U.S. patent application number 12/365240 was filed with the patent office on 2009-05-28 for reusable and recyclable modular wall system for a construction barrier.
Invention is credited to Aaron D. Barnes, Douglas B. Spear.
Application Number | 20090133354 12/365240 |
Document ID | / |
Family ID | 40668551 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090133354 |
Kind Code |
A1 |
Spear; Douglas B. ; et
al. |
May 28, 2009 |
Reusable and Recyclable Modular Wall System for a Construction
Barrier
Abstract
A modular wall system includes a plurality of wall panels, each
with a core, a front skin, a rear skin, and at least one edging
piece along at least one edge. The edging piece has first and
second edgewise extensions extending first and second lengths,
respectively, and defining an intermediate groove, wherein the
first extension is adjacent the front skin, and wherein the first
length is greater than the second length. A floor track has a base
flange and a substantially vertical panel-receiving channel. At
least one vertically oriented H-spline is provided for resting on
the floor track and being positioned between two adjacent wall
panels. The H-spline has a front flange and a rear flange joined by
a web, wherein the front flange has a transverse width adapted to
be received in the intermediate grooves of edging pieces of the
adjacent wall panels while permitting substantially flush abutment
of the front skins of the adjacent wall panels. The lesser length
of the second edgewise extensions of the edging pieces provides a
gap for receiving the web. The rear flange extends over a portion
of the rear skins of the adjacent wall panels. A top channel is
disposed along a top of the modular wall system and receives a
plurality of the wall panels. A first side channel is disposed
along a side of the modular wall system and receives at least one
of the wall panels.
Inventors: |
Spear; Douglas B.;
(Clarkston, MI) ; Barnes; Aaron D.; (Whitelake,
MI) |
Correspondence
Address: |
MACMILLAN SOBANSKI & TODD, LLC
ONE MARITIME PLAZA FIFTH FLOOR, 720 WATER STREET
TOLEDO
OH
43604-1619
US
|
Family ID: |
40668551 |
Appl. No.: |
12/365240 |
Filed: |
February 4, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61074565 |
Jun 20, 2008 |
|
|
|
Current U.S.
Class: |
52/588.1 ;
52/309.1; 52/582.2; 52/586.2; 52/656.4; 52/745.13 |
Current CPC
Class: |
E04G 21/243 20130101;
E04C 2/388 20130101; E04C 2/20 20130101; E04G 21/24 20130101; E04C
2002/3455 20130101; E04C 2/3405 20130101; E04B 2/7453 20130101;
E04G 21/3209 20130101 |
Class at
Publication: |
52/588.1 ;
52/586.2; 52/582.2; 52/656.4; 52/309.1; 52/745.13 |
International
Class: |
E04B 2/18 20060101
E04B002/18; E04C 2/38 20060101 E04C002/38; E04C 2/20 20060101
E04C002/20 |
Claims
1. A modular wall system for temporary erection at a construction
site, comprising: a plurality of wall panels each having a core, a
front skin, a rear skin, and at least one edging piece along at
least one edge, wherein the edging piece has first and second
edgewise extensions extending first and second lengths,
respectively, and defining an intermediate groove, wherein the
first extension is adjacent the front skin, and wherein the first
length is greater than the second length; a floor track having a
base flange and a substantially vertical panel-receiving channel;
at least one vertically oriented H-spline resting on the floor
track and positioned between two adjacent wall panels, the H-spline
having a front flange and a rear flange joined by a web, wherein
the front flange has a transverse width adapted to be received in
the intermediate grooves of edging pieces of the adjacent wall
panels while permitting substantially flush abutment of the front
skins of the adjacent wall panels, wherein the lesser length of the
second edgewise extensions of the edging pieces provides a gap for
receiving the web, and wherein the rear flange extends over a
portion of the rear skins of the adjacent wall panels; a top
channel disposed along a top of the modular wall system and
receiving a plurality of the wall panels; and a first side channel
disposed along a side of the modular wall system and receiving at
least one of the wall panels.
2. The modular wall system of claim 1 further comprising: a hinge
disposed along a substantial length of the top channel; a canopy
channel attached to the top end channel via the hinge; and a top
wall panel mounted within the canopy channel and adapted to be
mounted to relatively permanent structure at the site.
3. The modular wall system of claim 1 further comprising: a hinge
disposed along a substantial length of the first side channel; a
second side channel attached to the first side channel via the
hinge; a extension floor track having a base flange and a
substantially vertical panel-receiving channel, the extension floor
track extending non-parallel from the floor track; and a side wall
panel mounted within the second side channel and the vertical
panel-receiving channel of the extension floor track.
