Wall panel

Information

  • Patent Grant
  • 6301847
  • Patent Number
    6,301,847
  • Date Filed
    Wednesday, June 21, 2000
    24 years ago
  • Date Issued
    Tuesday, October 16, 2001
    23 years ago
Abstract
A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface. The sidewalls are positioned on opposite sides of the core in the fixture and engage the second surface. The sidewalls are attached to the core member. A method for making the panel includes providing a fixture. The frame members are inserted in the fixture so that each one engages a fixture surface. A wall member is mounted on each side of the frame, with a filler member disposed inside the frame between the wall members.
Description




BACKGROUND OF THE INVENTION




The present invention relates generally to a wall panel system, and in particular, to an improved wall panel, components therefore and a method for making the wall panel.




Panel systems are commonly used to divide large, open office space into separate work spaces. For example, Herman Miller, Inc., the assignee of the present application, manufacturers and sells two such work space management systems: the ACTION OFFICE® system and the ETHOSPACE® system. Often, wall panels arranged in such systems include an internal frame with a sheet of wall board or comparable material attached to the side of the frame. Typically, the frame is made from roll-formed or extruded metal, with the wall board adhesively secured to the side of the metal frame members. Each side of the wall panel usually is covered with a fabric that is either bonded to the frame, or attached with an elastic band, so as to provide an aesthetically pleasing appearance to the user.




Adjacent wall panels in the system typically are connected to one another with a variety of connector assemblies. For example, wall panels placed end-to-end commonly are connected to each other, while wall panels oriented perpendicular to each other in a two-way, three-way or four-way configuration typically are connected to a corner post located at the junction of the intersecting panels. Typically, a cover is attached to those sides of the corner post not connected to a wall panel so as to provide an aesthetically pleasing surface that matches the surface of the adjacent panels.




Wall panels often are provided with wire management capabilities, typically including horizontal wire channels positioned at the top and bottom of the panel. Wall panels may also include vertical channels, typically formed by the vertical frame members, that extend between the top and bottom of the panel. Typically, wall panels having a horizontal channel at the top of the panel also provide a top cap to cover the channel. When a corner post is interposed between panels, a cap also is installed on top of the corner post to provide a continuous, unbroken line across the top of a system of wall panels.




Wall panels may also include power distribution systems, whereby the wall panels can be electrically connected so as to provide the user with access to power in each work space created by the system of wall panels.




SUMMARY OF THE INVENTION




Briefly stated, one aspect of the invention is directed to an improved wall panel. The wall panel includes a rectangular frame, a pair of sheetlike wall members and two thin decorative sheets. The rectangular frame includes two spaced apart, and generally parallel vertical side frame members and spaced apart and generally parallel horizontal lower and upper frame members. The frame members are connected at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The sheetlike wall members, preferably made of fiberboard, have an inner surface attached to the side walls of each frame member.




The thin decorative sheets, preferably cloth, cover the outer surface of the wall members on each side of the panel.




In a preferred embodiment, the sidewall members include a substantially flat leg portion having an inner surface attached to the core member and an outer surface attached to the wall member. The sidewall member includes an edge portion extending laterally outward from the leg portion. Preferably, the edge portion is configured as a C-shaped channel facing inwardly away from the wall panel surface. When the frame members are assembled into a rectangular frame, the edge portions extend around the periphery of the wall panel. The sidewalls, including the edge portions, form a shallow recess on opposite sides of the panel. Each recess has a bottom surface defined by the outer surface of the leg portions. The wall members are received in the recesses on opposite sides of the panel.




In another aspect of the invention, a thin barrier sheet, or scrim, is disposed between the decorative sheet and the outer surface of the wall member as a fire blocking member. The barrier sheet preferably includes a thin aluminum foil layer laminated to a fiberglass layer.




The wall panel also includes an inner filler member disposed between the wall members. The filler member extends between the upper and lower horizontal frame members. Preferably, the inner surface of the wall members are attached to the filler member.




In a preferred embodiment of the invention, the sidewall members on the upper horizontal frame member extend upwardly from the upper core member to form a horizontal channel running substantially the length of the wall panel. The bottom of the channel is defined by the upper surface of the upper core member and the sides of the channel are defined by the upwardly extending sidewall members. A top cap is releasably secured to the upper frame member to cover the channel.




In one aspect of the invention, the wall panel also includes at least one vertical channel communicating with the upper horizontal channel and a bottom portion of the wall panel. Preferably, the vertical channel is defined by an inner surface of one of the vertical core members, a partition member spaced apart from the inner core surface of the vertical core member and the inner surface of the wall member. Preferably, the partition member extends between the inner surfaces of the opposing wall members and is attached to at least one of the wall members. The partition member also extends substantially between the upper and lower frame members.




In another aspect of the invention, a power distribution system is provided at the base of the wall panel. The power distribution system includes a power distribution server, including a harness and a module receptacle, which is attached to a bottom of the lower frame member. The power distribution system is adapted to be electrically connected with power distribution systems located in adjacent panels. In addition, an outlet box is attached to one of the inner surfaces of the wall members between the upper and lower frame members. The other wall member has an opening provided to allow access to the outlet box. The outlet box is electrically connected to the power distribution system with an electrical conduit disposed in the vertical channel.




In another aspect of the invention, a plastic strip is attached to the decorative sheet at each of its edges. The strip includes a first hook member that is adapted to engage the edge portion of the sidewall member. Preferably, the strip also includes a second hook member that is adapted to receive a tool member which can be used to stretch the decorative sheet between opposing frame members while simultaneously disposing the first hook member on the edge portion of the side wall.




In another aspect of the invention, wall panels placed end-to-end are attached using an upper and lower draw block that engage hanger brackets attached to the ends of the wall panels. A draw rod operably engages the draw blocks which pull the hanger brackets and corresponding panels together.




In yet another aspect of the invention, a corner post is provided for connecting two or more panels at 90°. The corner post includes an elongated tube having a pair of inwardly facing channels formed on each side of the tube. A plate member is secured inside each end of the tube; the upper plate having a threaded hole in the middle of the plate.




The corner post is provided with a height adjustable cap which includes a post member and a cover member supported by the post member. The post member threadably engages the hole in the upper plate and can be rotated to adjust the height of the cover. In this way, the cover can be raised or lowered to provide a smooth transition between adjacent wall panel top caps.




In another aspect of the invention, an outwardly facing groove is formed in each corner of the tube. A cover has diagonally oriented beaded portions. The cover is attached to the corner post by releasably engaging two of the corner grooves with the beaded portions. The post cover is used to cover those sides of the corner post not connected to a wall panel, thereby providing an aesthetically pleasing appearance.




