Modular wall system

Abstract

A modular wall system is provided. The modular wall system includes a support base, a plurality of horizontal panels, each having opposite vertical edges, and a plurality of vertical members secured to the support base. Each of the vertical members has at least one groove for receiving the opposite vertical edges of the horizontal panels. A decorative layer is applied on at least the exterior surfaces of the horizontal panels and the vertical members.

1 . A modular wall system comprising:
 a support base;   a plurality of vertical members secured to said support base, each of said vertical members defining at least one groove;   a plurality of horizontal panels, each comprising opposite vertical edges that are recessed in said grooves of said vertical members; and   a decorative layer applied on at least the exterior surfaces of said horizontal panels and said vertical members;   wherein an upper horizontal edge of each of said horizontal panels comprises an upper horizontal keyway and a lower horizontal edge of each of said horizontal panels comprises a lower horizontal key for engagement with a respective upper horizontal keyway of another of said horizontal panels in a vertically-stacked configuration,   wherein a depth of said upper horizontal keyways is greater than a height of said lower horizontal keys, thereby defining, in the vertically stacked configuration, a horizontal conduit disposed within each of said horizontal panels.   
   
   
       2 . The modular wall system of  claim 1 , wherein at least one of said opposite vertical edges of said horizontal panels comprises a tongue for engagement with said at least one groove of each of said vertical members. 
   
   
       3 . The modular wall system of  claim 1 , wherein one of said vertical edges of each of said horizontal panels defines a groove and said opposite vertical edge of each of said horizontal panels comprises a tongue for engagement with a respective groove of another of said horizontal panels in a horizontally-aligned configuration. 
   
   
       4 . The modular wall system of  claim 3 , wherein a depth of said grooves is greater than a height of said tongues, thereby defining a vertical conduit disposed within said modular wall system. 
   
   
       5 . (canceled) 
   
   
       6 . (canceled) 
   
   
       7 . The modular wall system of  claim 1 , wherein each of said horizontal panels comprises at least one vertical anchor protruding from a lower horizontal edge thereof, and said support base defines at least one bore for receiving said at least one vertical anchor. 
   
   
       8 . The modular wall system of  claim 3 , further comprising a plurality of horizontal caps covering an upper horizontal edge of said modular wall system. 
   
   
       9 . The modular wall system of  claim 8 , wherein a lower horizontal edge of each of said horizontal caps comprises a lower key for engagement with said upper keyway of an uppermost of said horizontal panels. 
   
   
       10 . The modular wall system of  claim 9 , wherein a depth of said upper horizontal keyway is greater than a height of said lower key, thereby defining a horizontal conduit disposed along a top portion of said modular wall system. 
   
   
       11 . The modular wall system of  claim 1 , wherein each of said horizontal panels defines at least one conduit. 
   
   
       12 . The modular wall system of  claim 1 , wherein each of said vertical members further comprises:
 a structural vertical member; and   a plurality of pilaster panels covering said structural vertical member, at least one of said pilaster panels defining a groove for receiving one of said opposite vertical edges of one of said horizontal panels.   
   
   
       13 . The modular wall system of  claim 12 , wherein at least one of said opposite vertical edges of said horizontal panels comprises a tongue and defines a groove, and at least one pilaster panel on each of said vertical members comprises a tongue and defines a groove, each for engaging a respective one of said groove and tongue of one of said opposite vertical edges of one of said horizontal panels. 
   
   
       14 . The modular wall system of  claim 12 , further comprising a plurality of fastener devices that secure said horizontal panels to said pilaster panels. 
   
   
       15 . The modular wall system of  claim 14 , wherein said fastener devices are cam-locks. 
   
   
       16 . The modular wall system of  claim 12 , wherein each of said structural vertical members comprises:
 a hollow construction; and   at least one bayonet projection projecting upwards from an upper end of said structural vertical member, said at least one bayonet configured for engagement with a hollow lower end of another structural vertical member during a vertically-stacked configuration of said vertical members,   wherein each of said structural vertical members defines at least one horizontal aperture in communication with a conduit defined within said modular wall system.   
   