4. The modular wall system of claim 1 further comprising: a
plurality of angle braces, each attached to a respective rear
flange of a respective H-spline and to a relatively permanent
structure at the site.
5. The modular wall system of claim 4 wherein the relatively
permanent structure is comprised of a floor or ground underlying
the modular wall.
6. The modular wall system of claim 4 wherein the relatively
permanent structure is comprised of an upper structure of a
building on the site.
7. The modular wall system of claim 1 further comprising: a locking
pin mounted through aligned holes in the vertical panel-receiving
channel and one of the plurality of wall panels.
8. The modular wall system of claim 1 further comprising: a locking
pin mounted through aligned holes in the top channel and one of the
plurality of wall panels.
9. The modular wall system of claim 1 further comprising: a
plurality of locking pins including at least a first locking pin
mounted through aligned holes in the vertical panel-receiving
channel and one of the plurality of wall panels and a second
locking pin mounted through aligned holes in the top channel and a
different one of the plurality of wall panels.
10. The modular wall system of claim 1 including a pre-hung door
section for installation between a pair of wall panels in the
modular wall system, the door section comprising: a frame having
outwardly extending C-channels at its sides and top and a sill at
its bottom; a door panel hung within the frame; and a plurality of
locking pins mounted through respective aligned holes in the
C-channels and respective wall panels on each lateral side of the
door section.
11. The modular wall system of claim 10 further comprising: a
lintel wall panel inserted into the C-channel at the top of the
frame; and a pair of H-splines mounted to the lateral sides of the
lintel wall panel.
12. The modular wall system of claim 1 wherein the core, front
skin, rear skin, and edging piece of each wall panel are comprised
of recyclable plastic.
13. The modular wall system of claim 12 wherein the core is
corrugated.
14. The modular wall system of claim 1 wherein the floor track,
H-spline, top channel, and side channel are comprised of extruded
aluminum.
15. The modular wall system of claim 1 wherein the floor track
further comprises a resilient layer applied to the base flange.
16. A method of installing a modular wall system for temporary
erection at a construction site, the method comprising the steps
of: laying a floor track, wherein the floor track has a base flange
and a substantially vertical panel-receiving channel; inserting a
first wall panel into the panel-receiving channel, wherein the
first wall panel has a core, a front skin, a rear skin, and at
least a first edging piece along at least one edge, wherein the
first edging piece has first and second edgewise extensions
extending first and second lengths, respectively, and defining a
first intermediate groove, wherein the first extension is adjacent
the front skin, and wherein the first length is greater than the
second length; inserting an H-spline onto the first edging piece
and resting on the floor track, wherein the H-spline has a front
flange and a rear flange joined by a web, wherein the front flange
has a transverse width adapted to be received in the first
intermediate groove of the first edging piece of the first wall
panel, wherein the lesser length of the second edgewise extensions
of the first edging piece provides a gap for receiving the web, and
wherein the rear flange extends over a portion of the rear skin of
the first wall panel; inserting a second wall panel into the
panel-receiving channel, wherein the second wall panel has a core,
a front skin, a rear skin, and at least a second edging piece along
at least one edge, wherein the second edging piece has first and
second edgewise extensions extending first and second lengths,
respectively, and defining a second intermediate groove, wherein
the first extension is adjacent the front skin, and wherein the
first length is greater than the second length, wherein the front
flange of the H-spline further receives the second intermediate
groove of the second edging piece of the second wall panel, wherein
the lesser length of the second edgewise extensions of the second
edging piece provides a gap for receiving the web, wherein the rear
flange extends over a portion of the rear skin of the second wall
panel, and wherein there is substantially flush abutment of the
front skins of the first and second wall panels; inserting a top
channel over the first and second wall panels; and inserting a
first side channel disposed along a side of one of the wall
panels.
17. The method of claim 16 further comprising the step of: bracing
the H-spline to a relatively permanent structure on the site.
18. The method of claim 16 further comprising the step of: bracing
at least one of the top channel or first side channel to a
relatively permanent structure on the site.
19. The method of claim 18 wherein the braced top channel or side
channel is hinged to a C-channel, and wherein the bracing step is
comprised of: inserting a third wall panel into the C-channel; and
attaching the third wall panel to a relatively permanent structure
on the site.
