Wall panel systems and methods of assembling and refinishing wall panel systems

Abstract

A wall panel system includes a plurality of extruded composite building panels for mounting to a wall that can be repaired or refinished. The panels include a plurality of ribs for contacting the wall and a lip for overlapping one of the plurality of panels immediately below. The wall panel system includes joint clips and flashings that over lap seams between abutting panels.

What is claimed is: 
     
         1 . A wall panel system for mounting to a wall, the wall panel system comprising:
 a panel comprising:
 opposite side ends; 
 an upper end; 
 a lower end opposite the upper end; 
 a front surface; 
 a rear surface opposite the front surface; 
 a first rib on the rear surface that extends outwardly from the rear surface, the first rib having a rib surface for contacting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the first rib; and 
 a second rib on the rear surface that extend outwardly from the rear surface, the second rib having a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the second rib, wherein the rib depth of the second rib is greater than the rib depth of the first rib. 
   
     
     
         2 . The wall panel system according to  claim 1 , wherein the rib surface of the first rib and the rib surface of the second rib are coplanar. 
     
     
         3 . The wall panel system according to  claim 2 , wherein the panel is one of plurality of panels, wherein the panels are arranged in a stacked and parallel abutting end-to-end orientation;
 the lower end of the panel comprises a lip configured to overlap the upper end of one of the plurality of panels immediately below.   
     
     
         4 . The wall panel system according to  claim 3 , wherein the panel comprises a plurality of holes aligned parallel with the upper end, and wherein the lip of the lower end is configured to over lap the plurality of holes of one of the plurality of panels immediately below. 
     
     
         5 . The wall panel system according to  claim 4 , wherein the lip comprises a sloped surface configured to have flush contact with the front surface of one of the plurality of panels immediately below. 
     
     
         6 . The wall panel system according to  claim 5 , wherein the front surface comprises a sloped surface that is parallel to the sloped surface of the lip. 
     
     
         7 . The wall panel system according to  claim 1 , wherein panel comprises a papermaking sludge and a polymer composition having a synthetic polymer resin. 
     
     
         8 . The wall panel system according to  claim 7 , wherein the panel comprises a blowing agent. 
     
     
         9 . The wall panel system according to  claim 1 , wherein the panel is one of plurality of panels, and wherein the panels are arranged in a stacked and parallel abutting end-to-end orientation;
 wherein the panel further comprises a third rib on the rear surface that extend outwardly from the rear surface, the third rib having a rib surface for contracting the wall and a rib depth defined as a distance between the rear surface and the rib surface of the third rib, wherein the rib depth of the third rib is greater than the rib depth of the second rib, the rib surface of the third rib and the rib surface of the second rib are coplanar.   
     
     
         10 . The wall panel system according to  claim 9 , wherein the third rib further comprises a groove configured to receive the upper end one of the plurality of panels immediately below. 
     
     
         11 . The wall panel system according to  claim 1 , wherein the panel further comprises:
 a first portion having a front surface and an inner surface, the first portion having a plurality of scores each including a first score depth defined as a distance between the front surface and the inner surface;   a second portion having a rear surface and an inner surface that abuts the inner surface of the first portion, wherein the second portion is removably coupled to the first portion such that scores can be included in the second portion to mimic the scores included in the first portion.   
     
     
         12 . The wall panel system according to  claim 11 , wherein the first portion and the second portion extrude as a unitary panel; and wherein the first portion and the second portion comprise a papermaking sludge and a polymer composition having a synthetic polymer resin. 
     
     
         13 . The wall panel system according to  claim 12 , wherein the first and second portions comprise an additive including a colorant. 
     
     
         14 . The wall panel system according to  claim 13 , wherein the second portion has a maximum score depth plane defined between the rear surface of the second portion and the inner surface of the second portion; and wherein the second portion is configured to receive a plurality of scores each having a second score depth defined as the distance between the inner surface of the second portion and the maximum score depth plane. 
     
     
         15 . The wall panel system according to  claim 14 , wherein the second score depth is equivalent to the first score depth. 
     
     
         16 . A wall panel system for mounting to a wall, the wall panel system comprising:
 a first panel and a second panel each having an opposite side ends, an upper end, a lower end opposite the upper end, and opposite front and rear surfaces, wherein one opposite end of the first panel abuts one opposite end of the second panel to define a seam;   each of the panels includes a plurality of aligned holes that are parallel to the upper surface and positioned closer to the upper surface than the lower surface; and   a joint clip for coupling the panels such that the panels remain coupled to each other as the panels thermally deform, the joint clip has a first pin that is received in one of the plurality of holes of the first panel and a second pin that is received in one of the plurality of holes of the second panel.   
     
     
         17 . The wall panel system according to  claim 16 , wherein each joint clip comprises a base configured to couple with the first and second pins, wherein the base overlaps the seam. 
     
     
         18 . The wall panel system according to  claim 17 , wherein the first and second pins each comprise a barb configured to elastically deform and secure the joint clip to the pair of panels. 
     
     
         19 . The wall panel system according to  claim 16 , further comprising:
 a flashing for covering the seam, each flashing having an upper end, a lower end, a first flashing hole and a second flashing hole aligned with the first flashing hole, the first and second flashing hole are parallel to the upper end of the flashing and positioned closer to the upper end of the flashing than the lower end of the flashing;   wherein the first flashing hole aligns with one of the plurality of holes of the first panel and the second flashing hole aligns with one of the plurality of holes of the second panel.   
     
     
         20 . The wall system according to  claim 18 , wherein the first and second flashing holes receive the first and second pins of the joint clip. 
     
     
         21 . The wall system according to  claim 16 , wherein the pair of panels comprise a composite material comprising a papermaking sludge and a polymer composition comprising a synthetic polymer resin. 
     
     
         22 . The wall panel system according to  claim 21  wherein the composite material further comprises a blowing agent.