In another aspect of the invention, a method is provided for manufacturing the vertical side frame members. In particular, the method includes providing a core member, a pair of sidewall members each having an edge portion, and a hanger bracket. The hanger bracket is attached to the core member. The core member and attached hanger bracket are then positioned in a fixture such that the hanger bracket engages a first surface of the fixture. The sidewall members are positioned in the fixture on both sides of the core member such that the edge portion of each sidewall member engages a second and third surface of the fixture, respectively, positioned predetermined distances from the first surface. The sidewall members are then attached to the core member.




A similar method is provided for making the upper and lower horizontal frame members, wherein the fixture surfaces are positioned to support the edge portion of the sidewall members and the outer surface of the core member.




A method also is provided for manufacturing the improved wall panel. In particular, one of the sheetlike wall members is placed in a fixture. The side frame members and upper and lower horizontal frame members also are positioned in the fixture. The wall member fills the recess formed by the sidewall members on one side of the rectangular frame. Adhesive is applied to one of the sidewall members and wall member before the frame is disposed on the wall member. Adhesive also is applied to both sides of the filler member. One or more partition members is adhesively attached to the inner surface of the wall member so as to form a vertical channel with the inner surface of one of the side core members. The filler member is inserted into the space formed by the frame members and the partition members. The second sheetlike wall member is then disposed in the recess on the opposite side of the frame. The wall members are attached to each frame member with mechanical fasteners. A decorative sheet and barrier sheet are secured over the outer surface of each wall member.




The present invention provides significant advantages over other wall panel systems and methods of manufacture. In particular, the three-piece frame member construction, i.e a pair of sidewall members attached to a core member, yields a simple, inexpensive structural part that provides several advantages over roll-formed or extruded metal channels. By using a wood core member, the side wall members can be easily attached to the core with staples, rather than by welding or other more expensive methods of manufacture. Similarly, the wall members can be stapled directly to the frame members, as well as adhesively secured, so as to improve the strength of the panel. In addition, various accessories, such as the power distribution server, can be easily mounted to the bottom of the panel with wood fasteners, without providing mounting holes in the lower frame member. Moreover, the wood can be easily cut to length for each frame member, or shortened so as to provide access to the vertical channel, without wasting material or making complicated cuts or stampings in the sheet metal.




Also important, the three-piece frame member construction allows the manufacturer to provide precise dimensions between the outermost surface of the hanger bracket and the outermost surface of the side wall members. This dimension is critical when two panels are installed adjacent to each other. For example, when two panels are connected, the adjacent hanger brackets are pulled together by a wedge block, as explained below. When connected in this manner, the panel-to-panel interface, or joint between the panels, is defined by the distance between the adjacent outer surfaces of opposing edge portions covered with fabric. Thus, by maintaining the distance between the outer surface of the edge portion and the hanger bracket as a constant, the joints at each panel interface are kept constant, ie., have the same gap between panels. Moreover, when a wall panel has a thicker fabric installed around the edge portions, the distance between the edge portion and hanger bracket can be increased so that the gap between panels, when connected, remains the same, regardless of the fabric thickness.




The vertical channel also provides significant advantages. For example, wires can be easily routed from the top of the panel to the bottom. The channel also provides ideal passage for the electrical conduit running from the outlet box installed inside the panel. In addition, because the channel is inside of the frame and adjacent to the box, rather than on the outside of the frame, the frame member does not have to be pierced in order to rout the wiring to the outlet box. Moreover, wires disposed in the channel are not exposed when the panels are disconnected and cannot therefore be caught or hooked by the panel-to-panel connectors.




The improved corner post also provides significant advantages over similar devices. For example, the corner post cover is height adjustable, so that it can be adjusted to provide a continuous line across the top of a system of panels. Moreover, the grooves provided in the corner post tube provide a simple but efficient way to attach covers, whether they be flat, or formed at 90°. As such, the orientation of the tube is irrelevant to the placement of connecting panels and/or post covers. Because the tube is symmetrical, the cover and panels can be arranged in any configuration, without having to reorient the tube member.




Yet another significant advantage is the method of fabric attachment. In particular, the double-hook strip configuration allows an installer to use a tool to install the fabric. As such, the installer can apply a considerable force to tightly stretch the fabric between opposing frame members to thereby provide a smooth and pleasing appearance. Moreover, the releasable hook allows the user to easily replace the fabric if it becomes damaged or if a color change is desired. The new fabric can be installed quickly and easily without adhesives or difficult to install elastic bands that run around the periphery of the wall panel. Indeed, adjacent panels need not even by disconnected in order to install a new sheet of fabric, thereby avoiding the task of disassembling the panels.




Finally, the wall panel construction lends itself to improved manufacturability and overall quality. Most importantly, as described above, each frame member can be made with extremely tight tolerances so that the gap between panels is maintained as a constant when the wall panels are assembled as a system. Moreover, by locating the frame members to outside dimensions in the fixture, the overall panel construction is improved by providing extremely tight tolerances for the height and width of each panel. The improved quality associated with this method of manufacture in turn facilitates and eases installation of the panels while providing an improved overall look for the system.




The present invention, together with further objects and advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is an exploded perspective view of the wall panel.





FIG. 2

is an exploded perspective view of the wall panel with a top cap, base cover and power distribution system.





FIG. 3

is an exploded view of a wall panel end cover.





FIG. 4

is an exploded view of a corner post configuration.





FIG. 5

is an exploded view of an alternative embodiment of a corner post configuration.





FIG. 6

is an enlarged perspective view of a panel-to-panel light seal.





FIG. 7

is an enlarged exploded view of a corner post cap.





FIG. 8

is a side view of a wall panel.





FIG. 9

is an end view of a wall panel with the power distribution server omitted.





FIG. 10

is a cross-sectional view of the wall panel taken along line


10





10


of FIG.


8


.





FIG. 11

is a cross-sectional view of the wall panel taken along line


11





11


of FIG.


8


.





FIG. 12

is a bottom view of the wall panel taken along line


12





12


of

FIG. 8

, with the power distribution server omitted.





FIG. 13

is a perspective view of the power distribution bracket.





FIG. 14

is a cross-sectional view of the wall panel taken along line


14





14


of

FIG. 8

with the power distribution server not shown.





FIG. 15

is a cross-sectional view of the wall panel taken along line


15





15


of FIG.


8


.





FIG. 16

is a cross-sectional view of the wall panel taken along line


16





16


of FIG.


8


.





FIG. 17

is a cross-sectional view of the wall panel taken along line


17





17


of FIG.


8


.





FIG. 18

is a partial perspective view of the top cap.