20. A modular wall system for temporary erection at a construction
site, comprising: a plurality of wall panels each having a core, a
front skin, a rear skin, and at least one edging piece along at
least one edge, wherein the edging piece has first and second
edgewise extensions extending first and second lengths,
respectively, and defining an intermediate groove, wherein the
first extension is adjacent the front skin, and wherein the first
length is greater than the second length; a floor track having a
base flange and a substantially vertical panel-receiving channel;
at least one vertically oriented H-spline resting on the floor
track and positioned between two adjacent wall panels, the H-spline
having a front flange and a rear flange joined by a web, wherein
the front flange has a transverse width adapted to be received in
the intermediate grooves of edging pieces of the adjacent wall
panels while permitting substantially flush abutment of the front
skins of the adjacent wall panels, wherein the lesser length of the
second edgewise extensions of the edging pieces provides a gap for
receiving the web, and wherein the rear flange extends over a
portion of the rear skins of the adjacent wall panels; and a brace
for bracing the H-spline to a relatively permanent structure on the
site.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to provisional application
61/074,565, filed Jun. 20, 2008, entitled "Modular Temporary
Construction Safety/Privacy Wall" which is incorporated herein by
reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates in general to construction
barriers, and, more specifically, to a modular wall system for
temporary installations.
[0004] Temporary walls or partitions are often used at construction
sites such as renovation or remodeling projects in malls, hotels,
office buildings, and other public or private venues. The walls
provide a safety and security barrier while the renovation or
remodeling project is in progress. The walls also block dust and
noise from entering public spaces in front of the wall.
[0005] Even though the need for a construction barrier is
temporary, typical practice is to build walls using conventional
metal stud and drywall structures. Such walls are expensive, time
consuming, and are labor intensive to install and remove. In order
to provide a finished look and to provide an acceptable surface for
applying graphics (e.g., a "Coming Soon" message), the time and
expense of finishing the drywall (i.e., taping, mudding, sanding,
and painting) is necessary. The typical barrier walls generate
large amounts of solid waste when torn down. An average wall 70
feet long and 12 feet high generates about one ton of debris that
ends up in a landfill. Thus, there is a need for a temporary
safety/privacy wall system that can be installed and removed
quickly, with less labor, and lower cost while reducing solid
waste.
SUMMARY OF THE INVENTION
[0006] A preferred embodiment of a modular wall of the invention
employs a wall panel which may be comprised of a core bonded with a
perimeter edge piece and a plastic skin of about 0.060 thickness or
may be a single piece construction with the core, edge piece, and
skin integrally formed. The core may have a honeycomb shape or a
corrugated shape, for example. The wall panels may be comprised of
a polymer such as polypropylene or acrylonitrile butadiene styrene
(ABS). Top and bottom tracks of extruded aluminum receive the wall
panels and allow for only 0.060 play after a panel is installed. A
joiner spline between adjacent panels is comprised of an extruded
H-channel that provides about 3'' support on the back side of the
panels and about 2.0'' internal support via a groove in each edge
piece. Panels at side and/or top ends of the wall are attached to
the main section of the wall by a continuous hinge, thereby
allowing them to be turned at an angle to the main section. The
bottom track may be secured to the floor or ground or may rest in
place. The bottom track may be provided with a non-slip rubber tape
to protect the floor surface. Panels are stood up and slid into the
bottom track with the H-splines being placed between adjacent
panels. The top track is slid on and fastened to the panels
approximately every 8' with a through pin and cotter pin. The
modular wall structure is tied back to existing structure of the
site about every 4' at the top or bottom of the wall with aluminum
angle braces. The front plastic skins of the panels are in a flush
abutment to provide a smooth surface that can be decorated with
desired graphics. At the time of removal, the parts of the modular
wall are easily disassembled and most of the parts can be reused to
construct another barrier at a different construction site. The
materials for any parts that were modified too much to be reused
can be easily recycled.
