U.S. patent application number 15/495768 was filed with the patent office on 2018-01-11 for wall panel framing system.
The applicant listed for this patent is Averve, LLC. Invention is credited to Michael Dobija.
Application Number | 20180010336 15/495768 |
Document ID | / |
Family ID | 52131865 |
Filed Date | 2018-01-11 |
United States Patent
Application |
20180010336 |
Kind Code |
A1 |
Dobija; Michael |
January 11, 2018 |
WALL PANEL FRAMING SYSTEM
Abstract
Structures used for dividing, supporting, disguising and/or
cladding, for example, modular wall panel systems can include frame
members that can include or be in the form of a rail having a panel
engaging portion with a generally planar mounting surface
configured to accept at least one fastener, the panel engaging
portion including first and second lateral sides on opposite sides
of the generally planar mounting surface. First and second channels
can include side walls extending generally parallel to the
generally planar mounting surface, the first and second channels
facing away from each other.
Inventors: |
Dobija; Michael; (Laguna
Beach, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Averve, LLC |
Laguna Beach |
CA |
US |
|
|
Family ID: |
52131865 |
Appl. No.: |
15/495768 |
Filed: |
April 24, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14322425 |
Jul 2, 2014 |
9631364 |
|
|
15495768 |
|
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|
61842298 |
Jul 2, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2/765 20130101;
E04B 9/30 20130101; E04F 13/0817 20130101; E04B 2/7453 20130101;
E04B 9/245 20130101; E04B 2002/7461 20130101; E04F 13/083 20130101;
E04B 2/7854 20130101; E04F 13/0891 20130101 |
International
Class: |
E04B 9/30 20060101
E04B009/30; E04B 9/24 20060101 E04B009/24; E04F 13/08 20060101
E04F013/08; E04B 2/74 20060101 E04B002/74 |
Claims
1. A frame, comprising: a rail having a panel engaging portion
comprising a generally planar mounting surface configured to accept
at least one fastener, the panel engaging portion including first
and second lateral sides on opposite sides of the generally planar
mounting surface; and at least first and second channels, each
channel comprising side walls extending generally parallel to the
generally planar mounting surface, the first and second channels
facing away from each other.
2. A frame according to claim 1, wherein a first side wall of the
first channel and a first sidewall of the second channel are
coplanar.
3. A frame according to claim 2, wherein the first sidewall of the
first channel and the first sidewall of the second channel include
exterior surfaces, the exterior surfaces forming portions of the
generally planar mounting surface.
4. A frame according to claim 3, wherein the exterior surfaces are
spaced apart with a third channel formed therebetween, the third
channel extending generally parallel to the first and second
channels.
5. A frame according to claim 3, wherein the exterior surfaces are
not spaced apart and form a single generally planar mounting
surface.
6. A frame according to claim 1, wherein at least one sidewall of
each of the first and second channels includes a longitudinally
extending recess.
7. A frame according to claim 6, wherein both of the first and
second channels include first and second sidewalls, and wherein
both of the first and second sidewalls of the first and second
channels include juxtaposed recesses configured to provide
engagement with an enlarged portion of a member extending into the
first and second channels.
8. A frame according to claim 1, wherein the rail is a first rail,
in combination with a second rail extending generally perpendicular
to the first rail, the second rail including a second generally
planar mounting surface arranged so as to be generally coplanar
with the generally planar mounting surface of the first rail, the
second rail coupled to the first rail with a bracket contacting
only sides of the first and second rails opposite the generally
planar mounting surface.
9. A wall, comprising: a frame having at least a panel engaging
portion comprising a generally planar mounting surface configured
to accept at least one fastener, the panel engaging portion
including first and second lateral sides on opposite sides of the
generally planar mounting surface; at least first and second
channels, each channel comprising side walls extending generally
parallel to the generally planar mounting surface, the first and
second channels facing away from each other; and a planar member
connected to and at least partially supported by the frame.
10. A wall according to claim 9, wherein a first side wall of the
first channel and a first sidewall of the second channel are
coplanar.
11. A wall according to claim 10, wherein the first sidewall of the
first channel and the first sidewall of the second channel include
exterior surfaces, the exterior surfaces forming portions of the
generally planar mounting surface.
12. A wall according to claim 11, wherein the exterior surfaces are
spaced apart with a third channel formed therebetween, the third
channel extending generally parallel to the first and second
channels.
13. A wall according to claim 11, wherein the exterior surfaces are
not spaced apart and form a single generally planar mounting
surface.
14. A wall according to claim 9, wherein at least one sidewall of
each of the first and second channels includes a longitudinally
extending recess.
15. A wall according to claim 14, wherein both of the first and
second channels include first and second sidewalls, and wherein
both of the first and second sidewalls of the first and second
channels include juxtaposed recesses configured to provide
engagement with an enlarged portion of a member extending into the
first and second channels.
16. A wall according to claim 9, wherein the rail is a first rail,
in combination with a second rail extending generally perpendicular
to the first rail, the second rail including a second generally
planar mounting surface arranged so as to be generally coplanar
with the generally planar mounting surface of the first rail, the
second rail coupled to the first rail with a bracket contacting
only sides of the first and second rails opposite the generally
planar mounting surface.
17. A method of building a wall, comprising: supporting a first
frame member having a panel engaging portion comprising a generally
planar mounting surface configured to accept at least one fastener,
the panel engaging portion including first and second lateral sides
on opposite sides of the generally planar mounting surface and at
least first and second channels, each channel comprising side walls
extending generally parallel to the generally planar mounting
surface, the first and second channels facing away from each other;
connecting a second frame member to the first frame member; and
connecting a panel to at least one of the first and second frame
members so as to support the panel above a ground.