FIG. 19

is an exploded perspective view of two wall panels placed end-to-end without the fabric installed.





FIG. 20

is a side view of two wall panels connected together without the fabric installed.





FIG. 21

is a side view of the fabric sheet.





FIG. 22

is a cross-section of the strip attached to the fabric.





FIG. 23

is a cross-section of an alternative embodiment of the strip attached to the fabric.





FIG. 24

is a side view of the inside corner of the upper horizontal channel.





FIG. 25

is a perspective view of the power distribution server.





FIG. 26A

is a top view of a wall panel junction showing a three-way connection of power distribution servers located in the adjacent wall panels.





FIG. 26B

is a top view of a wall panel junction showing a two-way connection of power distribution servers located in the adjacent wall panels.





FIG. 26C

is a top view of a wall panel junction showing a four-way connection of power distribution servers located in the adjacent wall panels.





FIG. 27

is a top view of the power distribution server.





FIG. 28

is a perspective view of the upper and lower draw blocks.





FIG. 29

is a perspective view of an alternative configuration of the upper and lower draw blocks.





FIG. 30

is a perspective view of an alternative configuration of the upper and lower draw blocks.





FIG. 31

is a side view of two wall panels connected to a corner post.





FIG. 32

is a top cross-sectional view of three wall panels connected to a corner post.





FIG. 33

is a top cross-sectional view of two wall panels connected to a corner post.





FIG. 34

is a perspective view of a corner post base cover.





FIG. 35

is a perspective view of a draw rod and draw blocks engaging a corner post.





FIG. 36

is a perspective view of a draw rod with a partial end cover.





FIG. 37

is a side view of a draw rod and draw blocks engaging a corner post.





FIG. 38

is an exploded side view of different height wall panels with a draw rod and draw blocks interposed between the panels.





FIG. 39

is a partial inner perspective view of a draw rod with a partial end cover.





FIG. 40

is a partial outer perspective view of a draw rod with a partial end cover.





FIG. 41

is an exploded perspective view of a hanger bracket mounted on a permanent wall.





FIG. 42

is a partial cross-sectional view of the hanger bracket mounted on a permanent wall.





FIG. 43

is a perspective view of a brace member installed on a wall panel.





FIG. 44

is a side view of a brace member installed on a wall panel.





FIG. 45

is a perspective view of a brace member.





FIG. 46

is a perspective view of a fabric installation tool.





FIG. 47

is a top view of the fabric installation tool engaging a fabric sheet on a wall panel.





FIG. 47A

is an partial enlarged view of an installation tool with an alternative blade configuration.





FIG. 48

is a perspective view of an alternative embodiment of the fabric installation tool.





FIG. 49

is a top view of the fabric installation tool of

FIG. 44

engaging a fabric sheet on a wall panel.





FIG. 50

is a perspective view of a vertical side frame member tool fixture.





FIG. 51

is an end view of the side frame tool fixture with a side frame member installed therein.





FIG. 52

is a schematic of an automated took fixture for assembling the side frame member.





FIG. 53

is a perspective view of a upper and lower frame member tool fixture.





FIG. 54

is an end view of the upper frame tool fixture with an upper frame member installed therein.





FIG. 55

is a perspective view of the wall panel assembly fixture.





FIG. 56

is a side view of a dual staple gun engaging a wall panel installed in the wall panel assembly fixture.





FIG. 57

is a perspective view of a end cover support bracket.





FIG. 58

is an end view of a wall panel with a power distribution server attached to the bottom of the wall panel as taken along line


58





58


of FIG.


31


.





FIG. 59

is a bottom perspective exploded view of a wall panel and power distribution server.











DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




Referring to the drawings,

FIG. 1

shows an improved wall panel


10


including a rectangular frame


12


, a pair of sheetlike wall members


120


and a pair of thin decorative sheets


130


. The frame


12


includes two spaced apart, and generally parallel vertical side frame members


14


and spaced apart and generally parallel horizontal lower and upper frame members


18


,


16


.




Each frame member


14


,


16


,


18


includes an elongated core member


28


,


30


,


32


and a pair of elongated sidewall members


34


,


36


,


38


. Preferably, the core member is made of wood. As used herein, the terms “wood” and “wooden” are intended to have relatively broad meanings, including but not limited to, solid wood and wood products, such as particle board, fiber board and laminated strand lumber.




Most preferably, the side core members


28


are made of laminated strand lumber, such as the


38


# density material available from TrusJoist/MacMillan Ltd. Partnership in Deerwood, Minn. The horizontal core members


30


,


32


preferably are made of


45


# density particle board. Alternatively, other materials, such as foamed polymers or composites, may be used.




Each sidewall member


34


,


36


,


38


includes a substantially flat leg portion


42


,


54


,


56


and edge portion


40


,


58


,


60


respectively. The edge portion


40


,


58


,


60


extends laterally outward from the leg portion


42


,


54


,


56


. Preferably, the sidewall members are made from


12


gauge steel sheet metal and are roll formed. However, it should be understood that other materials, such as plastic could also be used. Each leg portion has an inner


44


,


45


,


43


and outer surface


46


,


47


,


49


; the inner surface


44


,


45


,


43


engages the side surface of the core member. Preferably, the inner surface


44


,


45


,


43


is mechanically fastened to the side


52


,


53


,


57


of the core member, for example, by using staples


700


, as shown in FIG.


16


. Alternatively, adhesive, nails, rivets or screws can be used to secure the sidewall member to the core member.




As shown in

FIG. 1

, the sidewall members


34


of each vertical frame member include an end portion


68


that extends upwardly past the top end


20


of the side core member


28


along the longitudinal direction of the vertical frame member


14


. The upwardly extending end portions


68


of the sidewall members


34


overlap the sidewall members


36


of the upper frame member


18


, which include leg portions


54


that extend upwardly from the upper frame core member


30


. Each end of the upper frame member sidewall members


36


includes a flange portion


580


stepped inwardly from the leg portion


54


, as shown in

FIGS. 1 and 2

. The flange portion


580


extends from and is integrally formed with the leg portion. The upwardly extending end portions


68


overlap and are attached to the corresponding stepped flange portions


580


and the wall member


120


, preferably with mechanical fasteners. Because the flanged portion


580


is stepped inwardly, the outer surfaces


46


,


49


are flush. The edge portion


58


of the upper frame member and the edge portion


40


of the vertical frame are mitered at approximately 45° at the point of intersection in order to form a corner.




