam wall panel 1, items such as safes, circuit breaker panels and telephone equipment panels can be concealed when not in use, and accessed when desired.
FIG. 6 illustrates an alternative preferred embodiment in which [0067] cable grooves 15 are precut into one or more segments of the foam wall panel 1. The cable grooves 15 act as cable troughs which allow cables to be run through the entire length of the foam wall panel 1. In addition, openings for wiring outlets 16 can also be precut. In the preferred embodiment, the cable grooves 15 are concealed by removable segments 14 to secure them inside the cable trough, and provide an aesthetically pleasing appearance.
FIG. 7 illustrates another alternative embodiment of the invention in which [0068] illumination panels 17 have been embedded into the foam wall panel 1. In this embodiment, the illumination panel 17 is an EL lamp. When the foam wall panel 1 is fabricated, the EL lamp is embedded just under the surface. The EL lamp was chosen as the illumination panel 17 because of it's great flexibility in terms of surface area, low-power requirements, and low heat generation. Power for the EL lamp is supplied via power line 18 which is threaded through grooves 15 to an exit point on the side of the foam wall panel 1. A small controller (not shown) which is external to the foam wall panel 1 can be used to control activation of the EL lamp. In addition, the controller is preferably programmable so that it can selectively sequence a plurality of EL lamps on and off. An advantage provided by the illumination devices 17 is that since they are embedded below the surface of the foam wall panel 1, they are invisible when the illumination device 17 is not activated.
Those skilled in the art will recognize that alternative illumination devices can also be used. For example, LEDs can be embedded into the [0069] foam wall panel 1. The LEDs provide a different lighting effect than the illumination panel 17 and may be more desirable for some applications. Of course, there may be some decorative applications where a combination of different illumination devices 17 can be used in combination to create the specific effect. The use of multiple illumination devices also allows multiple colors to be used, which in turn increases the variety of effects that can be achieved.
In FIG. 8A, and exploded perspective view of an alternative preferred embodiment is shown. In this figure, a [0070] simulated wood panel 21 is fabricated from foam segments. A central panel segment 22 is shown along with upper and lower edges 23 are shown being moved into position against the central panel segment 22. In addition, with the right side edges 24 are also shown being moved into position against central panel segment 22. The use of the segments allows the manufacturing process to be simplified. The simulated wood panel 21 can be assembled at the installation site. In addition, color can be applied at either the fabrication site or the installation site.
FIG. 8B is a perspective view of the embodiment in FIG. 8A after the foam segments have been assembled into a single [0071] simulated wood panel 21. The foam segments can be fabricated by any of the foregoing techniques, including laser cutting, molding, cutting devices, etc. Yet another embodiment of the invention is the use of foam beams whose surfaces are prepared the same manner as the simulated wood panels 21. These foam beams can have any geometric shape, and can be made to resemble any type of material (e.g., wood, coral, stone, etc.). Beams such as this are typically used as ceiling decorations.
Another ceiling application for the foam panels is to create standard size panels for use in drop-down ceilings which have the advantage in that they can have custom designs engraved on them at the installation site by using the equipment provided by the installation kit. [0072]
As can be seen by the foregoing description of the various embodiments, this invention can be implemented in a variety of ways. The [0073] foam wall panels 1 can have any desired size or shape. In a preferred embodiment, a surface is fabricated from small foam wall panels 1 that are incorporated into a kit for a do-it-yourself project. It preferably would have a preselected number of panels to cover a specific area size on a wall, floor, or ceiling. In addition, it would have all of the materials necessary to secure the foam wall panels 1 to a support surface. Alternatively, foam wall panels 1 can be fabricated in larger sizes such that it would replace drywall, and be installed in panels sizes roughly equivalent to drywall panels. A kit can also be provided for ceiling replacement in which the appropriate type and number of ceiling panels, along with attachment supplies are provided. In addition to use on floors, walls, or ceilings, foam wall panels 1 can also be shaped such that they can be used as crown molding, ceiling beams, etc. A significant advantage provided by this invention is that it provides a kit that allows an unskilled individual to self install a wall which appears to be a custom wall. The individual can do this without having to secure skilled labor, without having to spend an excessive amount of time to complete, and without having to spend an excessive amount of money to purchase. As a result, the individual can make improvements to the individual's home which would not have been economically possible or practically possible using expensive and labor-intensive prior art techniques.
Other variations of the invention include the use of semi finished or “canvas” panels which are finished at the installation site by cutting, stamping, coloring, and/or sealing with surface hardeners, paint, etc. Likewise, large blocks of foam can be used to create sculptures. The blocks can be cut and/or rough formed during fabrication and finished by an artist at another location by sculpting via hot knife or cutting tool. The artist can, for aethetic reasons, then seal or paint the surface of the sculpture to provide a hardened surface. [0074]
While the installation and/or repair kits discussed herein have been designed to assist an unskilled individual or do-it-yourselfer, those skilled in the art will recognize that skilled tradesmen can also take advantage of the benefits and advantages of the invention. [0075]
While the invention has been described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in detail may be made therein without departing from the spirit, scope, and teaching of the invention. For example, the material used to construct the wall panels may be any foam material which is suitable for its intended purpose, the size and shape of the panels, and the designs created thereon can vary. The wall panels may be created with or without optional features such as integrated illumination, removable segments, etc. Accordingly, the invention herein disclosed is to be limited only as specified in the following claims.[0076]