18. A method according to claim 17, wherein a first side wall of
the first channel and a first sidewall of the second channel are
coplanar.
19. A method according to claim 18, wherein the first sidewall of
the first channel and the first sidewall of the second channel
include exterior surfaces, the exterior surfaces forming portions
of the generally planar mounting surface.
20. A method according to claim 19, wherein the exterior surfaces
are spaced apart with a third channel formed therebetween, the
third channel extending generally parallel to the first and second
channels.
Description
TECHNICAL FIELD
[0001] The inventions disclosed herein generally relate to systems
and components for framed structures that divide, support,
surround, disguise and clad multiple variations of end uses,
including but without limitation, frames for substrates and
decorative finishes which include panels supported by free standing
frame or a frame system either directly attached are offset from an
existing structure such as a wall, column, plaster, or ceiling
deck.
DESCRIPTION OF THE RELATED TECHNOLOGY
[0002] Conventional wall panel systems include framing systems for
mounting wall panels to existing walls. Some conventional systems
mount panels directly to an existing wall and do not allow for
adjustment of the distance of the wall panel system from the
existing wall nor do they offer much flexibility in the arrangement
or method of fixing a panel to an existing wall.
SUMMARY OF THE INVENTIONS
[0003] In accordance with some embodiments, a frame can include a
rail having a panel engaging portion comprising a generally planar
mounting surface configured to accept at least one fastener, the
panel engaging portion including first and second lateral sides on
opposite sides of the generally planar mounting surface. The frame
can also include at least first and second channels, each channel
comprising side walls extending generally parallel to the generally
planar mounting surface, the first and second channels facing away
from each other.
[0004] In some embodiments, a wall can include a frame having at
least a panel engaging portion comprising a generally planar
mounting surface configured to accept at least one fastener, the
panel engaging portion including first and second lateral sides on
opposite sides of the generally planar mounting surface.
Additionally, the wall can also include at least first and second
channels, each channel comprising side walls extending generally
parallel to the generally planar mounting surface, the first and
second channels facing away from each other. A planar member can be
connected to and at least partially supported by the frame.
[0005] In some embodiments, a method of building a wall can include
supporting a first frame member having a panel engaging portion
comprising a generally planar mounting surface configured to accept
at least one fastener, the panel engaging portion including first
and second lateral sides on opposite sides of the generally planar
mounting surface and at least first and second channels, each
channel comprising side walls extending generally parallel to the
generally planar mounting surface, the first and second channels
facing away from each other. The method can also include connecting
a second frame member to the first frame member, and connecting a
panel to at least one of the first and second frame members so as
to support the panel above a ground.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The above-mentioned aspects, as well as other features,
aspects, and advantages of the present technology will now be
described in connection with various embodiments, with reference to
the accompanying drawings. The illustrated embodiments, however,
are merely examples and are not intended to be limiting. Like
reference numbers and designations in the various drawings indicate
like elements.
[0007] FIG. 1 illustrates an embodiment of a modular wall panel
system.
[0008] FIG. 2 is a perspective view of an embodiment of a main rail
of a panel system with panels installed onto the main rails.
[0009] FIG. 3 is a perspective view of a panel engaging side of the
main rail of FIG. 2.
[0010] FIG. 4 is a perspective view of the wall engaging side of
the main rail of FIG. 2 having a standoff assembly and a
bracket.
[0011] FIG. 5 is a top view of an embodiment of the bracket of FIG.
4.
[0012] FIG. 6 is a perspective view of an embodiment of an outside
corner rail coupled to a main rail and an edge rail.
[0013] FIG. 7 is a perspective view of an embodiment of a compound
main rail outside corner coupled to a main rail and an edge
rail.
[0014] FIG. 8 is a perspective view of a one embodiment of a main
rail with panels installed on two sides of the main rails.
[0015] FIG. 9 is a partially exploded perspective view of the main
rail of FIG. 8 incorporating rail inserts.
[0016] FIG. 10 is a partially exploded perspective view of one
embodiment of panels mounted transverse to a main rail.
[0017] FIG. 11 is a perspective view of another embodiment of a
main rail with panels installed onto the main rails.
[0018] FIG. 12 is a perspective view of the panel engaging side of
a slotted main rail.
[0019] FIG. 13 is a perspective view of the slotted main rail of
FIG. 12 with panels installed on two sides of the slotted main
rails.
[0020] FIG. 14 is a partially exploded perspective view of the
slotted main rail of FIG. 12 incorporating slotted rail
inserts.
[0021] FIG. 15 is a perspective view of a slotted main rail of FIG.
12 with panels incorporating panel clips and battens installed onto
the slotted main rails.
[0022] FIG. 16A-C illustrate an optional installation sequence of a
panel incorporating panel clips into a pair of slotted main
rails.
[0023] FIG. 17 illustrates a perspective view of another
alternative embodiment of a main rail junction.
[0024] FIG. 18 is a perspective view of a frame for a wall
partition that can be formed with any of the embodiments of the
main rail and associated components of FIGS. 1-17.
[0025] FIG. 19 is a perspective view of a frame of a casework
structure that can be formed with any of the embodiments of the
main rail and associated components of FIGS. 1-17.
[0026] FIG. 20 is a perspective view of a frame of a room enclosure
that can be formed with any of the embodiments of the main rail and
associated components of FIGS. 1-17.
[0027] FIG. 21 is a perspective view of a chase cavity partition
that can be formed with any of the embodiments of the main rail and
associated components of FIGS. 1-17.
[0028] FIG. 22 is a perspective view of a merchandise fixture that
can be formed with any of the embodiments of the main rail and
associated components of FIGS. 1-17.
[0029] FIG. 23 is a perspective view of a wall finish frame that
can be formed with any of the embodiments of the main rail and
associated components illustrated in FIGS. 1-17.