[0007] More specifically, the modular wall system for temporary
erection at a construction site comprises a plurality of wall
panels. Each wall panel has a core, a front skin, a rear skin, and
at least one edging piece along at least one edge, wherein the
edging piece has first and second edgewise extensions extending
first and second lengths, respectively, and defining an
intermediate groove, wherein the first extension is adjacent the
front skin, and wherein the first length is greater than the second
length. A floor track has a base flange and a substantially
vertical panel-receiving channel. At least one vertically oriented
H-spline is provided for resting on the floor track and being
positioned between two adjacent wall panels. The H-spline has a
front flange and a rear flange joined by a web, wherein the front
flange has a transverse width adapted to be received in the
intermediate grooves of edging pieces of the adjacent wall panels
while permitting substantially flush abutment of the front skins of
the adjacent wall panels. The lesser length of the second edgewise
extensions of the edging pieces provides a gap for receiving the
web. The rear flange extends over a portion of the rear skins of
the adjacent wall panels. A top channel is disposed along a top of
the modular wall system and receives a plurality of the wall
panels. A first side channel is disposed along a side of the
modular wall system and receives at least one of the wall
panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a front side of a modular
wall of the present invention.
[0009] FIG. 2 is a perspective view of a rear side of the wall in
FIG. 1.
[0010] FIG. 3 is an end view of a floor track of the present
invention.
[0011] FIG. 4 is a top view of the floor track.
[0012] FIG. 5 is a front view of a wall panel.
[0013] FIG. 6 is a cross-sectional, perspective view of the wall
panel along lines 6-6 of FIG. 5.
[0014] FIG. 7 is a cross-sectional view through an edge piece of
the present invention.
[0015] FIG. 8 is an end view of an H-spline of the present
invention.
[0016] FIGS. 9 and 10 are cross-sectional views showing the joining
of adjacent wall panels with an H-spline.
[0017] FIG. 11 is a perspective view of a C-channel used as a top
channel or side channel of the present invention.
[0018] FIG. 12 is an end view showing hinged C-channels receiving
corresponding wall panels.
[0019] FIG. 13 is an exploded view showing a typical assembly of a
modular wall of the present invention.
[0020] FIG. 14 is a rear view showing multiple stacks of wall
panels using the present invention.
[0021] FIG. 15 is a front plan view showing a door section of the
present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Referring to FIG. 1, a modular wall system 10 can be erected
as a temporary barrier at a construction site 11 having a floor or
ground 12. Modular wall 10 includes a main wall section including a
plurality of wall panels 13-17 that are arranged to provide a
smooth planar face that can be decorated with graphics, for
example. Panels 13-17 are set in a floor track 18 that rests on and
may be attached or sitting freely on floor 12. A top channel 19 is
disposed along the tops of wall panels 13-17, and a pair of side
channels 21 and 22 are disposed over the lateral sides of panels 13
and 17, respectively, of the main wall section. As described in
greater detail below, floor tack 18 includes a base flange and a
substantially vertical panel-receiving channel while top channel 19
is substantially C-shaped to receive the wall panels. A plurality
of locking pins 22-26 interlock wall panels 13-17 with floor track
18 and top-channel 19, respectively. Each pin passes through
aligned holes in the respective floor track 18 or top channel 19
and the respective wall panel 13-17. Preferably, the locking pins
may be alternated between the top and bottom of the wall panels for
adjacent panels, as shown, so that each panel is locked to either
the top channel or the floor track. Thus, locking pin 22 interlocks
the bottom of wall panel 13 to floor track 18. Locking pin 23
interlocks wall panel 14 with top channel 19. A greater or lesser
number of pins may be employed depending upon the specific width of
wall panels 13-17, or for other considerations.
[0023] The main wall section typically is placed out in front of
the area being reconstructed (i.e., in a spot not being modified).
Therefore, floor track 18 may include a resilient layer at the
bottom thereof, such as a rubber tape, to protect floor 12 as is
described in greater detail below. Furthermore, the wall will
typically turn at the sides or top in order to tie back to existing
structure. Thus, a side wall section includes a wall panel 27
received in a side channel 28 and a floor track extension 29. Side
channel 28 is preferably connected via a continuous hinge with side
channel 20. A top channel 30 and side channel 31 are also disposed
around wall panel 27, which is locked in place by additional
locking pins 32 and 33, for example. Side channel 31 may be
attached to an existing wall of the construction site (e.g., by
nails or screws) to help support the entire wall and to complete
the barrier on the respective side. On the opposite end of wall 10,
a wall panel 34 provides a similar end closure to the existing
construction site and is retained in a side channel 35, top channel
36, and side channel 37, while being locked in place by a locking
pin 38. A top of the wall may be formed in a similar fashion by
providing top wall panels on channels hinged with the top channels
of the other wall portions and attached to the existing
construction site in a similar manner. If used, the side wall
section(s) and top wall section(s) can also be interconnected with
specially-cut pieces of wall panels (e.g., a triangular gable
piece) mounted in appropriately cut side channels in order to close
any resulting openings in the barrier.