   
       17 . The modular wall system of  claim 12 , wherein each of said structural vertical members comprises at least one horizontal flange at a bottom end thereof, each of said at least one horizontal flange defining at least one aperture. 
   
   
       18 . The modular wall system of  claim 17 , further comprising:
 a plurality of bolts protruding upwardly from said support base, each of said bolts protruding though a respective one of said apertures of said horizontal flanges of a lowermost of said structural vertical members; and   at least one adjustment nut threaded onto each of said bolts, wherein rotation of said at least one adjustment bolt adjusts the height of said respective structural vertical member, thereby leveling said modular wall system.   
   
   
       19 . The modular wall system of  claim 17 , further comprising at least one locking pin protruding upwardly from each of said pilaster panels, through a respective aperture of said horizontal flanges of said structural vertical members, and into a respective pilaster panel, during a vertically-stacked configuration of said vertical members. 
   
   
       20 . The modular wall system of  claim 16 , further comprising a plurality of pilaster caps covering an upper end of each of said vertical members. 
   
   
       21 . The modular wall system of  claim 20 , further comprising at least one locking pin protruding upwardly from each of said pilaster panels and into a respective pilaster cap. 
   
   
       22 . The modular wall system of  claim 20 , wherein a lower horizontal surface of each of said pilaster caps comprises an indentation for engagement with said bayonet projection of an uppermost of said structural vertical members. 
   
   
       23 . The modular wall system of  claim 1 , wherein each of said horizontal panels comprises a closed cell foam panel sandwiched between two laminate skins. 
   
   
       24 . The modular wall system of  claim 23 , wherein an exterior surface of said laminate skins is textured. 
   
   
       25 . The modular wall system of  claim 24 , wherein said laminate skins are moisture resistant. 
   
   
       26 . The modular wall system of  claim 25 , wherein said decorative layer comprises a film layer laminated on said moisture-resistant laminate skins. 
   
   
       27 . The modular wall system of  claim 16 , wherein each of said pilaster panels comprises a closed cell foam panel sandwiched between two laminate skins. 
   
   
       28 . The modular wall system of  claim 27 , wherein an exterior surface of said laminate skins is textured. 
   
   
       29 . The modular wall system of  claim 28 , wherein said laminate skins are moisture resistant. 
   
   
       30 . The modular wall system of  claim 29 , wherein said decorative layer comprises a film layer laminated on said moisture-resistant laminate skins. 
   
   
       31 . The modular wall system of  claim 1 , wherein said decorative layer comprises a film layer laminated on said exterior surfaces of said horizontal panels and said vertical members. 
   
   
       32 . The modular wall system of  claim 1 , wherein said decorative layer is bonded directly to said exterior surfaces of said horizontal panels and said vertical members. 
   
   
       33 . The modular wall system of  claim 1 , wherein said decorative layer comprises an image of rock, stone, brick, concrete, concrete block, stucco, terracotta, wood, or metal. 
   
   
       34 . A modular wall system comprising:
 a plurality of support bases set at predetermined distances from each other;   a plurality of vertical members, each secured to a respective one of said support bases having at least one vertical groove;   a plurality of horizontal panels, each having an exterior surface that spans the distance between two vertical members and opposite vertical projections that extend beyond the exterior surface and are dimensioned to be received in a respective vertical groove; and   a decorative layer affixed on said exterior surfaces of said horizontal panels and said vertical members;   wherein the plurality of horizontal panels have a keyway extending along a substantial upper horizontal length thereof and a key extending along a substantially lower length thereof, the key and keyway being sized to matingly engage one another;   wherein when the key and keyway are matingly engaged to one another, the key is sized such that it does not fill the entire depth of the keyway, thus creating a horizontal conduit through each horizontal joint between panels.   
   
   
       35 . The modular wall system of  claim 34 , wherein each of said horizontal panels comprises a closed cell foam panel. 
   
   
       36 - 38 . (canceled)