[0030] FIG. 24 is a perspective view of a utility chase wall cavity
frame that can be formed with any of the embodiments of the main
rail and associated components illustrated in FIGS. 1-17.
[0031] FIG. 25 is a perspective view of a pilaster surround frame
that can be formed with any of the embodiments of the main rail and
associated components illustrated in FIGS. 1-17.
[0032] FIG. 26 is a perspective view of a wall niche frame that can
be formed of any of the embodiments of the main rail and associated
components illustrated in FIGS. 1-17.
[0033] FIG. 27 is a perspective view of a frame for a canopy that
can be formed with the main rail in any associated components
illustrated in FIGS. 1-17.
[0034] FIG. 28 is a perspective view of a perimeter soffit chase
frame which can be formed with any of the embodiments of the main
rail and associated components illustrated in FIGS. 1-17.
[0035] FIG. 29 is a perspective view of a drop soffit chase cavity
frame which can be formed with any of the embodiments of the main
rail and associated components of FIGS. 1-17.
[0036] FIG. 30 is a perspective view of a baffle structure which
can be formed with any of the embodiments of the main rail and
associated components illustrated in FIGS. 1-17.
[0037] FIG. 31 is a perspective view of a perimeter wall soffit
structure which can include prefabricated corner and end sections
which can be formed with any of the embodiments of the main rail
and associated components illustrated in FIGS. 1-17.
[0038] FIG. 32 is a perspective, exploded view of a butt joint used
in the frame of FIG. 31.
[0039] FIG. 33 is a perspective view of a perimeter wall soffit
structure frame identifying various optional prefabricated
portions.
[0040] FIG. 34 is a perspective view of a prefabricated and
structure portion that can be used in conjunction with thief frame
of FIG. 33.
[0041] FIG. 35 is a perspective view of a prefabricated outside
corner structure that can be used with the frame of FIG. 33.
[0042] FIG. 36 is a perspective view of a prefabricated outside
corner structure that can be used in the frame of FIG. 33.
[0043] FIG. 37 is a perspective view of a prefabricated rail set
structure that can be used with the frame of FIG. 33.
DETAILED DESCRIPTION
[0044] The following detailed description is merely illustrative in
nature and is not intended to limit the embodiments of the subject
matter or the application and uses of such embodiments. As used
herein, the word "exemplary" means "serving as an example,
instance, or illustration." Any implementation described herein as
exemplary is not necessarily to be construed as preferred or
advantageous over other implementations. Furthermore, there is no
intention to be bound by any expressed or implied theory presented
in the proceeding technical field, background, brief summary, or
the following detailed description.
[0045] Certain terminology may be used in the following description
for the purpose of reference only, and thus are not intended to be
limiting. For example, terms such as "upper", "lower", "above", and
"below" refer to directions in the drawings to which reference is
made. Terms such as "proximal", "distal", "front", "back", "rear",
and "side" describe the orientation and/or location of portions of
the component within a consistent but arbitrary frame of reference
which is made clear by reference to the text and the associated
drawings describing the component under discussion. Such
terminology may include the words specifically mentioned above,
derivatives thereof, and words of similar import. Similarly, the
terms "first", "second", and other such numerical terms referring
to structures do not imply a sequence or order unless clearly
indicated by the context.
[0046] Additionally, the term "wall" as used herein is intended to
refer to any structure that provides a barrier, whether it be flat
or curved, stepped or has a different shape. Additionally, the term
wall, and some contexts, refers to an individual structural feature
such as sides of a channel, in other contexts refers to a portion
of a structure formed with any of the frames noted below, and in
other contexts, refers to a wall of a structure such as a residence
or commercial property.
[0047] Embodiments described herein generally relate to structures
that divide, support, disguise and clad a multiple variation of end
uses. Some of the embodiments disclosed below are described in the
context modular wall panel systems because some of the inventions
disclosed herein have particular utility in that environment of
use. However, the inventions disclosed herein can be used in many
other contexts, such as, but without limitation, ceiling, fixtures,
caseworks, soffits, exhibits, furniture, etc.
[0048] With reference to FIGS. 1 and 2, a framing system 100 can be
configured to support panels 200. In some environments of use, the
panels can be supported so as to be offset from an existing
interior residential or commercial wall or ceiling. Various
embodiments of the system 100 described herein can be used to
support a variety of panels 200, which may include, for example,
substrate materials configured to receive a field finish or
decorative panels.
[0049] One example of a substrate material is drywall. Examples of
a decorative panels include wood veneer and porcelain panels. Other
materials can also be used.
[0050] In some embodiments, the system 100 can provide a strong,
thin, and light weight framing system for a wall. The system 100
can allow a user such as a tenant of a residential or commercial
property to change the aesthetic appearance and shape of a room
without modifying the existing walls which may be structural and/or
may include electrical wires or pipes or other plumbing
fixtures.
[0051] In addition, some embodiments can provide space between the
wall panel system 100 and the existing wall such that the space can
be used to accommodate electrical wiring, plumbing, acoustical
blanket, lighting, or other materials the tenant may wish to hide
from view. In some embodiments, the components of the system 100
can be assembled into a frame only approximately 3/4'' thick,
minimizing overall thickness of the resulting wall and thus
minimizing the reduction in the size of the room in which the wall
panel system 100 is installed.
[0052] FIGS. 1 and 2 illustrate an embodiment of a modular wall
panel system 100. In some embodiments, the wall panel system 100
can be configured to support panels 200 which are visible to
occupants of the room in which the wall panel system 100 is
installed. The wall panel system 100 can include various components
which may include, for example, various rails including, for
example, main rails 300, outside corner rails 500, inside corner
rails 600, and edge rails 700. In some embodiments, rails can be
configured to comprise the corner or edge of the wall panel system
100, described in greater detail below with reference to FIG.
