PVC wall panel system

[0002] Not Applicable

[0003] Not Applicable.

[0004] This invention relates to panel systems, and in particular, to a PVC panel system which can be used to easily erect non-load bearing walls, for example in animal enclosures. Although the invention is described to wall panel systems for use with animal enclosures, the broader applicability of the invention will be apparent to those skilled in the art.

[0005] Animal enclosures, such as farrowing pens, and other walls in hog houses, are often made of wood. The wood walls have to be framed with wood studs. The wall frame then must be covered, for example, with sheets of plywood. This is a time consuming, and hence, expensive procedure. Further, wood is porous. The dirt from, for example, a hog house, can become lodged in the ply wood wall, even if the wall is painted. It is thus difficult to keep the walls clean, and hence sanitary, even when painted. Further, the painted walls will need to be repainted periodically. Additionally, animals often like to chew on wood, requiring the replacement of portions of walls. Furthermore, the use of typical stud walls does not allow for quick and easy removal of the walls, should it be decided to partition the space differently within a hog house.

[0006] A wall panel system of the present invention includes a plurality of inter-connecting panels which are framed by top, bottom, and side channel members. The panels are tongue and groove panels, and have a tongue extending from one side of the panel and a groove formed in the opposite side of the panel. The panel is preferably hollow, and includes a plurality of dividers which define chambers within the panel.

[0007] The bottom channel member has a back leg, a front leg, and a bottom surface extending between the back and front legs. In one variation, the bottom channel member includes a heel extending rearwardly from the back leg of the bottom channel member.

[0008] The top channel member can either be an integral, one-piece assembly or a two-piece assembly. In the one piece assembly, the top channel member includes a back leg, a front leg, and an upper surface extending between the back and front wall. The one-piece top channel member can also have a heel extending forwardly from the channel member's front leg.

[0009] The two piece top channel member includes a fixed member and a locking leg mountable to the fixed member. The fixed member includes a back leg, a top surface, and a rearwardly facing groove at the free end of the top surface. The locking leg includes a finger which is received in the groove. In a first embodiment, the locking leg includes a single panel which extends down from the fixed member when mounted to the fixed member. When this embodiment is used, fasteners are driven through the locking leg and into the panel to secure the locking leg in place. Preferably, the fasteners are driven through the joints between the panels, so that the fasteners are driven through the tongues and grooves of adjacent panels.

[0010] In an alternate embodiment, the fixed member has a pair of generally parallel grooves. The locking leg has a pair of parallel arms, each of which has a finger which is received in the fixed member groove. When this embodiment is used, connection of the locking leg to the fixed member will substantially prevent the fixed member from moving relative to the fixed member and panel, and fasteners are not required. The locking leg can, for example be generally “U”-shaped, “V”-shaped, or “y”-shaped. It can also be shaped generally like a “4” or an inverted “h”.

[0011] The side channel members are used to secure the wall made from the system to side walls in the room in which the wall is being erected. The top and bottom channel members are used to form the side channel members. The first side channel member can be made from either the top or bottom channel members. The second side channel member is preferable made from the top two-piece top channel member.

[0012] A method of assembling a wall from the components is also disclosed.

[0013] FIG. 1 is a perspective exploded view showing the components of an illustrative embodiment of a wall panel system of the present invention;

[0014] FIG. 2 is a top plan view of the wall panel of the system;

[0015] FIG. 2A is an enlarged fragmentary view of the tongue end of the panel taken along line 2A—2A of FIG. 2;

[0016] FIG. 2B is an enlarged fragmentary view of the groove end of the panel taken along line 2B—2B of FIG. 2;

[0017] FIG. 3 is a cross-sectional view showing the connection of two panels to each other;

[0018] FIG. 4 is an end elevational view of a bottom channel member of the assembly;

[0019] FIG. 5 is an end elevational view of a two-piece top channel member of the assembly;

[0020] FIGS. 6A-C are top plan views showing the assembly of the wall panel system;

[0021] FIG. 7 is an elevational view of the wall panel used with alternate bottom and top channels messages, the figure showing, in phantom lines, a panel being erected;

[0022] FIGS. 8A-E are elevational views showing the assembly of the wall panel system with a second alternative top channel member; and

[0023] FIGS. 9A-C are elevational views showing other alternative top channels members.

