U.S. patent application number 09/791131 was filed with the patent office on 2001-10-18 for apparatus and method for centering a wall panel component.
This patent application is currently assigned to Herman Miller, Inc.. Invention is credited to Beck, Robert L., Dame, Paul G., De Leon, Ernesto C., Emaus, Paul M., Hoogland, Timothy A., Martin, David B., McLung, Duane G., Newhouse, Thomas J., Weise, Richard C..
Application Number | 20010029713 09/791131 |
Document ID | / |
Family ID | 27361123 |
Filed Date | 2001-10-18 |
United States Patent
Application |
20010029713 |
Kind Code |
A1 |
Beck, Robert L. ; et
al. |
October 18, 2001 |
Apparatus and method for centering a wall panel component
Abstract
A wall panel including a rectangular frame, a pair of wall
members and a thin decorative sheet covering the wall members. The
frame includes two spaced apart, generally parallel vertical frame
members and spaced apart, generally parallel horizontal lower and
upper frame members. The horizontal frame members are connected to
the vertical frame members at opposite ends thereof to form the
rectangular frame. In one embodiment, each of the frame members
includes a core member and a pair of sidewall members attached to
opposite sides of the core member. The wall members are attached to
the sidewalls on opposing sides of the frame members. In another
embodiment, inner wall members are attached to the opposing sides
of the frame members, and outer wall members are thereafter
attached to the inner wall member. A decorative sheet covers the
outer surface of each outer wall member. The wall panels are
connected to each other with a connector member. Light seal members
are disposed on one of the wall panel or connector member to span
at least a portion of a gap formed between at least a portion of
the connected wall panels. Upper wall panels can also be mounted to
various configurations of lower wall panels using a variety of
connector members. Locator members and openings are provided to
locate a wall member on a core assembly. An apparatus and method
for positioning the locator members and openings is also
provided.
Inventors: |
Beck, Robert L.; (Zeeland,
MI) ; Dame, Paul G.; (Holland, MI) ; De Leon,
Ernesto C.; (West Olive, MI) ; Emaus, Paul M.;
(Kentwood, MI) ; Hoogland, Timothy A.; (Zeeland,
MI) ; Martin, David B.; (Jenison, MI) ;
McLung, Duane G.; (Kalamazoo, MI) ; Newhouse, Thomas
J.; (Grand Rapids, MI) ; Weise, Richard C.;
(Coopersville, MI) |
Correspondence
Address: |
Andrew D. Stover
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
Herman Miller, Inc.
|
Family ID: |
27361123 |
Appl. No.: |
09/791131 |
Filed: |
February 22, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09791131 |
Feb 22, 2001 |
|
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09178061 |
Oct 26, 1998 |
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6223485 |
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09178061 |
Oct 26, 1998 |
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08864459 |
May 28, 1997 |
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6167665 |
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60018956 |
Jun 7, 1996 |
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Current U.S.
Class: |
52/239 ;
52/126.3; 52/282.2; 52/282.5; 52/481.2; 52/586.1 |
Current CPC
Class: |
E04B 2002/749 20130101;
E04B 2002/7487 20130101; E04B 2002/7488 20130101; E04B 2/7425
20130101; E04B 2002/7468 20130101; E04B 2002/7479 20130101 |
Class at
Publication: |
52/239 ;
52/126.3; 52/481.2; 52/282.2; 52/282.5; 52/586.1 |
International
Class: |
E04B 002/82; E04H
001/00; E04H 003/00; E04H 005/00 |
Claims
We claim:
1. A wall panel comprising: a rectangular frame comprising a pair
of spaced apart, generally parallel vertical side frame members,
and spaced apart generally parallel horizontal lower and upper
frame members, said horizontal frame members connected to said
vertical frame members at opposite ends thereof to form said
rectangular frame, each of said frame members having an outer
surface; a pair of first sheetlike wall members attached to
opposite sides of said frame, each of said first wall members
having at least one peripheral edge lying substantially flush with
or inward from the outer surface of at least one frame member; a
pair of second sheetlike wall members attached to said first wall
members, each of said second wall members having at least one
peripheral edge extending beyond said outer surface of at least one
of said frame members, wherein said second wall members and said
outer surface of said at least one frame member form a channel
therebetween; and a thin decorative sheet covering an outer surface
of each of said second wall members.
2. The invention of claim 1 wherein said frame members are made of
wood.
3. The invention of claim 1 further comprising a thin barrier sheet
disposed between each of said second wall members and said
decorative sheet on each side of said wall panel.
4. The invention of claim 1 further comprising a filler member
disposed between said pair of first wall members and extending
between said horizontal frame members.
5. The invention of claim 1 wherein said at least one frame member
comprises said upper frame member and wherein said channel is
formed by said second wall members extending upwardly from said
upper frame member, and further comprising a channel member mounted
to an upper surface of said upper horizontal frame member within
said channel.
6. The invention of claim 5 further comprising a top cap releasably
secured to said channel member.
7. The invention of claim 6 wherein said channel member comprises
an inwardly facing ridge, and wherein said top cap has a pair of
downwardly facing flange members, each of said flange members
having a ribbed portion, said ribbed portion engaging said ridge
whereby said top cap is releasably secured to said channel.
8. The invention of claim 1 further comprising a strip member and
wherein said second wall member has an edge; said strip member
disposed along at least a portion of said edge.
9. The invention of claim 1 further comprising a vertical channel
communicating with said channel formed between said second wall
members and said outer surface of said at least one frame member
and a bottom portion of said panel.
10. The invention of claim 9 wherein said upper horizontal frame
member has an opening communicating with said vertical channel.
11. The invention of claim 10 wherein said vertical channel is
defined by the inner surface of one of said side frame members and
a spaced apart partition member extending between said upper and
lower horizontal frame members.
12. The invention of claim 9 further comprising a second vertical
channel spaced apart from the first vertical channel.
13. The invention of claim 1 wherein each of said vertical side
frame members further comprises a hanger bracket attached to the
outer surface thereof, said hanger brackets each having a plurality
of slots arranged along its length.
14. The invention of claim 13 wherein each of said hanger brackets
comprises a pair of channels.
15. The invention of claim 1 further comprising a support leg
secured to the bottom of the frame, said support leg adapted to
support said assembly on a floor in a spaced apart relationship
with said floor, and further comprising a base cover attached to
and extending downwardly from the lower frame member.
16. The invention of claim 1 further comprising a bracket attached
to the bottom of said lower frame member, and a power distribution
system secured to said bracket, said power distribution system
comprising a power harness and a receptacle module adapted to
receive an electrical plug, said harness adapted to be electrically
connected with an electrical distribution system in an adjacent
panel.
17. The invention of claim 16 further comprising an electrical
outlet box attached to said wall panel between said upper and lower
frame members, and an electrical conduit electrically connecting
said outlet box with said harness, said electrical conduit disposed
in said vertical channel.
18. The invention of claim 1 wherein one of each of said pair of
first wall members and each of said pair of second wall members
have at least one locator opening and wherein the other of each of
said pair of first wall members and each of said pair of second
wall members comprises at least one locator member disposed
thereon, said locator members received in said locator openings
whereby said second wall members are located on said first wall
members.
19. The invention of claim 18 wherein said locator member comprises
a post member and wherein said locator opening is shaped to receive
said post member.
20. The wall panel of claim 18 wherein said at least one locator
opening comprises at least a first and second opening, wherein said
second opening is slotted, and said at least one locator member
comprises at least a first and second locator member, wherein said
first locator member is received in said first opening and said
second locator member is received in said slotted opening.
21. A wall panel comprising; a core; a wall member mounted to said
core; one of said core and said wall member having at least one
locator opening; and at least one locator member disposed on the
other of said core and said wall member, wherein said at least one
locator member is received in said at least one locator opening,
whereby said wall member is located on said core.
22. The invention of claim 21 wherein said at least one locator
opening comprises at least a first and second opening, wherein said
second opening is slotted, and wherein said at least one locator
member comprises at least a first and second locator member,
wherein said first locator member is received in said first opening
and said second locator member is received in said slotted
opening.
23. The invention of claim 21 wherein said at least one locator
member comprises a base portion attached to a surface of one of
said core and said wall member and a post member extending from
said base portion.
24. The invention of claim 21 wherein said core comprises a frame
and a pair of wall members attached to said frame.
25. An apparatus for centering a component of a wall panel in said
apparatus, said component having opposite side edges, said
apparatus comprising: a frame; a first and second longitudinally
extending fence moveably supported by said frame in a spaced apart
and parallel relationship, said first and second fences adapted to
engage the opposite side edges of said component; a first rack
connected to said first fence and a second rack connected to said
second fence; and a pinion gear meshing with said first and second
racks on opposite sides of said pinion gear whereby said first and
second racks are operably connected to move an equal amount in
opposite directions relative to each other so as to cause said
first and second fences to move toward or away from each other,
whereby said movements of said fences cooperates to center said
component in said apparatus.
26. The invention of claim 25 further comprising a tool component
connected to said apparatus.
27. The invention of claim 26 wherein said tool component comprises
a router.
28. The invention of claim 27 wherein said router is positioned
proximate the midpoint between said first and second fences.
29. The invention of claim 25 further comprising a referencing
device moveably attached to said frame, said referencing device
moveable between a referencing position wherein said referencing
device is adapted to engage said wall panel component and a stored
position wherein referencing device is disengaged from said wall
panel component.
30. The invention of claim 25 wherein said pinion gear and said
first and second racks are positioned adjacent one end of said
apparatus, and wherein said apparatus further comprises a second
pinion gear and a third and fourth rack positioned adjacent an
opposite end of said apparatus, said third and fourth racks
connected to said first and second fences respectively.
31. The invention of claim 25 further comprising a longitudinally
extending shaft rotatably mounted to one of said first and second
fences and having a first and second gear attached to opposite ends
thereof, said first gear meshing with a third rack secured to said
frame and said second gear meshing with a fourth rack secured to
said frame.
32. An apparatus for conveying a wall panel while applying a press
load thereto, said apparatus comprising: a frame; a drive roller
mounted to said frame; a belt adapted to carry the wall panel, said
belt operably connected to said drive roller; a plurality of
rollers moveably supported by said frame above said belt, said
rollers adapted to engage the wall panel as it is carried by said
belt.
33. The invention of claim 32 further comprising a second belt
connected to said first belt, and wherein said frame comprises a
bed comprising a groove, wherein said second belt is disposed in
said groove so as to maintain the alignment of said first belt.
34. The invention of claim 32 wherein each of said plurality of
rollers extends laterally over said belt so as to have a
substantially perpendicular relationship to the longitudinal
movement of said belt.
35. The invention of claim 34 wherein each of said plurality of
rollers comprises opposite ends, and wherein said ends of said
rollers are moveably supported by said frame in a vertical
direction, whereby said rollers are adapted to move toward and away
from the upper surface of said belt.
36. A method of assembling a wall panel comprising: providing a
first and second wall panel component, forming at least one locator
opening in one of said first and second wall panel components;
attaching at least one locator member to the other of said first
and second wall panel components; disposing said locator member in
said locator opening; and attaching said first wall panel component
to said second wall panel component.
37. The method of claim 36 wherein said step of forming said at
least one locator opening comprises engaging opposite sides of said
one of said first and second wall panel components with a pair of
fences and moving said fences relative to each other to center said
one of said first and second wall panel components in a machine,
and forming said locator opening in said one of said first and
second wall panel components between said fences.
38. A method for pressing a wall panel as it is conveyed from one
location to another, said method comprising: carrying said wall
panel on a belt; engaging said wall panel with a plurality of
rollers positioned above said belt, said plurality of rollers
applying a pressing load as the weight of said plurality of rollers
is carried by said wall panel.
39. A wall panel comprising: a sheet like wall member having an
inner surface, an outer surface and a plurality of edges; a strip
member comprising a first and second flange, said first flange
overlying at least one of said edges of said wall member and said
second flange overlying a portion of said inner surface of said
wall member; a thin decorative sheet covering the outer surface of
said wall member; and a plurality of fasteners inserted through
said decorative sheet and said strip member and attaching said
decorative sheet and said strip to said wall member.
40. A system of wall panels comprising: a connector member; a pair
of wall panels arranged in an end to end configuration and
connected to each other with said connector member, said wall
panels having a gap formed between at least a portion thereof; a
top cap attached to at least one of said wall panels; and a light
seal member disposed on at least one of said top cap and said
connector member, said light seal member spanning at least a
portion of said gap formed between said wall panels.
41. The system of claim 40 wherein said light seal member is
disposed on said connector member.
42. The system of claim 41 wherein said connector member comprises
a draw rod and a pair of draw blocks, said draw blocks engaging
said wall panels to connect one wall panel to the other, said light
seal member disposed on one of said draw blocks.
43. The system of claim 41 wherein said light seal member comprises
an upwardly extending leg that spans at least a portion of said
gap.
44. The system of claim 40 wherein said connector member comprises
a corner post, and wherein said light seal member is disposed on
said corner post.
45. The system of claim 44 wherein said light seal member comprises
a base portion supported on said corner post and a plurality of arm
members extending upwardly from said base portion, said arm members
spanning at least a portion of said gap.
46. The system of claim 45 wherein each of said arm members
includes a flexible flange portion, said flange portion spanning at
least a portion of said gap.
47. The system of claim 40 wherein said light seal member is
disposed on said cap member and comprises a downwardly extending
leg portion that spans at least a portion of said gap.
48. The system of claim 47 wherein said light seal member is
disposed on said connector member and a second light seal member is
disposed on said cap member, said light seal members cooperating to
span at least a portion of said gap.
49. A system of wall panels comprising: a first connector member; a
pair of lower wall panels arranged in an end-to-end configuration
with one panel connected to the other with said first connector
member; a spanner member connecting an upper portion of each of
said pair of lower wall panels; and an upper wall panel connected
to said spanner member with a second connector member.
50. The system of claim 49 further comprising a second upper wall
panel, said second upper wall panel connected to said first upper
wall panel and to said spanner member with said second connector
member.
52. The system of claim 49 wherein said second connector member
comprises a pair of draw blocks and a draw rod, one of said draw
blocks engaging said spanner member and said upper wall panel and
said other draw block engaging said upper wall panel.
53. A system of wall panels comprising: a first and second lower
wall panel arranged in an end-to-end configuration, said first wall
panel having a greater height than said second wall panel; a first
connector member connecting said first and second lower wall
panels; a bracket member mounted to said second wall panel; an
upper wall panel disposed above said second lower wall panel; and a
second connector member connecting said upper wall panel to said
first lower wall panel and to said bracket member.
54. The system of claim 53 further comprising a spanner member
connecting a top portion of said first lower wall panel and a top
portion of said upper wall panel.
55. The system of claim 54 further comprising a second upper wall
panel mounted above said first lower wall panel and a third
connector member connecting said second upper wall panel to said
spanner member.
56. A system of wall panels comprising: a lower wall panel; an
upper wall panel disposed above said lower panel; a bracket member
mounted to said lower wall panel; a first connector member having a
length approximate the combined height of the lower and upper wall
panels; a second connector member connecting said lower wall panel
and said first connector member; a third connector member
connecting said upper wall panel to said bracket member and to said
first connector member.
57. The system of claim 56 wherein said first connector member
comprises a hanger bracket.
58. The system of claim 56 wherein said third connector member
comprises a first draw block engaging said first connector member
and said upper wall panel, a draw rod and a second draw block
engaging said bracket member and said upper wall panel.
59. The system of claim 56 wherein said first connector member
comprises a corner post.
60. The system of claim 56 wherein said first connector member
comprises a corner post and a corner post extension mounted to a
top of said corner post.
61. The system of claim 59 wherein said first connector member
further comprises a draw rod, an upper draw block and a lower draw
block.
Description
[0001] This application is a continuation-in-part of U.S.
application Ser. No. 08/864,459, filed May 28, 1997, which claims
the benefit of U.S. Provisional Application Ser. No. 60/018,956,
filed Jun. 7, 1996, the entire disclosures of which are both hereby
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a wall panel
system, and in particular, to an improved wall panel, components
therefore, a method for making the wall panel and various
configurations or systems of wall panels.
[0003] Panel systems are commonly used to divide large, open office
space into separate work spaces. For example, Herman Miller, Inc.,
the assignee of the present application, manufacturers and sells
two such work space management systems: the ACTION OFFICE.RTM.
system and the ETHOSPACE.RTM. system. Often, wall panels arranged
in such systems include an internal frame with a sheet of wall
board or comparable material attached to the side of the frame.
Typically, the frame is made from roll-formed or extruded metal,
with the wall board adhesively secured to the side of the metal
frame members. Each side of the wall panel usually is covered with
a fabric that is either bonded to the frame, or attached with an
elastic band, so as to provide an aesthetically pleasing appearance
to the user.
[0004] Adjacent wall panels in the system typically are connected
to one another with a variety of connector assemblies. For example,
wall panels placed end-to-end commonly are connected to each other,
while wall panels oriented perpendicular to each other in a
two-way, three-way or four-way configuration typically are
connected to a corner post located at the junction of the
intersecting panels. Typically, a cover is attached to those sides
of the corner post not connected to a wall panel so as to provide
an aesthetically pleasing surface that matches the surface of the
adjacent panels.
[0005] Wall panels often are provided with wire management
capabilities, typically including horizontal wire channels
positioned at the top and bottom of the panel. Wall panels may also
include vertical channels, typically formed by the vertical frame
members, that extend between the top and bottom of the panel.
Typically, wall panels having a horizontal channel at the top of
the panel also provide a top cap to cover the channel. When a
corner post is interposed between panels, a cap also is installed
on top of the corner post to provide a continuous, unbroken line
across the top of a system of wall panels.
[0006] Wall panels may also include power distribution systems,
whereby the wall panels can be electrically connected so as to
provide the user with access to power in each work space created by
the system of wall panels.
SUMMARY OF THE INVENTION
[0007] Briefly stated, one aspect of the invention is directed to
an improved wall panel. The wall panel includes a rectangular
frame, a pair of sheetlike wall members and two thin decorative
sheets. The rectangular frame includes two spaced apart, and
generally parallel vertical side frame members and spaced apart and
generally parallel horizontal lower and upper frame members. The
frame members are connected at opposite ends thereof to form the
rectangular frame. The sheetlike wall members, preferably made of
fiberboard, have an inner surface attached to the side of each
frame member. The thin decorative sheets, preferably cloth, cover
the outer surface of the wall members on each side of the
panel.