7.
[0053] In some embodiments, components modular wall panel system
100 can be configured to couple to one another to form a
free-standing or supported frame for supporting panels 200 and/or
other devices. For example, in addition to supporting panels 200,
the modular wall panel system 100 can be configured to couple to an
existing wall. In some embodiments, the system 100 can be mounted
at ceiling and floor for support with no attachment to penetrate
the existing wall surface. In some embodiments, the modular wall
panel system 100 can be configured to couple to an existing ceiling
and support panels 200 offset (e.g., downwardly) from the
ceiling.
[0054] FIG. 2 illustrates a perspective view of an assembly of main
rails 300 forming a junction 400, with panels 200 installed onto
the main rails 300. In some embodiments, as illustrated in FIG. 2,
a junction 400 can include the intersection of a rail such as a
main rail 300 arranged vertically and another rail, such as another
main rail 300, arranged horizontally. A main rail 300 is one type
of rail which can be configured to support panels 200, other rails
can also be used. In some embodiments, as noted above, rails can be
configured to be oriented either vertically or horizontally.
[0055] FIG. 3 illustrates a perspective view of the panel engaging
side of the junction 400 of FIG. 2. In some embodiments, rails can
be configured to support panels 200 on the panel engaging side of
the rails. In some embodiments, each rail can include a panel
engaging portion 305 configured to be engageable for supporting at
least one panel 200. The panel engaging portion 305 can be smooth
and flat or it can incorporate surface features such as knurls,
slots, or other patterns of raised ridges to provide additional
engagement with panels 200. In some embodiments, the panel engaging
portion 305 can include a generally planar mounting surface
configured to accept at least one fastener 800, which can include
for example, stainless steel sheet metal self-tapping screws, or
other types of fasteners.
[0056] In some embodiments, the main rail 300 can be constructed of
a material, which may include, for example, aluminum, capable of
accepting fasteners 800. In some embodiments, fasteners 800 can be
utilized to fasten the panels 200 to the rails. The fasteners can
be installed through the panel 200 and into the panel engaging
portion 305. In some embodiments, the panel engaging portion 305
can be about 1.5'' wide (e.g., in a direction perpendicular to the
longitudinal direction of the main rail 400) to mimic the width of
a "2.times.4" stud often used in construction. In other
embodiments, different widths can be used to support a variety of
panels 200. In some embodiments, the main rails 400 can have
generally or substantially uniform cross sections and thus can be
made from extruded aluminum. However, main rails 300 formed from
extruded aluminum can have some feature that disrupt the generally
or substantially uniform cross sections, using post-extrusion
machining techniques, such as drilling, milling, cutting, punching,
etc. which are well known in the art.
[0057] In some embodiments, rails, and as illustrated in FIG. 3,
main rails 300, can include a panel engaging portion 305. In some
embodiments, main rails 300 can include a first side 310 and a
second side 320 on opposite sides of the panel engaging portion
305. In some embodiments, a first side 310 can include a first
channel 311 comprising a first sidewall 315 and a second sidewall
316. In some embodiments, the first sidewall 315 and second
sidewall 316 can be substantially parallel to the mounting surface
of the panel engaging portion 305. In some embodiments, the first
sidewall 315 can be a portion of the panel engaging portion 305. In
some embodiments, a second side 320 can include a second channel
321 wherein the first channel 311 and second channel 321 are facing
away from each other. In some embodiments, the first channel 311
and second channel 321 can be configured to accept additional
components of the modular wall panel system 100, which can include,
for example, a gusset 900 or an angle 1200, which are configured to
couple components of the modular wall panel system 100
together.
[0058] In some embodiments, the first channel 311 and second
channel 321 can be configured to accept a gusset 900. The gusset
900 can be configured to be couplable to multiple components of the
modular wall panel system 100. In some embodiments, a gusset 900
can comprise a piece of sheet metal. In some embodiments, a gusset
900 can be substantially triangular. In some embodiments, a gusset
900 can be configured to slide within a first channel 311 or second
channel 321 of a vertically oriented main rail 300 and also within
a first channel 311 or second channel 321 of a horizontally
oriented main rail 300.
[0059] In some embodiments, a gusset 900 can help to maintain a
substantially perpendicular relationship between a vertically
oriented rail and a horizontally oriented rail. In some
embodiments, a gusset 900 can be affixed to a rail via at least one
fastener 800. In some embodiments, the first channel 311 or second
channel 321 of the rail and the gussets 900 can be configured to
have a friction fit when the gusset 900 is inserted into a first
channel 311 or second channel 321 of the rail in order to affix the
gusset 900 to the rail.
[0060] In some embodiments, the first channel 311 and second
channel 321 can include a recess 318 formed along the length of
each channel 311, 321. In some embodiments, the recess 318 can be
partially formed in the first sidewall 315 and the second sidewall
316, forming a recess or detent in both of the sidewalls 315, 316
of the channels 331, 332.
[0061] In some embodiments, the recess 318 can be configured to
accept a protrusion formed on the surface of another component of
the modular wall panel system 100, which can include, for example,
a gusset 900, or angle 1200. In some embodiments, gussets 900,
angles 1200, or other components of the wall panel system 100 can
include protrusions (not illustrated) which are configured to lock
the component in place when inserted into a channel 331, 332 of a
rail. In some embodiments, the sidewalls 315, 316 of a channel 311,
321 may deflect when the component is inserted into the channel
311, 321, and then return to their default position once the
protrusion reaches the bore 318 of the channel 311, 321. In some
embodiments, the protrusion can include a bead formed thereon the
gusset 900 or angle 1200.