[0024] Corresponding reference numerals will be used throughout the several figures of the drawings.

[0025] The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention. It describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what we presently believe to be the best mode of carrying out the invention.

[0026] An illustrative portion of the wall panel system 1 of the present invention is shown generally in FIG. 1. The wall panel system 1 includes a plurality of wall panels 3 (only one of which is shown in FIG. 1) which are connected as described below. The wall panels 3 are framed by a bottom channel member 5, a top channel member 7, a right end channel member 9, and a left end channel member 11. As shown in FIG. 1, the right and left end channels are identical to the top channel member 7. The individual panels 3 are about 32″ wide and can have any desired height. For example, they can extend fully between a floor and ceiling, or they can be gate height (i.e., three to four feet). The bottom and top channel members can also be about 32″ long. However, if desired, they can be longer or shorter than the wall panels 3. The side channel members 9 and 11 have a length sufficient to span the distance between the top and bottom channel members. Preferably, the wall panel 3 and the channel members 5, 7, 9, and 11 are all made from polyvinyl chloride (PVC). They can then be easily formed, for example by an extrusion or similar process. Because the components are made from PVC, they are not porous, as is wood, for example. Thus, dirt from an animal enclosure will not penetrate the surface of walls built with the wall panel system, and the walls can be easily cleaned. Further, PVC panels have an unsatisfying taste to animals, such as hogs. Thus, animals will not chew through the panels as readily as they would, for example, through wood panels. The PVC preferably also includes ultraviolet light inhibitors to protect the components from deterioration from sunlight and flame retardants. The PVC components can also be provided with other additives to give the wall panel system other desired qualities.

[0027] The components of the wall panel system 1 are assembled, as described below, to form walls, fences, dividers, or the like to divide a large room or space into smaller sections. For example, in the case of a hog house, the wall panel system can be used to separate farrowing pens from nursery pens. As described below, the assembled walls can be easily taken down to rearrange the way in which the space is divided.

[0028] The wall panel 3 has a front surface 15, a back surface 17, a top edge 19, a bottom edge 21, a tongue side 23, and a groove side 25. The front and back surfaces are spaced from each other, and a plurality of dividers 27 extend between the front and back surfaces 15 and 17. The dividers 27, in conjunction with the front and back surfaces 15 and 17, define chambers 29 which are sized to receive reinforcing boards 30, such as 2×4 boards. The panel chambers 29 are sized so that the boards 30 can be easily slipped into the chambers, but will not move around much in the chambers.

[0029] The tongue side 23 has an end surface 31 (FIG. 2A) from which a tongue 33 extends. Preferably, the tongue 33 extends the full length of the tongue side 23. The groove side 25 has an end surface 41 (FIG. 2B) in which a groove 43 is formed. The tongue 33 and groove 43 are sized so that the tongue 33 of a panel 3awill be received in the groove 43 of an adjacent panel 3bto join the panels, as seen in FIG. 3. The side wall 33aof the tongue 33 and the side walls 43aof the groove 43 are not perpendicular with the end walls 31 and 41 of the tongue side 23 and groove side 25, respectively. The tongue side wall 33aforms a slight acute angle α with the panel tongue side end surface 31. The groove side walls 43aform a slight acute angle β, preferably of about 85°, with the panel groove side end wall 41. As shown in FIG. 3, when the two adjacent panels 3a,bare assembled together, a screw 45 can be passed through one surface of the panel 3ato pass through the groove 43 of the panel 3band the tongue 33 of the panel 3a.

[0030] The bottom channel member 5 (FIG. 4) has a back leg 51 and a front leg 53 joined by a bottom surface 55 extending between the back and front legs 51 and 53. The front and back legs 51 and 53 are spaced apart a distance approximately equal to the width of the panel 3 so that the panel 3 will fit snugly in the bottom channel 5. The front leg 53 is shorter than the back leg 51. Preferably, the front and back legs are both offset from the vertical, and are angled slightly toward each other. The bottom channel member legs are sufficiently thin so that they can flex during installation of the panel 3 in the channel member 5. The bottom channel member 5 will thus grip the wall panel 3 when the panel is placed in the channel member 5.

