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 Wall panel covering

Details
Inventors: Schondelmayer, Gerald; Weise, Richard;
Assignee:
Primary Examiner: Stephan; Beth A.
Assistant Examiner: Glessner; Brian E.
Attorney, Agent or Firm:

A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface. The sidewalls are positioned on opposite sides of the core in the fixture and engage the second surface. The sidewalls are attached to the core member. A method for making the panel includes providing a fixture. The frame members are inserted in the fixture so that each one engages a fixture surface. A wall member is mounted on each side of the frame, with a filler member disposed inside the frame between the wall members.

DETAILED DESCRIPTION Briefly stated, one aspect of the invention is directed to an improved wall panel.
The wall panel includes a rectangular frame, a pair of sheetlike wall members and two thin decorative sheets.
The rectangular frame includes, two spaced apart, and generally parallel vertical side frame members and spaced apart and generally parallel horizontal lower and upper frame members.
The frame members are connected at opposite ends thereof to form the rectangular frame.
Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member.
The sheetlike wall members, preferably made of fiberboard, have an inner surface attached to the side walls of each frame member.
The thin decorative sheets, preferably cloth, cover the outer surface of the wall members on each side of the panel.
In a preferred embodiment, the sidewall members include a substantially flat leg portion having an inner surface attached to the core member and an outer surface attached to the wall member.
The sidewall member includes an edge portion extending laterally outward from the leg portion.
Preferably, the edge portion is configured as a C-shaped channel facing inwardly away from the wall panel surface.
When the frame members are assembled into a rectangular frame, the edge portions extend around the periphery of the wall panel.
The sidewalls, including the edge portions, form a shallow recess on opposite sides of the panel.
Each recess has a bottom surface defined by the outer surface of the leg portions.
The wall members are received in the recesses on opposite sides of the panel.
In another aspect of the invention, a thin barrier sheet, or scrim, is disposed between the decorative sheet and the outer surface of the wall member as a fire blocking member.
The barrier sheet preferably includes a thin aluminum foil layer laminated to a fiberglass layer.
The wall panel also includes an inner filler member disposed between the wall members.
The filler member extends between the upper and lower horizontal frame members



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