[0024] The rear side of wall 10 is shown in FIG. 2. Visible from
the rear side of wall 10 are H-splines 40-44 which are placed
between adjacent wall panels. Each spline 40-44 may be preferably
mounted to surrounding structures to support modular wall 10. In
particular, a plurality of angle braces may attached the H-splines
to a floor or ceiling in the construction site using double sided
tape or other bonding materials. Additional angle braces may also
attach the side channels or top channel to a relatively permanent
structure of the construction site, if desired. As shown in FIG. 2,
angle braces 46-48 and 49 are each attached to a respective
H-spline 40-42 and 44 and to floor 12. The angle braces may extend
a sufficient distance away from wall 10 to allow them to be
attached away from a finished portion of floor 12 and to provide
adequate lateral support for wall 10. Angle braces may also be used
to anchor to overhead structure. Thus, an angle brace 50 connected
to H-spline 43 is tied back to a ceiling structure 51 within the
construction site.
[0025] On the side section of wall 10, FIG. 2 shows an extension
floor track 45 receiving the side wall panel 34.
[0026] FIGS. 3 and 4 shows a floor track 18 in greater detail. A
base flange 55 supports a pair of side walls 56 and 57 to create a
substantially vertical panel-receiving channel 58 into which a wall
panel 59 may be inserted, as shown in phantom. Base flange 55 has a
resilient layer 60 along the bottom side thereof in order to
protect the floor surface on which it is mounted. Layer 60 may be
comprised of a rubber tape, for example. Base flange 55 may contain
holes (not shown) for receiving floor fasteners when it is desired
to anchor floor track 18 to the floor or ground. Walls 56 and 57
include aligned holes 61 and 62 to receive the locking pins. Sets
of such aligned holes may be provided at regular intervals to
receive locking pins for every other wall panel. In a preferred
embodiment, track 18 is comprised of extruded aluminum which may be
cut to various standard lengths and finished by drilling the
aligned holes for the locking pins.
[0027] FIG. 5 shows a wall panel 65 comprising a sandwich structure
with a corrugated core, front and rear skins, and edging pieces
around the periphery. As shown in FIG. 6, the corrugated core 66
has a front skin 67 and a rear skin 68 bonded to corresponding flat
surfaces of the corrugations. In an alternative embodiment, a
honeycomb core can be employed wherein an approximately one inch
thick core has a closed cellular structure. A first edge piece 69
and a second edge piece 70 are also bonded to front and rear skins
67 and 68, as shown. The width of panel 65 is adapted to fit within
the various channels of the floor track, top channels, and side
channels with a clearance of about 0.060 inches. Preferably, panel
65 may be about 1.125 inches thick and may be provided in standard
4 foot by 8 foot sizes. It may also be desirable to provide a width
up to 5 feet and lengths up to 20 feet. All the components of the
sandwich panel may preferably be comprised of 100% polypropylene
thermoplastic or 100% ABS thermoplastic. All four edge pieces on a
particular wall panel preferably comprise the grooved shape shown
in FIG. 6 so that every edge can optionally be received in either
an H-spline or any of the top or side channels. Pre-drilled holes
(not shown) may be provided through one or more of the edge pieces
for receiving locking pins described below. Although a glued,
composite structure is shown for panel 65, it may also be desirable
to form the panels from a single piece of extruded or molded
polymer providing the same overall shape.
[0028] FIG. 7 shows an edge piece 69 formed (e.g., either extruded
or molded) of a thermoplastic having a main body 71 with a first
edgewise extension 72 and a second edgewise extension 73 defining
an intermediate groove 74. First edgewise extension 72 is adjacent
to the front skin of the sandwich panel and has a length greater
than the length of second edgewise extension 73. The difference in
length is to provide a gap for receiving the H-spline as described
in detail below.
[0029] FIG. 8 shows an end view of an H-spline 40 including a front
flange 75 and a rear flange 76 joined by a web 77. Each beam of
front flange 75 has a transverse width D.sub.1 adapted to be
received in the intermediate grooves of the edging pieces of
adjacent wall panels. Likewise, the thickness D.sub.2 of front
flange 75 is adapted to fit within the intermediate grooves while
leaving a small amount of play for easy insertion. Web 77 has a
length L.sub.1 adapted to receive the second extension on each
adjacent wall panel. The H-spline is likewise preferably formed
from extruded aluminum and is provided in various standard lengths
matched to (e.g., slightly shorter than) the standard heights of
the wall panels.
