Simulated monolithic predecorated wall construction

Claim 2

In simulated monolithic predecorated wall construction, a substantially flat joint including two adjacent predecorated wall boards, each comprising a core panel having on its front side a substantially flat surface having a marginal portion and a recessed marginal surface extending from said marginal portion of said flat surface to an edge, said recessed marginal surface having a substantially greater width than depth with a minimum width of about 0.75 inch, and a decorative sheet laminated only to said flat surface, but not to said marginal portion nor to said recessed marginal surface, one of said decorative sheets on one of said core panels including one flap extending over one of said marginal portions and one of said recessed marginal surfaces adjacent thereto at least adjacent one of said edges prior to completion of said joint, the other of said decorative sheets on the other of said core panels including another flap extending over the other of said marginal portions and the other of said recessed marginal surfaces adjacent thereto at least beyond the other of said edges to overlap with said one flap prior to completion of said joint, said core panels being arranged with said front sides substantially flush, said reCessed marginal surfaces adjacent, said edges in substantially abutting relationship and said flaps adjacent, a hardened joint cement layer filling the space between said recessed marginal surfaces and flaps to substantially the level of said flat surfaces, and upon completion of said joint, said flaps being adhered to and extending over said marginal portions and said cement layer into substantially edge abutting and flush relationship to form a practically invisible seam produced by folding said flaps back out of the way to expose said marginal portions and recessed marginal surfaces prior to said filling of said space with said cement layer, adhering said flaps to said marginal portions, cement layer and each other with said flaps overlapping, cutting through the overlapping portions of said flaps over said cement layer, removing the overlapping marginal edge portion of the overlying flap and the overlapped marginal edge portion of the underlying flap and readhering the remainder of the overlying flap to the underlying one of said marginal portions and said cement layer.

Claim 3

The joint of claim 3 wherein each of said core panels includes a set cementitious core enclosed on opposite sides and each of said abutting edges with a fibrous facing layer, said marginal surfaces taper edgewise toward the rear sides of said core panels and have a minimum width to depth ratio of about 3.75/1, and each of said decorative sheets includes an inner fibrous backing layer laminated to said fibrous facing layer and an outer plastic layer forming a decorative front wall surface.

Claim 4

The joint of claim 3 wherein each of said core panels is of elongated, generally rectangular shape and has on its front side a substantially flat central surface having opposite marginal portions and arranged between recessed marginal surfaces extending from said opposite marginal portions of said flat central surface to opposite edges of said core panel, said recessed marginal surfaces having a substantially greater width than depth with a minimum width of about 0.75 inch, and a decorative sheet laminated only to said flat central surface, but not to said marginal portions thereof nor to said recessed marginal surfaces, throughout the length of said front side and including one flap extending over one of said marginal portions and one of said recessed marginal surfaces adjacent thereto and terminating substantially flush with one longitudinal edge of said core panel prior to completion of said joint and another flap extending over the opposite marginal portion and the opposite recessed marginal surface adjacent thereto at least beyond the opposite longitudinal edge of said core panel to overlap with an adjacent flap corresponding to said one flap prior to completion of said joint, said core panels being arranged with said front sides substantially flush, said one recessed marginal surface on one of said core panels adjacent said opposite recessed marginal surface on the other of said core panels, said one longitudinal edge of said one core panel in substantially abutting relationship with said opposite longitudinal edge of said other core panel and said one flap on said one core panel adjacent said other flap on said other core panel, a hardened joint cement layer filling the space between said adjacent recessed marginal surfaces and flaps to substantially the level of said flat central surfaces, and upon completion of said joint, said one adjacent flap being adhered to and extending over said one marginal portion and said cement layer but terminating short of said one abutting edge and said other adjacent flap being adhered to and extending over said opposite marginal portion and said cement layer beyond said other abutting edge into substantially edge abutting and flush relationship with said one adjacent flap to form a practically invisible seam produced by folding said flaps back out of the way to expose said marginal portions and recessed marginal surfaces prior to said filling of said space with said cement layer, adhering said adjacent flaps to said marginal portions, cement layer and each other with said adjacent flaps overlapping, cutting through the overlapping portions of said adjacent flaps over said cement layer, removing the overlapping marginal edge portion of the overlying flap and the overlapped marginal edge portion of the underlying flap and readhering the remainder of the overlying flap to the underlying one of said marginal portions and said cement layer.

Claim 5

The joint of claim 5 wherein each of said core panels includes a set gypsum core enclosed on its two opposite sides and two longitudinal edges with a paper facing layer, said recessed marginal surfaces taper edgewise toward the rear sides of said core panels and have a minimum width to depth ratio of about 3.75/1, and each of said decorative sheets includes an inner cloth backing layer laminated to said paper facing layer and an outer polyvinyl chloride layer forming a decorative front wall surface.