As shown in

FIGS. 1

,


2


,


9


and


10


, an elongated hanger bracket


70


is mounted to the outer surface


50


of each vertical core member. The hanger bracket


70


includes two spaced apart, inwardly facing channels


72


connected by a bridge portion


74


that is fastened to the core


28


, preferably with a plurality of fasteners


540


. Fasteners


542


also secure each end of each channel


72


to the core member


28


. Each channel


72


has an inner leg


76


, an outer leg


78


and an outer surface member


82


. The inner legs


76


of the channels and the bridge portion


74


form an outwardly facing channel


300


. The outermost comers


84


on each bracket, formed by the intersection of the outer leg and the surface member, have a plurality of slots


86


running the length of the hanger bracket. The outer surface member


82


of the inwardly facing channels


72


defines the outermost surface of each end of the wall panel. The slots


86


in the hanger bracket are adapted to receive and support various components attached to the wall panel. For example, overhead units and worksurface bracket supports, not shown in the Figures, typically engage the wall panel at the slots. For example, a cantilever bracket assembly adapted to engage the hanger bracket is described in U.S. Provisional Application Serial No. 60/019,285, entitled CANTILEVER BRACKET ASSEMBLY and filed Jun. 7, 1996, the disclosure of which is hereby incorporated by reference.




As shown in

FIGS. 2

,


8


,


9


and


44


, the inner surface


43


of the upwardly extending sidewalls


36


on the upper frame member and the outer surface


62


of the upper core member


30


form a horizontal channel


88


which runs the width of the panel. At each end of the wall panel, the upper end


20


of the vertical side core member


28


lies substantially flush with, or slightly higher than, the outer surface


62


of the upper core member


30


so that wires, cables and the like can be passed easily from one panel to the next. In this way, the upper end


20


of the vertical core member


28


helps to define a portion of the bottom of the horizontal channel


88


.




As shown in

FIGS. 43-45

, a brace member


92


can be mounted at each end of the channel to provide additional support for the panel. The brace member


92


includes a pair of sidewall members


94


disposed along the inner surface


45


of the sidewall members. The brace member


92


also includes a bottom plate


97


attached to the end


20


of the core member and a second bottom plate


96


attached to the outer surface


62


of the upper core member


30


. It should be understood that the sidewall members can also be attached to the wall members. An opening


95


is provided between the plates to provide access to a vertical channel


108


. The brace member


92


provides additional support for loads applied laterally to the top or side of the panel. In particular, the brace member helps distribute the load between opposing wall members, the upper frame member and the vertical frame member.




As shown in

FIGS. 2

,


16


and


18


, the top portion of each sidewall leg portion on the upper frame members includes an inwardly facing ridge


98


that runs substantially the length of the upper frame member


18


. Intermittent openings


100


are provided along the top portion. The openings are provided to locate the sidewalls in various tool fixtures during the assembly of the frames and wall panel.




A top cap


110


is attached to the upper frame member


18


. The top cap


110


includes a pair of downwardly facing flanges


112


that have a ribbed portion


114


running the length of the flanges. The ribbed portion


114


engages the ridge


98


formed on the inside of each sidewall member and releasably secures the top cap to the upper frame member. Each of the flanges


112


also includes an edge portion


113


that is angled inwardly from the ribbed portion


114


. The edge portion


113


facilitates installation of the top cap by engaging the ridges on the upper frame member as the top cap is first inserted into the channel


88


. As the top cap


110


is pushed downwardly, the edge portions


113


slide along the ridge so that-the flanges are biased inwardly until the ribbed portion engages the ribbed portion


114


. The flanges


112


then spring back to their original position, as the ribbed portion releasably locks the top cap to the upper frame member. In this way, the top cap


110


covers and encloses the channel


88


.




In a preferred embodiment, the ends


102


of the upper core member are spaced apart from the ends


104


of the vertical core member to form an opening


106


between the members near each end of the panel as shown in FIG.


17


. These openings


106


provide access to a vertical channel


108


, or tube, that extends between the upper horizontal channel


88


and the bottom of the wall panel, as shown in

FIGS. 2

,


8


,


10


, and


11


. Each vertical channel


108


is formed and defined by the inner surface


48


of the vertical core member, a partition member


140


that extends between the upper and lower horizontal frame members


16


,


18


and the inner surface


122


of the wall member


120


.




The ends


103


of the lower horizontal core member are spaced apart from the lower end


105


of the vertical core members so as to provide access to the vertical channel


108


from the bottom of the panel as shown in FIG.


12


. In addition, the sidewall members


38


on the lower frame member extend outwardly past the end


103


of the core member along the longitudinal direction of the frame member, as shown in FIG.


1


. The sidewalls


34


are cut away at the lower end


105


of the vertical side core member to provide an exposed portion


550


of the side core member. The outwardly extending bottom sidewall members


38


overlap the exposed portion, and lie flush with the side frame sidewalls


34


. The edge portions


60


,


40


intersect and are mitered at approximately 45° to form a corner. The lower core member


32


also includes a groove


33


running the length of the core member along the middle of the outer surface


66


.




As shown in

FIGS. 10

,


14


and


16


, the edge portions


40


,


58


,


60


of each sidewall member are preferably configured as a C-shaped channel that runs the length of each side wall member. When the frame members are connected, the edge portions


40


,


58


,


60


run substantially around the entire periphery on each side of the panel. Each channel includes an inner leg


116


that extends laterally outward in a perpendicular relationship from the leg portion and an outer leg


118


that defines the outer peripheral edge of the wall panel. A intermediate surface member


124


connects the inner


116


and outer leg


118


. The surface member


124


is in substantially the same plane as the outer surface


126


of the wall member as shown in

FIGS. 14-16

. The inner leg


116


of the edge portion and the outer surface


46


,


47


,


49


of the sidewall leg portions


42


,


54


,


56


define a shallow, outwardly facing recess on each side of the frame. The recess is shaped to receive the sheetlike wall member


120


. Preferably, the wall member


120


substantially fills the recess and is bounded around its periphery by the inner legs


116


of the side walls.




As just described, each wall member is attached to one side of the frame with staples


702


, as shown in FIG.


16


. The wall members stabilize and strengthen the wall panel. Preferably, the wall member


120


is made of ½ inch thick fiberboard, such as the industrial insulation board available from Masonite in Lisbon Falls, Me., which is sanded, ironed and sealed. Preferably, the wall member


120


is tackable, so that a user can attach various items to the wall member with tacks, or the like. Other materials, such as particle board or mineral board are also acceptable. Preferably, the wall member


120


is both adhesively secured to the outer surface


46


,


47


,


49


of the sidewalls and is mechanically fastened to the core members


34


,


36


,


38


through the sidewall members, preferably by stapling. The overlapping portions of the sidewall members


34


,


36


of the vertical frame and the upper frame members are mechanically fastened to each other and to the wall member


120


from the inside out, preferably with screws


121


as described above and shown in

FIGS. 1

,


2


and


8


.