[0062] FIG. 4 illustrates a perspective view of the wall engaging
side of the junction 400 of FIG. 2. In some embodiments, rails, and
as illustrated in FIG. 4, main rails 300, can include a wall
engaging portion 330. In some embodiments, the wall engaging
portion 330 can be configured to engage a standoff 1000.
[0063] In some embodiments, a standoff 1000 can be configured to
couple a rail, such as a main rail 300, to an existing wall. In
some embodiments, the standoff 1000 can be configured to be
adjustable in length, allowing the installer to change the offset
between the rail and the existing wall during installation. The
adjustment can allow the installer to gain access behind a
partially constructed wall to finish the installation of the system
100. In some embodiments, the standoff 1000 can include means for
locking the standoff at a particular offset length. In some
embodiments, a fastener can serve as means for locking the standoff
1000 into a desired length.
[0064] In some embodiments, a standoff 1000 can include a rail
coupling member 1010 configured to couple to the wall engaging
portion 330 of the rail. In some embodiments, the rail can include
a rear channel 331 formed in the wall engaging portion 330 of the
rail. The rail coupling member 1010 can be configured to fit within
the rear channel 331 of the rail. The rear channel 331 can be
configured to accept the rail coupling member 1010 of the standoff
1000. In some embodiments, the rail coupling member 1010 can be
slid within the rear channel 331 until the desired location is
achieved.
[0065] In some embodiments, a standoff 1000 can also include a wall
coupling member 1020. The wall coupling member 1020 can be
configured to be coupled to an existing wall. In some embodiments,
the wall coupling member 1020 can include at least one aperture
configured to accept a fastener 800. In some embodiments, a
fastener 800 can be utilized to couple the standoff 1000 to the
existing wall.
[0066] In some embodiments, a sleeve member 1030 can be configured
to accept the ends of the members 1010, 1020 of the standoff 1000,
members 1010, 1020 to slide within the receiving portion 1030 so as
to allow the distance between the rail and the existing wall to be
varied during construction. Optionally, the receiving portion 1030
can include a slot 1035 through which fasteners (not shown) can
extend to engage the members 1010, 1020. In some embodiments, a
standoff 1000 can be configured to engage two rails instead of a
single rail and an existing wall.
[0067] As illustrated in FIG. 4, a bracket 1100 can be utilized to
couple at least one vertically oriented rail to at least one
horizontally oriented rail. For example, a bracket 1100 can couple
multiple rails together and add structural integrity to the wall
panel system 100. In some embodiments, the bracket 1100 can be
configured to engage the wall engaging portion 330 of each rail. In
some embodiments, the bracket 1100 can be configured to follow the
contours of the wall engaging portion 330 of each rail. In some
embodiments, the bracket 1100 can be configured to be coupled to
the wall engaging portion 330 of each rail via at least one
fastener 800. The bracket 1100 can include at least one aperture to
accept a fastener 800. In some embodiments, the width of the
bracket 1100 can be optimally dimensioned to fit within the rear
channel 331 of a rail.
[0068] FIG. 5 illustrates a top view of the bracket of FIG. 4. In
some embodiments, the bracket 1100 can include a first rear channel
engaging portion 1110 configured to engage the rear channel 331 of
a rail. In some embodiments, the bracket can include a second rear
channel engaging portion 1120 configured to engage the rear channel
331 of a rail. In some embodiments, the bracket can include a third
rear channel engaging portion 1130 configured to engage the rear
channel 331 of a rail. In some embodiments, each rear channel
engaging portion 1110, 1120, 1130 can be connected via a recessed
portion 1140, 1150. In some embodiments, the first channel engaging
portion 1110 is connected to the second rear channel engaging
portion 1120 via the first recessed portion 1140. In some
embodiments, the first channel engaging portion 1110 is connected
to the third rear channel engaging portion 1130 via the second
recessed portion 1150. In some embodiments, the first, second, and
third rear channel engaging portions 1110, 1120, 1130 share a first
plane, allowing the bracket 1100 to maintain continuity among the
rails it is coupled to and thus maintain a consistent and flat
panel engaging surface in order to mount panels 200. In some
embodiments, the recessed portions 1140, 1150 are configured to
clear portions of the wall engaging portion 330 as illustrated in
FIG. 4. In some embodiments, the first and second recessed portions
1140, 1150 share a second plane. In some embodiments, the first
plane is offset from the second plane. In some embodiments, the
offset between the first and second planes matches the depth of the
rear channel 331 of the wall engaging portion 330 of a rail.
[0069] FIG. 6 illustrates a perspective view of an embodiment of an
outside corner rail 500 coupled to a main rail 300 and an edge rail
700. In some embodiments, the modular wall panel system 100 can
include a corner rail 500 configured to arrange panels 200 so as to
form an "outside corner" of a wall. In some embodiments, the rail
can be configured to be positioned at an outside corner where the
visible surface of each panel 200 mounted to the rail are splayed
away from one another, as illustrated in FIG. 6 and by the outside
corner rail 500 of FIG. 1, or an inside corner where the visible
surface of each panel 200 mounted to the rail are splayed towards
one another, as illustrated by the inside corner rail 600 of FIG.
1. In some embodiments, as illustrated in FIG. 6, the corner rail
can be configured to orient panels 200 at a corner angle which may
include, for example, approximately 90 degrees, forming a square
corner. In some embodiments, the corner rail 500 can include first
and second sides 510, 520 as described above, only except the sides
510, 520 are angled relative to one another, and in some
embodiments, are perpendicular to one another.
[0070] In some embodiments, the corner rail 500 can include first
and second channels 511, 521 as described above, only except the
channels 511, 521 do not face directly away from each other, but
are angled relative to each other, and in some embodiments, are
perpendicular to each other. In some embodiments, a corner rail 500
can incorporate first rear channel 530 and a second rear channel
540 similar to the rear channel 331 described above. The first rear
channel 530 can be angled relative to the second rear channel 540.