[0008] In one embodiment, each of the frame members includes a core
member and a pair of sidewall members attached to opposite sides of
the core member. The sidewall members preferably include a
substantially flat leg portion having an inner surface attached to
the core member and an outer surface attached to the wall member.
The sidewall member includes an edge portion extending laterally
outward from the leg portion. Preferably, the edge portion is
configured as a C-shaped channel facing inwardly away from the wall
panel surface. When the frame members are assembled into a
rectangular frame, the edge portions extend around the periphery of
the wall panel. The sidewalls, including the edge portions, form a
shallow recess on opposite sides of the panel. Each recess has a
bottom surface defined by the outer surface of the leg portions.
The wall members are received in the recesses on opposite sides of
the panel.
[0009] In another embodiment of the wall panel, a pair of inner
sheetlike wall members are attached to the rectangular frame to
form a core assembly. In this embodiment, the frame members are
preferably of a one-piece wooden construction. A pair of outer wall
members are then attached to the inner wall members of the core
assembly. The outer wall members extend outwardly from the
periphery of the inner wall members to form a channel between
them.
[0010] In one aspect of the invention, the core assembly includes
at least one locator opening therethrough. The outer wall members
each include at least one locator member that is received in the at
least one locator opening as the wall members are mounted to the
core assembly. The locator members and openings are arranged on the
wall members and core assembly, respectively, so that the wall
members are centered on the core assembly from side to side. The
locator members and openings can also be arranged so as to ensure
that the top of the wall member is positioned a predetermined
distance from the top of the core assembly, or channel thereon, so
as to provide a uniform and continuous line or appearance along the
top of a plurality of wall panels arranged in a system of wall
panels.
[0011] In another aspect of the invention, a thin barrier sheet, or
scrim, is disposed between the decorative sheet and the outer
surface of the wall member as a fire blocking member. The barrier
sheet preferably includes a thin aluminum foil layer laminated to a
fiberglass layer.
[0012] The wall panel also includes an inner filler member disposed
between the wall members. The filler member extends between the
upper and lower horizontal frame members. Preferably, the inner
surface of the wall members are attached to the filler member.
[0013] In one embodiment of the invention, the sidewall members on
the upper horizontal frame member extend upwardly from the upper
core member to form a horizontal channel running substantially the
length of the wall panel. The bottom of the channel is defined by
the upper surface of the upper core member and the sides of the
channel are defined by the upwardly extending sidewall members. A
top cap is releasably secured to the upper frame member to cover
the channel.
[0014] In another embodiment, a channel member is attached to the
upper horizontal frame member in the space formed between the outer
wall members to further define a horizontal channel. A top cap is
secured to the channel member to cover the channel.
[0015] In one aspect of the invention, the wall panel also includes
at least one vertical channel communicating with the upper
horizontal channel and a bottom portion of the wall panel.
Preferably, the vertical channel is defined by an inner surface of
one of the vertical frame members, a partition member spaced apart
from the inner surface of the vertical member and the inner surface
of the wall member. Preferably, the partition member extends
between the inner surfaces of the opposing wall members and is
attached to at least one of the wall members. The partition member
also extends substantially between the upper and lower frame
members.
[0016] In another aspect of the invention, a power distribution
system is provided at the base of the wall panel. The power
distribution system includes a power distribution server, including
a harness and a module receptacle, which is attached to a bottom of
the lower frame member. The power distribution system is adapted to
be electrically connected with power distribution systems located
in adjacent panels. In addition, an outlet box is attached to one
or more of the wall members between the upper and lower frame
members. At least one of the wall members has an opening provided
to allow access to the outlet box. The outlet box is electrically
connected to the power distribution system with an electrical
conduit disposed in the vertical channel.
[0017] In another aspect of the invention, a plastic strip is
attached to the decorative sheet at each of its edges. The strip
includes a first hook member that is adapted to engage the edge
portion of the sidewall member of the frame members in one
embodiment of the wall panel. Preferably, the strip also includes a
second hook member that is adapted to receive a tool member which
can be used to stretch the decorative sheet between opposing frame
members while simultaneously disposing the first hook member on the
edge portion of the side wall.
[0018] In an alternative embodiment a strip member is disposed
along the periphery of the wall member to protect the edges thereof
and is covered with the thin decorative sheet. A plurality of
fasteners are used to attach the decorative sheet and strip member
to the wall member.
[0019] In another aspect of the invention, wall panels placed
end-to-end are attached using an upper and lower draw block that
engage hanger brackets attached to the ends of the wall panels. A
draw rod operably engages the draw blocks which pull the hanger
brackets and corresponding panels together.
[0020] In yet another aspect of the invention, a corner post is
provided for connecting two or more panels at 90.degree.. The
corner post includes an elongated tube having a pair of inwardly
facing channels formed on each side of the tube. A plate member is
secured inside each end of the tube; the upper plate having a
threaded hole in the middle of the plate.
[0021] The corner post is provided with a height adjustable cap
which includes a post member and a cover member supported by the
post member. The post member threadably engages the hole in the
upper plate and can be rotated to adjust the height of the cover.
In this way, the cover can be raised or lowered to provide a smooth
transition between adjacent wall panel top caps.
[0022] In another aspect of the invention, an outwardly facing
groove is formed in each corner of the tube. A cover has diagonally
oriented beaded portions. The cover is attached to the corner post
by releasably engaging two of the corner grooves with the beaded
portions. The corner post cover is used to cover those sides of the
corner post not connected to a wall panel, so as to thereby provide
an aesthetically pleasing appearance.
[0023] In another aspect of the invention, one or more upper,
stackable wall panels are mounted to one or more lower wall panels,
or to a corner post, using a combination of connector members,
including various brackets, spanner members, draw blocks and draw
rods. In one embodiment, a corner post extension is provided to
facilitate the attachment of the upper, stackable panel to a corner
post and lower wall panel.
[0024] In another aspect of the invention, a variety of seal
members are provided for spanning or blocking the gaps formed
between adjacent wall panels, or between the corner post and any
wall panel attached thereto.
[0025] In another aspect of the invention, a method is provided for
manufacturing the vertical side frame member of one embodiment of
the wall panel. In particular, the method includes providing a core
member, a pair of sidewall members each having an edge portion, and
a hanger bracket. The hanger bracket is attached to the core
member. The core member and attached hanger bracket are then
positioned in a fixture such that the hanger bracket engages a
first surface of the fixture. The sidewall members are positioned
in the fixture on both sides of the core member such that the edge
portion of each sidewall member engages a second and third surface
of the fixture, respectively, positioned predetermined distances
from the first surface. The sidewall members are then attached to
the core member.
[0026] A similar method is provided for making the upper and lower
horizontal frame members, wherein the fixture surfaces are
positioned to support the edge portion of the sidewall members and
the outer surface of the core member.
[0027] A method also is provided for manufacturing the various wall
panel embodiments. In particular, and with respect to a first
embodiment, one of the sheetlike wall members is placed in a
fixture. The side frame members and upper and lower horizontal
frame members also are positioned in the fixture. The wall member
fills the recess formed by the sidewall members on one side of the
rectangular frame. Adhesive is applied to one of the sidewall
members and wall member before the frame is disposed on the wall
member. Adhesive also is applied to both sides of the filler
member. One or more partition members is adhesively attached to the
inner surface of the wall member so as to form a vertical channel
with the inner surface of one of the side core members. The filler
member is inserted into the space formed by the frame members and
the partition members. The second sheetlike wall member is then
disposed in the recess on the opposite side of the frame. The wall
members are attached to each frame member with mechanical
fasteners. A decorative sheet and barrier sheet are secured over
the outer surface of each wall member.
[0028] In a second embodiment, the frame members are connected to
form a frame. A first pair of inner wall members are attached to
the frame, with a filler member and one or more partition members
disposed therein, to form a core assembly. Preferably, the first
pair of wall members each have a peripheral edge that is
substantially flush with the outer surface of the frame members.
When to assembled, the frame and first pair of wall members form a
core assembly. The second pair of wall members are then attached to
the first pair of wall members of the core assembly and have at
least one peripheral edge that extends beyond the peripheral edge
of the inner wall members so as to form a channel therebetween. The
decorative sheet and barrier material are secured over the outer
surface of the second, or outer, pair of wall members.
[0029] In another aspect, a system is provided for centering the
outer wall member on a core assembly. The system includes a machine
for centering and providing a plurality of locator holes in the
core assembly and a machine for centering and disposing a plurality
of corresponding locator members on the outer wall members. The
outer wall members are then centered on the core assembly by mating
the locator members and holes.
[0030] The present invention provides significant advantages over
other wall panel systems and methods of manufacture. In particular,
the frame member, comprising either a three-piece construction of a
pair of sidewall members attached to a core member, or a core
member by itself, yields a simple, inexpensive structural part that
provides several advantages over roll-formed or extruded metal
channels. By using a wood core member, the sidewall members can be
easily attached to the core with staples, rather than by welding or
other more expensive methods of manufacture. Similarly, the wall
members can be stapled directly to the frame members, as well as
adhesively secured, so as to improve the strength of the panel. In
addition, various accessories, such as the power distribution
server, can be easily mounted to the bottom of the panel with wood
fasteners, without providing mounting holes in the lower frame
member. Moreover, the wood can be easily cut to length for each
frame member, or shortened so as to provide access to the vertical
channel, without wasting material or making complicated cuts or
stampings in the sheet metal.
[0031] Also important, the three-piece frame member construction
allows the manufacturer to provide precise dimensions between the
outermost surface of the hanger bracket and the outermost surface
of the sidewall members. This dimension is critical when two panels
are installed adjacent to each other. For example, when two panels
are connected, the adjacent hanger brackets are pulled together by
a wedge block, as explained below. When connected in this manner,
the panel-to-panel interface, or joint between the panels, is
defined by the distance between the adjacent outer surfaces of
opposing edge portions covered with fabric. Thus, by maintaining
the distance between the outer surface of the edge portion and the
hanger bracket as a constant, the joints at each panel interface
are kept constant, i.e., have the same gap between panels.
Moreover, when a wall panel has a thicker fabric installed around
the edge portions, the distance between the edge portion and hanger
bracket can be increased so that the gap between panels, when
connected, remains the same, regardless of the fabric
thickness.
[0032] Alternatively, an outer wall member can be centered on a
core assembly. In this way, the dimensions between the outer edge
of the wall member and the outermost surface of the hanger bracket
can be maintained relatively constant so as to provide a relatively
uniform gap between adjacent wall panels.
[0033] The vertical channel also provides significant advantages.
For example, wires can be easily routed from the top of the panel
to the bottom. The channel also provides ideal passage for the
electrical conduit running from the outlet box installed inside the
panel. In addition, because the channel is inside of the frame and
adjacent to the box, rather than on the outside of the frame, the
frame member does not have to be pierced in order to rout the
wiring to the outlet box. Moreover, wires disposed in the channel
are not exposed when the panels are disconnected and cannot
therefore be caught or hooked by the panel-to-panel connectors.
[0034] The improved corner post also provides significant
advantages over similar devices. For example, the corner post cover
is height adjustable, so that it can be adjusted to provide a
continuous line across the top of a system of panels. Moreover, the
grooves provided in the corner post tube provide a simple but
efficient way to attach covers, whether they be flat, or formed at
90.degree.. As such, the orientation of the tube is irrelevant to
the placement of connecting panels and/or post covers. Because the
tube is symmetrical, the cover and panels can be arranged in any
configuration, without having to reorient the tube member.
[0035] Yet another significant advantage is the various methods of
fabric attachment. In one embodiment, the double-hook strip
configuration allows an installer to use a tool to install the
fabric. As such, the installer can apply a considerable force to
tightly stretch the fabric between opposing frame members to
thereby provide a smooth and pleasing appearance. Moreover, the
releasable hook allows the user to easily replace the fabric if it
becomes damaged or if a color change is desired. The new fabric can
be installed quickly and easily without adhesives or difficult to
install elastic bands that run around the periphery of the wall
panel. Indeed, adjacent panels need not even by disconnected in
order to install a new sheet of fabric, thereby avoiding the task
of disassembling the panels.
[0036] Alternatively, the strip member disposed along the edge of
the wall panel protects the edge from impact damage and the like.
In addition, the strip member anchors the fasteners used to secure
the decorative sheet to the wall member.
[0037] Another significant advantage is the ability to install one
or more upper, stackable wall panels on one or more lower wall
panels or corner posts. In particular, a system of wall panels can
be easily and quickly reconfigured to provide more or less privacy
by adding one or more upper wall panels without affecting the
connection of the lower wall panel (or panels) to adjacent wall
panels or corner posts. The combination of spanner members, support
brackets, draw blocks and draw rods can be installed or removed
quickly and easily with minimum effort, while simultaneously
providing a robust, rigid structure.
[0038] Finally, the wall panel construction lends itself to
improved manufacturability and overall quality. Most importantly,
as described above, each frame member can be made with extremely
tight tolerances so that the gap between panels is maintained as a
constant when the wall panels are assembled as a system. Or, in an
alternative embodiment, the wall members can be centered on the
core assembly so as to maintain similar uniform gaps. By locating
the frame members to outside dimensions in the fixture, the overall
panel construction is improved by providing extremely tight
tolerances for the height and width of each panel. The improved
quality associated with this method of manufacture in turn
facilitates and eases installation of the panels while providing an
improved overall look for the system.
[0039] The present invention, together with further objects and
advantages, will be best understood by reference to the following
detailed description taken in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is an exploded perspective view of the wall
panel.
[0041] FIG. 2 is an exploded perspective view of the wall panel
with a top cap, base cover and power distribution system.
[0042] FIG. 3 is an exploded view of a wall panel end cover.
[0043] FIG. 4 is an exploded view of a corner post
configuration.
[0044] FIG. 5 is an exploded view of an alternative embodiment of a
corner post configuration.
[0045] FIG. 6 is an enlarged perspective view of a panel-to-panel
light seal.
[0046] FIG. 7 is an enlarged exploded view of a corner post
cap.
[0047] FIG. 8 is a side view of a wall panel.
[0048] FIG. 9 is an end view of a wall panel with the power
distribution server omitted.
[0049] FIG. 10 is a cross-sectional view of the wall panel taken
along line 10-10 of FIG. 8.
[0050] FIG. 11 is a cross-sectional view of the wall panel taken
along line 11-11 of FIG. 8.
[0051] FIG. 12 is a bottom view of the wall panel taken along line
12-12 of FIG. 8, with the power distribution server omitted.
[0052] FIG. 13 is a perspective view of the power distribution
bracket.
[0053] FIG. 14 is a cross-sectional view of the wall panel taken
along line 14-14 of FIG. 8 with the power distribution server not
shown.
[0054] FIG. 15 is a cross-sectional view of the wall panel taken
along line 15-15 of FIG. 8.
[0055] FIG. 16 is a cross-sectional view of the wall panel taken
along line 16-16 of FIG. 8.
[0056] FIG. 17 is a cross-sectional view of the wall panel taken
along line 17-17 of FIG. 8.
[0057] FIG. 18 is a partial perspective view of the top cap.
[0058] FIG. 19 is an exploded perspective view of two wall panels
placed end-to-end without the fabric installed.
[0059] FIG. 20 is a side view of two wall panels connected together
without the fabric installed.
[0060] FIG. 21 is a side view of the fabric sheet.
[0061] FIG. 22 is a cross-section of the strip attached to the
fabric.
[0062] FIG. 23 is a cross-section of an alternative embodiment of
the strip attached to the fabric.
[0063] FIG. 24 is a side view of the inside corner of the upper
horizontal channel.
[0064] FIG. 25 is a perspective view of the power distribution
server.
[0065] FIG. 26A is a top view of a wall panel junction showing a
three-way connection of power distribution servers located in the
adjacent wall panels.
[0066] FIG. 26B is a top view of a wall panel junction showing a
two-way connection of power distribution servers located in the
adjacent wall panels.
[0067] FIG. 26C is a top view of a wall panel junction showing a
four-way connection of power distribution servers located in the
adjacent wall panels.
[0068] FIG. 27 is a top view of the power distribution server.
[0069] FIG. 28 is a perspective view of the upper and lower draw
blocks.
[0070] FIG. 29 is a perspective view of an alternative
configuration of the upper and lower draw blocks.
[0071] FIG. 30 is a perspective view of an alternative
configuration of the upper and lower draw blocks.
[0072] FIG. 31 is a side view of two wall panels connected to a
corner post.
[0073] FIG. 32 is a top cross-sectional view of three wall panels
connected to a corner post.
[0074] FIG. 33 is a top cross-sectional view of two wall panels
connected to a corner post.
[0075] FIG. 34 is a perspective view of a corner post base
cover.
[0076] FIG. 35 is a perspective view of a draw rod and draw blocks
engaging a corner post.
[0077] FIG. 36 is a perspective view of a draw rod with a partial
end cover.
[0078] FIG. 37 is a side view of a draw rod and draw blocks
engaging a corner post.
[0079] FIG. 38 is an exploded side view of different height wall
panels with a draw rod and draw blocks interposed between the
panels.
[0080] FIG. 39 is a partial inner perspective view of a draw rod
with a partial end cover.
[0081] FIG. 40 is a partial outer perspective view of a draw rod
with a partial end cover.
[0082] FIG. 41 is an exploded perspective view of a hanger bracket
mounted on a permanent wall.
[0083] FIG. 42 is a partial cross-sectional view of the hanger
bracket mounted on a permanent wall.
[0084] FIG. 43 is a perspective view of a brace member installed on
a wall panel.
[0085] FIG. 44 is a side view of a brace member installed on a wall
panel.
[0086] FIG. 45 is a perspective view of a brace member.
[0087] FIG. 46 is a perspective view of a fabric installation
tool.
[0088] FIG. 47 is a top view of the fabric installation tool
engaging a fabric sheet on a wall panel.
[0089] FIG. 47A is an partial enlarged view of an installation tool
with an alternative blade configuration.
[0090] FIG. 48 is a perspective view of an alternative embodiment
of the fabric installation tool.
[0091] FIG. 49 is a top view of the fabric installation tool of
FIG. 44 engaging a fabric sheet on a wall panel.
[0092] FIG. 50 is a perspective view of a vertical side frame
member tool fixture.
[0093] FIG. 51 is an end view of the side frame tool fixture with a
side frame member installed therein.
[0094] FIG. 52 is a schematic of an automated tool fixture for
assembling the side frame member.