As shown in

FIGS. 1

,


8


and


10


-


11


, a filler member


150


is installed inside the rectangular frame


12


. The filler member


150


is disposed between the wall members


120


and each side of the frame, and extends between the upper and lower horizontal frame members


16


,


18


. In a preferred embodiment, the filler member


150


is a honeycomb structure made from corrugated cardboard. The honeycomb is adhesively secured to the inner surface


122


of each wall member. The honeycomb increases the strength of the panel and provides sound dampening for the panel. Preferably, the honeycomb filler member is bounded along each vertical end by the partition members


140


installed to form the vertical channels


108


. In this way, the vertical channels are separated from the honeycomb filler member.




The partition member


140


includes a mounting flange


142


and a boundary flange


144


as shown in FIG.


1


. Referring to

FIGS. 10 and 11

, the mounting flange


142


is adhesively bonded to the inner surface


122


of one of the wall members


120


. The boundary flange


144


extends between the two wall members


120


and can be attached to the side of the honeycomb filler member.




Referring to

FIGS. 1 and 2

, a thin barrier sheet


530


, or scrim, is disposed between the decorative sheet


130


and the wall member


120


. The barrier sheet


530


preferably includes a layer of aluminum foil laminated to a thin layer of fiberglass. The barrier sheet


530


is preferably about 0.005 inches thick and is used as a fire blocking material. A commercially available barrier sheet is the MANNIGLAS 1207® wet-lay glass fiber mat produced by Lydall Corporation. The barrier sheet can be attached to the wall member with adhesive or mechanical fasteners. Alternatively, the barrier sheet can wrap around the outer leg of the edge portion beneath the decorative sheet, which is attached to the leg with a strip member as described below.




Referring to

FIGS. 1 and 2

, each thin decorative sheet


130


is disposed over one of the outer surfaces


126


of the wall members. The decorative sheet is preferably a cloth fabric, although it should be understood that other flexible materials would be suitable for covering the wall panel. Referring to

FIGS. 10

,


14


,


15


and


16


, the sheet is wrapped around the edge portion


40


,


58


,


60


of each sidewall member and is attached to the outer leg


118


of the edge portion. Preferably, a strip


160


is attached to each edge


132


of the sheet. The strip may be sewn to the sheet or adhesively bonded For example, as shown in

FIGS. 21-23

, the strip is attached with a double-sided tape


162


and sewn to the sheet.




Referring to

FIGS. 21 and 23

, the strip


160


, preferably made from plastic, includes a first hook member


164


adapted to engage the outer leg


118


. The strip


160


is attached to the outer surface


136


of the fabric sheet


130


so that the first hook member


164


faces outwardly towards the edge of the fabric. Before installing the fabric, however, the fabric is folded over as shown in

FIGS. 22-23

so that the strip


160


is positioned along the inner surface


134


of the fabric and so that the first hook


164


faces inwardly away from the folded edge


133


of the fabric. The first hook member


164


is disposed on the outer leg


118


of the edge portion of the sidewall member as shown in

FIGS. 14-16

.




Excess portions of the decorative sheet, or fabric, extend outwardly from each corner of the fabric sheet between the ends of the adjacent strip members to form a corner patch


138


of material as shown in FIG.


21


. The corner patch


138


is tucked inside the eight corners formed by the edge portion channels


40


,


58


,


60


of the vertical, upper and lower frame members as the first hook member is installed on the outer leg of each channel. As shown in

FIG. 24

, a flexible corner block


146


is inserted into intersecting channels


40


,


58


at one of the upper corners to hold the excess fabric, or corner patch


138


, in the channels. Preferably, the corner block


146


is made of foam, although other resilient and flexible materials, such as rubber, may also be used. By tucking the excess fabric, or corner patch


138


, into the channels


40


,


58


, the exterior, exposed corner


148


of the wall panel is covered and provided with an aesthetically pleasing appearance.




In a preferred embodiment, the strip


160


also includes a second hook member


166


. In one embodiment, shown in

FIG. 23

, the second hook member


166


is positioned opposite of the first hook


164


and faces the same direction as the first hook member, i.e., opens inwardly away from the folded edge


133


of the fabric when it is folded over on itself. In a second embodiment, shown in

FIG. 22

, the second hook


168


is positioned at the end of the strip and opens outwardly away from the outer surface


136


of the fabric. In either embodiment, the second hook member


166


,


168


is adapted to allow an installer to stretch tightly the fabric


130


while installing the first hook


164


on the outer leg


118


of the sidewall member.




To facilitate the installation of the fabric


130


, a tool


170


is provided. The tool


170


includes a mounting block


171


, a blade


172


, a handle


174


and a housing


176


as shown in

FIGS. 46-47

. The mounting block


171


is mounted to the housing and includes a lip portion


173


adapted to engage the second hook


168


, and a guide member


175


configured as a hook that is adapted to be disposed around the end of the strip and first hook


164


. The tool also includes a plurality of wheels


180


,


181


rotatably mounted to the housing


176


and adapted to rotatably engage the side of the wall panel as the tool is moved around the periphery of the panel while engaging the strip


160


.




To install the sheet of fabric, at least one edge


132


is installed by disposing the first hook


164


on one of the sidewall member outer legs


118


as shown in

FIGS. 14-16

. The installer then engages the fabric with the tool by inserting the lip portion


173


in one of the second hooks


166


,


168


on one of the remaining strips, as shown in

FIG. 47

, and moves the tool along the edge of the wall panel. As the tool moves along the edge of the panel, the lip portion


173


, which is inserted into the second hook


168


as the guide member


175


encircles the end of the strip, pulls the strip inwardly so that the first hook


164


can be inserted onto the outer leg


118


as the end of the strip and first hook passes through the space between the core member, or hanger bracket, and the free edge of the outer leg


118


. The blade


172


includes an edge


180


that is adapted to engage the strip and force the hook member past the outer leg. Thus, the installer uses the tool


170


to stretch the fabric


130


and force the first hook


164


of the strip past the end portion and dispose it on the outer leg


118


. It should be understood that various tool configurations would work equally well for stretching and mounting the fabric sheet.




In another embodiment, the tool includes a second blade member


710


having an edge


602


, as shown in

FIG. 47A

The blade member


710


is adapted to engage the second hook and install the first hook on the sidewall as described above with the lip portion. As shown in

FIG. 47A

, the barrier sheet


530


is wrapped around the outer leg


118


and secured to the sidewall beneath the first hook.




