Patent Application
20210156145
The disclosed technology relates to methods of forming a temporary wall system, more specifically to a method of forming a temporary wall system by attaching a track to floor and ceiling, forming wall panels, and mounting the wall panels on the track.
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. These walls provide a safe environment while the renovation or remodeling project is in progress. They may also block dust and noise from entering public spaces on the other side of the wall. Typically, temporary walls or partitions are constructed on site using traditional building materials, such as lumber and drywall or plywood. This is costly, time-consuming and creates debris. Additionally, such temporary walls are difficult to reuse after no longer being needed at a particular location.
Accordingly, there is a need for a method of constructing a temporary wall system that is significantly less time-consuming, requires less materials, creates significantly less debris, is easy to disassemble, and is reusable.
Disclosed herein is a method of forming a temporary wall system, including attaching a track to a floor and ceiling, attaching a first cover panel to a front surface of a plurality of insulation layers, attaching a second cover panel to a rear surface of the plurality insulation layers to form a singular wall panel. The plurality of such singular wall panels are connected, to each other via a tongue and groove system to form a wall that spans the length of the track, and then mounted onto the track. In one embodiment, the track includes a width substantially equal to the width of the wall, such that the track supports the wall therein in an upstanding position.
In some embodiments, the method includes first mounting each singular wall panel onto the track and then attaching each of the plurality of wall panels to each other via the tongue and groove system while on the track to form the wall.
In some embodiments, the track is attached to the floor and ceiling of an area by mounting the track onto the floor and fastening the track with fasteners.
In some embodiments, the first cover panel is sprayed on the entire surface, or substantially the entire surface, of one side with a bulk spray adhesive, the front surface of each of the plurality of insulation layers is also sprayed with a bulk spray adhesive. These are then attached to each other.
In some embodiments, the second cover panel is sprayed on the entire surface of one side, or substantially the entire surface, with a bulk spray adhesive, the rear surface of the plurality of insulation layers (attached to the first cover panel) is sprayed with a bulk spray adhesive. These second cover panel is then attached to the rear surface of the plurality of the insulation layers.
In some embodiments, each of the plurality of insulation layers includes a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer.
In some embodiments, the first cover panel and the second cover panel each include a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side. The tongue and groove are complimentary in that they mate and fasten with each other.
In some embodiments, the plurality of wall panels are attached to each other by joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel in sequential fashion and joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel in sequential fashion. The joining of the plurality of wall panels to each other forms the wall.
In some embodiments, the wall is mounted on the track by sliding the wall into the track such that the wall is coextensive with the track.
For purposes of this disclosure, the following definitions are used. “Temporary” is defined as “being designed to be constructed and deconstructed multiple times without structural damage.” “Mount” is defined as “place or fix an object or item in its operating position, and/or to attach the object or item to a support, and/or to arrange the object or item for use or display” “Track” used interchangeably with “rail” and “channel”, is defined as “a receptacle that provides a path on which another object slides along an axis of movement, such as a horizontal axis, the receptacle forming a frame for a wall.” “J-track” is defined as “a track including a pair of side walls or legs, wherein a first side wall includes a height that is less than a height of a second sidewall.” A “wall” is a “partition which partially or fully separates a space into two spaces, at least, where the wall is situated.” “Panel” is defined as “a resilient flat or curved planar structure that forms part of a wall, and/or a board set to cover a part or all of an exterior side of a wall, and/or is co-planar with a wall.” “Insulation” is defined as “material designed by a manufacturer or installer thereof to insulate (prevent passage of heat and/or cold) a wall or room within a building.” “Layer” is defined as “one of a plurality of separable like-kind units.” “Cover” is “a layer thinner than an insulation layer sized to fit over, or substantially fit over, a largest plane of an insulation layer.” “Bulk Spray” is defined as “spray provided in a pressurized container, such as a cylinder, that comes in bulk.” “Coextensive” is defined as “equal or coincident in space or having the same spatial boundaries.” “Upstanding” refers to/is defined as “the positioning of an object or item such that the object or item is vertically or perpendicularly erect or upright relative to the floor.” “Adhesive” is defined as “any substance or material, such as glue, cement, mucilage, or paste, that when applied to one or both surfaces of two separate items binds the surfaces together and resists their separation.”
