FIELD OF THE DISCLOSURE
The present disclosure relates to interior wall systems of the sort that can be built into existing interior spaces such as those of offices, schools, homes and the like.
BACKGROUND OF THE DISCLOSURE
Most large office buildings are typically erected with only the exterior and a few load bearing interior walls being completed. The additional interior walls are later added depending on the needs of the occupants.
Interior walls can also be constructed according to conventional techniques wherein wooden or metal studs extend from floor to ceiling at regularly spaced intervals. Wall panels are then nailed or screwed to the studs. This type of construction requires additional work to cover the holes created by the nails to achieve a finished look. This finishing requires considerable time and therefore, considerable expense. Also, these types of wall cannot be taken down or moved without severely damaging the materials used to construct them.
Decorative interior wall systems are well known. Such systems are commonly used, for example, to finish the open spaces of office buildings, schools, and theaters. One type of interior wall system is a modular partition wall system which is composed of multiple wall panels arranged side-by-side and vertically in a rectangular array.
Another type of known interior wall system comprises a framing structure of U-shaped channel members into which prefinished wall panels are inserted. This system requires that the U channels be made of heavy gauge metal to prevent the side flanges of the U channels from deforming which would allow the wall panels to fall out. Also, this type of interior wall system typically does not adequately keep out noise from one room to the next, nor is it very sturdy.
Decorative interior wall systems that can be constructed from glass panels (whether transparent, translucent, or opaque) have become increasingly popular due to their aesthetic aspects. Such wall systems are commonly referred to as “glass walls.” Generally speaking, they can be time-consuming to install because the members making up the framing structure are often complex, and thus the cost of such systems can be high. Glass, however, is not the only type of aesthetically appealing material used in decorative interior walls. Wood, metal, and textile-based designs can also be incorporated into adaptable interior wall systems.
SUMMARY OF THE DISCLOSURE
According to a preferred embodiment, a wall system is configured for mounting a plurality of rectangular solid panels. The wall system comprises a plurality of vertical support members, each vertical support member having at least three sets of two support clips slidably attached to first and second adjacent vertical support members. Each of the support clips has a front portion which projects horizontally outward from the vertical support members. At least one guide pin extends vertically through the front portion of each support clip. A plurality of rectangular solid panels, each having at least two cylindrical bores on an upper surface and at least two cylindrical bores on a lower surface, such that each cylindrical bore is adapted to receive one of the guide pins whereby a first of the rectangular solid panels is secured upon the two support clips of the first set of support clips on the first and second vertical support members, respectively, and beneath the two support clips of the second set of support clips on the first and second vertical support members. A second of the rectangular panels is secured upon second set of support clips on the first and second vertical support members and beneath third set of two support clips on the first and second vertical support members.
According to another preferred embodiment, a method of mounting a plurality of rectangular solid panels of a wall system comprises providing at least first and second adjacent vertical support members. A first set of two support clips each with a front portion which projects horizontally outward therefrom is secured to the at least first and second adjacent vertical support members so that the two support clips of the first set are horizontally aligned with each other. Each of the plurality of rectangular solid panels is provided with at least two cylindrical bores on an upper surface and at least two cylindrical bores on a lower surface. A first of the rectangular solid panels is mounted to the front portion of the first set of support clips with a guide pin disposed between each of the front portions of the two support clips of the first set and the two cylindrical bores on the bottom surface of the first rectangular solid panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and advantages of the present invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying figures (FIGURES). The figures are intended to be illustrative, not limiting.
Certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. The cross-sectional views may be in the form of “slices”, or “near-sighted” cross-sectional views, omitting certain background lines which would otherwise be visible in a “true” cross-sectional view, for illustrative clarity.
Often, similar elements may be referred to by similar numbers in various figures (FIGs) of the drawing, in which case typically the last two significant digits may be the same, the most significant digit being the number of the drawing figure (FIG).
FIG. 1A is a straight-on, front view of a typical installed embodiment of a wall system for supporting decorative panels, according to an embodiment of the present invention.
FIG. 1B is a sectional side view through lines A-A of FIG. 1A, according to an embodiment of the present invention.
FIG. 1C is schematic views of the fronts, backs, and edges of the decorative panels, according to an embodiment of the present invention.
FIG. 2A shows the view of the support framework that carries the decorative panels, according to an the present embodiment invention.
