Warp resistant panels

Patent metadata

Field	Value
Publication number	US-12434267-B2
Application number	US-202017606666-A
Country	US
Kind code	B2
Filing date	Jul 28, 2020
Priority date	Jul 30, 2019
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A composite wood prefabricated wall panel configured for reduced moisture absorption includes a composite wood panel body, one or more connection components, and a priming layer. The composite wood panel body includes a front face, a rear face, and at least one edge. The one or more connection components are affixed to the rear face or the at least one edge, and the one or more connection components are configured to secure the composite wood prefabricated wall panel to one or more structural members of a prefabricated wall system. The priming layer is disposed over one or more surfaces of the composite wood panel body.

First claim

I claim:

1. A composite wood prefabricated wall panel configured for reduced moisture absorption and reduced warping after installation, comprising:
a composite wood panel body comprising a front face and a rear face;
a first connection component affixed to the rear face at a top edge, the first connection component having an arm that extends away from the rear face and is angled downwards towards a bottom edge of the rear face, the first connection component being configured to hang the composite wood prefabricated wall panel from one or more structural members of a prefabricated wall system, wherein the first connection component hangs from the one or more structural member by angling the composite wood panel such that the first connection component engage from above then, once the first connection component is engaged with the one or more structural members, the composite wood panel pivots downwards about the first connection component;
a second connection component affixed to the rear face at the bottom edge, the second connection component comprising opposing arms that form an engagement channel shaped to receive a corresponding engagement protrusion associated with one or more structural members of the prefabricated wall system and being configured to secure the composite wood prefabricated wall panel to the one or more structural members of the prefabricated wall system, wherein the second connection component engages with the one or more structural members after the composite wood panel pivots downwards about the first connection component, preventing the composite wood prefabricated wood panel from warping;
a paint priming layer disposed over at least the rear face and the front face of the composite wood panel body, wherein the paint priming layer comprises a paint primer configured to prepare the composite wood panel body to receive a layer of paint or another aesthetic layer; and
an aesthetic layer disposed over at least the paint priming layer disposed over the front face of the composite wood panel body, wherein at least 50% of the paint priming layer disposed over the rear face omits the aesthetic layer;
wherein the paint priming layer, the first connection component, and the second connection component are positioned to retain the composite wood prefabricated wall panel so that it refrains from warping while installed on the prefabricated wall system.

2. The composite wood prefabricated wall panel of claim 1 , wherein when the composite wood prefabricated wall panel is secured to the one or more structural members of the prefabricated wall system:
the rear face, top edge, and bottom edge are substantially concealed from view from within an interior of a room at least partially formed by the prefabricated wall system.

3. The composite wood prefabricated wall panel of claim 1 , wherein when the composite wood prefabricated wall panel is secured to the one or more structural members of the prefabricated wall system:
the front face is directed away from the one or more structural members and toward an interior of a room at least partially formed by the prefabricated wall system, and
the rear face is directed toward the one or more structural members and away from the interior of the room.

4. The composite wood prefabricated wall panel of claim 1 , wherein when the composite wood prefabricated wall panel is secured to the one or more structural members of the prefabricated wall system:
the composite wood prefabricated wall panel is arranged opposite to a separate composite wood prefabricated wall panel secured to the prefabricated wall system, and
the rear face and a separate rear face of the separate composite wood prefabricated wall panel are oriented toward one another.

5. The composite wood prefabricated wall panel of claim 1 , wherein the aesthetic layer comprises thermofoil.

6. The composite wood prefabricated wall panel of claim 1 , wherein the aesthetic layer comprises paint.

7. The composite wood prefabricated wall panel of claim 1 , wherein the aesthetic layer comprises fabric.

8. The composite wood prefabricated wall panel of claim 1 , wherein the aesthetic layer comprises veneer.

9. The composite wood prefabricated wall panel of claim 1 , wherein the composite wood prefabricated wall panel omits hinges.

10. The composite wood prefabricated wall panel of claim 1 , wherein the paint priming layer is disposed over all edges of the composite wood panel body.

11. The composite wood prefabricated wall panel of claim 1 , wherein the composite wood panel body comprises medium density fiberboard.

12. The composite wood prefabricated wall panel of claim 1 , wherein the paint priming layer comprises an oil-based priming agent, a latex-based priming agent, or a shellac-based priming agent.

13. A prefabricated wall system configured for reduced moisture absorption and reduced warping after installation, comprising:
a plurality of composite wood prefabricated wall panels, including at least a first composite wood prefabricated wall panel and a second composite wood prefabricated wall panel, wherein:
the first composite wood prefabricated wall panel comprises:
a first front face and a first rear face;
a first paint priming layer disposed over at least the first front face and the first rear face, wherein the first paint priming layer comprises a paint primer configured to prepare the first composite wood prefabricated wall panel to receive a layer of paint or another aesthetic layer; and
a first aesthetic layer disposed over the first paint priming layer disposed over first front face, wherein at least 50% of the paint priming layer disposed over the first rear face omits the first aesthetic layer;
a first connection component affixed to the first rear face at a first top edge, the first connection component having an arm that extends away from the first rear face and is angled downwards towards a first bottom edge of the first rear face, the first connection component being configured to hang the composite wood prefabricated wall panel from one or more structural members of a prefabricated wall system, wherein the first connection component hangs from the one or more structural member by angling the first composite wood panel such that the first connection component engages from above then, once the first connection component is engaged with the one or more structural members, the first composite wood panel pivots downwards about the first connection component;
a second connection component affixed to the first rear face at the first bottom edge, the second connection component comprising opposing arms that form an engagement channel shaped to receive a corresponding engagement protrusion of the one or more structural members, wherein the second connection component engages with the one or more structural members after the composite wood panel pivots downwards about the first connection component, preventing the first composite wood prefabricated wood panel from warping;

the second composite wood prefabricated wall panel comprises:
a second front face and a second rear face; and
a second paint priming layer disposed over at least the second front face and the second rear face, wherein the second paint priming layer comprises a paint primer configured to prepare the second composite wood prefabricated wall panel to receive a layer of paint;
a third connection component affixed to the second rear face at a second top edge, the third connection component having an arm that extends away from the second rear face and is angled downwards towards a second bottom edge of the second rear face, the third connection component being configured t

Assignees

• Dirtt Environmental Solutions

Inventors

• Gosling Geoff W

Classifications

• B44C5/043

  containing wooden elements · CPC title

• B44C5/0461

  used as wall coverings · CPC title

• B44C1/10

  Applying flat materials, e.g. leaflets, pieces of fabrics (paperhanging B44C7/00) · CPC title

• Y10S428/9133

  Decorative article for viewing from one side only, e.g. plaque · CPC title

• B32B21/02

  the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard · CPC title