[0095] FIG. 53 is a perspective view of a upper and lower frame
member tool fixture.
[0096] FIG. 54 is an end view of the upper frame tool fixture with
an upper frame member installed therein.
[0097] FIG. 55 is a perspective view of the wall panel assembly
fixture.
[0098] FIG. 56 is a side view of a dual staple gun engaging a wall
panel installed in the wall panel assembly fixture.
[0099] FIG. 57 is a perspective view of a end cover support
bracket.
[0100] FIG. 58 is an end view of a wall panel with a power
distribution server attached to the bottom of the wall panel as
taken along line 58-58 of FIG. 31.
[0101] FIG. 59 is a bottom perspective exploded view of a wall
panel and power distribution server.
[0102] FIG. 60 is a side view of a core assembly of an alternative
embodiment of the wall panel.
[0103] FIG. 60A is a partial view of the wall panel of FIG. 60 with
an alternative positioning of the opening for the support leg.
[0104] FIG. 61 is an exploded view of an alternative embodiment of
a wall member.
[0105] FIG. 62 is an exploded view of an alternative embodiment of
the wall panel assembly.
[0106] FIG. 63 is a vertical, cross-sectional view of the
alternative embodiment of the wall panel assembly shown in FIG.
62.
[0107] FIG. 64 is a top view of a top channel.
[0108] FIG. 65 is an end view of the top channel.
[0109] FIG. 66 is a side view of the protective strip.
[0110] FIG. 67 is an end view of the protective strip.
[0111] FIG. 68 is an exploded assembly view of a corner post with
seal members and a corner post cap.
[0112] FIG. 69 is a top view of a seal member.
[0113] FIG. 70 is a perspective view of the alternative corner post
configuration shown in FIG. 68 with a cover member being applied
thereto.
[0114] FIG. 71 is a perspective view of the corner post
configuration shown in FIG. 70 with a cover member being applied
thereto.
[0115] FIG. 72 is a partial top view of the seal member and cover
member.
[0116] FIG. 73 is an exploded assembly view of alternative light
seal members fling applied to a pair of wall panels placed end to
end.
[0117] FIG. 74 is a partial cross-sectional view of a light seal
member disposed on an upper draw block.
[0118] FIG. 75 is a side view of a pair of upper wall panels
attached to a pair of lower wall panels of equal height positioned
in an end to end configuration.
[0119] FIG. 76 is a side view of an upper wall panel attached to a
pair of lower wall panels of equal height positioned in an end to
end configuration.
[0120] FIG. 77 is a side view of an upper wall panel attached to a
short lower wall panel positioned in an end to end configuration
with an adjacent tall lower wall panel.
[0121] FIG. 78 is a side view of an upper wall panel attached to a
tall lower panel positioned in an end-to-end configuration with an
upper wall panel attached to a short lower wall panel.
[0122] FIG. 79 is a side view of an upper wall panel attached to a
lower wall panel.
[0123] FIG. 80 is a side view of an upper wall panel attached to a
lower wall panel and to a corner post having a corner post
extension.
[0124] FIG. 81 is a side view of an upper wall panel attached to a
lower wall panel and to a corner post without an extension.
[0125] FIG. 82 is an exploded perspective view of a lower spanner
assembly.
[0126] FIG. 83 is a side view of the lower spanner assembly.
[0127] FIG. 84 is a top view of the spanner.
[0128] FIG. 85 is a side view of the corner post extension.
[0129] FIG. 86 is a bottom view of the corner post extension.
[0130] FIG. 87 is a top view of upper wall panel support
bracket.
[0131] FIG. 88 is a side view of the upper wall panel support
bracket.
[0132] FIG. 89 is an end view of the upper wall panel support
bracket.
[0133] FIG. 90 is a side view of an alternative embodiment of a
lower draw block.
[0134] FIG. 91 is a top view of the lower draw block shown in FIG.
90.
[0135] FIG. 92 is an end view of the lower draw block shown in FIG.
90.
[0136] FIG. 93 is an end view of an alternative embodiment of a
clip for a cover member.
[0137] FIG. 94 is a cover member assembly.
[0138] FIG. 95 is a front view of the outlet box mounted in the
wall panel using an alternative bracket assembly.
[0139] FIG. 96 is an end view of a bracket member used to install
the outlet box in the wall panel.
[0140] FIG. 97 is a cross-sectional view of the assembly shown in
FIG. 95.
[0141] FIG. 98 is a perspective view of a bracket member and a
corner post extension.
[0142] FIG. 99 is a side view of a core assembly having a pair of
locator holes disposed therethrough.
[0143] FIG. 100 is a side view of a wall member with a pair of
locator members disposed thereon.
[0144] FIG. 101 is a plan view of a locator member.
[0145] FIG. 102 is a cross-sectional view of the locator member
taken along line 102-102 of FIG. 101.
[0146] FIG. 103 is an exploded perspective view of a wall panel
assembly.
[0147] FIG. 104 is a plan view of a machine used to make locator
openings in a core assembly.
[0148] FIG. 105 is a partial side view of the machine shown in FIG.
104.
[0149] FIG. 106 is a partial end view the machine shown in FIG.
104.
[0150] FIG. 107 is a plan view of a machine used to dispense and
attach locator members to a wall member.
[0151] FIG. 108 is a side view of the machine shown in FIG.
107.
[0152] FIG. 109 is an end view the machine shown in FIG. 107.
[0153] FIG. 110 is a side view of a locator dispenser tool.
[0154] FIG. 111 is an end view of the tool shown in FIG. 110.
[0155] FIG. 112 is a plan view of the tool shown in FIG. 110.
[0156] FIG. 113 is a plan view of a press conveyor machine.
[0157] FIG. 114 is a side view of the machine shown in FIG.
113.
[0158] FIG. 115 is an end view the machine shown in FIG. 113.
[0159] FIG. 116 is an enlarged plan view of the rack and pinion
mechanism used in the machines shown in FIGS. 104 and 107.
[0160] FIG. 117 is an enlarged end view of the rack and pinion
mechanism and encoding device.
[0161] FIG. 118 is an enlarged side view of the rack and pinion
mechanism and encoding device.
[0162] FIG. 119 is an exploded perspective view of a corner post
extension with a light seal member and corner post cap.
[0163] FIG. 120 is an exploded perspective view of a support
bracket and a short lower wall panel positioned in an end to end
configuration with a tall lower wall panel.
[0164] FIG. 121 is an exploded side view of an upper wall panel, a
tall lower wall panel, a short lower wall panel, a support bracket
member, a spanner member and a connector member.
[0165] FIG. 122 is an exploded side view of a pair of upper wall
panels, a pair of lower wall panels, a pair of spanner members and
a connector member.
[0166] FIG. 123 is an exploded perspective view of a spanner member
and a pair of lower wall panels.
[0167] FIG. 124 is an exploded side view of an upper wall member, a
pair of lower wall panels, a spanner member and a connector
member.
[0168] FIG. 125 is an exploded side view of a lower wall panel, an
upper wall panel and connector members including a stand-alone
hanger bracket.
[0169] FIG. 126 is an exploded perspective view of an upper wall
panel supported by a pair of lower wall panels, a pair of end cover
brackets and a light seal member.
[0170] FIG. 127 is a perspective view of the components shown in
FIG. 126 with an end cover being applied thereto.
[0171] FIG. 128 is an exploded perspective view of a stand-along
hanger bracket being applied to a tall lower wall panel attached to
a short lower wall
[0172] FIG. 129 is an exploded perspective view of an end cover,
light seal member and top cap being applied to an upper wall panel
secured to the tall lower wall panel shown in FIG. 128.
[0173] FIG. 130 is a partial cross-sectional view of two belts
supported by the press conveyor machine bed taken along line
130-130 of FIG. 114.
[0174] FIG. 131 is an end view of an alternative embodiment of a
lower draw block.
[0175] FIG. 132 is an end view of the lower draw block shown in
FIG. 131.
[0176] FIG. 133 is an exploded view of an alternative embodiment of
the corner post extension.
[0177] FIG. 134 is an end view of an alternative embodiment of a
clip for a cover member.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
[0178] Referring to the drawings, FIG. 1 shows an improved wall
panel 10 including a rectangular frame 12, a pair of sheetlike wall
members 120 and a pair of thin decorative sheets 130. The frame 12
includes two spaced apart, and generally parallel vertical side
frame members 14 and spaced apart and generally parallel horizontal
lower and upper frame members 18, 16.
[0179] Each frame member 14, 16, 18 includes an elongated core
member 28, 30, 32 and a pair of elongated sidewall members 34, 36,
38. Preferably, the core member is made of wood. As used herein,
the terms "wood" and "wooden" are intended to have relatively broad
meanings, including but not limited to, solid wood and wood
products, such as particle board, fiber board and laminated strand
lumber. Most preferably, the side core members 28 are made of
laminated strand lumber, such as the 38# density material available
from TrusJoist/MacMillan Ltd. Partnership in Deerwood, Minn. The
horizontal core members 30, 32 preferably are made of 45# density
particle board. Alternatively, other materials, such as foamed
polymers or composites, may be used.
[0180] Each sidewall member 34, 36, 38 includes a substantially
flat leg portion 42, 54, 56 and edge portion 40, 58, 60
respectively. The edge portion 40, 58, 60 extends laterally outward
from the leg portion 42, 54, 56. Preferably, the sidewall members
are made from 12 or 24 gauge steel sheet metal and are roll formed.
However, it should be understood that other materials, such as
plastic could also be used. Each leg portion has an inner 44, 45,
43 and outer surface 46, 47, 49; the inner surface 44, 45, 43
engages the side surface of the core member. Preferably, the inner
surface 44, 45, 43 is mechanically fastened to the side 52, 53, 57
of the core member, for example, by using staples 700, as shown in
FIG. 16. Alternatively, adhesive, nails, rivets or screws can be
used to secure the sidewall member to the core member.
[0181] As shown in FIG. 1, the sidewall members 34 of each vertical
frame member include an end portion 68 that extends upwardly past
the top end 20 of the side core member 28 along the longitudinal
direction of the vertical frame member 14. The upwardly extending
end portions 68 of the sidewall members 34 overlap the sidewall
members 36 of the upper frame member 18, which include leg portions
54 that extend upwardly from the upper frame core member 30. Each
end of the upper frame member sidewall members 36 includes a flange
portion 580 stepped inwardly from the leg portion 54, as shown in
FIGS. 1 and 2. The flange portion 580 extends from and is
integrally formed with the leg portion. The upwardly extending end
portions 68 overlap and are attached to the corresponding stepped
flange portions 580 and the wall member 120, preferably with
mechanical fasteners. Because the flanged portion 580 is stepped
inwardly, the outer surfaces 46, 49 are flush. The edge portion 58
of the upper frame member and the edge portion 40 of the vertical
frame are mitered at approximately 45.degree. at the point of
intersection in order to form a corner.
[0182] As shown in FIGS. 1, 2, 9 and 10, an elongated hanger
bracket 70 is mounted to the outer surface 50 of each vertical core
member. The hanger bracket 70 includes two spaced apart, inwardly
facing channels 72 connected by a bridge portion 74 that is
fastened to the core 28, preferably with a plurality of fasteners
540. Fasteners 542 also secure each end of each channel 72 to the
core member 28. Each channel 72 has an inner leg 76, an outer leg
78 and an outer surface member 82. The inner legs 76 of the
channels and the bridge portion 74 form an outwardly facing channel
300. The outermost corners 84 on each bracket, formed by the
intersection of the outer leg and the surface member, have a
plurality of slots 86 running the length of the hanger bracket. The
outer surface member 82 of the inwardly facing channels 72 defines
the outermost surface of each end of the wall panel. The slots 86
in the hanger bracket are adapted to receive and support various
components attached to the wall panel. For example, overhead units
and work surface bracket supports, not shown in the Figures,
typically engage the wall panel at the slots. For example, a
cantilever bracket assembly adapted to engage the hanger bracket is
described in co-pending U.S. application Ser. No. 60,019,285
entitled CANTILEVER BRACKET ASSEMBLY (Attorney Docket No. 5280-020)
and filed Jun. 7, 1996, the disclosure of which is hereby
incorporated herein by reference.
[0183] As shown in FIGS. 2, 8, 9 and 44, the inner surface 43 of
the upwardly extending sidewalls 36 on the upper frame member and
the outer surface 62 of the upper core member 30 form a horizontal
channel 88 which runs the width of the to panel. At each end of the
wall panel, the upper end 20 of the vertical side core member 28
lies substantially flush with, or slightly higher than, the outer
surface 62 of the upper core member 30 so that wires, cables and
the like can be passed easily from one panel to the next. In this
way, the upper end 20 of the vertical core member 28 helps to
define a portion of the bottom of the horizontal channel 88.
[0184] As shown in FIGS. 43-45, a brace member 92 can be mounted at
each end of the channel to provide additional support for the
panel. The brace member 92 includes a pair of sidewall members 94
disposed along the inner surface 45 of the sidewall members. The
brace member 92 also includes a bottom plate 97 attached to the end
20 of the core member and a second bottom plate 96 attached to the
outer surface 62 of the upper core member 30. It should be
understood that the sidewall members can also be attached to the
wall members. An opening 95 is provided between the plates to
provide access to a vertical channel 108. The brace member 92
provides additional support for loads applied laterally to the top
or side of the panel. In particular, the brace member helps
distribute the load between opposing wall members, the upper frame
member and the vertical frame member.
[0185] As shown in FIGS. 2, 16 and 18, the top portion of each
sidewall leg portion on the upper frame members includes an
inwardly facing ridge 98 that runs substantially the length of the
upper frame member 18. Intermittent openings 100 are provided along
the top portion. The openings are provided to locate the sidewalls
in various tool fixtures during the assembly of the frames and wall
panel.
[0186] A top cap 110 is attached to the upper frame member 18. The
top cap 110 includes a pair of downwardly facing flanges 112 that
have a ribbed portion 114 running the length of the flanges. The
ribbed portion 114 engages the ridge 98 formed on the inside of
each sidewall member and releasably secures the top cap to the
upper frame member. Each of the flanges 112 also includes an edge
portion 113 that is angled inwardly from the ribbed portion 114.
The edge portion 113 facilitates installation of the top cap by
engaging the ridges on the upper frame member as the top cap is
first inserted into the channel 88. As the top cap 110 is pushed
downwardly, the edge portions 113 slide along the ridge so that the
flanges are biased inwardly until the ribbed portion engages the
ribbed portion 114. The flanges 112 then spring back to their
original position, as the ribbed portion releasably locks the top
cap to the upper frame member. In this way, the top cap 110 covers
and encloses the channel 88.
[0187] In a preferred embodiment, the ends 102 of the upper core
member are spaced apart from the ends 104 of the vertical core
member to form an opening 106 between the members near each end of
the panel as shown in FIG. 17. These openings 106 provide access to
a vertical channel 108, or tube, that extends between the upper
horizontal channel 88 and the bottom of the wall panel, as shown in
FIGS. 2, 8, 10, and 11. Each vertical channel 108 is formed and
defined by the inner surface 48 of the vertical core member, a
partition member 140 that extends between the upper and lower
horizontal frame members 16, 18 and the inner surface 122 of the
wall member 120.
[0188] The ends 103 of the lower horizontal core member are spaced
apart from the lower end 105 of the vertical core members so as to
provide access to the vertical channel 108 from the bottom of the
panel as shown in FIG. 12. In addition, the sidewall members 38 on
the lower frame member extend outwardly past the end 103 of the
core member along the longitudinal direction of the frame member,
as shown in FIG. 1. The sidewalls 34 are cut away at the lower end
105 of the vertical side core member to provide an exposed portion
550 of the side core member. The outwardly extending bottom
sidewall members 38 overlap the exposed portion, and lie flush with
the side frame sidewalls 34. The edge portions 60, 40 intersect and
are mitered at approximately 45.degree. to form a corner. The lower
core member 32 also includes a groove 33 running the length of the
core member along the middle of the outer surface 66.
[0189] As shown in FIGS. 10, 14 and 16, the edge portions 40, 58,
60 of each sidewall member are preferably configured as a C-shaped
channel that runs the length of each side wall member. When the
frame members are connected, the edge portions 40, 58, 60 run
substantially around the entire periphery on each side of the
panel. Each channel includes an inner leg 116 that extends
laterally outward in a perpendicular relationship from the leg
portion and an outer leg 118 that defines the outer peripheral edge
of the wall panel. A intermediate surface member 124 connects the
inner 116 and outer leg 118. The surface member 124 is in
substantially the same plane as the outer surface 126 of the wall
member as shown in FIGS. 14-16. The inner leg 116 of the edge
portion and the outer surface 46, 47, 49 of the sidewall leg
portions 42, 54, 56 define a shallow, outwardly facing recess on
each side of the frame. The recess is shaped to receive the
sheetlike wall member 120. Preferably, the wall member 120
substantially fills the recess and is bounded around its periphery
by the inner legs 116 of the side walls.
[0190] As just described, each wall member is attached to one side
of the frame with staples 702, as shown in FIG. 16. The wall
members stabilize and strengthen the wall panel. Preferably, the
wall member 120 is made of 1/2 inch thick fiberboard, such as the
industrial insulation board available from Masonite in Lisbon
Falls, Me., which is sanded, ironed and sealed. Preferably, the
wall member 120 is tackable, so that a user can attach various
items to the wall member with tacks, or the like. Other materials,
such as particle board or mineral board are also acceptable.
Preferably, the wall member 120 is both adhesively secured to the
outer surface 46, 47, 49 of the sidewalls and is mechanically
fastened to the core members 34, 36, 38 through the sidewall
members, preferably by stapling. The overlapping portions of the
sidewall members 34, 36 of the vertical frame and the upper frame
members are mechanically fastened to each other and to the wall
member 120 from the inside out, preferably with screws 121 as
described above and shown in FIGS. 1, 2 and 8.
[0191] As shown in FIGS. 1, 8 and 10-11, a filler member 150 is
installed inside the rectangular frame 12. The filler member 150 is
disposed between the wall members 120 and each side of the frame,
and extends between the upper and lower horizontal frame members
16, 18. In a preferred embodiment, the filler member 150 is a
honeycomb structure made from corrugated cardboard. The honeycomb
is adhesively secured to the inner surface 122 of each wall member.
The honeycomb increases the strength of the panel and provides
sound dampening for the panel. Preferably, the honeycomb filler
member is bounded along each vertical end by the partition members
140 installed to form the vertical channels 108. In this way, the
vertical channels are separated from the honeycomb filler
member.