FIG. 2B is a detail view of three exemplary decorative panels in relationship to the support framework, according to an embodiment of the present invention.
FIG. 3 shows one of the vertical frame members along with two supporting clips, according to an embodiment of the present invention.
FIG. 4A is an oblique view showing the upper side portion of a standard clip, according to an embodiment of the present invention.
FIG. 4B is an oblique view showing the lower side portion of a standard clip, according to an embodiment of the present invention.
FIG. 5A is an oblique view showing the upper side portion of a side clip, according to an embodiment of the present invention.
FIG. 5B is an oblique view showing the lower side portion of a side clip, according to an embodiment of the present invention.
FIG. 6A is an orthogonal top view of a standard clip, according to an embodiment of the present invention.
FIG. 6B is an orthogonal bottom view of a standard clip, according to an embodiment of the present invention.
FIG. 6C is an orthogonal side view of a standard clip, according to an embodiment of the present invention.
FIG. 6D is an orthogonal frontal view of a standard clip, according to an embodiment of the present invention.
FIG. 7 is an orthogonal top view of a standard clip showing characteristic dimensions, according to an embodiment of the present invention.
FIG. 8 is an orthogonal detail view of a junction between the framework and a vertical member, according to an embodiment of the present invention.
FIG. 9 is a sectional view of the relationship between a clip and two decorative panels, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DISCLOSURE
The present wall system 10 can be installed as a free-standing wall, anchored to the floor and ceiling. The wall system 10 is configured for mounting a plurality of rectangular solid panels 12, or it can be used over an existing internal wall, in which case it might be secured to the existing wall as well as to the floor and ceiling. Typically, the wall system is used as an indoor system, however it is within the terms of the present invention to use an embodiment as an outdoor wall system.
FIG. 1A is a straight-on front view of the present internal wall system 10, showing twenty-four 24 decorative solid panels 12 supported on an underlying support framework 14. As shown in FIG. 1C, the panels 12 are preferably rectangular solids having front and rear surfaces 12a and 12b, respectively, upper and lower surfaces 12c and 12d, respectively, and side surfaces 12e and 12f. On both the upper and lower surfaces 12c and 12d, there are two spaced blind bores 56a,56b projecting into the panels. (The term “blind bore” means a hole having a bottom; i.e., a “blind bore” is not a “through” hole.) Each of the blind bores 56a,56b has a flat bottom 59a,59b (shown in FIG. 9), respectively, adapted to be engaged by one end of the guide pin 43. The axes of the bores are perpendicular to the upper and lower surfaces 12c and 12d. The decorative surface 12a is shown as having texture. In net effect, any first and second of the plurality of rectangular solid panels 12 disposed one above the other, one has a lower surface 12d that is disposed directly above the upper surface 12c of the other.
The support framework 14 consists of two side rigid structural support members 16,16′, left and right respectively, disposed between an elongated top rigid support member 18 and an elongated bottom rigid support member 20. A plurality of vertical support members 22 are also disposed between the elongated bottom support member 20 and the elongated top support member 18. Each of the rigid support members can be constructed of steel angle, a box section, an I-beam, or a channel made for example of a rigid material such as steel. Although the term steel is used herein to describe a material used in the construction of parts of the preferred embodiments, it is also within the terms of the present embodiments to use other materials including but not limited to other metals such as aluminum, bronze and brass and other non-metallic materials such as for example reinforced plastics.
FIG. 1B is a sectional side view in the direction of A-A of FIG. 1A showing one vertical member 22 to which are slidably attached support clips 24 that both carry the weight of the panels 12 and also restrain and stabilize the top edges 13 of the panels. The vertical supports members 22 are attached to the top and bottom steel angles 18,20, respectively, by way of a segment of angle steel segment 26 that is bolted or welded to the respective parts 18,22.
