Warp resistant panels

Patent metadata

Field	Value
Publication number	US-2022205238-A1
Application number	US-202017606666-A
Country	US
Kind code	A1
Filing date	Jul 28, 2020
Priority date	Jul 30, 2019
Publication date	Jun 30, 2022
Grant date	—

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

We claim:

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

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 or the at least one edge to which the one or more connection components are affixed is 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 the priming layer is disposed over the rear face.

4 . The composite wood prefabricated wall panel of claim 3 , 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.

5 . The composite wood prefabricated wall panel of claim 3 , 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.

6 . The composite wood prefabricated wall panel of claim 1 , further comprising an aesthetic layer disposed over at least the priming layer disposed over the front face of the composite wood panel body.

7 . The composite wood prefabricated wall panel of claim 6 , wherein the aesthetic layer comprises fabric, thermofoil, paint, or veneer.

8 . The composite wood prefabricated wall panel of claim 6 , wherein the priming layer disposed over the rear face or the at least one edge to which the one or more connection components are affixed omits/omit the aesthetic layer.

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 priming layer is disposed over the front face, the rear face, and 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 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, 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; and a first priming layer disposed over at least the first front face and the first rear face, and the second composite wood prefabricated wall panel comprises: a second front face and a second rear face; and a second priming layer disposed over at least the second front face and the second rear face; and a frame module, comprising at least a vertical structural member and a horizontal structural member, wherein: the first composite wood prefabricated wall panel and the second composite wood prefabricated wall panel are selectively securable to the frame module, and when the first composite wood prefabricated wall panel and the second composite wood prefabricated wall panel are secured to the frame module, the first rear face and the second rear face are oriented toward one another.

14 . The prefabricated wall system of claim 13 , wherein the first composite wood prefabricated wall panel comprises a connection component affixed over the first priming layer disposed over the first rear face.

15 . The prefabricated wall system of claim 13 , wherein the first front face of the first composite wood prefabricated wall panel comprises an aesthetic layer disposed over the first priming layer, and wherein the first rear face of the first composite wood prefabricated wall panel omits the aesthetic layer.

16 . The prefabricated wall system of claim 13 , wherein the first priming layer is disposed over the first front face, the first rear face, and all edges of the first composite wood prefabricated wall panel.

17 . The prefabricated wall system of claim 13 , wherein the first composite wood prefabricated wall panel comprises medium density fiberboard.

18 . A method for forming a composite wood prefabricated wall panel with reduced moisture absorption properties, comprising:
obtaining composite wood panel body, the composite wood panel body comprising a front face, a rear face, and at least one edge; disposing a priming layer over the front face and the rear face of the composite wood panel body; and affixing one or more connection components to the rear face over the priming layer.

19 . The method of claim 18 , further comprising:
disposing the priming layer over all edges of the composite wood panel body.

20 . The method of claim 18 , further comprising:
disposing an aesthetic layer over the priming layer on the front face; and refraining from disposing the aesthetic layer over the priming layer on the rear face.

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