[0192] The partition member 140 includes a mounting flange 142 and
a boundary flange 144 as shown in FIG. 1. Referring to FIGS. 10 and
11, the mounting flange 142 is adhesively bonded to the inner
surface 122 of one of the wall members 120. The boundary flange 144
extends between the two wall members 120 and can be attached to the
side of the honeycomb filler member.
[0193] Referring to FIGS. 1 and 2, a thin barrier sheet 530, or
scrim, is disposed between the decorative sheet 130 and the wall
member 120. The barrier sheet 530 preferably includes a layer of
aluminum foil laminated to a thin layer of fiberglass. The barrier
sheet 530 is preferably about 0.005 inches thick and is used as a
fiberglass blocking material. A commercially available barrier
sheet is the MANNIGLAS 12077 wet-lay glass fiber mat produced by
Lydall Corporation. The barrier sheet can be attached to the wall
member with adhesive or mechanical fasteners. Alternatively, the
barrier sheet can wrap around the outer leg of the edge portion
beneath the decorative sheet, which is attached to the leg with a
strip member as described below.
[0194] Referring to FIGS. 1 and 2, each thin decorative sheet 130
is disposed over one of the outer surfaces 126 of the wall members.
The decorative sheet is preferably a cloth fabric, although it
should be understood that other flexible materials would be
suitable for covering the wall panel. Referring to FIGS. 10, 14, 15
and 16, the sheet is wrapped around the edge portion 40, 58, 60 of
each sidewall member and is attached to the outer leg 118 of the
edge portion. Preferably, a strip 160 is attached to each edge 132
of the sheet. The strip may be sewn to the sheet or adhesively
bonded. For example, as shown in FIGS. 21-23, the strip is attached
with a double-sided tape 162 and sewn to the sheet.
[0195] Referring to FIGS. 21 and 23, the strip 160, preferably made
from plastic, includes a first hook member 164 adapted to engage
the outer leg 118. The strip 160 is attached to the outer surface
136 of the fabric sheet 130 so that the first hook member 164 faces
outwardly towards the edge of the fabric. Before installing the
fabric, however, the fabric is folded over as shown in FIGS. 22-23
so that the strip 160 is positioned along the inner surface 134 of
the fabric and so that the first hook 164 faces inwardly away from
the folded edge 133 of the fabric. The first hook member 164 is
disposed on the outer leg 118 of the edge portion of If the
sidewall member as shown in FIGS. 14-16.
[0196] Excess portions of the decorative sheet, or fabric, extend
outwardly from each corner of the fabric sheet between the ends of
the adjacent strip members to form a corner patch 138 of material
as shown in FIG. 21. The corner patch 138 is tucked inside the
eight comers formed by the edge portion channels 40, 58, 60 of the
vertical, upper and lower frame members as the first hook member is
installed on the outer leg of each channel. As shown in FIG. 24, a
flexible corner block 146 is inserted into intersecting channels
40, 58 at one of the upper comers to hold the excess fabric, or
corner patch 138, in the channels. Preferably, the corner block 146
is made of foam, although other resilient and flexible materials,
such as rubber, may also be used. By tucking the excess fabric, or
corner patch 138, into the channels 40, 58, the exterior, exposed
corner 148 of the wall panel is covered and provided with an
aesthetically pleasing appearance.
[0197] In a preferred embodiment, the strip 160 also includes a
second hook member 166. In one embodiment, shown in FIG. 23, the
second hook member 166 is positioned opposite of the first hook 164
and faces the same direction as the first hook member, i.e., opens
inwardly away from the folded edge 133 of the fabric when it is
folded over on itself. In a second embodiment, shown in FIG. 22,
the second hook 168 is positioned at the end of the strip and opens
outwardly away from the outer surface 136 of the fabric. In either
embodiment, the second hook member 166, 168 is adapted to allow an
installer to stretch tightly the fabric 130 while installing the
first hook 164 on the outer leg 118 of the sidewall member.
[0198] To facilitate the installation of the fabric 130, a tool 170
is provided. The tool 170 includes a mounting block 171, a blade
172, a handle 174 and a housing 176 as shown in FIGS. 46-47. The
mounting block 171 is mounted to the housing IQ and includes a lip
portion 173 adapted to engage the second hook 168, and a guide
member 175 configured as a hook that is adapted to be disposed
around the end of the strip and first hook 164. The tool also
includes a plurality of wheels 180, 181 rotatably mounted to the
housing 176 and adapted to rotatably engage the side of the wall
panel as the tool is moved around the periphery of the panel while
engaging the strip 160.
[0199] To install the sheet of fabric, at least one edge 132 is
installed by disposing the first hook 164 on one of the sidewall
member outer legs 118 as shown in FIG. 14-16. The installer then
engages the fabric with the tool by inserting the lip portion 173
in one of the second hooks 166, 168 on one of the remaining strips,
as shown in FIG. 47, and moves the tool along the edge of the wall
panel. As the tool moves along the edge of the panel, the lip
portion 173, which is inserted into the second hook 168 the guide
member 175 encircles the end of the strip, pulls the strip inwardly
so that the first hook 164 can be inserted onto the outer leg 118
as the end of the strip and first hook passes through the space
between the core member, or hanger bracket, and the free edge of
the outer leg 118. The blade 172 includes an edge 180 that is
adapted to engage the strip and force the hook member past the
outer leg. Thus, the installer uses the tool 170 to stretch the
fabric 130 and force the first hook 164 of the strip past the end
portion and dispose it on the outer leg 118. It should be
understood that various tool configurations would work equally well
for stretching and mounting the fabric sheet.
[0200] In another embodiment, the tool includes a second blade
member 710 having an edge 602, as shown in FIG. 47A. The blade
member 710 is adapted to engage the second hook and install the
first hook on the sidewall as described above with the lip portion.
As shown in FIG. 47A, the barrier sheet 530 is wrapped around the
outer leg 118 and secured to the sidewall beneath the first
hook.
[0201] As shown in FIGS. 48-49, yet another embodiment of the tool
182 includes a handle member 184 having a curvilinear surface grip
185, a surface member 552, a mounting block 554 having a lip
portion 556 and a blade 186. As just described, the lip portion
engages the second hook, while the blade pushes the strip, and
first hook, against the outer leg 118. The surface member is
preferably made of plastic, such as Delrin, so that it slides
easily along the edge of the panel without damaging or tearing the
fabric. This embodiment could also employ a second blade member as
just described. It should also be understood that alternative
embodiments, such as a simple putty knife, also can be used to
engage the second hook, stretch the fabric and dispose the first
hook on the outer leg of the edge portion.
[0202] The strip and hook arrangement disclosed herein is ideally
suited for attaching fabric to a wall panel. For example, if the
fabric were to become stained, worn or torn, an installer can
remove the fabric quickly and easily by using a tool in the
opposite manner as described above to disengage the first hook from
the outer leg on the sidewall member. Moreover, the fabric can be
removed when the panel is connected to adjacent panels if using a
tool that can be inserted into the gap between the panels to engage
the second hook member. This provides significant advantages over
the prior art fabric attachments, which were either permanently
secured to the panel or were retained by an elastic band running
around the periphery of the panel. In either configuration, the
panel had to be disconnected from the adjacent panels so as to
access and remove the band or to remove the adhesive.
[0203] It should also be understood by one skilled in the art that
the strip and hook fabric attachment device can also be used to
secure fabric to objects besides wall panels, such as chairs,
cabinets, etc. All that is needed is an edge on which to secure the
hook member. Thus, the attachment of the fabric to the wall panel
as described above is meant to be illustrative rather than
limiting.
[0204] The lower horizontal frame member, shown in FIGS. 12, 14, 58
and 62, includes a mounting strip 190 and a bracket 200 mounted to
the outer surface 66 of the lower core member. As shown in FIG. 14,
the outer surface 66 preferably extends below the end portions of
the sidewalls. The side surface 67 of the portion of the lower core
member extending below the leg portion of the sidewall member is
stepped inward to permit the hook member on the strip to be
installed on the outer leg. The groove 33 runs along the outer
surface of the core member.
[0205] The bracket 200 includes several tab members 202 which are
adapted to engage and support a power distribution server 220,
including an electrical power harnesses 222, as shown in FIGS. 2
and 59. Referring to FIGS. 12 and 13, the tab members 202 form
slots 203 that receive bracket hooks 560 extending upwardly from
the power distribution server as shown in FIG. 59. In operation,
the harness 222 is installed by sliding the bracket hooks 560 into
the slots 203 until the end of the bracket 560 passes a resilient
locking tab 578 which springs downwardly to releasably secure the
harness 222 on the bracket 200. When the wall panel is particularly
long, the bracket may also include stabilizer brackets 570 that
extend downwardly from the bracket and include two arms that engage
the harness.
[0206] Referring to FIGS. 25-27, the harness includes a receptacle
bracket 566, a spring tab 572 and a plurality of module bracket
hooks 574. A plurality of receptacle modules 226 are secured to the
harness by engaging the bracket hooks 574 with mounting lugs 564
disposed on the module. Each module 226 is electrically connected
to the harness 222 at one of a four receptacle ports 576.
Similarly, conduit 276 from an outlet box installed in the panel,
as described below, preferably includes a connector that can
electrically engage one of the receptacle ports in place of a
receptacle module. For a complete description of the power
distribution server, including the power harnesses, one is directed
to U.S. Pat. No. 5,013,252, issued to Neinhuis et al. on May 7,
1991, the disclosure of which is hereby incorporated herein by
reference. The harness also includes electrical connector ports 224
positioned at the end of the harness and which provide a means for
electrically connecting adjacent panels, such that a first panel
receives power from a second panel. A commercially available
harness, Model No. 225409, is sold by PENT Assemblies of
Kendallville, Ind. FIGS. 26A-C show various configurations of
panels electrically interconnected. In this way, an entire system
of panels can be electrically connected and provide power to users
at individual work spaces.
[0207] Referring to FIGS. 14 and 62, the mounting strip 190 is
disposed between the bracket 200 and the core member 32. The
mounting strip 190 has a pair of elongated grooves 194 running
longitudinally along the edges of the mounting strip 190. The
mounting strip supports a base cover 230. The base cover 230
includes a pair of side walls 232 and a bottom wall 234, as shown
in FIGS. 14, 15 and 62. The side walls 232 and bottom wall 234 are
hinged along the longitudinal length of the base cover, preferably
by using a flexible hinge material 236. The cover members can also
be mechanically hinged. The upper portion of each wall includes a
beaded flange 238 that is disposed in the groove 194 in the
mounting strip. When mounted on the mounting strip, the base cover
230 forms and defines a horizontal channel for storing and
protecting cables and wires beneath the panel. The lower horizontal
channel also provides a concealed passage way for the cables and
wires as they pass from one panel to the next.
[0208] Referring to FIG. 2, the bottom wall 234 of the base cover
includes a slot 240 at each end which is adapted to receive a
support leg 250 extending down from the vertical frame members 14,
as explained below. The side walls 232 extend between the lower
edge of the wall panel and the floor and include openings 242
adapted to allow a user to access outlets in the modules 226
secured to the power distribution server, which is mounted to the
bottom of the lower frame member. Each end of the side wall 232 on
the base cover includes a flexible strip 244 that extends outwardly
from the end of the panel. When two panels are installed
end-to-end, the opposing flexible strips 244 overlap and conceal
the gap between the panels.
[0209] Referring to FIGS. 2 and 15, the wall panel is supported on
and spaced apart from the floor by a support leg 250 attached to
each vertical frame member 14. A support bracket 260 is mounted to
the bottom of each core member 28 on the inner surface 48 of the
core member. The bracket 260 is mounted in the space 106 provided
between the end of the lower core member and the bottom end of the
vertical core member, as shown in FIG. 12. The bracket 260 includes
a U-shaped sleeve portion 262 and a pair of flanges 264. The
flanges 264 are fastened to the inner surface of the core member 28
such that the sleeve portion 262 forms an opening 266 with the
surface of the core member.
[0210] The support leg 250 includes a shaft 252 having a shoulder
254 and a foot 256. An upper portion of the shaft is received in
the opening 266 formed by the support bracket and core member until
the shoulder 254 of the shaft engages the bottom of the 260
bracket. The bottom of the shaft 252 is threaded and threadably
engages the foot member 256 whereby the height of the wall panel
can be adjusted by rotating the foot 256 relative to the shaft
252.
[0211] An alternative construction of the wall panel is shown in
FIGS. 60-63. For the sake of clarity and simplicity, parts and
assemblies previously described above with reference to other wall
panel constructions are referred to and identified by the same
reference number. As best illustrated in FIG. 62, the wall panel
includes a core assembly 800 and a pair of outer sheetlike wall
members 920. The core assembly is shown in FIG. 60, and includes
upper and lower horizontal frame members 816, 818 and vertical side
frame members 814. Each frame member is preferably made of wood and
has a rectangular cross section, similar to the core members 28,
30, 32 of frame member 14, 16, 18 without sidewall members attached
thereto. Opposite ends of the vertical frame members are attached
to opposite ends of the horizontal frame members with fasteners,
adhesive, and/or the like. The upper and lower horizontal frame
members 816, 818 each have a pair of openings 806 that provide
access to a pair of vertical channels. Similar to the construction
of the wall panel shown in FIGS. 1-2 and 8-12, a filler member 150
is disposed between the upper and lower horizontal frame members,
while partition members 140 extend between the filler member and
the vertical side frame members to form a pair of vertical raceways
108. A first and second sheetlike inner wall members 820 are
mounted to opposite sides of the filler member and frame members to
complete the core assembly with adhesive, such as glue, and/or
mechanical fasteners. The wall members 820 are preferably made of a
relatively thin hardboard, e.g., 1/4 inch, although other
thicknesses would also work. The wall members close off and form
the vertical raceways 108 inside the core assembly. The periphery
or edges of the wall members 820, preferably lie flush with, or
inward from, the outer surface 50, 62, 66 of the frame members.
[0212] As shown in FIG. 60, a hole 822 is positioned through the
lower horizontal frame member and is shaped to receive the shaft
252 of the support leg. A stiffener block 824 can be inserted
inside the core assembly at each of the junctures of the lower
frame member and the side frame members to strengthen the panel and
to provide further support for the support leg shaft.
Alternatively, as shown in FIG. 60A, the hole is positioned in the
end of each vertical frame member and extends longitudinally
therein. The shaft 252 of the support leg is press fit into the
hole. A stiffener 826, preferably a piece of plywood, can also be
mounted to the inner surface of the vertical frame member to
prevent the frame member from splitting when the support leg is
installed. The plywood is secured to the frame member with adhesive
and/or by fasteners used to install the hanger member 70 to the
outer surface of the frame member, as described above. The
fasteners extend through the frame member on opposite sides of the
hole and thereby help to support the frame member around the shaft
so as to prevent the frame member from splitting.
[0213] Referring to FIG. 61, a plurality of protective strip
members 922 (shown as four) are positioned around the periphery of
wall member 920. Each strip member, shown in FIGS. 66 and 67, is
L-shaped and has a long flange and a short flange. The short flange
924, which has a length substantially the same as, or slightly less
than, the thickness of the wall member, is disposed along the edge
932 of the wall member to protect it from impact damage and the
like. The long flange is disposed along the inner surface of the
wall member. The strip members 922 preferably run the length of the
edge of the wall member upon which they are disposed, although it
should be understood that a plurality of strip members having
shorter lengths could be placed end to end to cover the entire
length of the wall member edge. The ends 928 of the long flange are
tapered, or mitered, to mate with the ends of adjacent strip
members at each corner of the wall member. As shown in FIGS. 61 and
62, a thin decorative sheet 930, preferably a fabric, is then
applied over the panel, with a barrier sheet 530 inserted
therebetween if desired. The decorative sheet is attached to the
wall member by applying a plurality of fasteners 934 through the
decorative sheet and strip members and into the wall member as
shown in FIG. 62. The strip members 922 anchor the fasteners, shown
as staples, and help prevent the decorative sheet from being pulled
from the wall member. The strip members 922 cab be attached to the
wall member using the fasteners 934 for attaching the decorative
sheet, or they can first be attached to the wall member using
additional fasteners or adhesive.
[0214] After the decorative sheet is mounted to the wall member,
each wall member 920 is mounted to the core assembly using an
adhesive, preferably a hot melt, applied between the wall member
920 and the wall member 820 of the core assembly. Alternatively, or
in combination with the adhesive, the wall members 920 can also be
mounted to the core assembly with fasteners, such as barbed
fasteners, nails, staples and the like. When installed, the
periphery, or edges, of the wall members 920 extends beyond the
periphery of the wall member 820 along the top and sides of the
core assembly so as to form channels along three sides of the wall
panel, with the channel formed along the top of the panel
preferably being the deepest. The wall members can also overhang or
extend beyond the bottom periphery of the wall member 820 so as to
form a channel along the bottom of the wall panel. Hanger brackets
70 are disposed in the relatively shallow channels along the sides
of the wall panel and are secured to the vertical side frame
members such that the slots 86 of the hanger brackets are exposed
beyond the edge of the wall members 920. The slots 86 are
configured to receive and support various components.
[0215] As shown in FIG. 103, the wall member 920 can be centered on
the core assembly 800 from side to side such that there is an equal
overhang of the wall members on each side of the wall panel. The
centering of the wall members on the core assembly provides an
equal exposure of the hanger brackets 70, and slots therein, on
each side of the wall panel. In particular, and referring to FIGS.
99 and 103, the core assembly 800 has a pair of locator openings
1230, 1232 bored therethrough along the centerline of the panel.
The upper locator opening 1230 is preferably circular, while the
lower locator opening 1232 is preferably slotted along the vertical
direction. Preferably, the upper locator opening has a 1/2 inch
diameter, while the lower locator opening is 1/2 inch side and 11/4
inches long. Obviously, it should be understood that other
diameters and sizes would also work. It should also be understood
that the location of the circular and slotted openings could be
interchanged, or that both openings could be circular or slotted,
or assume any other shape, including for example a rectangular or
triangular shape. The term "opening" as used herein is meant to
include a hole, recess, bore, hollow, notch or similar passage, and
is not limited to an opening extending all of the way through the
core assembly, or even the wall member, but may alternatively
extend only partially thereinto. Moreover, it should be understood
that one or more locator openings, and preferably more than one,
can be used to locate the wall member 920 on the core assembly, and
that the disclosure of two locator openings is meant to be
illustrative, rather than limiting. Preferably, the upper locator
opening is keyed off of or located a predetermined with respect to
the top of the core assembly, or a channel attached thereto. For
example, in one embodiment, the locator openings are keyed off of
or located a predetermined distance from the upper surface of the
ridges on the channel, which surface acts as a reference.