[0031] In an alternative embodiment (FIG. 7), the bottom channel member 5′ includes a heel 59 extending beyond the bottom channel member back leg 51′. The heel 59 is a continuation of the bottom surface 55′.

[0032] The top channel member 7, shown in detail in FIG. 5, is a two-piece assembly including a fixed member 61 and a pivotable locking leg 63. The fixed member 61, as described below, is mounted to the ceiling of the room in which the panel system is installed to be above the bottom channel member 5. The top and bottom channel members thus define a generally vertical plane. The fixed member 61 is generally in the shape of an angle bracket and includes a back wall 65 and a top wall 67. The back leg 65 can be formed so that it is not perpendicular to the fixed member top wall 7. As seen in FIG. 5, the fixed member back leg 65 forms an acute angle (slightly less than 90°) with the fixed member top wall 67. The top wall 67 includes a rearwardly facing groove 69 at its front end 71. The groove 69 extends the length of the top channel member 7. The pivotable locking leg 63 has a finger 73 which extends from the top of the pivotable locking leg 63 and is sized to be received in the groove 69 of the fixed member 61, so as to be able to pivot from a raised position in which the top channel member is substantially open along its front as seen in FIG. 6A to a lowered position in which the top channel member is closed along its front as seen in FIG. 6C and the locking leg 63 is generally parallel to the fixed member back leg. Thus, as can be appreciated, the top channel member 7 does not really define a true channel until the locking leg 63 is pivoted to, or otherwise placed in, its lowered position.

[0033] As noted above, the side channel members 9 and 11 are identical to the top channel member 7, and thus are not described. If desired, one of the side channel members can be identical to the bottom channel member 5, as seen in FIGS. 6A-C.

[0034] To assemble and install a wall, divider, etc. using the panel system 1, the bottom channel member 3 is secured to the floor F of the building in which the wall is being installed. A fastener 57 (FIG. 7) is driven through the bottom channel member 5 and into the floor F to anchor the channel member 5 in place. Preferably, the fastener 57 is a corrosion resistant screw-type anchor. When the bottom channel 5 is used the fastener 57 is driven through the channel member bottom 55. When the bottom channel member 5′ is used, the fastener 57 is driven through the heel 59. The fixed member 61 of the top channel 7 is anchored to the ceiling above the bottom channel so that the bottom and top channel members are in the same plane. A sufficient number of top and bottom channel members are anchored in place to extend the full length of the wall to be built. If the wall to be built will extend between two other walls, the sides of the wall to be built are framed in with the side channel members 9 and 11. Thus, the side channels 9 and 11 are mounted to the walls between which the wall to be erected will extend. One of the side channel members is identical to the top channel member 5. The other channel member can be identical to either the bottom or top channel members.

[0035] Once the channel members are in place, panels 3 are inserted in place. To install the panels, a first panel 3 is held at a low angle with its bottom edge over the bottom channel front leg 53 and extending into the bottom channel member. The panel 3 is then tilted to a vertical position, so that the panel 3 is fully received in the bottom channel member 5. The panel 3 is inserted into the top channel member through the open front of the top channel member. The top of the panel 3 should then be in contact with the top channel member back leg 65. The top of the panel 3 need not extend all the way to the top channel upper surface 67. All that is necessary is that it overlap the top channel member back leg 65. This first panel is then urged along the bottom channel member 5 so that the side of the panel 3 will be received in the side channel member 9.

[0036] After the first panel is urged into the side channel member 9, the pivotal locking leg 63 of the first side channel is pivoted until it lies against the front surface 15 of the wall panel 3. Fasteners are then driven through the front wall 55 into the wall panel 3 to secure the wall panel 3 in place. If fasteners, such as screws, bolts, etc., are to be used, a piece of lumber should be inserted in the appropriate chamber 29 of the panel for the screw to be driven into. The pivotal locking leg can be positioned relative to the fixed member either before the panel 3 is erected into place, or after the panel 3 is erected. The assembly of the wall system 1 is described using top channel member for the side channel member 9. However, a bottom channel member could also be used for the first side channel member 9. For reasons which will become apparent below, the a top channel member is used for the second side channel member 11.