In some embodiments, the first rear channel 530 is perpendicular to
the second rear channel 540.
[0071] In some embodiments, the modular wall panel system 100 can
include an edge rail 700 as illustrated in FIG. 6. In some
embodiments, the edge rail 700 can include a panel engaging portion
705 (not visible in FIG. 6), a first side 710, a second side 720,
and a wall engaging portion 730 including a rear channel 731. In
some embodiments, the first side 710 of the edge rail 700 is
similar to the first side 310 of the main rail 300 as described
above in reference to FIG. 3. In some embodiments, the second side
720 of the edge rail 700 can include a transverse surface engaging
portion 750. The transverse surface engaging portion 750 can be
configured to couple to a surface, which may include, for example,
a floor or a ceiling, which is perpendicular to the panel engaging
portion 705 of the edge rail 700. In some embodiments, the
transverse surface engaging portion 750 is oriented perpendicular
to the panel engaging surface 705 of the edge rail 700. In some
embodiments, the transverse surface engaging portion 750 can
include at least one aperture configured to accept a fastener 800
to couple the edge rail 700 to a floor, ceiling, or wall.
[0072] In some embodiments, the bracket 1100 described above in
relation to FIGS. 4 and 5 can be utilized when coupling additional
components of the modular wall panel system 100 to a corner rail as
well. In some embodiments, due to the configuration of the corner
rail, the bracket 1100 can be offset towards the additional
component, which may include, for example, a main rail 300 or an
edge rail 700. In some embodiments, a different embodiment of the
bracket 1100 could be utilized which is designed particularly for
use with corner rails. In some embodiments, a corner rail bracket
could comprise a first rear channel engaging portion 1110, a second
rear channel engaging portion 1120, and a first recessed portion
1140 (not illustrated).
[0073] FIG. 7 illustrates a perspective view of one embodiment of a
compound main rail outside corner 500' coupled to a main rail 300
and an edge rail 700. In some embodiments, rather than using a
corner rail 500 to arrange panels 200 at a corner of a wall,
multiple main rails 300 can be arranged perpendicular to one
another and coupled together with an angle 1200 as illustrated in
FIG. 7. In some embodiments, the modular wall panel system 100
incorporates an angle 1200. An angle 1200 can be configured to
couple multiple rails to one another at a corner. In some
embodiments, an angle 1200 can be configured to be inserted into
the first channel 311 of one main rail 300 and into the second
channel 321 of another main rail 300, coupling the main rails 300
together and maintaining a perpendicular relationship between the
main rails 300, forming a compound main rail corner 500'. In some
embodiments, the compound main rail corner 500' can comprise an
outside corner, as illustrated in FIG. 7 and also similar to the
outside corner rail 500 in FIG. 1. In some embodiments, the
compound main rail corner 500' can comprise an inside corner,
similar to the inside corner rail 600 of FIG. 1. In some
embodiments, an angle 1200 can comprise a bent piece of sheet
metal. In some embodiments, an angle 1200 can be affixed to a rail
via at least one fastener 800. In some embodiments, the first and
second channels 311, 321 of the rail and the angle 1200 can be
configured to have a friction fit when the angle 1200 is inserted
into a first or second channel 311, 321 of the rail in order to
affix the angle 1200 to the rail.
[0074] In some embodiments, rather than utilizing an edge rail 700
to couple the modular wall panel system 100 to a floor, ceiling, or
wall, an angle 1200 can be utilized in the first or second channel
311, 321 of a main rail 300 (not illustrated) to form the
equivalent of the transverse surface engaging portion 750 of the
edge rail 700 described above in relation to FIG. 6.
[0075] FIG. 8 illustrates a perspective view of a one embodiment of
a junction 400 with panels 200 installed on two sides of the main
rails 300. FIG. 9 illustrates a partially exploded perspective view
of the main rail junction 400 of FIG. 8 incorporating rail inserts
1300. In some situations it may be advantageous to have panels 200
mounted on more than one side of the main rails 300. In some
embodiments, the main rails 300 can be configured to engage and
support panels 200 on both sides of the main rails 300, as
illustrated in FIG. 8. In some embodiments, the modular wall panel
system 100 can include a rail insert 1300 configured to be affixed
to the wall engaging portion 330 of a main rail 300. In some
embodiments, the rail insert 1300 can include a panel engaging
portion 1305 configured to engage and support at least one panel
200. In some embodiments, the rail insert 1300 includes a rear
channel engaging portion 1361, opposite the panel engaging portion
1305, configured to engage the rear channel 331 of a main rail 300.
In some embodiments, the rear channel engaging portion 1361 of the
rail insert 1300 can include a sub-channel engaging portion 1362,
configured to engage the sub-channel 332 of the main rail 300. In
some embodiments, the rear channel engaging portion 1361 and
sub-channel engaging portion 1362 can be configured to achieve a
friction fit when inserted into the rear channel 331 and
sub-channel 332 of a main rail 300. In some embodiments, fasteners
800 can be used to affix the rail insert 1300 to a main rail
300.
[0076] FIG. 10 illustrates a partially exploded perspective view of
one embodiment of panels 200 mounted transverse to a main rail 300.
In some situations, it can be advantageous to mount panels 200
perpendicular to the panel engaging portion 305 of a main rail 300.
In some embodiments, the modular wall panel system 100 can include
an adapter 1400, as illustrated in FIG. 10, to couple at least one
panel 200 to a main rail 300 and orient the at least one panel 200
perpendicular to the panel engaging portion 305 of the main rail
300. In some embodiments, the adapter 1400 can include at least one
aperture configured to accept a fastener 800. In some embodiments,
a fastener 800 can pass through the adapter 1400 and engage the
first or second channel 311, 321 of the main rail 300, securing the
adapter 1400 to the first or second side 310, 320 of the main rail
300. In some embodiments, an adapter 1400 may be formed integrally
in a rail.