[0030] FIGS. 9 and 10 illustrate the installation of panels 16 and
17 onto H-spline 40. As they are joined, front flange 75 enters
grooves 74. Web 77 occupies a gap formed between second edgewise
extensions 73 that results from their length being shorter than the
lengths of front edgewise extensions 72. First edgewise extensions
72 together with the front skins come into abutment to provide a
smooth, almost undetectable seam.
[0031] FIG. 11 shows a C-channel 78 that can be employed for both a
top channel and a side channel depending on the particular needs of
an individual installation. It may contain pairs of aligned holes
(not shown) for receiving locking pins and other features to
facilitate attachment to fixed structures (i.e., relatively
permanent structures) at the construction site. The C-channel may
preferably be comprised of extruded aluminum about 1/8 inch
thick.
[0032] Side or top wall sections may be added to a wall system
using a pair of hinged C-channels as shown in FIG. 12. Thus, a
first C-channel 80 is joined to a second C-channel 81 by a
substantially continuous hinge 82 using a conventional hinge
structure and method of attachment (e.g., spot welding) known to
those skilled in the art. A wall panel 83 is inserted into
C-channel 80 and a wall panel 84 is inserted into C-channel 81. A
locking pin 85 passes through aligned holes in C-channel 80 and the
edge piece of wall panel 83. Pin 85 has a radial hole 86 disposed
on one side of C-channel 80 and a head 87 on the other side of
C-channel 80. A cotter pin or padlock (not shown) may be installed
into radial hole 86 to keep pin 85 in place and to prevent
unauthorized persons from dismantling the modular wall.
[0033] FIG. 13 illustrates an exploded view of a modular wall
system of the present invention. After laying a floor track and
floor track extensions of appropriate length and location, a wall
panel 90 is inserted into a panel-receiving channel of the floor
track. An H-spline 91 is inserted onto an edging piece of panel 90
and rests on the floor track. An adjacent wall panel (not shown) is
inserted on the opposite side of H-spline 91 and additional wall
panels and H-splines are set up according to the desired size of a
wall. A top channel 92 is inserted over the wall panels and into
abutment with the H-splines. A plurality of locking pins (not
shown) may be inserted through the respective floor track, top
channel, and wall panels, and locked in place. It should be noted
that the lengths of the H-splines are less than the lengths of the
wall panels since the H-splines extend only between the upper edge
of the floor tracks and the lower edge of the top channel. While
wall panels and H-splines are being added to the wall, angle
bracings may be periodically attached in order to brace the
H-splines to relatively permanent structures at the site. Side
channels 93 are also added as appropriate. The top channel and side
channels are also preferably braced to relatively permanent
structures via respective angle braces or additional wall sections.
To add a side wall section, a hinged C-channel and wall panels may
be added as represented by assembly 94. Likewise, a top wall
section or canopy can be added via an assembly 95 with a hinged
C-channel that creates a canopy channel to receive a corresponding
top wall panel.
[0034] A higher wall can be achieved by stacking wall panels
between vertical H-splines running continuously (i.e., when using
wall panels of a lesser height than the full height of a wall).
Thus, a wall 100 shown in FIG. 14 has a floor track 101 and a top
track 102 separated by a plurality of vertical H-splines 103-106. A
plurality of tall panels 107 are interspersed with a plurality of
short wall panels 108 with intervening horizontal H-splines 109. By
staggering the horizontal seams of the wall panels, improved wall
stability is obtained.
[0035] A door may be created within the modular wall as shown in
FIG. 15. A floor track 110 extends to a door frame 111 and contains
a wall panel 112. Another floor track 113 extends from the opposite
side of door frame 111 and contains a wall panel 114. A top channel
115 extends over wall panels 112 and 114. Door frame 111 includes
outwardly extending side C-channels 116 and 117 and a top outwardly
extending C-channel 118. A door assembly 120 is prehung within
frame 111 and may have a latch assembly 121. A sill 122 extends
between the side C-channels of frame 111. The outwardly extending
side C-channels 116 and 117 are attached to wall panels 112 and 114
and floor tracks 110 and 113, respectively, by a plurality of
locking pins 123 passing through respective aligned holes. A lintel
wall panel 124 may be inserted between the outwardly extending top
C-channel 118, top channel 115, and additional short H-splines (not
shown) to fill any space present above the prehung door
assembly.
* * * * *