[0216] Referring to FIGS. 100 and 103, the wall member 920 includes
two locator members 1234, which are receive in the locator
openings. The locator members 1234 are attached along the
centerline of the wall member 920. The upper locator member is
received in the upper locator opening which is circular and
dimensioned to receive the locator member without play so as to
determine the top-to-bottom positioning of the wall member with
respect to the core assembly. The lower locator opening, which is
slotted, can accommodate some tolerance buildup, or other slop, in
the placement of the locator members along the vertical axis, as it
is not intended to locate the wall member along the vertical
direction, but is dimensioned to closely receive the locator member
in the lateral or side-to-side direction so to prevent any play
therealong. In this way, the upper and lower locator member and
openings work in combination to center the wall member on the core
assembly from side-to-side, while the upper locator member and
opening position the wall member on the core assembly from top to
bottom.
[0217] Each locator member includes a base portion 1236 and a post
member 1238 extending outwardly therefrom. The post member 1238 has
a rounded nose portion 1239 that facilitates its insertion into the
locator openings positioned in the core assembly. The locator
members are preferably made of high density polyethylene, although
it should be understood that other materials, including other types
of plastic, wood or metal would also work. The post member 1238 is
shaped to be received in the locator holes 1232, 1234, and
preferably has a length less than one half the thickness of the
core assembly so that the post members 1238 on the opposing wall
members 920 can be inserted in the same locator openings 1232, 1234
from both sides of the core assembly.
[0218] The base portion 1236, which is preferably flat, circular
and relatively thin, is attached to the inner surface of the wall
member 920 with a plurality of mechanical fasteners, such as
staples, nails or the like. Alternatively, or in combination with
the mechanical fasteners, the bottom surface of the base portion
can be attached to the wall member with an adhesive or the like,
including for example a two sided tape, glue or other bonding
agent.
[0219] Preferably, the upper locator member is keyed off of or
located a predetermined distance from the top edge of the wall
member, which acts as a reference. The location of the upper
locator member is correlated to the location of the upper locator
opening with respect to the top of the core assembly, or channel
thereon, such that a uniform appearance is provided from wall panel
to wall panel when the core assembly and wall member components are
assembled to form the wall panels.
[0220] It should be understood that the predetermined distance
between the upper locator opening and the top of the core assembly,
or channel, and the predetermined distance between the locator
member and the top edge of the wall member are not by themselves
(individually) important. Rather, one of skill in the art should
understood that it is the relationship between the two
predetermined distances that is important, as it is that
relationship that ensures that the wall member is properly located
on the core assembly from top to bottom. Thus, the predetermined
distance of the locator opening from the its reference, whether it
be the top of the core assembly, or a surface on the channel
attached thereto, refers to any distance arbitrarily set, but
preferably calculated so that the upper locator opening is below
and does not pass through the upper horizontal frame member. The
predetermined distance of the locator member from the top edge of
the wall member is then calculated so as to ensure that the wall
member extends a certain distance above the core assembly, and
preferably to the top of the channel attached thereto. Conversely,
the predetermined location of the locator member can first be
calculated, with the predetermined location of the locator opening
thereafter set.
[0221] When attaching the wall member 920 to the core assembly 800,
the locator members 1234 are disposed in the locator openings 1230,
1232, which are dimensioned to receive the locator members, so as
to ensure that the wall member is centered on the core assembly
from side to side. In addition, the upper locator opening, which is
preferably not slotted and therefore controls the position of the
upper locator member, ensures that the top edge of the wall member
is also located a predetermined distance with the respect to the
top of the core assembly, or the channel member attached thereto,
as the locator member is received in the upper locator opening.
Although the locator members and openings are shown as being
located along the centerline of the wall member and core assembly
respectively, it should be understood that the locator members and
holes could be located off the center line and still function to
center the wall member on the core assembly as long as the location
of the locator members and openings are keyed off the side surfaces
of the wall member and core assembly so as to provide an equal
overhang as explained above.
[0222] One of skill in the art should also understand, as explained
in more detail below, that the locator members and openings could
be reversed, with the locator members attached to the core
assembly, and with the locator openings disposed in the wall
members.
[0223] As shown in FIGS. 62-65, 99 and 103, the top channel member
940, or liner, is mounted to the top of the upper horizontal frame
member 816 in the channel formed between the upper portions of the
opposing wall members 920. The channel member can be attached to
the upper horizontal frame member with fasteners, adhesive, or a
combination thereof, before or after the wall members are secured
to the core assembly. As with the sidewalls of the upper frame
member described above, each leg 942 of the top channel includes an
inwardly facing ridge 944 or lip portion that engages the ribbed
portion 114 of the top cap 110. In a preferred embodiment, the
upper surface of the ridge 944 serves as the reference for locating
the position of the upper locator opening. The top channel also
includes a pair of openings that are aligned with the openings 946
in the upper frame member and the vertical raceway 108 beneath it.
The top channel member can be made of plastic, metal or any other
suitable material.
[0224] In a preferred embodiment, an outlet box 270 is installed
inside the wall panel frame between the upper and lower frame
members 16, 18, 816, 818. As shown in FIGS. 8 and 11, the outlet
box 270 is first attached, preferably with bolts, to a plate member
272, preferably a piece of hardboard. The plate member 272 is then
attached, preferably by adhesive bonding, to the inner surface 122
of one of the wall members. The opposite wall member has an opening
274 aligned with the outlet box 270 so as to allow the user access
to the box. An outlet cover 275 can be installed over the opening.
The outlet box is electrically connected to the power distribution
server with an electrical conduit 276 that is disposed in the
vertical channel 108, as described above. Outlets, which are not
shown, are installed in the outlet box. It should be understood
that the same or similar box can be installed to provide access to
data and communication wiring and cables. The outlet box also can
be field installed by cutting a hole in one of the thin sheets, the
barrier sheet and the wall member.
[0225] In an alternative embodiment, the outlet box can be
installed using a bracket that is mounted inside the panel as shown
and described in U.S. application Ser. No. 08/892,016, entitled
Mounting Bracket Assembly for an Outlet Box and filed Jul. 14,
1997, the entire disclosure of which is hereby incorporated herein
by reference.
[0226] In yet another alternative embodiment, shown in FIGS. 95-97,
a pair of brackets 950 each include a flange portion 952 and a hook
portion 954 extending laterally from the flange portion. The flange
portion 952 is attached to the wall member 820 of the core assembly
with a pair 956 of fasteners. The wall member 920 is then laid over
the flange portion 952 and attached to the wall member 820 as
described above. The hook portion engages an outwardly facing edge
of the outlet box and holds the back of the outlet box against the
inner surface of the opposing wall member 820.
[0227] The wall panels can be connected to form a system of panels
that defines and divides large office spaces into work spaces. For
example, the wall panels can be connected end-to-end in a simple
linear arrangement as shown in FIGS. 19 and 20. In such an
arrangement, the panels are positioned adjacent to each other such
that opposing outer surfaces 80 of the hanger brackets are in a
proximal relationship. A connector member connects the adjacent
hanger brackets and generally includes an upper and lower draw
block and a draw rod, although, as explained below, other connector
member confirmations can further include a corner post, or can be
configured as a hanger bracket. For example, as shown in FIGS.
28-30, an upper draw block 280 is provided which has a downwardly
facing V-shaped draw surface 282 defined by four wedge members 284.
The upper draw block 280 includes a middle portion 286 that has a
hole 288. Similarly, a lower draw block 290 has an upwardly facing
V-shaped draw surface 292 defined by four wedge members 294. A draw
rod 296 connects the two draw blocks 280, 290.
[0228] Referring to FIGS. 19-20, the upper draw block 280 is
positioned such that the wedge members 284 engage the top edge 298
of the hanger bracket on the adjacent panels by inserting the wedge
members 284 into the inwardly facing channels 72. The middle
portion 286 of the draw block is disposed in the space formed
between the outwardly facing channels 300, which is formed by the
inner legs of the channel and the bridge portion.
[0229] Similarly, the lower draw block 290 is inserted into the
bottom end of the channels 72 such that the wedge members 294
engage the bottom edge 302 of the hanger bracket 70 and the middle
portion is received in the space formed by the channels 300. The
draw rod 296 is rotatably connected to the lower draw block and
threadably engages the upper draw block. Alternatively, the draw
rod can be rotatably secured to the upper draw block and threadably
secured to the lower draw block, or it can be threadably secured to
both. The draw rod is disposed in the space formed by the two
outwardly facing channels 300 of the opposing hanger brackets as
shown in FIGS. 32-33. When rotated, the draw rod threadably engages
the upper draw block, pulling it closer to the lower draw block. As
the draw rod is tightened, the draw surfaces 282, 292 of the draw
blocks operably engage the ends 298, 302 of the hanger brackets and
pull the hanger brackets together. In an alternative embodiment
shown in FIG. 29, the draw blocks include a flat surface 304
between the wedge members 306. When drawn together, the ends of the
hanger brackets engage the flat surface 304, wherein the hanger
brackets are locked into position between the wedge members.
[0230] As shown in FIG. 30, one embodiment of the draw blocks
includes a landing 308 and a tang member 310 extending from the
landing on one side of the opening 288. This configuration
facilitates the installation of the draw blocks and draw rod. In
particular, the installer can rest the land portion 308 of the
upper draw block on the bridge portion 74 of one of the hanger
brackets, while the tang member 310 is disposed in the channel 300
to align the draw block with the hanger bracket. In this way, the
connector assembly, i.e., the draw rod and two draw blocks, can be
positioned and retained by a first panel as the second wall panel
is moved into place next to the first panel. The draw rod 296 and
blocks 280, 290 can then be lifted up and aligned with the channels
72 on the ends of both panels. The draw rod 296 is then tightened
as explained above so as to connect the two panels.
[0231] As shown in FIGS. 4-5 and 31-33, two or more panels can also
be connected in a perpendicular relationship. In such a
configuration, the connector member further includes a corner post
320 installed between adjacent panels and one or more pairs of draw
rods and upper and lower draw blocks connecting the panels to the
corner post. The corner post 320 includes a substantially square,
elongated tube 322 and an upper and lower plate 324, 326 mounted
inside each end of the tube, preferably by welding. Each plate 324,
326 includes a threaded hole 328 in the middle of the plate. A pair
of inwardly facing channels 330 are formed longitudinally along
each side of the tube 322. The inwardly facing channels 330 also
form an outwardly facing channel between them. Preferably, the tube
322 is made from two overlapping C-shaped pieces 332, 334 welded
together as shown in FIGS. 32-33.
[0232] Referring to FIGS. 4 and 5, each corner of the tube includes
an outwardly facing groove 336 that runs longitudinally along the
length of the tube 322. As shown in FIGS. 32 and 33, the groove 336
is preferably formed by the outer legs of the channels 330, which
are joined at the comers of the tube at approximately
90.degree..
[0233] As shown in FIG. 31, each wall panel is connected to the
corner post in the same way as described above. An upper and lower
draw block 280, 290 engage the top and bottom edge of the two
channels 330 on the side of the tube and the two channels 72 of the
hanger bracket mounted on the side of the wall panel being
connected. The draw rod 296, connecting the draw blocks, is
tightened to pull the draw blocks together and to pull the wall
panel towards the corner post so that the hanger bracket engages
the side of the tube. It should be understood that one, two, three
or four wall panels can be connected to the corner post at any time
depending on the desired configuration.
[0234] As shown in FIGS. 5 and 33, when two wall panels are
connected to the corner post 320 at 90.degree., the opposing two
sides of the corner post are concealed by an V-shaped cover member
340 adapted to be disposed on the adjacent, perpendicular sides of
the corner post. The cover member 340 includes two wall members 341
joined in a substantially perpendicular relationship. The cover
member 340 includes a beaded portion 342 running longitudinally
along the side edges 344 of the cover. The beaded portions 342 are
adapted to engage the outwardly facing groove 336 formed along each
corner of the tube 322. The beaded portion 342 extends diagonally
inward from the cover at approximately 45.degree.. A tab 343 is
formed along the inside of the beaded portion. The tab buts up
against the top edge of the tube so as to ensure that the cover
member is located at the proper height along the length of the
tube. In addition, a patch or similar marker can be attached to the
inside of the cover member to indicate which end is up. The upper
end of the cover member includes a horizontal flange portion 345.
The cover member 340 includes an outer layer of fabric 346 that
matches the thin sheet of fabric disposed on the adjacent wall
panels.
[0235] When two wall panels are arranged in a 180.degree.
relationship on opposite sides of the tube, a flat cover member 348
can be installed on one or both of the exposed sides of the tube
322 as shown in FIGS. 4 and 32. The flat cover member 348 includes
diagonally facing beaded portions 350 running longitudinally along
its length. In addition, the flat cover member 348 includes a
locator tab member 343 and a upper horizontal flange 345.
[0236] Referring to FIG. 4, a support member 352 is attached to the
bottom of the tube member 322. The support member 352 includes a
base portion 354, a leg 356 and a foot 358. The base portion 354 is
attached to the lower plate 326 secured in the bottom end of the
tube 322. A base cover 360 is installed on the support member 352
to conceal the support member 352 and the space below the panel.
The base cover 360 extends between the base portion 354 and the
foot 358. The foot 358 includes a bottom member 362 and a pair of
cylindrical lug members 364 positioned on opposite sides of the
bottom member 362. The base portion 354 includes slotted portions
366 positioned on the same side as the lug members 364. The base
cover 360 includes upwardly facing tab members 368 that engage the
slotted portions 366 and a pair of flange members 368 that engage
the lug members. The leg 356 is preferably a thin shaft that allows
cables and wires to pass between the leg 356 and base cover 360 as
they are passed between adjacent panels. In this way, the cover 360
forms part of the lower horizontal channel. It should be understood
that the support does not engage the floor, but rather is provided
to support the base cover member, which conceals and protects wires
in the lower channel.
[0237] When two panels are attached to a corner post at 90.degree.,
the support does not include a foot. In this arrangement, the
support includes a base portion 372 and a leg 374 as shown in FIG.
5. The base cover 376, shown in FIG. 30, includes two walls 378, a
base plate 380 and a guide plate 382. The base portion 372 includes
a slot 384 and two tab members 386 on two sides of the base
portion. A lip portion 388 is positioned on the top of each base
cover wall 378. When installed, the lip portion 388 is inserted
into the slot 384 as the two tab members 386 engage the bottom of
the lip 388 to releasably secure the base cover 376 to the base
portion 372. The guide plate 382 extends between the walls 378 and
lies parallel to the base plate 380. The guide plate 382 includes a
slot 384 adapted to receive the leg 374 of the support. The base
plate 380 includes an opening 390 that is adapted to receive an end
of the leg, which includes a lug 392. In this way, the base cover
is supported by the support base portion and is stabilized by the
leg.
[0238] As shown in FIGS. 4, 5 and 7, the corner post 320 also
includes a cap assembly 400 adapted to span the gap between
adjacent top caps 110 installed on top of each wall panel.
Preferably, the cap assembly 400 is plastic. FIGS. 4, 5 and 7 show
the cap assembly which includes a post member 420. The post member
420 has a threaded end 404 that threadably engages the threaded
hole 328 in the upper plate 324 secured in the end of the tube 322.
The cap 400 also includes a base member 406, a lock member 408 and
a cover member 410. The base member 406 includes a step portion 412
on each side of the base and a primary post member 414 extending
upwardly from the middle of each side of the top surface 416 of the
base member. Each primary post member 414 includes a shaft portion
418 and a head portion 420. Each primary post member 414 is slotted
so as to make the head and shaft portions flexible and resilient.
Two secondary post members 424, positioned on opposite sides of the
primary post member, extend upwardly from each step portion 412 of
the base member. A cylindrical sleeve portion 426 extends
downwardly from the bottom of the base member 406. An opening 407
is formed in the base member and overlies the cylindrical sleeve
portion 426. The sleeve portion 426 is adapted to receive the top
of the post member 402, so that the post member supports and
rotatably engages the base member 406. The post member 420 includes
a slot 409, or other configuration for receiving a tool, such that
the post member 420 can be accessed through the opening 407 and
rotated from above the base member 406. Alternatively, the post
member includes is ribbed such that the shaft thereof is grippable
and can be gripped and rotated by a user. The post member 402
allows the height of the corner post cap to be adjusted as it
threadably engages the upper plate 324 in the tube 322. In
addition, the post member 420 is slender so that cables, wires and
the like can be disposed around the post member as they pass from
the upper horizontal channel 88 of one panel to the next.
[0239] The lock member 408 is rectangular and includes openings 428
adapted to receive the secondary post members 424. The lock member
408 also includes four openings 430 adapted to receive the head and
shaft of the primary post member 414. A shoulder is disposed inside
each opening so that when the primary post member is inserted into
the opening, the head extends through the plate member and engages
the shoulder to thereby releasably secure the plate member to the
base member. The cover member 410 is releasably secured to the top
of the lock member 408. The cover member 410 is attached to the
lock member with a two-sided tape or adhesive mechanical, although
it should be understood that other mechanical fasteners could also
be used. Alternatively, the cover member and lock member can be
integrally formed as a single member.
[0240] Referring to FIGS. 3-7, a light seal member 432 is provided
to connect the top cap on the wall panel with the corner post cap.
The light seal member 432 includes a mounting flange 434 having two
holes: a slotted hole 436 and a round hole 438. The holes 436, 438
are adapted to receive the secondary post members 424. The mounting
flange 434 also includes a semicircular cut-away portion 440. The
light seal member 432 is installed on the base member 406 by
inserting the secondary post members 424 into the openings 436, 438
in the mounting flange 434. The bottom of the mounting flange 434
engages the step portion 412 so that the top of the flange lies
flush with the top surface of the base member 406. The cut-away
portion 440 is disposed around the primary post member 414. The
lock member 408 is installed on the base member 406 so as to
releasably secure the light seal 432 to the base member 406.