FIG. 2A is a straight-on view of one arrangement of the support framework 14, with the decorative panels 12 removed, including four vertical steel supports 22 and support clips 24,25,27. Each vertical support 22 has an upper end 22a, which connects to the upper elongated support member 18, and a lower end 22b, which connects to the lower elongated support member 20. Note support clips 25 disposed on the left side 16 (as shown in FIG. 2A) and support clips 27 on the right side 16′. Support clips 25,27 are called side support clips, left and right respectively, and they are different from the bilateral clips 24 in a way that is described hereinbelow, in relation to FIGS. 5A,5B, which illustrates the left-side support clip 25, with right-side support clip 27 being a mirror image of clip 25. The structural support 14 is comprised of top member 18, bottom member 20 and left and right side members 16,16′, respectively. The top and bottom members 18,20 are made of steel angles that are secured to the ceiling and floor (not shown), respectively. The steel angles 18,20 have dimensions in the range of 7×7 cm to 8×8 cm, with thicknesses in the ranged of 5 to 8 mm. The side members 16,16′ are box section steel measuring in the range of 7×7 cm to 8×8 cm. The vertical steel supports 22 are about 7 to 8 cm wide and about 5 to 8 mm thick.
Two main support clips 24 are shown mounted upon a vertical support 22 in FIG. 3 and in oblique top and bottom views in FIGS. 4A and 4B. Each clip 24 comprises a front portion 32 and a body portion 34. The front portion 32 is made of 3 to 4 mm steel or similar material; it projects horizontally outward from the vertical support member 22, the plane of the flat front portion being perpendicular to the vertical support member. Holes 42 receive guide pins 43, which are not shown in FIGS. 4A and 4B. The body portion 34 consists of a front end 36, a back end 38 and two sides 40. The body portion 34 of each of support clip 24,25,27 includes a rectangular passageway 41 through which one of the vertical support members 22 is slidably received and thence locked into place by at least three cone-point set screws 30 which, in combination with the body portion, are a locking structure for securing the support clips 24,25,27 to desired locations on the vertical support members, which are received therethrough. The parts 34,36,40 of the body portion 34 are made of 6 to 7 mm steel or similar material, and they are secured to one another by bolts, welding, or silver solder. The front portion 32 and the body portion 34 are welded to one another in the junction 33. A rectangular buttress 44, made of 3 to 4 mm thick steel, is welded to the front portion 32 and the front face 35 of the body portion 34. The buttress 44 provides bending moment support between the front portion 32 and the body portion 34, given that the front portion carries the substantial weight of the decorative panel 12 disposed immediately above and which necessarily imposes a bending moment upon the region of the connection 33 between the front portion and the body portion. A cone point set screw 30 is shown in the approximate middle of the visible side 40. One such cone point set screw 30 is shown in each of the FIGS. 4A and 4B. There are at least three cone-point set screws 30 in each clip 24, comprising a locking support structure, secure each support clip to a desired location on a vertical support member 22 which is received therethrough. The cone point set screws 30 secure the clips 24 in vertical position on the vertical members 22. The set screw 30 shown in each of FIGS. 4A and 4B have corresponding screws that are not shown in the respective sides that are out of view, though, of course, the two respective views or FIGS. 4B and 4B show each of two different cone point set screws. Also, out of view in FIGS. 4A and 4B, is a rear cone point set screw disposed approximately in the center of the back end 38. All three cone-point set screws are shown, in partially blocked views, as 30,30′, and 30″ in FIG. 6A.
The left-side side clip 25 design is illustrated in oblique top and bottom views in FIGS. 5A and 5B. Each side clip 25 comprises a front portion 32′ and a body portion 34. The single difference in design between the side clip 25 and the main clip 24 is that a one wing 35 (shown in FIG. 4A as a shaded region) of the top portion 32 of the main clip 24 has been removed so that the side clips are able to abut, in an aesthetic way, the left side member 16 of the frame work 14, as shown in FIG. 2A. Thus the top portion 32′ of the side clip 25 is the only portion of the side clip that is different from the design of the main clip 24. In all other respects, the design of the side clip 25 is the same as that of the main clip 24.
The right-side support clip 27 is not shown in detail but its location in relation to the right side member 16′ is shown in FIG. 2A. In design, the right side support clip 27 is a mirror image of the left side support clip 25.
FIG. 6A shows the main clip 24 in orthogonal top view. FIG. 6B shows the main clip 24 in orthogonal bottom view. FIG. 6C shows the main clip 24 in orthogonal side view. And FIG. 6D shows the main clip 24 in orthogonal front view. Note that the ends of the three cone type set screws 30,30′,30″ are partially visible in FIGS. 6A and 6B inside the slot 41 that receives the vertical support member 22. The components of the clip are as delineated in FIGS. 4A and 4B, with the exception of two guide pins 43, each of which has a diameter of about 1 cm disposed in the holes 42 in the front portion 32 of the clip 24. Guide pins 43 can be constructed of any desirable material such as for example, metal, plastic, Delrin or wood. The designs of the left and right side support clips 25,27 differ from the design of the main clip 24 only with respect to, with respect to the left-side support clip 25, the shaded portion 35 of the front portion 32, as shown in FIG. 4A, and the corresponding side of the front portion in the case of the right-side support clip 27.