As shown in

FIGS. 48-49

, yet another embodiment of the tool


182


includes a handle member


184


having a curvilinear surface grip


185


, a surface member


552


, a mounting block


554


having a lip portion


556


and a blade


186


. As just described, the lip portion engages the second hook, while the blade pushes the strip, and first hook, against the outer leg


118


. The surface member is preferably made of plastic, such as Delrin, so that it slides easily along the edge of the panel without damaging or tearing the fabric. This embodiment could also employ a second blade member as just described. It should also be understood that alternative embodiments, such as a simple putty knife, also can be used to engage the second hook, stretch the fabric and dispose the first hook on the outer leg of the edge portion.




The strip and hook arrangement disclosed herein is ideally suited for attaching fabric to a wall panel. For example, if the fabric were to become stained, worn or torn, an installer can remove the fabric quickly and easily by using a tool in the opposite manner as described above to disengage the first hook from the outer leg on the sidewall member. Moreover, the fabric can be removed while the panel is connected to adjacent panels if using a tool that can be inserted into the gap between the panels to engage the second hook member. This provides significant advantages over the prior art fabric attachments, which were either permanently secured to the panel or were retained by an elastic band running around the periphery of the panel.




In either configuration, the panel had to be disconnected from the adjacent panels so as to access and remove the band or to remove the adhesive.




It should also be understood by one skilled in the art that the strip and hook fabric attachment device can also be used to secure fabric to objects besides wall panels, such as chairs, cabinets, etc. All that is needed is an edge on which to secure the hook member. Thus, the attachment of the fabric to the wall panel as described above is meant to be illustrative rather than limiting.




The lower horizontal frame member, shown in

FIGS. 12

,


14


and


58


, includes a mounting strip


190


and a bracket


200


mounted to the outer surface


66


of the lower core member. As shown in

FIG. 14

, the outer surface


66


preferably extends below the end portions of the sidewalls. The side surface


67


of the portion of the lower core member extending below the leg portion of the sidewall member is stepped inward to permit the hook member on the strip to be installed on the outer leg. The groove


33


runs along the outer surface of the core member.




The bracket


200


includes several tab members


202


which are adapted to engage and support a power distribution server


220


, including an electrical power harnesses


222


, as shown in

FIGS. 2 and 59

. Referring to

FIGS. 12 and 13

, the tab members


202


form slots


203


that receive bracket hooks


560


extending upwardly from the power distribution server as shown in FIG.


59


. In operation, the harness


222


is installed by sliding the bracket hooks


560


into the slots


203


until the end of the bracket


560


passes a resilient locking tab


578


which springs downwardly to releasable secure the harness


222


on the bracket


200


. When the wall panel is particularly long, the bracket may also include stabilizer brackets


570


that extend downwardly from the bracket and include two arms that engage the harness.




Referring to

FIGS. 25-27

, the harness includes a receptacle bracket


566


, a spring tab


572


and a plurality of module bracket hooks


574


. A plurality of receptacle modules


226


are secured to the harness by engaging the bracket hooks


574


with mounting lugs


564


disposed on the module. Each module


226


is electrically connected to the harness


222


at one of a four receptacle ports


576


. Similarly, conduit


276


from an outlet box installed in the panel, as described below, preferably includes a connector that can electrically engage one of the receptacle ports in place of a receptacle module. For a complete description of the power distribution server, including the power harnesses, one is directed to U.S. Pat. No. 5,013,252, issued to Neinhuis et al. on May 7, 1991, the disclosure of which is hereby incorporated by reference. The harness also includes electrical connector ports


224


positioned at the end of the harness and which provide a means for electrically connecting adjacent panels, such that a first panel receives power from a second panel. A commercially available harness, Model No. 225409, is sold by PENT Assemblies of Kendallville, Ind.

FIGS. 26A-C

show various configurations of panels electrically interconnected. In this way, an entire system of panels can be electrically connected and provide power to users at individual work spaces.




Referring to

FIG. 14

, the mounting strip


190


is disposed between the bracket


200


and the core member


32


. The mounting strip


190


has a pair of elongated grooves


194


running longitudinally along the edges of the mounting strip


190


. The mounting strip supports a base cover


230


. The base cover


230


includes a pair of side walls


232


and a bottom wall


234


, as shown in

FIGS. 14 and 15

. The side walls


232


and bottom wall


234


are hinged along the longitudinal length of the base cover, preferably by using a flexible hinge material


236


. The cover members can also be mechanically hinged. The upper portion of each wall includes a beaded flange


238


that is disposed in the groove


194


in the mounting strip. When mounted on the mounting strip, the base cover


230


forms and defines a horizontal channel for storing and protecting cables and wires beneath the panel. The lower horizontal channel also provides a concealed passage way for the cables and wires as they pass from one panel to the next.




Referring to

FIG. 2

, the bottom wall


234


of the base cover includes a slot


240


at each end which is adapted to receive a support leg


250


extending down from the vertical frame members


14


, as explained below. The side walls


232


extend between the lower edge of the wall panel and the floor and include openings


242


adapted to allow a user to access outlets in the modules


226


secured to the power distribution server, which is mounted to the bottom of the lower frame member. Each end of the side wall


232


on the base cover includes a flexible strip


244


that extends outwardly from the end of the panel. When two panels are installed end-to-end, the opposing flexible strips


244


overlap and conceal the gap between the panels.




Referring to

FIGS. 2 and 15

, the wall panel is supported on and spaced apart from the floor by a support leg


250


attached to each vertical frame member


14


. A support bracket


260


is mounted to the bottom of each core member


28


on the inner surface


48


of the core member. The bracket


260


is mounted in the space


106


provided between the end of the lower core member and the bottom end of the vertical core member, as shown in FIG.


12


. The bracket


260


includes a U-shaped sleeve portion


262


and a pair of flanges


264


. The flanges


264


are fastened to the inner surface of the core member


28


such that the sleeve portion


262


forms an opening


266


with the surface of the core member.




The support leg


250


includes a shaft


252


having a shoulder


254


and a foot


256


. An upper portion of the shaft is received in the opening


266


formed by the support bracket and core member until the shoulder


254


of the shaft engages the bottom of the


260


bracket. The bottom of the shaft


252


is threaded and threadably engages the foot member


256


whereby the height of the wall panel can be adjusted by rotating the foot


256


relative to the shaft


252


.




In a preferred embodiment, an outlet box


270


is installed inside the wall panel frame between the upper and lower frame members


16


,


18


. As shown in

FIGS. 8 and 11

, the outlet box


270


is first-bolted to a plate member


272


, preferably a piece of hardboard. The plate member


272


is adhesively bonded to the inner surface


122


of one of the wall members. The opposite wall member has an opening


274


aligned with the outlet box


270


so as to allow the user access to the box. An outlet cover


275


can be installed over the opening. The outlet box is electrically connected to the power distribution server with an electrical conduit


276


that is disposed in the vertical channel


108


, as described above. Outlets, which are not shown, are installed in the outlet box. It should be understood that the same or similar box can be installed to provide access to data and communication wiring and cables. The outlet box also can be field installed by cutting a hole in one of the thin sheets, the barrier sheet and the wall member.