[0241] The light seal member 432 includes an insert portion 442
with a rib 444 defining an end of the insert portion 442. The
insert portion 442 is adapted to be received in the open end of the
top cap 110 mounted on each wall panel. The light seal member 432
also includes downwardly extending legs 446. The legs extend
downwardly between the upwardly extending sidewall members 36 of
the adjacent upper frame member and the cover member 340, 348
disposed on the side of the corner post so as to prevent light from
penetrating the gap between the two members. Each leg 446 also
includes a beveled edge 448 that mates with an opposing edge of an
adjacent leg when two light seals are installed at 90.degree. to
each other. The light seal is preferably made of plastic and the
legs can be trimmed to the proper length before installation.
[0242] Referring to FIG. 6, a light seal member 450 is provided to
bridge the gap between the top caps on two panels placed end-to-end
and connected to each other. In this embodiment, the light seal
member 450 includes two insert portions 452 facing away from each
other and that are separated by a rib 454. The insert portions 454
are received in each wall panel top cap 110. The rib 454 provides a
smooth and continuous transition between the top caps 110. The legs
456 of the light seal extend downwardly and conceal the gap between
the adjacent upwardly extending sidewalls of the two panels.
[0243] Referring to FIGS. 68-72, a corner post light seal member
960 is shown. The light seal includes a base portion 962 that is
supported on the upper plate member of the corner post. The base
portion 962 includes an opening that is aligned with the opening
328 in the upper plate member that receives the post member, such
that the post member 420 can be disposed through the hole in the
base portion and threadably engage the plate member. A plurality of
arm portions 966 extend upwardly from the base portion. Each arm
portion includes a pair of flexible fins 968 that extend laterally
outwardly from the arm portion in a substantially perpendicular
relationship to each other. The fins span at least a portion of the
gap formed between adjacent wall panels oriented at right angles,
or between the various wall panels and cover members. The flexible
fins 968 are folded or bent inwardly to fit beneath the cover
member 340 that is mounted to one or more sides of the corner post
as shown in FIG. 72.
[0244] As shown in FIGS. 68 and 70, a light seal member 970 is
shown with relatively short downwardly extending legs that overlap
with the upwardly extending arms and fins of the light seal. The
light seal member 970 includes a mounting flange 434 with a slotted
hole 436, a round hole 438 and a cut out 440, which mate with the
post members in the manner described above with respect to light
seal member 432. The corner post light seal configuration shown in
FIGS. 68-72 has several advantages. First, because the light seal
member is supported by the corner post and includes upwardly
extending arm portions, it does not need to be removed when the top
caps are removed for wiring changes and the like. In addition, the
light seal member 970 can be configured with shorter legs, and is
more easily installed.
[0245] As shown in FIGS. 73 and 74, another embodiment of a light
seal member 980 includes a base portion 982 that is supported on
top of an upper draw block 280 and draw rod 290. In particular, the
base portion has a recess 984 shaped to receive the draw block 280
as the end of the draw rod 290 extends upwardly in an opening 987
formed in the base portion. The light seal member includes a pair
of upwardly extending arm portions 986 that bridge the gap between
adjacent wall panels positioned in an end-to-end configuration. A
light seal member 990 similar to member 450 shown in FIG. 6, but
with shorter legs 992, is then installed between the adjacent top
caps installed on top of the wall panels arranged in the end-to-end
configuration. Again, the light seal member 980 remains seated on
the draw block when the top cap is removed for access to the top
channel, and the top cap can be more easily installed because of
the relatively short length of the legs extending downwardly from
the light seal.
[0246] Referring to FIGS. 36 and 38-40, a connector member is
provided to attach a shorter wall panel to a taller wall panel. In
this configuration, the connector member includes an upper and
lower draw block and a draw rod. The upper draw block 460 includes
a pair of wedge members 462 on one side and a pair of hook members
464 on the opposite side. The hook members 464 are adapted to
engage the slots 86 in the hanger bracket 70 attached to the side
of the taller wall panel. The wedge members 462 engage the top 298
of the hanger bracket channels 72 on the shorter wall panel as
described above. To connect the panels, the draw rod 296 is
tightened to pull the two wall panels together. A light seal 470 is
installed on the shorter panel so that its legs 472 are disposed on
either side of the upper draw block 460. An insert portion 474 of
the light seal 470 is received in the top cap 110 attached to the
top of the shorter panel. The end of the light seal 470 is defined
by a flat surface 478 which extends downwardly from a rib 476. The
flat surface 478 abuts the hanger bracket 70 on the taller
panel.
[0247] Referring to FIGS. 3, 36, 39 and 57, a pair of end cover
brackets 480 are installed on the exposed end of any wall panel
which is not connected to another wall panel or a corner post. The
end cover bracket 480 includes a pair of outwardly facing grooves
482 running along opposite side edges of the bracket. A end cover
484 is attached to the bracket 480 on the end of the panel to
provide a finished appearance. The cover 484 comprises a channel
with a top wall 486 closing the upper end of the channel. The end
cover also includes a pair of U-shaped brackets 488 mounted inside
the channel. The brackets each include inwardly facing flanges 490
which are inserted into the grooves 482 in the end cover bracket
mounted to the end of the wall panel. A light seal can be installed
between the end cover and the top cap of the wall panel, as shown
in FIGS. 3 and 36.
[0248] When installing a shorter panel adjacent to a taller panel,
an end cover bracket 480 is mounted to the exposed portion of the
hanger bracket and wall panel end extending above the shorter
panel. A short end cover 485, shown in FIGS. 36 and 40, is mounted
on the bracket so that the exposed upper portion of the taller wall
panel is covered. A light seal 450 is then installed between the
end cover and the top cap on the taller wall panel.
[0249] Alternatively, as shown in FIGS. 126 and 127, a clip 2002
has a plurality of offset tabs 2004. The flanges 490 of the bracket
480 are received in the spaces formed between the tabs 2004 as the
end cover, with its brackets 480, is slid onto the clips 2002. The
clips 2002 are attached to the hanger brackets with a pair of
fasteners 2008.
[0250] Referring to FIGS. 41-42, the wall panel also can be
attached to a permanent wall 494. In this arrangement, a mounting
plate 496 is disposed inside a channel-shaped cover 498 having a
top wall 499, similar to an end cover. A hanger bracket 70, the
cover 498 and mounting plate 496 are mounted on the permanent wall
494 with a plurality of fasteners. The wall panel is connected to
the hanger bracket with a connector member, including an upper and
lower draw block and draw rod, as described above, with a light
seal 450 being inserted between the cover and the top cap of the
adjacent panel.
[0251] As shown in FIGS. 75-81 and 120-129, one or more upper,
stackable wall panels 1000 can be installed on top of one or more
lower wall panels in various configurations. Each upper, stackable
wall panel is preferably of the same construction as one of the
wall panels described above, although it should be understood that
wall panels of various constructions can be attached using the
connector members described herein. Hanger brackets 70 are attached
to the vertical side frame members of the upper wall member and
extend downwardly from the bottom of the panel so that the bottom
of the hanger brackets 70 overlies and is spaced apart from the top
of the hanger brackets 270 mounted on the ends of the lower wall
panel. As with the wall panels described above, each upper panel
includes a upper channel forming a horizontal wire raceway that can
be closed off with a top cap, and a pair of vertical wire raceways
108 that are aligned with the vertical raceways in the lower wall
panels. The upper channel can be formed by the space between the
wall members, or can include a separate channel member 940.
[0252] Referring to FIGS. 75 and 122-123, a pair of lower wall
panels are positioned end-to-end and connected with a connector
member, which includes upper and lower draw blocks and a draw rod
as described above. A spanner member 1020, shown in FIGS. 82-84, is
then disposed in the upper horizontal channels in each of the wall
panels and is attached thereto with a plurality of fasteners 1022
which secure the spanner to the upper horizontal frame members of
the adjacent lower wall panels. As used herein, the term spanner
member is meant to refer to a member, such as a brace or bracket,
that spans or bridges the distance between two adjacent members,
shown as wall panels. The spanner member is formed as a channel
member 1024 having a pair of openings 1028 formed in the base 1023
of the channel that are aligned with and provide access to the
vertical raceways 108 of the wall panels that the spanner member
connects. The channel member also has a cut out portion 1026 in the
middle of the member that overlies the upper draw block and draw
rod connecting the lower panels to each other. The spanner member
also includes a bracket member 1030 having two side portions 1032,
each with two flanges 1034 extending outwardly from the side
portion. The side portions are joined by a cross member 1036 that
forms a horizontal support surface. The bracket is inserted in the
cut out portion of the channel member and the four flange portions
are welded, or otherwise attached, to side walls 1025 of the
channel member to strengthen the spanner assembly. As shown in FIG.
83, the bottom of the cross member 1036 is spaced above the bottom
surface of the channel member to provide clearance for the
underlying draw block and draw rod.
[0253] When used as a lower spanner member, a draw block 1040,
shown in FIGS. 82 and 83, is inserted in the cutout prior to the
bracket member being attached to the channel member. The draw block
1040 includes a pair of shelf portions 1042 extending from each
side of the draw block. The shelf portions engage a top edge 1027
of the cutout on each of the channel sidewalls. The draw block also
includes wedge members and draw surfaces, with a flat space
therebetween, as described above with reference to the other draw
blocks. The bottom surface of the draw block is supported by the
bracket member cross member 1036 such that the draw block is
trapped between the bracket member and channel member.
[0254] Referring to FIG. 75, a spanner member 1020 is also mounted
across and within the top channels of the upper stackable wall
panels, such that the openings 1028 are aligned with the vertical
raceways 108 of the upper wall panels. The upper spanner member
does not include a draw block, but is mounted over an upper draw
block 280 that engages the hanger brackets on the adjacent upper,
stackable panels. Draw blocks 280 and 1040 are connected with a
draw rod 296. In this way, an upper connector member, including
draw rod 296 and draw blocks 280, 1040, overlies the connector
member connecting the lower panels and is used to connect the upper
panels to one another and to the lower panels. In particular, the
draw rod 296 is rotated so as to draw the upper and lower draw
blocks 280, 1040 toward each other so as to thereby pull the hanger
brackets together and to mount the upper, stackable wall panels to
the lower wall panels.
[0255] Now referring to FIGS. 76 and 124, an upper stackable wall
panel 1000 is shown as being mounted to a pair of lower wall panels
arranged in an end-to-end configuration. In this arrangement, a
spanner member 1020 with a draw block 1040 is installed in the
lower wall panels over a draw block 280 as described above and as
shown in FIG. 123. An upper draw block 280 is then installed on the
hanger bracket of the upper, stackable panel and a draw rod 296 is
used to clamp the upper, stackable panel to the lower panels. In
this way, the connector member, which includes the draw rod 296 and
the upper and lower draw blocks 280 and 1040, connects the upper,
stackable panel to the lower panels. A cover member can then be
installed over the exposed hanger member and draw rod of the upper,
stackable wall panel.
[0256] Now referring to FIGS. 77 and 120-121, a taller lower panel
is shown attached to a shorter lower wall panel using a connector
member, including draw block 460, in the manner described above
with reference to FIGS. 36 and 38-40. An upper, stackable panel can
then be installed on top of the shorter lower wall panel to
equalize the height of the adjacent panels. In this configuration,
a support bracket 1060, 3060, shown in FIGS. 87-89 and 120
respectively, is mounted to the shorter lower wall panel.
[0257] In one embodiment, the support bracket 1060 is formed as a
channel 1062 with a base 1066 and a pair of side walls 1064. A
support member 1068 includes a vertical flange that extends
upwardly from one end of the bracket to close the channel on that
end. A horizontal support flange 1070 extends outwardly from the
vertical flange and includes an opening 1072. The support flange
has a T-shaped configuration that is shaped to support a draw block
1080, shown in FIGS. 90-92.
[0258] In an alternative embodiment, shown in FIG. 120, the support
bracket 3060 has a channel 3062 with a base 3066 and a pair of
sidewalls 3064. The end of the channel is closed by a support
member 3068, which formed as an upstanding channel that nests
between the sidewalls 3064. The support member can be attached to
the sidewalls by welding, with fasteners, or any other well known
method of attachment. The support member has a pair of mounting
holes 3063.
[0259] As shown in FIGS. 90-92, the draw block 1080 includes a
middle portion 1082 having a threaded opening 1084 running
therethrough and a pair of draw surfaces 1086 formed along the top
of wedge members 1088 disposed on outwardly extending side portions
1092. A ledge 1090 or shelf is formed on each side portion at the
base of each wedge member and is designed to engage the lower end
of the hanger bracket attached to the upper, stackable wall panel.
The draw block is attached to the closed end of the channel. In
particular, the draw block is disposed on top of the support flange
1070 with the middle portion and wedge members extending upwardly
therefrom and is secured to the flange with a bolt 1102, or like
fastener extending through the hole in the flange member.
Alternatively, the draw block can be secured to the flange member
by welding or the like. The bottom of the support flange, and the
head of the bolt extending therethrough, is spaced above and
provides clearance for the underlying draw block that clamps the
shorter lower wall panel to the taller lower wall panel.
[0260] In an alternative embodiment of the draw block 4080, which
is similar to the draw block 1080 as shown in FIGS. 131 and 132,
the side portions 4092 act as a spacer and extend outwardly from
the middle portion (away from the draw surfaces) so as to ensure
that the threaded opening is aligned with the draw rod. The draw
block 4080 also has a pair of mounting holes 4094 disposed
laterally through the side portions 4092. The mounting holes 4094
are positioned to be aligned with the mounting holes 3063 in the
support member 3068. The draw block 4080 is then mounted to the
vertical support member 3068 with a pair of fasteners, shown as
bolts. Alternatively, the draw block could be welded to the support
member, or adhesively secured thereto.
[0261] The support bracket 1060, 3060, with the draw block 1080,
4080 attached thereto, is disposed in the top channel of the lower
wall panel such that an opening 1065 formed in the support bracket
overlies and is aligned with the vertical raceway and such that the
sidewalls of the support bracket are laterally supported by the
channel sidewalls. The support bracket is mounted to the upper
frame member with a plurality of fasteners, adhesive, or a
combination thereof.
[0262] Referring to FIGS. 77 and 121, a spanner member 1020 is
installed between the upper, stackable wall panel and the taller
lower wall panel as described above with reference to FIG. 75. A
draw block 280 is mounted on the adjacent hanger members and a
short draw rod 296 is used to connect the upper and lower draw
blocks 280, 1080 so as to thereby mount the upper panel to the
shorter and taller lower wall panels. The draw rod 296 and upper
and lower draw blocks 280, 1080 comprise a connector member, which
connects the upper panel to the shorter and taller lower wall
panels and overlies the connector member, which includes a pair of
draw blocks and a draw rod, connecting the lower wall panels. The
draw rod 296 threadably engages the upper portion of the hole 1084
in the draw block 1080, while the bolt 1102 threadably engages the
lower portion thereof. Alternatively, the draw rod can be rotatably
secured to the draw block.
[0263] Now referring to FIG. 78, a shorter lower panel is again
shown as attached to a taller lower panel, with a first upper,
stackable panel attached to the lower panel in the manner just
described, except that the spanner member 1020 connecting the
taller lower panel and the first stackable wall panel includes a
draw block 1040, again with the draw block and cross member spaced
above the upper draw block 280, which is part of the connector
member used to clamp the first stackable wall panel to the taller
lower wall panel and to the shorter lower wall panel. In addition,
a second stackable panel is attached to the top of taller lower
panel in the same manner as described above with reference to FIG.
76.
[0264] Now referring to FIGS. 79 and 125, an upper stackable wall
panel is shown as attached to a lower wall panel, with the two
panels forming an exposed end of the wall panel assembly. In this
configuration, a stand-alone hanger bracket 70 functions as a
connector member. The hanger bracket 70 has a length equal to the
combined height of the lower and upper wall panels and is placed
adjacent the two panels. A second connector member, including an
upper draw block 460, along with a draw rod 296 and a lower draw
block 290, are used to connect the stand-alone hanger bracket, or
first connector member, to the lower wall panel as described above
with reference to FIGS. 36 and 38-40. In particular, the wedge
members 462 engage the hanger bracket 70 on the lower panel, while
the hook members 464 engage the slots 86 on the stand-alone hanger
bracket 70. A support bracket 1060, 3060, with draw block 1080,
4080 attached thereto, is then butted up against the hanger bracket
70 so as to overlie the draw block 460. An upper draw block 280, a
draw rod 296 and lower draw block 1080, 4080, which function as a
third connector member, is used to connect the upper panel to the
hanger bracket connector member and to the lower panel. In
particular, the upper draw 280 is installed to engage the hanger
bracket on the upper, stackable panel and the stand-alone hanger
bracket. The second draw rod 296 is then used to clamp the upper,
stackable panel to the stand-alone hanger bracket and to the
support bracket 1060 mounted to the lower wall panel as described
above. It should be understood that the stand-alone hanger bracket,
or first connector member, the draw blocks 460, 290 and draw rod
296, or second connector member, and the draw blocks 280, and 1080,
4080, or third connector member, can also be considered in
combination as a single connector member for connecting the upper
wall panel to the lower panel.
[0265] A cover 1110, shown in FIGS. 93-94 is then installed on the
exposed stand-alone hanger bracket to provide a finished
appearance. In this configuration, the exposed portion of the
stand-alone hanger bracket is opposite of the exposed portion of a
hanger bracket attached to the end of the panel. To facilitate the
attachment of the cover member to the inverted hanger bracket, a
pair of clip members 1112 are installed inside the cover 1110. Each
clip member 1112 includes a resilient arm portion 1114 having an
end portion 1116 that releasably engages the slots of the hanger
bracket. An alternative embodiment of the clip 6116 having
resistant arm portions 6114 and end portions 6116 that releasably
engage the slots is shown in FIG. 134.
[0266] Now referring to FIG. 80, a pair of lower wall panels are
shown as attached to a corner post as described above. As described
above, the corner post 320, in combination with one or more pairs
of draw rods 296 and upper and lower draw blocks 280, 290, function
as a connector member to connect the lower wall panels. A corner
post extension 1120, shown in FIGS. 85 and 86, is then mounted to
the top of the corner post, and can also be considered as part of
the connector member. In a first embodiment, the corner post
extension has the same construction as the corner post described
above (with the same reference numbers calling out those aspects
that are the same), except that the lower plate member 326 is
mounted distally from the lower end of the extension. In addition,
each side of the extension has a cut out 1126 along the lower end
of the extension below the lower plate member. A leg portion 1128,
formed as a L-shaped angled member, is welded in each corner of the
extension and extends downwardly therefrom. The extension 1120 is
mounted on the corner post such that the leg portions 1128 are
disposed in each inner corner of the upper portion of the corner
post and are supported on the upper plate member 324 of the corner
post. A bolt 1130 is then installed through the plate member and
threadably engages the upper plate member in the corner post 320 to
clamp the extension to the corner post. Alternatively, as shown in
FIG. 98, a draw rod 296 is inserted through the opening in the
upper plate of the extension member. The draw rod extends through
the lower plate until it engages the hole in the upper plate of the
corner post. In the embodiment shown in FIGS. 85 and 86, a window
1132 is provided in the extension, both to install the bolt, as
well as to provide access for a tool or the like to tighten the
bolt.