Any device or step to a method described in this disclosure can comprise or consist of that which it is a part of, or the parts which make up the device or step. The term “and/or” is inclusive of the items which it joins linguistically and each item by itself. “Substantially” is defined as at least 95% of the term being described and/or “within a tolerance level known in the art and/or within 5% thereof. Any device or aspect of a device or method described herein can be read as “comprising” or “consisting” thereof.
The present disclosed technology provides a method of forming a temporary wall system by mounting a track onto a floor and/or ceiling, attaching cover panels to front and rear surfaces of insulation layers to form wall panels, attaching the wall panels to each other via tongue and groove systems disposed on the cover panels to form a wall, and mounting the wall on the track. The method provides an efficient means for erecting a temporary wall that is both easy to assemble and disassemble, which significantly increases reusability.
Referring now to the Figures,
Referring now to
In one embodiment, the track 200 is attached to a floor and/or ceiling of an area by mounting the track 200 onto the floor and then fastening the track to the floor with fasteners 205, as shown in
In some embodiments, the track 200 comprises an elongated track including a first side wall 210 and a second side wall 215. The first side wall 210 and the second side wall 215 define a rectangularly shaped groove 220 therebetween that extends longitudinally through the entirety of the elongated track. In embodiments, the track comprises a J-track, wherein the second side wall 215 includes a height greater than a height of the first side wall 210 for providing added support to the wall 225 and/or plurality of wall panels 230 mounted therein, as shown in
In some embodiments, the first cover panel 235 is attached to the front surface of each of the plurality of insulation layers 240 with a bulk spray adhesive 245, as shown in
In some embodiments, the second cover panel 250 is also attached to the rear surface of each of the plurality of insulation layers 240 with a bulk spray adhesive 245, as shown in
In some embodiments, each of the plurality of insulation layers 240 comprises a thermal insulation board 255 comprising a rigid cellular polyisocyanurate foam core disposed coextensively between a first foil facer and a second foil facer, as shown in
In some embodiments, the first cover panel 235 and the second cover panel 250 each comprise a first side including a tongue 260 extending along an edge of the first side and an opposing second side including a groove 265 extending along an edge of the second side, as shown in
In one embodiment, the first cover panel 235 and the second cover panel 250 are attached to a respective insulation layer such that the first sides of the first and second cover panels 235, 250 are parallelly aligned on a first side of a respective insulation layer, while the second opposing sides of the first and second cover panels 235, 250 are parallelly aligned on a second side of the respective insulation layer, as shown in
In another embodiment, the first cover panel 235 and the second cover panel 250 are attached to a respective insulation layer such that the first side of the first cover panel 235 and the second side of the second cover panel 250 are parallelly aligned on a first side of the respective insulation layer, while the second side of the first cover panel 235 and the first side of the second cover panel 250 are parallelly aligned on the second side of the respective insulation layer. Thus, each of the plurality of wall panels 230 has a tongue 260 and a groove 265 on a first side that are parallelly aligned and a tongue 260 and a groove 265 on a second opposing side that are parallelly aligned. In some embodiments, a second track 270 is mounted on the wall 225 to further secure the plurality of wall panels 230 to each other, as shown in
In embodiments, the temporary wall is formed first by attachment of the plurality of wall panels 50 and then is mounted onto the track by sliding the wall into the groove of track until the walls ends are coextensive with the tracks ends 60, as shown in
In other embodiments, the wall is formed by first sliding the plurality of wall panels into the track in sequential fashion 140, and then joining them via the tongue and grooves on the track 150, as shown by
While the disclosed technology has been taught with specific reference to the above embodiments, a person having ordinary skill in the art will recognize that changes can be made in form and detail without departing from the spirit and the scope of the disclosed technology. The described embodiments are to be considered in all respects only as illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. Combinations of any of the methods, systems, and devices described herein-above are also contemplated and within the scope of the disclosed technology.