The wall panels can be connected to form a system of panels that defines and divides large office spaces into work spaces. For example, the wall panels can be connected end-to-end in a simple linear arrangement as shown in

FIGS. 19 and 20

. In such an arrangement, the panels are positioned adjacent to each other such that opposing outer surfaces


80


of the hanger brackets are in a proximal relationship. An upper draw block


280


is provided which has a downwardly facing V-shaped draw surface


282


defined by four wedge members


284


, as shown in

FIGS. 28-30

. The upper draw block


280


includes a middle portion


286


that has a hole


288


. Similarly, a lower draw block


290


has an upwardly facing V-shaped draw surface


292


defined by four wedge members


294


. A draw rod


296


connects the two draw blocks


280


,


290


.




Referring to

FIGS. 19-20

, the upper draw block


280


is positioned such that the wedge members


284


engage the top edge


298


of the hanger bracket on the adjacent panels by inserting the wedge members


284


into the inwardly facing channels


72


. The middle portion


286


of the draw block is disposed in the space formed between the outwardly facing channels


300


, which formed by the inner legs of the channel and the bridge portion.




Similarly, the lower draw block


290


is inserted into the bottom end of the channels


72


such that the wedge members


294


engage the bottom edge


302


of the hanger bracket


70


and the middle portion is received in the space formed by the channels


300


. The draw rod


296


is rotatably connected to the lower draw block and threadably engages the upper draw block. The draw rod is disposed in the space formed by the two outwardly facing channels


300


of the opposing hanger brackets as shown in

FIGS. 32-33

. When rotated, the draw rod threadably engages the upper draw block, pulling it closer to the lower draw block. As the draw rod is tightened, the draw surfaces


282


,


292


of the draw blocks operably engage the ends


298


,


302


of the hanger brackets and pull the hanger brackets together. In an alternative embodiment shown in

FIG. 29

, the draw blocks include a flat surface


304


between the wedge members


306


. When drawn together, the ends of the hanger brackets engage the flat surface


304


.




As shown in

FIG. 30

, one embodiment of the draw blocks includes a landing


308


and a tang member


310


extending from the landing on one side of the opening


288


. This configuration facilitates the installation of the draw blocks and draw rod. In particular, the installer can rest the land portion


308


of the upper draw block on the bridge portion


74


of one of the hanger brackets, while the tang member


310


is disposed in the channel


300


to align the draw block with the hanger bracket. In this way, the connector assembly, i.e., the draw rod and two draw blocks, can be positioned and retained by a first panel as the second wall panel is moved into place next to the first panel. The draw rod


296


and blocks


280


,


290


can then be lifted up and aligned with the channels


72


on the ends of both panels. The draw rod


296


is then tightened as explained above so as to connect the two panels.




As shown in

FIGS. 4-5

and


31


-


33


, two or more panels can also be connected in a perpendicular relationship. In such a configuration, a corner post


320


is installed between adjacent panels. The corner post


320


includes a substantially square, elongated tube


322


and an upper and lower plate


324


,


326


mounted inside each end of the tube, preferably by welding. Each plate


324


,


326


includes a threaded hole


328


in the middle of the plate. A pair of inwardly facing channels


330


are formed longitudinally along each side of the tube


322


. The inwardly facing channels


330


also form an outwardly facing channel between them. Preferably, the tube


322


is made from two overlapping C-shaped pieces


332


,


334


welded together as shown in

FIGS. 32-33

.




Referring to

FIGS. 4 and 5

, each corner of the tube includes an outwardly facing groove


336


that runs longitudinally along the length of the tube


322


. As shown in

FIGS. 32 and 33

, the groove


336


is preferably formed by the outer legs of the channels


330


, which are joined at the corners of the tube at approximately 90°.




As shown in

FIG. 31

, each wall panel is connected to the corner post in the same way as described above. An upper and lower draw block


280


,


290


engage the top and bottom edge of the two channels


330


on the side of the tube and the two channels


72


of the hanger bracket mounted on the side of the wall panel being connected. The draw rod


296


, connecting the draw blocks, is tightened to pull the draw blocks together and to pull the wall panel towards the corner post so that the hanger bracket engages the side of the tube. It should be understood that one, two, three or four wall panels can be connected to the corner post at any time depending on the desired configuration.




As shown in

FIGS. 5 and 33

, when two wall panels are connected to the corner post


320


at 90°, the opposing two sides of the corner post are concealed by an V-shaped cover member


340


adapted to be disposed on the adjacent, perpendicular sides of the corner post. The cover member


340


includes a beaded portion


342


running longitudinally along the side edges


344


of the cover. The beaded portions


342


are adapted to engage the outwardly facing groove


336


formed along each corner of the tube


322


. The beaded portion


342


extends diagonally inward from the cover at approximately 45°. The cover member


340


includes an outer layer of fabric


346


that matches the thin sheet of fabric disposed on the adjacent wall panels.




When two wall panels are arranged in a 180° relationship on opposite sides of the tube, a flat cover member


348


can be installed on one or both of the exposed sides of the tube


322


as shown in

FIGS. 4 and 32

. The flat cover member


348


includes diagonally facing beaded portions


350


running longitudinally along its length.




Referring to

FIG. 4

, a support member


352


is attached to the bottom of the tube member


322


. The support member


352


includes a base portion


354


, a leg


356


and a foot


358


. The base portion


354


is attached to the lower plate


326


secured in the bottom end of the tube


322


. A base cover


360


is installed on the support member


352


to conceal the support member


352


and the space below the panel. The base cover


360


extends between the base portion


354


and the foot


358


. The foot


358


includes a bottom member


362


and a pair of cylindrical lug members


364


positioned on opposite sides of the bottom member


362


. The base portion


354


includes slotted portions


366


positioned on the same side as the lug members


364


. The base cover


360


includes upwardly facing tab members


368


that engage the slotted portions


366


and a pair of flange members


368


that engage the lug members. The leg


356


is preferably a thin shaft that allows cables and wires to pass between the leg


356


and base cover


360


as they are passed between adjacent panels. In this way, the cover


360


forms part of the lower horizontal channel. It should be understood that the support does not engage the floor, but rather is provided to support the base cover member, which conceals and protects wires in the lower channel.