[0267] In another embodiment of the corner post extension, shown in
FIG. 133, the leg portions 1128 are more elongated and hold the
corner post extension above the lower corner post to provide
clearance over the draw blocks used to mount the lower wall panel
or panels to the corner post. In addition, two plate members 323
and 325 are mounted in an upper portion of the corner post
extension. A draw rod 296 engages the plate member 323 and clamps
the corner post extension to the corner post below as it engages
the opening in the plate member disposed in the lower corner post
tube. The second plate member 325 includes a relative large opening
327 centered above the opening 328 in the first plate member so
that the draw rod can be installed and accessed through the opening
372 by a tool or the like. As shown in FIG. 119, a plate member
3020 is then mounted on the plate member 325 to cover the opening
325. The plate member 3020 is mounted to the plate member 325 with
a double-sided tape, adhesive, welding and/or fasteners. The plate
member 3020 also includes an opening 3021 adapted to threadably
receive the post member 402, which supports the corner post cap.
The corner post light seal is also supported by the plate member
3020.
[0268] Again referring to FIG. 80, the lower wall panels are
mounted to the corner post as described above. The extension is
then mounted to the corner post with the cut outs 1126 providing
clearance over the draw blocks used to mount the lower wall panel
or panels to the corner post. A support bracket 1060 is then
mounted in the upper channel of the lower panel with a draw block
1080 as described above. An upper draw block 280 is then installed
so as to engage the upper edge of the corner post extension 1120
and the hanger bracket 70 of the upper, stackable panel. A draw rod
296 is used to connect the draw blocks 280, 1080 so as to securely
mount the upper, stackable panel to the corner post extension and
lower panel. In this way, the draw rod 296, draw blocks 280, 1080
and corner post extension 1120 can be considered a connector member
connecting the upper panel to the lower panels. It should be
understood, that an upper panel could also be installed on the
other lower panel, or panels, in the same manner.
[0269] Referring to FIG. 81, a corner post 320 is shown as having a
height equal to the combined height of the lower and upper wall
panels. The lower wall panel is attached to the corner post using a
draw block 460. The corner post has a pair of slots formed in each
side which are shaped to receive the hook members 464 of the draw
block 460. The upper, stackable wall panel is then attached to the
lower wall panel and corner post using a support bracket 1060, 3060
with a draw block 1080, 4080 overlying the draw block 460, an upper
draw block 280 and a draw rod 296 as described above.
[0270] In an alternative embodiment, an upper stackable panel can
be attached to a lower wall panel simply by removing the hanger
brackets on both the upper and lower panel and replacing them with
a single hanger bracket having a length equal to the combined
height of the upper and lower panels. The hanger bracket is
attached to each wall panel using a plurality of fasteners to
secure one panel to the other.
[0271] In another embodiment, shown in FIGS. 128 and 129, a
stand-alone hanger bracket 70 is attached to the upper portion of
the hanger bracket of a lower wall panel with a plurality of
fasteners 5001. The stackable upper wall panel is then attached to
the stand-alone hanger bracket using a support bracket 1060, 3060
with a draw block 1080, 4080, draw rod 296 and draw block 280 in
the same manner as described above with respect to FIGS. 79 and
125.
[0272] In yet another embodiment, shown in FIG. 98, a support
bracket includes a base portion 1150 having an opening 1152 that
overlies and is aligned with the vertical channel. A flange 1154
extends downwardly from an outer edge of the opening and abuts the
inner surface of the vertical frame member. A plurality of
fasteners 1156 are used to secure the bracket to the upper
horizontal frame member and to the vertical frame member. A hanger
bracket 70 is attached, preferably by welding, to an outer end of
the bracket and extends upwardly therefrom. An upper wall panel is
then installed between opposing hanger brackets and attached
thereto with a plurality of fasteners. The hanger brackets can then
be secured to any one of an adjacent hanger bracket, corner post or
corner post extension (shown in FIG. 98) using the various draw
block assemblies described above. Alternatively, as shown in FIG.
98, a draw block 1190 having a horizontally oriented opening 1192
includes a hook portion 1194 that engages an upper edge of the
corner post extension. A fastener is installed through the opening
and threadably engages a hole in the upper portion of the adjacent
hanger bracket.
[0273] The construction of the frame members and panel, as
described above, is ideally suited for improved manufacturability
of the wall panel. In one embodiment, the method for making each
vertical frame member includes providing a core member 28, a hanger
bracket 70 and a pair of sidewall members 34, each having an edge
portion 40 with an outer leg 118 having an outer surface. The
hanger bracket 70 is attached to the outer surface 50 of the core
member as discussed above.
[0274] Referring to FIGS. 50-51, the core member 28 and hanger
bracket 70 are placed in a fixture 500, which has a first surface
502 spaced apart from a second to and third surface 504, 505. The
fixture 500 is rotatably attached to supports 506 at each end of
the fixture 500. In this way, fixture surfaces can be provided on
opposite sides of the same fixture for different frame members. The
fixture is simply rotated so that the surfaces to be employed are
accessible to the assembler.
[0275] As illustrated in FIG. 51, the core member 28 and hanger
bracket 70 are positioned in the fixture such that an outer surface
of the hanger bracket engages the first surface 502. The sidewalls
34 are then inserted into the fixture 500 on opposite sides of the
core member. The ends of the sidewalls and the ends of the core
member are positioned relative to each other in the fixture using a
locator pin as the outer leg 118 of the edge portions of the two
sidewalls engage the second and third surfaces 504, 505 of the
fixture respectively. The core member, hanger bracket and sidewalls
are clamped together in the fixture using a plurality of clamps
508. The sidewalls are then attached to the core member with a
plurality of fasteners, preferably staples. Alternatively, the
sidewalls can also be bonded to the core member using a suitable
adhesive, or bonded and mechanically fastened.
[0276] It should also be understood by one skilled in the art, that
various aspects of the assembly process can be automated. For
example, the hand clamps shown in FIG. 51 can be replaced with
pneumatically controlled clamps. Similarly, the fastening process
can be automated, whereby the application of adhesive and stapling
is done automatically.
[0277] By using a fixture as just described, the distance between
the outer surface of the hanger bracket and the outer leg of each
sidewall can be maintained as a relative constant with relatively
tight tolerances. Thus, when two panels are installed end-to-end,
the gap between adjacent opposing sidewalls will be maintained with
tight tolerances so as to provide a uniform appearance when viewing
a system of interconnected wall panels. In essence, the gap at each
joint between adjacent panels is maintained as a relative constant.
Moreover, this method of manufacture ensures that the slotted
portion of the hanger bracket is always maintained a constant
distance from the outer leg 118 of the sidewall edge portion. Thus,
the user is ensured that components can be consistently installed
on the hanger bracket without having to force the component past a
protruding sidewall.
[0278] Another advantage of this method is realized when different
thickness fabrics are installed on the panel. Typically, when a
thicker fabric is installed on one panel, the fabric fills more of
the gap between connected panels, and can therefore interfere with
the installation of components on the hanger brackets, as well as
creating a displeasing appearance as between adjacent joints. With
the current construction, the distance between the first and second
and third surfaces in the fixture can be altered to provide more or
less distance between them so as to accommodate thicker or thinner
fabrics respectively.
[0279] Referring to FIG. 52, a scanner 600 or caliper can be used
to measure the thickness of the fabric 130 being installed and
provide that data to a computer. The computer 602 employs logic and
actuates a servo motor 604 that changes the relative distance
between the first and second-and third surfaces so as to provide a
uniform gap between panels once the fabric is installed. It should
be understood that actuators could alternatively be used to adjust
the second and third surfaces relative to the first surface. In
this way, the second surface could be spaced a greater distance
from the first surface than the third surface is from the first
surface so as to accommodate two different thickness fabrics on
each side of the panel. For example, it may be desirable to employ
a heavy thick fabric on the outside wall of a panel system forming
a walkway which experiences a lot of abuse, while providing a
thinner fabric, for reasons of color selection etc., on the inside
wall of the system forming the workspace.
[0280] Another advantage is realized by using a wooden core member
in each of the frame members in that the sidewalls can be attached
extremely fast and inexpensively with staples, rather than by
expensive welding or mechanical screw and bolt type fasteners.
[0281] The upper and lower frame members are made in a similar
manner, except that the first fixture surface 620 engages the core
member rather than the hanger bracket as shown in FIGS. 53-54. The
sidewall members are installed so that the outer legs 118 engage
the second and third fixture surfaces 622, 623 respectively. The
bracket and mounting strip are installed on the outer surface of
the lower core member with mechanical fasteners. The groove 33
positioned along the bottom of the bottom core member allows space
for ends of a tool locator which positions the bracket and mounting
strip relative to the bottom of the panel.
[0282] A method is also provided to assemble the wall panel. The
method includes providing a plurality of fixtures 512 having
horizontal surfaces 514 and vertical surfaces 516. The fixtures 512
are arranged in a rectangular configuration on a bed 522, as shown
in FIGS. 55-56. A pedestal support 524 extends upwardly from the
bed in the middle of the fixture arrangement. Each fixture is
provided with a clamp 520. Adhesive is applied to the inner surface
of one of the wall members around its edge. The wall member is then
placed on the horizontal surface 514 of the fixtures with the inner
surface facing upward. The pedestal support 524 supports the outer
surface of the wall member. The four frame members, i.e., the
vertical frame members 14 and the upper and lower frame members 16,
18, are placed in the fixtures such that the sidewalls 34, 36, 38
of each frame engage the fixture surfaces oriented around the
panel. The sidewalls of the upper frame member are pinched together
and inserted between the upwardly extending sidewalls 68 of the
vertical frame members and then released so that the sidewalls
overlap. Similarly, the outwardly extending sidewalls 38 of the
lower frame member are overlapped with the exposed core of the
vertical frame members 550. The vertical surfaces 516 of the
fixture are magnetized with magnets 521 to attract and hold the
frame members to the vertical surfaces 516.
[0283] A partition member 140, with adhesive applied to the
mounting flange 142, is then installed at each end of the panel by
bonding the mounting flange to the inner surface 122 of the wall
member. The boundary flange 144 extends away from the wall member
to form the vertical channel 108. Because the partition member is
preferably made of cardboard, it can be easily installed by bonding
rather than be welding or mechanically fastening as would typically
be required for metal or wood partitions.
[0284] Adhesive is applied to both sides of the honeycomb filler
member 150 and it is disposed inside the frame on the inner surface
122 of the wall member 120. The filler member 150 substantially
fills the space between the upper and lower frame members and
between the two partition members. In a preferred embodiment, an
outlet box 270 is mounted to a hardboard base plate with a
fastener. The base plate is adhesively bonded to the inner surface
122 of the wall member. One of a portion of the partition member or
filler material is removed to allow the outlet box to be installed
on the inside of the frame. The outlet box can be installed between
the partition members, or such that one side of the box is aligned
with the partition member to thereby provide a wall defining the
inner surface of the vertical channel. The conduit 276 connecting
the outlet box to the power system is disposed in the vertical
channel and extends through the space between the bottom core
member and the vertical core member.
[0285] Adhesive is applied around the edges of the inner surface
122 of the second wall member. The wall member 120 is positioned in
the recess formed on a second side of the frame by the edge
portions of the sidewalls. When an outlet box has been installed on
the first wall member, a hole is cut in the second wall member so
as to be substantially aligned with the outlet box once the second
wall member is installed. The two wall members and frame are
clamped together and to the fixtures. A staple gun, preferably a
dual action staple gun 640 accessing both sides of the panel
simultaneously, as shown in FIG. 56, is used to mechanically fasten
the two wall members to the four frame members, and in particular,
to staple through the wall member and sidewall member and into the
core member. Fasteners are also installed in the overlapping
portions of the upwardly extending vertical sidewalls, the
sidewalls of the upper frame member and the wall member, as
described above. As described above, it should be understood that
various aspects of this assembly process could be automated. For
example, the clamping could be pneumatically controlled, and the
positioning of the wall members, filler member, partition members
and frame members could be automated.
[0286] Because the core members are preferably made out of wood,
the wall members can be easily and cheaply secured to the frame.
This construction avoids the use of expensive and time consuming
welding operations and/or the use of to expensive screw and bolt
type fasteners.
[0287] The support leg is installed by press fitting the upper
portion of the leg into the opening between the bracket and core
member. The foot member is attached to the leg member.
[0288] The barrier sheet is disposed on both sides of the wall
panel, and is either adhesively or mechanically attached to the
wall member or the frame members. Alternatively, the barrier sheet
can be wrapped around the edge portions of the sidewall members
underneath the decorative sheet, which secures the barrier sheet to
the wall panel, as shown in FIG. 47A.
[0289] Next, the decorative sheets are installed by disposing a
sheet on each side of the panel and attaching the strip to the edge
portion of each side wall as described above, including the steps
of tucking the excess fabric corner patch located at the corners
into the edge portion channel and inserting a flexible corner block
into each corner to secure the fabric in the channel.
[0290] It should be understood that all of the aforementioned steps
of manufacture can be interchanged without departing from the
spirit and scope of the invention. As such, it is intended that the
foregoing order of steps be regarded as illustrative rather than
limiting.
[0291] Additional steps can be included to accessorize the panel.
For example, a top cap typically is installed on each panel. In
addition, the power distribution system can be installed by
attaching the power distribution server, including the receptacle
modules and harnesses, to the bracket on the bottom of the lower
frame member. In addition, the base cover can be installed on the
mounting strip to conceal and protect the power distribution
system. The base cover is installed by securing the two side walls
to the mounting strip attached to the bottom of the lower frame
member.
[0292] In another aspect of assembly, a system is provided for
assembling the core assembly 800 component shown in FIGS. 60 and 62
and the wall member 920 components shown in FIGS. 61 and 62 to form
a wall panel, as shown in FIGS. 62 and 103. First, the top channel
member 940 is attached to the upper horizontal frame member 816.
The core assembly, with the attached top channel member, is then
transported to a station where a pair of hanger brackets 70 are
attached to the core assembly; one to each vertical side frame
member 814.
[0293] It should be understood that the term "core assembly," as
used herein, refers generally to an internal element of a wall
panel that supports or is connected to at least one outer wall
member. For example, the core assembly may include, but is not
limited to, the constructions disclosed herein, including for
example a frame having inner wall members attached thereto and a
filler member. The core assembly may further include hanger
brackets and a top channel. Alternatively, for the sake of the
centering aspect described herein below, the core assembly may be
comprised of a solid component, such as wood, or could be made of
other materials, such as metal or plastic, including for example, a
metal frame and/or wall members. It should also be understood that
the term "core assembly" is also meant to encompass a single
integral component, including for example, a single block of wood,
notwithstanding the use of the term "assembly" in conjunction with
the term "core."
[0294] In the exemplary embodiment, the core assembly 800,
including the attached top channel member 940 and hanger brackets
70, is transported to a machine having at least a pair of fences
driven by a pair of rack and pinion mechanism as shown in FIGS.
104-106 and 116-118. The core assembly 800 enters the machine
leading with the top channel member 940 as it is carried by a pair
of drive belts 1302 that run the longitudinal length of the machine
and which are driven by a motor 1304. Preferably, the belts are
V-belts that ride on pulleys. A referencing device 1306 includes
two cylinders 1308, 1310 and a link member 1312. Preferably, the
cylinders are air or gas driven (i.e., pneumatic) which are
relatively fast and clean, although it should be understood that
hydraulics could also work. In addition, mechanical linkages,
including for example drive belts and the like, could also be
provided to drive the link member.
[0295] The first cylinder 1308 is pivotally attached to a frame
1300 at horizontal axis 1316. A suitable cylinder is the cylinder
`A` Series Model #P3AM-0611C-CAA2 manufactured by NUMATICS. An
extensible shaft 1314 extends from the first cylinder and is
pivotally attached to the link, which is also pivotally attached to
the frame at axis 1320. A support bracket 1322 is mounted to the
link member. The second cylinder 1310 is mounted to the support
bracket, and includes an extensible shaft having a locator member
1324 attached to the end of the shaft. A suitable cylinder is the
cylinder model #F0311.24-M3 manufactured by BIMBA. The locator
member 1324 includes a C-shaped channel member 1326 and a
referencing block 1328 mounted inside the channel member 1326.
[0296] In operation, as shown in FIG. 105, the referencing device
1306 is moveable between a referencing position, where the device
engages the core assembly, and a stored position, where the
referencing device is moved below the plane of the upper belt
surface of the belts 1302, which support the core assembly. The
belts 1302 transport the core assembly out of the machine without
interference from the referencing device when it is pivoted to the
stored position. In one embodiment, the belts can transport the
core assembly into and out of the machine at speeds of about 100
ft/min. In operation, the cylinder 1308 is actuated to retract
shaft 1314 which rotates the link member 1312 counter clockwise
about axis 1320, with reference to FIG. 105.
[0297] As the link member 1312 is rotated about axis 1320, the
support bracket, cylinder 1310 and locator member 1324 are pivoted
from a vertical stored orientation (with the locator member facing
upwardly) below the upper surface of the belts 1302 to a horizontal
referencing orientation such that the channel member 1326 and
referencing block 1328 are open to and face the incoming top
channel member 940 of the core assembly as the core assembly is
transported along the machine on belts 1302. The cylinder 1310 is
actuated to extend the channel member and referencing block to
engage the top channel member 940 of the core assembly. In
particular, the referencing block engages the upper surface of the
ridges 944 formed along the top channel member 940 while the
channel member 1326, which is dimensioned to receive the top
channel member 940, prevents the sidewalls of the top channel
member 940 from spreading apart as the core assembly, and in
particular, the ridges 944, are butted up against the reference
block. In this way, the position of the core assembly from top to
bottom in the machine is referenced for further operation, whereby
successive core assemblies will have the same positioning of
locator openings. One should understand that other referencing
surfaces, or contacts, could also be used. For example, a
referencing device could be provided to engage the bottom of the
top channel member, or the outer most part of the sidewalls
thereof.
