WALL SURFACING AND METHOD OF APPLICATION

Description

FIELD OF THE INVENTION

The present invention relates generally to wall surfaces, more specifically but not by way of limitation, a sprayable wall material that is applied in layers or as a single layer to a prepped wall surface wherein the present invention provides an alternative to wall materials such as but not limited to drywall.

BACKGROUND

Wallboard, also known as gypsum or drywall, is the most common wall material utilized for finishing the walls of a structure. As is known in the art, drywall is screwed to the interior wall framing of a structure. Subsequent the fastening of the drywall, the joints of the drywall must be taped and floated. Taping and floating of drywall joints involves an intensive process utilizing specialized materials commonly known as drywall mud and tape. The application of these materials is commonly performed in several expanding layers wherein the objective thereof is to conceal the joint of the drywall. During application of these materials, the layers of materials are sanded ensuing application of the additional layer.

While conventional drywall is effective, there are many intrinsic problems with the use thereof. One issue is that installing and finishing drywall is a labor intensive and costly process. The mudding, taping and sanding of the joints and other areas of installed drywall can require a significant amount of time. Additionally, the amount of labor required to perform these tasks is significant. Drywall is also quite bulky and the sheets are commonly provided in eight to twelve foot lengths which requires significant storage space through the entire supply chain process from manufacture to retail and shipping. Lastly, drywall is easily damaged during shipping and installation which can lead to additional costs for installers or purchasers of the drywall.

Accordingly, there is a need for a sprayable wall surface material wherein the wall surface material of the present invention is applied utilizing suitable spraying techniques and employs a method that facilitates the application thereof to framed walls.

SUMMARY OF THE INVENTION

It is the object of the present invention to provide a wall surface material and method of applying wherein the present invention includes a sprayable material such as but not limited to a plaster and cellulose mixture or polyurethane.

Another object of the present invention is to provide a wall surface material that is configured to be sprayed onto a suitable support surface to provide an interior wall surface wherein the present invention includes a backing panel that is secured to wall framing.

A further object of the present invention is to provide a wall surface material and method of applying wherein the present invention further includes utilization of support members that are secured to the backing panel.

Yet a further object of the present invention is to provide a wall surface material that is configured to be sprayed onto a suitable support surface to provide an interior wall surface wherein the present invention employs upper and lower trim members.

Still another object of the present invention is to provide a wall surface material and method of applying wherein the present invention further includes corner support members and the use thereof.

An additional object of the present invention is to provide a wall surface material that is configured to be sprayed onto a suitable support surface to provide an interior wall surface wherein the method of the present invention further includes utilization of a cover sheet member that is temporarily applied to the wall material subsequent the spraying and troweling thereof.

Yet a further object of the present invention is to provide a wall surface material and method of applying wherein the method of the present invention includes a step of sanding the sprayed wall material.

To the accomplishment of the above and related objects the present invention may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact that the drawings are illustrative only. Variations are contemplated as being a part of the present invention, limited only by the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention may be had by reference to the following Detailed Description and appended claims when taken in conjunction with the accompanying Drawings wherein:

FIG. 1 is a front view of the backing panel of the present invention;

FIG. 2 is a profile view of the support member of the present invention;

FIG. 3 is a profile view of the trim member of the present invention;

FIG. 4 is a profile view of the corner member of the present invention; and

FIG. 5 is a flowchart of a method according to an embodiment of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings submitted herewith, wherein various elements depicted therein are not necessarily drawn to scale and wherein through the views and figures like elements are referenced with identical reference numerals, there is illustrated a wall material and method of applying 100 constructed according to the principles of the present invention.

An embodiment of the present invention is discussed herein with reference to the figures submitted herewith. Those skilled in the art will understand that the detailed description herein with respect to these figures is for explanatory purposes and that it is contemplated within the scope of the present invention that alternative embodiments are plausible. By way of example but not by way of limitation, those having skill in the art in light of the present teachings of the present invention will recognize a plurality of alternate and suitable approaches dependent upon the needs of the particular application to implement the functionality of any given detail described herein, beyond that of the particular implementation choices in the embodiment described herein. Various modifications and embodiments are within the scope of the present invention.

It is to be further understood that the present invention is not limited to the particular methodology, materials, uses and applications described herein, as these may vary. Furthermore, it is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention. It must be noted that as used herein and in the claims, the singular forms “a”, “an” and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “an element” is a reference to one or more elements and includes equivalents thereof known to those skilled in the art. All conjunctions used are to be understood in the most inclusive sense possible. Thus, the word “or” should be understood as having the definition of a logical “or” rather than that of a logical “exclusive or” unless the context clearly necessitates otherwise. Structures described herein are to be understood also to refer to functional equivalents of such structures. Language that may be construed to express approximation should be so understood unless the context clearly dictates otherwise.

References to “one embodiment”, “an embodiment”, “exemplary embodiments”, and the like may indicate that the embodiment(s) of the invention so described may include a particular feature, structure or characteristic, but not every embodiment necessarily includes the particular feature, structure or characteristic.