FIG. 7 shows, in an orthogonal bottom view, some characteristic dimensions A, B, C, etc, of an exemplary main support clip 24. The characteristic dimensions of the left and right side support clips 25.27 are the same as those of the main clip 24, given the exception of the only difference between the main clip and the side clips, as explained in reference to FIGS. 5A and 5B, i.e., with respect to the shaded portion 35 of the front portion 32, as shown in FIG. 4A. The ranges of dimensions are as follows, all dimensions are in centimeters:
A=7 to 8
B=7 to 8
C=1 to 2
D=8.5 to 9.5
E=9.5 to 10.5
F=1 to 1.5
G=0.5 to 1.0
H=2 to 3
I=2 to 3
J=1 to 1.5
K=1 to 1.5
L=1 to 1.5 Diameter
FIG. 8 is an orthogonal view of the junction of a vertical member 22 with the angle steel bottom portion 20 of the support framework 14. The vertical member 22 and the angle steel bottom portion 20 are secured to one another by way of two sides 50,52 of angle steel segment 26 which are bolted 60,62 or welded to the corresponding vertical members and the horizontal flange portion 20′ of the bottom portion. The junctions of the vertical members 22 with the top angle support member 18 are similar.
FIG. 9 shows, in cross sectional orthogonal side view, how the decorative panels 12 are supported by the front portion 32 of the clip 24, which is secured to the vertical member 22 by set screws 30. Also shown is one of the Delrin pins 43 that are disposed within the front portion 32 of the main and side clips 24,25. The guide pin 43 are received by two cylindrical blind bores 56a,56b in the panels 12, each bore have having a bottom 59a,59b, bottom and top respectively. Each bore 56a,56b has an axis 57 that is perpendicular to the upper and lower surfaces 12c,12d of each of the respective panels 12. Silicone setting blocks 54 serve to cushion each panel 12 against the front portion 32 of the clip 24. In use, at least one guide pin 43 projects through a front portion 32 of a clip 22 and is disposed between a cylindrical bore 56b in the lower surface 12d of a rectangular solid panel 12 and a cylindrical bore 56a in an upper surface 12c of a rectangular solid panel beneath it. That is to say, each cylindrical bore 56a in the upper surface 12c of a panel 12 and each cylindrical bore 56b in the lower surface 12d of a panel above is a blind bore with a bottom surface 59a,59b adapted to be engaged by one end of a guide pin 43.
FIG. 2B is a detail partial view of one version of the embodiment 10, with emphasis of one plurality of three rectangular solid decorative panels 12 designated as 12x,12y,12z disposed upon a plurality of, as shown, two vertical support members 22x,22y, and a second plurality of three rectangular solid decorative panels 12x′,12y′,12z′ disposed upon a plurality of two vertical support members 22y,22z. Also shown in FIG. 2B are at least three support clips 24a′,24b′,24c′ slidably attached to one of the vertical support members 22 and at least three support clips 24a″,24b″,24d″ slidably attached to an adjacent vertical support member 22. Each of the support clips 24a′, 24b′, 24c′, 24a″, 24b″, 24d″ has at least one guide pin 43 extending vertically through the front portion of each of the support clips. Each of the plurality of rectangular solid panels 12x,12y,12z has at least two cylindrical bores 56a on an upper surface 12c and at least two bores 56b on a lower surface 12d, each adapted to receive one of the guide pins 43 whereby a first rectangular solid panels 12x is secured between a first set of two vertically adjacent support clips 24a′,24b′ and a second set of two vertically adjacent support clips 24a″,24b″ disposed respectively on the vertical support members 22x,22y; a second rectangular solid decorative panels, 12y, is secured above the first rectangular solid panel between the first set of two vertically adjacent support clips 24b′,24c′ and a second set of two vertically adjacent support clips 24b″,24c″; and a third rectangular solid decorative panel, 12z, is secured above the second rectangular solid panel between the a first set of two vertically adjacent support clips 24c′,24d′ and a second set of two vertically adjacent support clips 24c″,24d″. Note that the first and second of the plurality of rectangular solid panels, consisting here of two rectangular solid panels 12x,12y, are disposed so that the lower surface 12d of the second or upper rectangular solid panel 12y is disposed directly above the upper surface 12c of the first or lower rectangular solid panel, and that the second and third of the plurality of rectangular solid panels, consisting here of two rectangular solid panels 12y,12z, are disposed so that the lower surface 12d of the third or upper rectangular solid panel 12z is disposed directly above the upper surface 12c of the second or lower rectangular solid panel 12y.