[0037] Although the locking leg 63 of the second channel member is separate from the fixed member 61, the two portions of the top channel 7 could be formed as a single piece, with the locking leg 63 pivotally attached, for example, by a living hinge, to the fixed member.

[0038] With the first panel 3ain place, a second panel 3bis installed in the same manner. It is inserted into the bottom channel and rotated up into place. It is then slid in the bottom channel so that the tongue 33 and groove 43 of two adjacent panels mate. After several panels have been erected, the first section of the pivotal locking leg 63 is installed in the top channel fixed member 61. This is done substantially in the same way as just described with the side channel member 9. The finger 73 of the pivotal locking leg is inserted in the fixed member groove 69 and rotated down until it lies against the front surface 15 of the panels. Screws 45 are then driven through the pivotal locking leg 63 at each tongue and groove connection, as seen in FIG. 3, to secure the wall panels in place relative to each other.

[0039] This process of installing panels 3 and the pivoting leg 63 of the top channel member is continued until the panels extend to the second side channel member 11. After the last panel 3 has been installed in the bottom channel member 5, the pivoting leg 63 of the side channel member 11 is inserted in place in the same manner as the pivoting leg 63 of the top channel members 7 and the first (or right) side channel member 9. Because the last panel to be inserted will not be able to be slid along the bottom channel a distance greater than the length of the bottom channel legs, the second side channel member 11 is made from the top channel member. Then, when the last panel is raised to its vertical position, the side surface of the panel 3 will rest against the back leg 65 of the top channel member 7 and the side channel member 11. The locking legs for the top and side channel members 7 and 11 can then be installed to finish the wall.

[0040] If other walls or gates will be mounted to the wall being erected, pieces of lumber (i.e., 2×4's) should be inserted in the appropriate chambers 29 of the panels 3 before the panels are inserted in the bottom channels 5.

[0041] An alternative one piece top channel member 7′ is shown in FIG. 7. The top channel member 7′ is substantially identical to the bottom channel member 5′. It includes a back leg 65′, a front leg 63′, and a top surface 67′ extending between the front and back legs. The top surface 67′ extends forwardly the front leg 63′ to form a heel 81 through which a fastener 83 is driven to anchor the top channel 7′ to the ceiling. If the top channel member 7 is used, the fastener is driven through the top surface 67.

[0042] Assembly of a wall using the top channel member 7′ is shown in FIG. 7. Initially, the bottom and top channel members are mounted to the bottom and top edges of the wall panel. When in a vertical position, the fastener is driven through the heels 59 and 81 of the bottom and top channel members 5′ and 7′ to secure the panel in place. Alternatively, the bottom channel member can be initially secured in place. The panel, with the top channel member mounted thereto, can then be inserted in the bottom channel member and pivoted up to a vertical position. The top channel member can then be secured to the ceiling.

[0043] An alternative two-piece top channel 7B is shown in FIGS. 8A-8E. The top channel 7B includes fixed member 61B and a locking leg 63B. The fixed member 61B, which is fixed to the ceiling or wall to frame in the top or sides of the panels, includes a back leg 65B and a top 67B. The top 67B includes a pair of generally parallel grooves 69A and 69B. The grooves 69A,B face rearwardly and preferably extend substantially the full length of the fixed member 61B. The locking leg 63B is snap-locked in the grooves of the top 67B. The pivoting leg 63B is generally U-shaped. It has a front arm 83 and a back arm 85 joined by a curved bottom 86. Each arm has a forwardly extending finger 87, 89 at its top. The locking leg 63B is formed of PVC, and its arms 83 and 85 are flexible.