Claims

I claim:

1. A foam panel system for attachment to a support surface, further comprising:

at least one foam panel having a front surface, a rear surface, and a peripheral edge;

the front surface having an esthetic treatment such that it resembles a preselected natural material, a man-made material, or an image;

means to attach the rear surface of the foam panel to a support surface;

the peripheral edge shaped such that when attached to a support surface, it aligns with a corresponding adjacent foam panel;

whereby a surface resembling natural or manmade materials is constructed by attaching one or more foam panels to support surface.

2. A system, as in claim 1, wherein the esthetic treatment is applied to the front surface of the foam panel by a laser, a mold, a hot die, a hot knife, and/or a grinding device.

3. A system, as in claim 1, wherein the foam panel has at least one removable and re-attachable segment.

4. A system, as in claim 3, wherein the removable and re-attachable segment extends through the foam panel such that when the removable and re-attachable segment is removed, an access port is created which allows access behind the foam panel.

5. A system, as in claim 3, wherein the removable and re-attachable segment extends through the foam panel such that when the removable and re-attachable segment is removed, a storage cavity under the surface of the foam panel is accessible.

6. A system, as in claim 1, wherein the foam panel further comprises:

at least one cable trough; and

at least one cover size to snugly and securely fit over the cable trough, and further sized to provide room for least one cable when the cover is installed over the cable trough.

7. A system, as in claim 2, further comprising a surface treatment which is applied to the front surface of foam panel.

8. A system, as in claim 7, wherein the surface treatment is to a plaster, an acrylic or a latex material.

9. A system, as in claim 1, further comprising an integral lamp embedded below the front surface of the foam panel such that when illuminated, the foam panel is illuminated.

10. A system, as in claim 9, wherein the integral lamp is an electroluminescent lamp.

11. A system, as in claim 9, wherein the integral lamp is an LED.

12. A foam panel kit for attachment of foam panels to a support surface, further comprising:

a plurality of foam panels, each having a front surface, a rear surface, and a peripheral edge;

the front surface of at least one of the foam panels having an esthetic treatment that resembles a preselected natural material, a man-made material, or an image;

means to attach the rear surface of each of the foam panels to a support surface; and

13. A kit, as in claim 12, wherein the esthetic treatment is applied to the front surface of the foam panel by a laser, a mold, and/or a hot die.

14. A kit, as in claim 13, wherein at least one of the foam panels has a removable and re-attachable segment.

15. A kit, as in claim 14, wherein the removable and re-attachable segment is sized such that when installed in the foam panel, a cavity is formed to provide concealed storage.

16. A kit, as in claim 14, wherein the removable and re-attachable segment extends through the foam panel such that when removed from the foam panel, an aperture is provided which allows access behind the foam panel.

17. A method of installing foam panels on a support surface, including the steps of:

installing a series of foam panels, each having a predetermined ornamental surface appearance onto a support surface, and each foam panel shaped such that it fits against a corresponding adjacent foam panel having an edge configured to snugly fit against the edge of the first foam panel; and

securing the foam panels to a support segment by adhesives, hook and loop material, screws, nails, tacks, tapcons, or staples.

18. A method, as in claim 17, including the additional step of:

providing at least one foam panel which has a removable and re-attachable segment, the removable and re-attachable segment sized such that it either extends through the foam panel such that when the removable and re-attachable segment is removed an aperture is created which allows access behind the foam panel, or it extends partially through the foam panel such that when the removable and re-attachable segment is removed from the foam panel an internal storage cavity is accessible.

19. A method, as in claim 17, including the additional steps of:

providing an integral illumination system inside the foam panel; and

controlling illumination of the foam panel by activating the integral illumination system;

whereby a surface area fabricated from foam panels can be selectively illuminated.

20. A method, as in claim 17, including the additional step of creating the predetermined ornamental surface appearance with a laser, a mold, and/or a hot die.