Continuing with the detail view illustrated in FIG. 2B, the third of the plurality of rectangular solid decorative panels, 12z, is shown disposed above the second rectangular solid panel 12y so that the lower surface 12d of the third rectangular solid panel is disposed directly above the upper surface 12c of the second rectangular solid panel, and the blind bores 56b in the lower surface of the panel 12z are disposed directly above the corresponding blind bores 56a in the upper surface 12c of the second panel 12y, the axes 57 of the respective blind bores being collinear.
Yet further illustrated in FIG. 2B is the wall system 10 configured for mounting a plurality of rectangular solid panels 12x,12y,12z. The system includes a plurality of vertical support members 22x,22y and at least three sets of two support clips 24a′,24a″; 24b′,24b″; 24d′,24c″ that are slidably attached to first and second adjacent vertical support members 22x,22y. Each of the support clips 24a′,24a″,24b′,24b″,24c′,24c′ has a front portion 32 which projects horizontally outward from the vertical support members and at least one guide pin 43 extending vertically through the front portion of each support clip. Each of the plurality of rectangular solid panels 12x,12y,12z has at least two cylindrical bores 56a on its upper surface 12c and at least two cylindrical bores 56b on its lower surface 12d, each cylindrical bore being adapted to receive one of the guide pins whereby the first of the rectangular solid panels 12x is secured upon first and second adjacent support clips 24a′,24a″ on the first and second adjacent vertical support members (22x,22y) and beneath the third and fourth support clips 24b′,24b″ on the first and second vertical support members, and a second of the rectangular panels 12y is secured upon the third and fourth support clips on the first and second vertical support members and beneath fifth and sixth support clips (24c′,24c″) on the first and second vertical support members.
FIG. 2B yet further shows a third vertical support member 22z having a plurality of support clips 24a′″,24b′″,24c′″,24d′″and a plurality of rectangular solid panels 12x′,12y′12z′ disposed one above the other and secured between the second and the third vertical support members 22y, 22z by the support clips 24a″, 24b″, 24c″, 24d″, 24a′″,24b′″, 24c′″, 24d′″.
Assembly Of The Wall System
The present decorative internal wall system 10 can be installed as a free-standing wall, anchored to the floor and ceiling, by a method of mounting a plurality of rectangular solid panels 12 upon a framework 14 having a plurality of vertical support members 22. Or it can be installed over an existing internal wall, in which case it might be secured to the existing wall as well as to the floor and ceiling.
If it is installed as a free-standing wall, the main frame parts 14,22 can be assembled, including being welded, offsite and brought into position such that the upper part of the frame 18 is anchored to the ceiling while the lower frame part 20 is anchored to the floor. The lowest set of slidable main clips 24 and end clips 25 can then be positioned and secured with the three cone-pointed set screws 30,30′,30″. The first course of decorative panels 12′ (FIG. 1A) is then set in place, one at a time, upon the respective clip pairs in such a way that the corresponding upper clips can be brought into place with their corresponding pins 43 can be received by the bores 56a,56b in the panels, and thus held in place. The panels 12 are all installed, one at a time, until the job is complete.
If it is not possible to assemble the main framework 14 offsite, then it can be assembled in situ. The upper and lower portions 18,20 of the framework 14 are fastened to ceiling and floor, leveled and aligned. The vertical members 22 are then cut to size and fitted with clips 24,25, and then welded or bolted into place using angle steel members 50. Assembly then follows the same sequence as described above.
If the internal wall system 10 is to cover an existing wall, then the procedures are as above, except as allowance might be made to secure the framework 14 to said existing wall.
Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, certain equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, etc.) the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more features of the other embodiments as may be desired and advantageous for any given or particular application.
Patent Application
20130047540