[0044] Application of the locking leg 63B is shown in FIGS. 8A-C. After the panel 3 has been raised to its vertical position, the finger 87 of the forward arm 83 is urged into the forward groove 69B. The finger 89 of the back arm 85 is then urged into the back groove 69A. As seen in FIGS. 8A-E, there is a gap between the top edge of the panel 3 and the top 67B of the top channel member 7B. This gap allows the back arm 85 to extend into the gap above the panel 3, as seen in FIG. 8B, so that the back arm finger 89 can be urged into the rear groove 69A. When the locking leg 63B is installed in the channel member top surface 67B, the locking leg back arm 85 butts up against the panel 3, as seen in FIG. 8C. The construction of the locking leg 63B substantially prevents the locking leg 63B from pivoting relative to the panel 3 and the top surface 67B. Thus, no fasteners are needed, as with the ceiling member 7 of FIG. 5.

[0045] Because no fasteners are needed to secure the locking leg 63B in the top channel fixed member 61B, the locking leg 63B can be easily removed from the top channel member 7B to allow for removal of the panel 3 when necessary. To remove the locking leg, 63B, an instrument I, such as a screwdriver, awl, etc. is pushed through the locking leg front arm 83 and is used to push against the back arm 85 to push the back arm finger 89 out of engagement with the fixed member back groove 69A. The instrument I can be inserted through pre-existing holes in the locking leg front arm 83, or the holes can be formed when they are needed. A second instrument 12, such as a screw driver or similar tool, is used to pry or pivot the locking leg back arm 85 downwardly so that the finger 89 will not reengage the rear groove 69A. A block B is preferably used as a pivot point for the instrument 12. This will provide for better leverage, and will reduce the possibility of marring the panel 3 with the instrument 12. Once the locking leg back arm 85 is disengaged from the groove 69A, the front arm can be easily disengaged from the front groove 69B, and the locking leg 63B can be removed from the fixed member 61B. With the locking leg 63B removed, the panel 3 can be tilted forward and removed from the bottom channel member.

[0046] There is a lot of dirt and dust in a hog house. Some of this dirt and dust accumulates in the bottom channel. Thus, it is desirable to periodically remove the panels 3 to thoroughly clean the bottom channel members. The panels also need to be removed when they are broken, whether by machinery or by animals. Further, if the hog house is to be repartitioned, the walls will need to be taken down. As can be appreciated, the use of locking leg 63B does not require the removal of a plurality of fasteners, which will make removal of the locking leg faster and easier than if the locking leg 63 of the top channel 7 were used. Because the locking leg 63B can be removed quickly and easily, the wall assembly I can be disassembled fairly quickly and easily.

[0047] Variations of the top channel 7B are shown in FIGS. 9A-9C. In these variations, the fixed portions 61C-E are substantially the same as the fixed portion 61B of FIGS. 8A-E. The only item that is changed is the configuration of the locking leg. Despite the variations, the operation of the locking legs of FIGS. 9A-9C is the same as that of the locking leg 57B of FIG. 8A. In FIG. 9A, the locking leg 63C is generally “V”-shaped. In FIG. 9B, the locking leg 63D is generally “y”-shaped. Lastly, in FIG. 9C, the locking leg 63E is generally “4”-shaped. The shape of the locking leg 63E can also be described to be generally in the shape of an inverted, reversed “h”. The locking legs 63B-E all have a front arm and a back arm with forwardly extending fingers which are received in the grooves of the top channel fixed member. The locking leg could take on any other desired shape that would include a front arm and a back arm.

[0048] As can be seen, the wall panel system of the present invention can be used to fairly easily and quickly erect walls in a room to subdivide a room. The walls made from the system are constructed fully of a sturdy plastic, such as PVC, and can be easily cleaned. Further, the walls can be fairly easily taken down, either for cleaning or for repartitioning the room.

[0049] As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. For example, the pivotal connection between the front wall 55 and the top wall 57 of the top channel member 51 can be made with a forwardly facing groove, rather than a rearwardly facing groove. The groove could be circular (or any other desired shape) and the front wall finger would be shaped correspondingly to be received in the groove. Alternatively, the groove 69 could be formed on the locking leg 63, and the front edge 71 of the top channel fixed member 63 would be shaped to be received in the groove. Although the panels 3 are essentially hollow, they can be made solid if desired. This, of course would increase the cost and weight of the panels. These examples are merely illustrative.