[0298] After, or at the same time, the core assembly is referenced
by the referencing device 1306, the fences 1340 are moved to center
the core assembly in the machine whereinafter the locator holes are
drilled and/or routed through the core assembly 800 adjacent the
top and bottom of the core assembly along the centerline thereof.
In particular, a pair of pinion gears 1350, each having a vertical
axis of rotation, each engage a pair of parallel racks 1352
extending along opposite sides of the pinion gear. A suitable
pinion gear is the model #NSS8P44 spur gear manufactured by
Browning. The fences 1340 are attached to one corresponding rack
1352 on each end of the machine and are supported on linear
bearings 1370 along each end. A suitable rack is the gear rack
model #4NSR8X11/4X48 manufactured by Browning, while a suitable
linear bearing can be configured from the combination of a pillow
block (model #PB-24-OPN) and rail assembly (model #SRA-24)
available from Thompson. Each fence includes a plurality of
laterally opening C-shaped brackets 1354 that support the core
assembly along its sides. Each bracket is shaped to receive the
core assembly, including the hanger brackets attached therealong.
The brackets 1354 are movably mounted on a track 1355 running
longitudinally along the length of the fence.
[0299] In one mode of operation, one of the fences 1340 is pushed
inwardly as it is supported by the bearings 1370 as the core
assembly is situated on the locator member 1324. As the fence is
pushed inwardly, the racks 1352, attached at opposite ends of the
fence being actuated, rotate the pinion gear 1350 so as to
simultaneously move the other pair of racks and attached fence on
the opposite side of the core assembly. In this way, the core
assembly is engaged on both sides by the fences, with both fences
moving toward each other at equal rates and distances so as to
center the core assembly in the machine. The actuated fence can be
pushed inwardly by hand, or can be acted upon by a cylinder or
other actuating device as explained below. Alternatively, the
pinion gear can be actuated, by way of a belt, chain or hand tool,
so as to simultaneously move both racks, and attached fences, to
center the core assembly in the machine.
[0300] Referring to FIGS. 116-117, on one end of the machine, a
gear 1360 is connected to the pinion gear 1350 positioned at that
end with a shaft 1362. The gear 1360 is then connected to another
gear 1364 with a belt 1366. The gear 1364 is attached to a shaft
extending from an encoder 1368, or controller/sensor. As the fences
move inwardly and the pinion gear 1350 rotates, the gear 1360
rotates the gear 1364 and spins the encoder 1368. The encoder can
be programmed, or be connected to a computer, so as to allow a tool
component to be activated for operation on the core assembly only
if the encoder registers a rotation of the gear 1364 corresponding
to a range of acceptable core assembly widths. In essence, the
encoder detects whether the core assembly is too wide, or not wide
enough, and prevents the tool component from being activated if the
core assembly falls outside the range. The encoder, or computer,
can also be programmed for several different ranges corresponding
to various core assembly widths. A suitable encoder is the
Allen-Bradley encoder model #845TK-F2500-25.
[0301] In addition to the movement of the fences being controlled
by the corresponding movement of the racks attached to each end
thereof, the machine can also be configured with a pair of shafts
1370 that are located beneath the fences and extend longitudinally
along the length of the machine, as best shown in FIGS. 105 and
106. The shafts 1370 are rotatably supported by a pair of brackets
1372 that extend downwardly from the fence. A gear 1374 is attached
to each end of each shaft. The gear meshes with a rack 1376 that is
fixedly attached to each end of the frame, preferably with a
plurality of bolts or like fasteners. A suitable rack and gear
arrangement includes the gear rack model #6NSR8X11/4X36 and the
spur gear model #NSS8H32, both manufactured by Browning. In
operation, the shafts 1370 are rotated so as to move the fences
1340 inwardly as the gears 1374 mesh with the racks 1376. In this
way, the shafts 1370 facilitate the centering of the core assembly
while also keeping the core assembly square in the machine.
[0302] In one embodiment, the shafts 1370 can also be actuated to
move the fences so as to center the core assembly in the machine.
In particular, as shown in FIG. 106, a shaft brake 1378 is disposed
around each shaft adjacent one end of the machine. The shaft brakes
1378 are pivoted by a cylinder 1380 that is pivotably secured to
the fence. The shaft brake 1378 is actuated to clamp onto the shaft
1370. The cylinder 1380 is then extended or retracted so as to
rotate the shaft brake and shaft, which in turn moves each of the
fences toward or away from each other as explained above. However,
it should be understood that the shafts 1370 can be used without
the shaft brakes so as to simply ensure that each end of the fence
is moved the same amount at the same time so as to keep the core
assembly square in the machine.
[0303] Referring to FIGS. 104-107, a plurality of tool components,
shown as three routers 1390, 1392, 1394 are suspended from a
framework 1355 above the core assembly. It should be understood
that other tool components could be provided to operate on the core
assembly when centered in the machine, such as various staple guns,
drills, routers, jigs, glue dispensers and the like, and the term
tool component is not limited to the disclosed router. The first
router 1390 is used with every core assembly and is programmed to
make a single, circular locator opening 1230 through the core
assembly, including through each of the inner wall members attached
to the frame, at a predetermined distance from the top of the core
assembly, as determined by the distance between the router bit, or
drill bit, and the locating member 1324. The second and third
routers 1392, 1394 are programmed to form a machine direction slot
through the core assembly. As such, the second and third routers
are moveably mounted to the frame on a slider 1396 or track so that
the routers can be actuated by a pneumatic cylinder 1393 to move in
the machine direction to form the slot 1232. A suitable slide is
the slide S-Series #5200-01.50-STO (S/N 289B) manufactured by
Electro Pneumatic Innovations (EPI). In contrast, the first router
is mounted to the frame without a machine direction slide. All
three routers 1390, 1392, 1394 are also moveably mounted to the
frame on a vertical slide 1397. A suitable slide is the slide
S-Series #5200-0.300-STO (S/N 289A) manufactured by EPI. The
routers are moved vertically along the slide 1397 by a pneumatic
cylinder 1399 to engage and disengage the core assembly with the
router bit. For example, one suitable actuator is the Kinechek
Slimline Model #1002-31-3 with mounting block #A10031 manufactured
by Deschner.
[0304] Only one of the second and third routers is used at a time,
with the second router 1392 being used for shorter core assemblies,
and the third router 1394 being used with longer core assemblies. A
suitable router for use as the first, second and/or third router is
a Porter Cables Model #6902 (23,000 rpm). Preferably, the router
bits are 1/2 inch carbide although other diameters, such as 3/4
inch would also work. The routers are oriented along the centerline
of the core assembly and are actuated to penetrate the core
assembly after the core assembly has been centered in the machine.
After the locator hole and slot are formed, the core assembly is
released as the referencing device pivots out of the way into the
stored position and is thereafter transported by the belts 1302 to
the next station where it is ready for mating with the wall members
920.
[0305] Referring to FIG. 61, the assembly of the wall member
involves first positioning the wall member 920 over a piece of
decorative sheet 930 and barrier sheet 530. The plurality of strip
members 824 are positioned around the periphery of the wall member.
The decorative sheet 930 is stretched from the top and bottom of
the wall member and attached to the wall member and strip members
along the top and bottom of the wall member. The decorative sheet
is then stretched from each side of the wall member and again
attached to the wall member and strip members along the sides of
the wall member. It should be understood that the order of
stretching the decorative sheet from the top and bottom and from
each side can be reversed, or can be done simultaneously. After the
decorative sheet and strip members are attached, any excess
decorative sheet material that may be gathered at the comers is
trimmed, folded and secured to the wall member, preferably with
staples or like fasteners.
[0306] The wall member 920 is then transported to a locator member
attachment machine that has many features and parts similar to the
router machine. Those parts and features are referenced by the same
reference numbers. In essence, both the router machine and locator
member attachment machine have the same bed for moving the wall
panel components, including the core assembly and wall member, and
centering those components for further operations thereto. In
particular, and referring to FIGS. 107-108, the locator member
attachment machine includes a pair of rack and pinion mechanisms
1350, 1352 and fences 1340 that center the wall member in the
machine as described above with respect to the core assembly in the
router machine. A referencing device includes a cylinder 1308
pivotally connected to the frame 1300 about axis 1316 and to a link
1312, which is also pivotally connected to the frame about axis
1320. A referencing block 1428 is mounted to the link 1312, such
that when the link is pivoted from the stored position beneath the
upper surface of the belts 1302 to the referencing position, it is
in position to engage the top edge of the wall panel as it is
transported by the belts 1302.
[0307] Referring to FIGS. 108 and 109, another embodiment for
moving the fences is shown. It should be understood that this
embodiment would also work with the fences on the router machine,
and conversely, the devices and methodologies for moving the fences
of the router machine would also work with the fences on the
locator member attachment machine. In particular, a cylinder 1402,
and preferably a pneumatic cylinder, is mounted to the frame. A
suitable cylinder is the cylinder model #5024-DXP manufactured by
BIMBA. A rod 1404 extends from the cylinder and is attached to a
bracket 1406 extending downwardly from one of the fences, as shown
in FIGS. 108 and 109. The cylinder 1402 can be actuated to move the
rod laterally so as to move the attached fence inwardly or
outwardly. As the fence 1340 is moved, it causes the pinion gears
1350 on the opposite ends of the machine to move, by way of the
attached racks 1352, so as to thereby cause the other fence to move
a corresponding amount by way of its attached racks 1352. In
addition, the fences each include a shaft 1370 having a pair of
gears 1374 that engage a rack 1376 on each end of the frame so as
to keep the fences, and wall member engaged thereby, square in the
machine. As shown in FIG. 109, the fences 1340 each include a
plurality of C-shaped bracket 1454 shaped to receive the wall
member therein. Again, the brackets 1454 are moveably mounted on a
track that extends along the length of the fence.
[0308] Referring to FIGS. 108 and 109, a plurality of tool
components, shown as two locator member dispensers 1500, are
suspended from a framework over the wall member. The first
dispenser is preferably fixed, while the second dispenser can be
moved between a plurality of positions. Each locator member
dispenser 1500 positions a locator member 1234 over the wall panel.
The position of each locator member is programmed to correspond to
the location of the locator openings, including the circular hole
or slot, positioned in the core assembly.
[0309] In particular, and referring to FIGS. 110-112, the dispenser
1500 includes a locator member magazine 1502 having a tray with a
horizontal holding portion 1504 and an angled portion 1506
extending upwardly from the horizontal portion. The tray is shaped
to slideably hold a plurality of locator members 1234. A pair of
cylinders 1508, 1510 each having a pin 1512, 1514 can be
successively operated to permit one locator member to slide from
the angled portion to the horizontal portion. In particular, the
lower cylinder 1508 is actuated to retract the pin 1512 so as to
allow the locator member, which was retained thereby, to slide down
onto the horizontal holding portion 1504. The upper cylinder 1510
is then actuated to retract the pin 1514 so as to permit another
locator member to move into position against the lower pin 1512,
which is extended to stop the locator member.
[0310] An arm member 1516 is pivotally about axis 1517 is moved
over the locator member positioned in the horizontal portion of the
tray. The arm includes and end portion 1520 that has a recess 1518
shaped to receive the locator member 1234. The arm is displaced
over the locator member while a vacuum is applied. The arm 1516 is
then pivoted outwardly about axis 1517 to position the locator
member along the centerline of the wall member. A pair of staple
guns 1522 are then successively actuated to secure the base portion
1236 of the locator member to the wall member with a pair of
flaring staples, whose ends flare out in the wall member as they
penetrate the member. The staple guns 1522 are moveable in the
lateral cross-machine direction on a slide 1528 and can be actuated
by an actuator, such a pneumatic cylinder, a screw mechanism, or
similar device. A suitable slide is the series SD slide model
#SDC23x11/2xM-J2-AR-AE, manufactured by PHD. In this way, the
staple guns can be successively moved into place to attach the
locator member. A slide 1529 is also provided to moveably mount the
staple guns in a vertical direction. An actuator, shown as a
cylinder, is also provided to move the staple guns. Similarly, a
slide 1531 and actuator control the vertical movement of the arm
1516 and end portion 1517, while a rotary actuator 1521 controls
the pivoting movement of the arm member 1516. A suitable rotary
actuator is the Series RA Rotary Actuator Model #RAS120x90-PB-MQ10
manufactured by PHD.
[0311] As shown in FIG. 111, the dispenser includes a guide 1551
that slideably engages a track 1553 that runs along the length of a
longitudinally extending frame member 1555. The dispenser 1500 also
includes a lock pin 1557 that can be retracted and extended to
engage a plurality of recesses 1559 in the track 1553. In
operation, the lock pin 1557 is retracted from one of the recesses
so that the dispenser 1500 can be slid along the track 1553 to a
new position where the lock pin 1557 can be extended to engage a
new recess in the track so as to lock the dispenser in position for
a subsequent operation. One of skill in the art should understand
that the positioning of the lock pin and recess could be
interchanged, with the lock pin located on the track, or frame
member, and the recess located on the dispenser. One of skill in
the art will also understand that the routers described above could
also be mounted to the frame on a track with a locking device.
[0312] As with the routers, preferably only two dispensers are used
with any one panel, depending on the size of the panel. However, it
should be understood that additional dispensers and routers can be
provided to provide a plurality of locator members and openings
numbering greater than two.
[0313] The locations of the locator members are determined by the
distance between the end portion 1520 of the arm and the reference
block 1428 that engages the top edge of the wall member. This
distance is programmed to correspond to the position of the locator
openings formed in the core assembly. After the locator members are
secured to the wall member, preferably along the centerline of the
wall member, the wall member is ready for mating with the core
assembly and can be carried from the machine by the belts.
[0314] One of skill in the art should understand that, in an
alternative embodiment, the position of the locator members and
openings could be reversed, with the locator members attached to
opposite sides of the core assembly, and with the locator openings
formed in the wall member, but preferably not passing all of the
way therethrough as explained above. The preferred construction is
with the locator openings in the core assembly, however, since only
one drilling, or routing, operation need be made when the locator
opening extends all of the way through the core assembly, as
opposed to separately drilling, or routing, each of the wall
members. Moreover, the concern with penetrating the entire
thickness of the wall member is eliminated, although the locator
opening could be made all of the way through the wall member if
necessary or desired.
[0315] At this stage, hot melt adhesive is applied to one or both
of the wall members 920 and/or the outer surface of the wall member
820 of the core assembly and the locator members 1234 are inserted
in the locator holes 1230, 1232. In addition, mechanical fasteners,
such as staples and the like, can be used to secure the wall member
to the core assembly. In this way, the wall members 920 are
centered on the core assembly so as to provide an equal overhang
along both sides of the panel, which thereby provides for equal
exposure to the hanger brackets and maintains equal gaps between
adjacent panels installed end to end.
[0316] After the wall members are located on the core assembly, the
completed wall panel is passed through a pinch roll to firmly bond
the wall members to the core assembly. A jig can be placed between
the sidewalls of the top channel member to provide support
therebetween so as to thereby prevent the sidewalls from being bent
toward one another or from otherwise being deformed. The wall panel
is thereafter transferred to a press conveyor 1600, shown in FIGS.
113-115, which is approximately 17 feet in length. The press
conveyor includes a belt 1602, preferably about 5-6 feet wide, that
carries and moves the wall panel though the press conveyor. The
belt preferably travels at a rate of about 4 ft/min. A second belt
1606 is welded, or vulcanized along the underside of the length of
the belt 1602. As shown in FIG. 130, the belt 1606, which is
preferably a V-belt, rides in a longitudinally extending (machine
direction) groove 1608 formed in the bed 1620 of the machine to
keep the belt 1602 centered and tracking on the machine. The belt
1602 is supported by the bed and is driven by a drive roller 1622.
The belt is also supported by roller 1634 on the opposite end of
the machine. The bed and frame are supported by four legs 1640,
which are height adjustable. In addition, a series of rollers 1630
underlie the belt to maintain the tension thereof. The drive roller
is driven, with a belt or chain 1624, by a motor 1626.
[0317] A plurality of gravity rollers 1604 engage the upper wall
member of the wall panel and apply a load thereto by way of their
weight being supported by the wall panel. Each roller 1604 is
moveably supported along both ends by a C-shaped bracket 1621 that
is slideably supported on a vertically oriented post 1641 mounted
in a side frame member 1610, which is configured as an outwardly
opening channel. Alternatively, the ends of the rollers can be
disposed in vertically oriented slots formed in the side frame
member. Lateral supports 1636 interconnect the side frame members
1610. The rollers are preferably steel. In a preferred embodiment,
the bottom surface of the rollers are positioned just slightly
below the plane formed by the upper surface of the wall panel, such
that as the wall panel is introduced into the press conveyor, the
crown on the rollers 1604 allows the rollers to ride up over the
edge of the wall panel and be supported thereon. For example, in
one embodiment, the rollers are positioned at about 2 and 7/8
inches above the belt 1602, have a diameter of about 2 and 1/2
inches and are positioned in a spaced apart and substantially
parallel relationship with a successive distance between each other
of about 6 inches from center to center. The press conveyor applies
a load by way of the weight of the rollers, which are about 30 lbs.
in an exemplary embodiment, to the wall panel as it is moved to a
next station. In addition, a spring 1651 is disposed around each
post 1641 between the upper flange of the frame member 1610 and the
top of the C-shaped bracket 1621. The springs 1651 bias the roller
against the wall panel as it travels along the length of the press
conveyor. The applied load prevents the wall members from peeling
back from the core after the wall panel leaves the pinch roll while
the adhesive or bonding agent sets up. The press conveyor, by
virtue of its length, can carry two or more wall panels at a time,
depending on their length.
[0318] When assembled in a system of panels, the horizontal channel
formed along the top and bottom of the panels provides the user
with an ideal and easy to access space for storing and routing
cables and wires, such as communication and data lines. Moreover,
the vertical channels in each panel allow the user to easily rout
wires and cables from the top of the panel to the bottom. In
addition, the vertical channels provide a ready-made space for
routing electrical conduit from the outlet mounted in the panel to
the base of the panel and the attached power distribution
system.
[0319] Although the present invention has been described with
reference to preferred embodiments, those skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention. As such, it
is intended that the foregoing detailed description be regarded as
illustrative rather than limiting and that it is the appended
claims, including all equivalents thereof, which are intended to
define the scope of the invention.
* * * * *