Referring in particular to the Figures submitted herewith, the wall material and method of applying 100 employs a sprayable material to facilitate the wall material and method of applying 100 as discussed herein. It should be understood within the scope of the present invention that the wall material of the present invention is sprayed onto the backing panel 10 employing suitable pressurized spraying equipment. Furthermore, it is contemplated within the scope of the present invention that the wall material could be comprised of numerous alternate compositions of material that are operable to achieve the desired outcome of spraying the material onto the backing panel and providing a suitable interior wall surface. The wall material of the present invention is provided in a sprayable consistency and is comprised of a mixture of materials such as but not limited to water, plaster and cellulose.

The backing panel 10 is configured to be mechanically secured to wall framing utilizing suitable techniques such as but not limited to staples or screws. The backing panel 10 is manufactured from a suitable material such as but not limited to galvanized aluminum or plastic and is manufactured to have a plurality of support members 12 that overlap. It is contemplated within the scope of the present invention that the backing panel 10 is provided in alternate sizes such as but not limited to four by eight feet sheets. The backing panel 10 is capable of being trimmed so as to facilitate accommodation of sizing and objects such as but not limited to rough openings for electrical and plumbing.

FIG. 2 provides a profile view of the support member 20 of the present invention. The support member 20 is secured to the wall framing adjacent the backing panel 10 and is placed in a horizontal level orientation approximately twenty four to thirty six inches apart. The support member 20 extends outward from the wall framing and is operable to provide a structural support for the wall material as the wall material is sprayed onto the backing panel 10. Further, the support members 20 provide a guide for a user as to the thickness level for application of the wall material wherein the top segment 24 provides the member to which the wall material is sprayed. The support member 20 is provided in various sizes in order to facilitate guidance of alternate thickness of installation of the wall material of the wall material and method of applying 100. The support member 20 includes base segments 21 that are configured to be adjacent the backing panel 10 and receive fasteners therethrough. Contiguously formed with the base segments 21 are the riser segments 22, 26 wherein the riser segments 22,26 extend outward from the opposing base segments 21. The top segment 24 is contiguously formed intermediate the opposing riser segments 22,26 and is parallel with the base segments 21.

The wall material and method of applying 100 employs the utilization of trim member 30. Trim member 30 is utilized at both the upper edge and lower edge of the backing panel 10. The trim member 30 is secured to the wall framing and extends outward from the backing panel 10 the same distance as the support member 20 in order to ensure a consistent thickness of application of the wall material therebetween. The trim member 30 is further installed at any door and window openings. The trim member 30 includes first portion 31 that is adjacent the backing panel 10 subsequent installation of the trim member 30. A second portion 32 is contiguously formed with the first portion 31 being perpendicular thereto. Third portion 33 is contiguously formed with the second portion 32 distal to the first portion 31 and extends upward therefrom being parallel with the first portion 31. The third portion 33 provides a location indicating a thickness to which the wall material should be sprayed in order to achieve a uniform thickness with the support members 20.

Referring now to FIG. 4 herein, the corner support member 40 of the present invention is illustrated therein. The corner member 40 is manufactured from a suitable rigid material and is secured to corner areas of wall framing to which the wall material and method of applying 100 is being applied. The corner member 40 includes wall portions 41 wherein the wall portions 41 are adjacent the backing panels 10 that are secured to the wall framing being perpendicularly oriented. Portions 42 extend outward from the wall portions 41 being perpendicular thereto. Corner portions 44 are contiguously formed with the portions 42 and are perpendicular to each other. Portions 42 extend outward from the wall portions 41 at a distance equivalent to the support members 20 and trim member 30 in order to facilitate a consistent thickness of the sprayed wall material of the wall material and method of applying 100.

Referring now to FIG. 5 submitted as a part hereof, the method of the wall material and method of applying 100 is outlined therein. It should be understood within the scope of the present invention that the steps of the method could occur in alternate orders and further include omission of some of the steps thereof. In step 501, the user will secure the backing panel 10 to the wall framing for which the user desires to apply the wall material of the present invention. Step 503, the backing panel 10 will be trimmed for fit in areas such as but not limited to electrical outlets and edges. In step 505, a plurality of support members 20 are installed at the spacing intervals discussed herein. Step 507, the trim members 30 are secured utilizing suitable techniques to the upper and lower edges of the backing panel 10. In step 509, where applicable, the corner members 40 are secured. Step 511, the wall material of the present invention is applied utilizing suitable spraying equipment. It should be understood within the scope of the present invention that the wall material could be applied in a single layer or multiple layers to achieve the desired overall thickness. Step 513, if necessary, the wall material is leveled with suitable equipment such as but not limited to a trowel. In step 515, a cover sheet is placed over the sprayed material. It should be understood within the scope of the present invention that the cover sheet is a lightweight sheet of plastic that is placed adjacent the sprayed wall material to hold in place while the wall material cures. It should further be understood within the scope of the present invention that the cover sheet may or may need to be utilized.

Step 517, the sprayed wall material is allowed to cure. In step 519, subsequent the curing of the wall material, the wall material is sanded utilizing suitable techniques and equipment to achieve a desired surface consistency and smoothness. Step 521, a user will apply a coating to the wall material such as but not limited to paint employing suitable equipment and techniques.

In the preceding detailed description, reference has been made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments, and certain variants thereof, have been described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other suitable embodiments may be utilized and that logical changes may be made without departing from the spirit or scope of the invention. The description may omit certain information known to those skilled in the art. The preceding detailed description is, therefore, not intended to be limited to the specific forms set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the appended claims.