[0077] FIG. 11 illustrates a perspective view of one embodiment of
a slotted main rail junction 400' with panels 200 installed onto
the slotted main rails 300'. FIG. 12 illustrates a perspective view
of the panel engaging side of a slotted main rail junction 400'. In
some embodiments, a slotted main rail 300' is an alternative
embodiment of the main rail 300 discussed above. In some
embodiments, the slotted main rail 300' shares many features with
the main rail 300, however some additional features will be
discussed below in relation to FIGS. 11-16.
[0078] In some embodiments, the slotted main rail 300' can include
a first panel engaging portion 306 and a second panel engaging
portion 307. In some embodiments, the first panel engaging portion
306 and the second panel engaging portion 307 are located adjacent
each other, and separated by a front channel 308. In some
embodiments, the slotted main rail 300' can include a first side
310' including a first channel 311', a second side 320' including a
second channel 321', and a wall engaging portion 330' (See FIG. 14)
including a rear channel 331'. In some embodiments, the slotted
main rail 300' can include a first rear offset channel 381 located
adjacent the rear channel 331'. In some embodiments, the slotted
main rail 300' can include a second rear offset channel 382 located
adjacent the rear channel 331'. In some embodiments, the first rear
offset channel 381 can be located on a first side of the rear
channel 331' and the second rear offset channel 382 can be located
on a second side of the rear channel 331'.
[0079] In some embodiments, the first or second channel 311', 321'
can include a first sidewall 315' and a second sidewall 316'. In
some embodiments, the first and second sidewalls 315', 316' can be
substantially parallel to the mounting surface of the first and
second panel engaging portions 306, 307. In some embodiments,
neither the first sidewall 315' nor the second sidewall 316' is a
portion of the panel engaging portions 306, 307. In some
embodiments, the slotted main rail 300' incorporates a first slot
371 formed in the first side 310' between the first panel engaging
portion 306 and the first sidewall 315'. In some embodiments, the
slotted main rail 300' incorporates a corresponding second slot 372
in the second side 320'. In some embodiments, the first slot 371
and second slot 372 are parallel to the first and second panel
engaging portions 306, 307.
[0080] FIG. 13 illustrates a perspective view of the slotted main
rail junction 400' of FIG. 12 with panels 200 installed on two
sides of the slotted main rails 300'. FIG. 14 illustrates a
partially exploded perspective view of the slotted main rail
junction 400' of FIG. 12 incorporating slotted rail inserts 1300',
1300''. As discussed above, in some situations it may be
advantageous to have panels 200 mounted on more than one side of
the main rails 300. In some embodiments, the slotted main rails
300' can be configured to engage and support panels 200 on both
sides of the slotted main rails 300', as illustrated in FIG. 13. In
some embodiments, the modular wall panel system 100 can include a
slotted rail insert 1300', 1300'' configured to be affixed to the
wall engaging portion 330' of a slotted main rail 300'. In some
embodiments, the slotted rail insert 1300' can include a panel
engaging portion 1305'. In some embodiments, the rail insert 1300''
can include a first panel engaging portion 1306 and a second panel
engaging portion 1307. In some embodiments, the first panel
engaging portion 1306 and the second panel engaging portion 1307
are located adjacent each other, and separated by a front channel
1308. In some embodiments, the slotted rail insert 1300', 1300''
includes a rear channel engaging portion 1361', opposite the panel
engaging portion 1305', 1306, 1307, configured to engage the rear
channel 331' of a slotted main rail 300'. In some embodiments, the
slotted rail insert 1300', 1300'' can include a first offset
channel engaging portion 1301 configured to engage the first rear
offset channel 381 of the slotted main rail 300'. In some
embodiments, the slotted rail insert 1300', 1300'' can include a
second offset channel engaging portion 1302 configured to engage
the second rear offset channel 382 of the slotted main rail 300'.
In some embodiments, the first offset channel engaging portion 1301
can be located on a first side of the rear channel engaging portion
1361' and the second offset channel engaging portion 1302 can be
located on a second side of the rear channel engaging portion
1361'. In some embodiments, the first offset channel engaging
portion 1301 and the second offset channel engaging portion 1302
can be configured to achieve a friction fit when inserted into the
first rear offset channel 381 and second rear offset channel 382 of
a slotted main rail 300'. In some embodiments, fasteners 800 can be
used to affix the slotted rail insert 1300', 1300'' to a slotted
main rail 300'.
[0081] FIG. 15 illustrates a perspective view of the slotted main
rail junction 400' of FIG. 12 with panels 200 incorporating panel
clips 210 and battens 1500 installed onto the slotted main rails
300'. FIG. 16A-C illustrate the installation sequence of a panel
200 incorporating panel clips 210 into a pair of slotted main rails
300'. In some embodiments, the slots 371, 372 of the slotted main
rail 300' can be used to engage and support panels 200, as
illustrated in FIG. 15. In some embodiments, the modular wall panel
system 100 can include at least one panel clip 210 affixed to a
panel 200. In some embodiments, a panel clip 210 can be configured
to engage a slot 371, 372 of a slotted main rail 300'. In some
embodiments, a panel clip 210 of a panel 200 can be installed in a
slot 371, 372 of a slotted main rail oriented vertically. In some
embodiments, a panel clip 210 of a panel 200 can be installed in a
slot 371, 372 of a slotted main rail 300' oriented horizontally. In
some embodiments, the panel clip 210 can be adhered to a panel 200
with an adhesive, avoiding the need to pass a fastener 800 through
the panel which can be undesired in certain circumstances which may
include, for example, extremely hard or brittle materials as well
as panels 200 which are intended to not be disturbed by fasteners
for aesthetic reasons.
[0082] In some embodiments, the modular wall panel system 100 can
include battens 1500 which can be a decorative portion of the
system 100. In some embodiments, battens 1500 can be configured to
be placed between panels 200. In some embodiments, a portion of the
batten 1500 can be configured to be inserted into the front channel
308, 1308 of either a slotted main rail 300' or a slotted rail
insert 1300. In some embodiments, the front channel 308, 1308 and
batten 1500 can be configured to achieve a friction fit when the
batten 1500 is inserted into the front channel 308, 1308. In some
embodiments, battens 1500 can be used to restrain panels 200 in
position. In some embodiments, battens can restrain the panel clip
210 of a panel 200 from leaving a slot 371, 372 of a slotted main
rail 300'. In some embodiments, the battens 1500 can include a
batten key channel 1510 configured to accept a batten key (not
illustrated), such that a batten key can be inserted into the
batten key channel 1510, rotated, and then pulled away from the
modular wall panel system 100, releasing the batten 1500 from the
modular wall panel system 100.
[0083] In some embodiments, a panel can include more than one panel
clip, as illustrated in FIG. 16A-C. In some embodiments, the
distance between a first slotted main rail 301 and a second slotted
main rail 302 and the size and distance between a first panel clip
211 and a second panel clip 212 of a panel 200 can be configured to
allow a panel 200 to be coupled to a pair of slotted main rails
301, 302 without moving either of the slotted main rails 301, 302
and without repositioning the panel clips 211, 212 on the panel
200. In some embodiments, as illustrated in FIG. 16A, a first panel
clip 211 of a panel 200 can be installed in a first slot 371 of a
first slotted main rail 301. In some embodiments, as illustrated in
FIG. 16B, the panel 200 can be slid all the way towards the first
slotted main rail 301, allowing the second panel clip 212 to clear
the second slotted main rail 302. In some embodiments, as
illustrated in FIG. 16C, the panel 200 can then be slid towards the
second slotted main rail 302, and a batten 1500 installed in the
first slotted main rail 301, restraining the panel 200 in
place.
[0084] FIG. 17 illustrates a perspective view of an alternative
embodiment of a main rail junction 400'', which can also be
configured to receive removable rail inserts 1300 noted above. In
some embodiments, the modular wall panel system can include an
alternative embodiment of the main rail 400''.
[0085] In some embodiments, the features described above in
relation to a particular component or type of rail can be applied
to other components of the modular wall panel system 100 including
different types or embodiments of rails. In addition, various
components described above may be able to be combined in additional
orientations or arrangements which may not have been illustrated or
discussed.
[0086] FIGS. 18-37 illustrate various different types of frames
that can be formed using any embodiments of the main rail 300,
300', 300'', main rail junctions 400, 400', 400'', outside corner
rails 500, 500', inside corner rails 600, 600', edge rails 700,
700', and rail inserts 1300, 1300' and associated components
described above, although only the reference numerals 300, 400,
500, 600, 700, etc are used below in some references to the
embodiments of FIGS. 18-37 for brevity.
[0087] FIGS. 31-37 further illustrate framing assemblies which can
benefit from the use of some prefabricated portions. For example,
as shown in FIGS. 31 and 33, a perimeter wall soffit structure can
include one or more of any of the following: prefabricated end
structure 460, prefabricated outside corner structure 462,
prefabricated inside corner structure 464, and prefabricated rail
set 466. Additionally, FIG. 32 illustrates a butt joint that can be
used to connect the various prefabricated pieces illustrated in
FIGS. 31 and 33-37 as well as to the various embodiments of the
other structures, prefabricated or not, such as the main rail 400,
400', 400'', edge rails 700, etc.
[0088] FIGS. 34-37 illustrate, schematically, optional
configurations of the end structure 460, outside corner structure
462, inside corner structure 464, and rail sets 466 that can be
used in the frame configuration illustrated in FIGS. 31 and 33, and
including optional dimensions that could be used in an example of
an installation configuration. Other dimensions can also be
used.
[0089] As used herein, the term "wall" refers to any service that
defines a boundary. Thus, in the figures described herein, various
structures are described including, for example, but without
limitation, facades, room partitions, casework structures, room
enclosures, Chase cavity partitions, merchandise fixtures, wall
finish frames, plaster surrounds, utility Chase wall cavities, wall
niches, canopies, ceilings, perimeter soffit Chase cavities, drop
soffit Chase cavities, baffled structures, etc. Any (external or
internal) surface of any of the above noted structures are
considered to be a "wall" as that term is used in the present
specification.
[0090] In some embodiments, various portions of the modular wall
panel system can be manufactured from any suitable material or
combination of materials which may include, for example, metals and
alloys such as for example, aluminum, steel, stainless steel,
titanium, iron, alloy, non-metal materials such as for example,
polymers, carbon, ceramics and other non-metallic materials such as
plastic, thermoplastic, thermoset, acrylonitrile butadiene styrene,
polycarbonate acetal, acrylic, nylon, polybutylene terephthalate,
polyester liquid crystal polymer, polypropylene, polycarbonate,
polyimide, polyethylene, carbon fiber, or combinations thereof.
[0091] In some embodiments, portions of the modular wall panel
system can be formed via extrusion, machining, injection molding,
casting, thermoforming, compression molding, blow molding, transfer
molding, three dimensional printing or any combination thereof. In
one embodiment, the material may be reinforced with glass or carbon
fibers. In some embodiments, different portions of the modular wall
panel system can be affixed to one another using securing means
which may include, for example fasteners, clips, adhesive, cement,
welding, press fits, interference fits, friction, clamps, etc.
* * * * *