When two panels are attached to a corner post at 90°, the support does not include a foot. In this arrangement, the support includes a base portion


372


and a leg


374


as shown in FIG.


5


. The base cover


376


, shown in

FIG. 30

, includes two walls


378


, a base plate


380


and a guide plate


382


. The base portion


372


includes a slot


384


and two tab members


386


on two sides of the base portion. A lip portion


388


is positioned on the top of each base cover wall


378


. When installed, the lip portion


388


is inserted into the slot


384


as the two tab members


386


engage the bottom of the lip


388


to releasably secure the base cover


376


to the base portion


372


. The guide plate


382


extends between the walls


378


and lies parallel to the base plate


380


. The guide plate


382


includes a slot


384


adapted to receive the leg


374


of the support. The base plate


380


includes an opening


390


that is adapted to receive an end of the leg, which includes a lug


392


. In this way, the base cover is supported by the support base portion and is stabilized by the leg.




As shown in

FIGS. 4

,


5


and


7


, the corner post


320


also includes a cap assembly


400


adapted to span the gap between adjacent top caps


110


installed on top of each wall panel. Preferably, the cap assembly


400


is plastic.

FIGS. 4

,


5


and


7


show the cap assembly which includes a post member


420


. The post member


420


has a threaded end


404


that threadably engages the threaded hole


328


in the upper plate


324


secured in the end of the tube


322


. The cap


400


also includes a base member


406


, a lock member


408


and a cover member


410


. The base member


406


includes a step portion


412


on each side of the base and a primary post member


414


extending upwardly from the middle of each side of the top surface


416


of the base member. Each primary post member


414


includes a shaft portion


418


and a head portion


420


. Each primary post member


414


is slotted so as to make the head and shaft portions flexible and resilient. Two secondary post members


424


, positioned on opposite sides of the primary post member, extend upwardly from each step portion


412


of the base member. A cylindrical sleeve portion


426


extends downwardly from the bottom of the base member


406


. The sleeve portion


426


is adapted to receive the top of the post member


402


, so that the post member supports and rotatably engages the base member


406


. The post member


402


allows the height of the corner post cap to be adjusted as it threadably engages the upper plate


324


in the tube


322


. In addition, the post member


420


is slender so that cables wires and the like can be disposed around the post member as they pass from the upper horizontal channel


88


of one panel to the next.




The lock member


408


is rectangular and includes openings


428


adapted to receive the secondary post members


424


. The lock member


408


also includes four openings


430


adapted to receive the head and shaft of the primary post member


414


. A shoulder is disposed inside each opening so that when the primary post member is inserted into the opening, the head extends through the plate member and engages the shoulder to thereby releasably secure the plate member to the base member. The cover member


410


is releasably secured to the top of the lock member


408


.




Referring to

FIGS. 3-7

, a light seal


432


is provided to connect the top cap on the wall panel with the corner post cap. The light seal


432


includes a mounting flange


434


having two holes: a slotted hole


436


and a round hole


438


. The holes


436


,


438


are adapted to receive the secondary post members


424


. The mounting flange


434


also includes a semicircular cut-away portion


440


. The light seal


432


is installed on the base member


406


by inserting the secondary post members


424


into the openings


436


,


438


in the mounting flange


434


. The bottom of the mounting flange


434


engages the step portion


412


so that the top of the flange lies flush with the top surface of the base member


406


. The cut-away portion


440


is disposed around the primary post member


414


. The lock member


408


is installed on the base member


406


so as to releasably secure the light seal


432


to the base member


406


.




The light seal


432


includes an insert portion


442


with a rib


444


defining an end of the insert portion


442


. The insert portion


442


is adapted to be received in the open end of the top cap


110


mounted on each wall panel. The light seal


432


also includes downwardly extending legs


446


. The legs extend downwardly between the upwardly extending sidewall members


36


of the adjacent upper frame member and the cover member


340


,


348


disposed on the side of the corner post so as to prevent light from penetrating the gap between the two members. Each leg


446


also includes a beveled edge


448


that mates with an opposing edge of an adjacent leg when two light seals are installed at 90° to each other. The light seal is preferably made of plastic and the legs can be trimmed to the proper length before installation.




Referring to

FIG. 6

, a light seal


450


is provided to bridge the gap between the top caps on two panels placed end-to-end and connected to each other. In this embodiment, the light seal


450


includes two insert portions


452


facing away from each other and that are separated by a rib


454


. The insert portions


454


are received in each wall panel top cap


110


. The rib


454


provides a smooth and continuous transition between the top caps


110


. The legs


456


of the light seal extend downwardly and conceal the gap between the adjacent upwardly extending sidewalls of the two panels.




Referring to FIGS.


36


and


38





40


, a connector is provided to attach a shorter wall panel to a taller wall panel. In this configuration, an upper draw block


460


includes a pair of wedge members


462


on one side and a pair of hook members


464


on the opposite side. The hook members


464


are adapted to engage the slots


86


in the hanger bracket


70


attached to the side of the taller wall panel. The wedge members


462


engage the top


298


of the hanger bracket channels


72


on the shorter wall panel as described above. To connect the panels, the draw rod


296


is tightened to pull the two wall panels together. A light seal


470


is installed on the shorter panel so that its legs


472


are disposed on either side of the upper draw block


460


. An insert portion


474


of the light seal


470


is received in the top. cap


110


attached to the top of the shorter panel. The end of the light seal


470


is defined by a flat surface


478


which extends downwardly from a rib


476


. The flat surface


478


abuts the hanger bracket


70


on the taller panel.




Referring to

FIGS. 3

,


36


,


39


and


57


, a pair of end cover brackets


480


are installed on the exposed end of any wall panel which is not connected to another wall panel or a corner post. The end cover bracket


480


includes a pair of outwardly facing grooves


482


running along opposite side edges of the bracket. A end cover


484


is attached to the bracket


480


on the end of the panel to provide a finished appearance. The cover


484


comprises a channel with a top wall


486


closing the upper end of the channel. The end cover also includes a pair of U-shaped brackets


488


mounted inside the channel. The brackets each include inwardly facing flanges


490


which are inserted into the grooves


482


in the end cover bracket mounted to the end of the wall panel. A light seal can be installed between the end cover and the top cap of the wall panel, as shown in

FIGS. 3 and 36

.




When installing a shorter panel adjacent to a taller panel, an end cover bracket


480


is mounted to the exposed portion of the hanger bracket and wall panel end extending above the shorter panel. A short end cover


485


, shown in

FIGS. 36 and 40

, is mounted on the bracket so that the exposed upper portion of the taller wall panel is covered. A light seal


450


is then installed between the end cover and the top cap on the taller wall panel.




Referring to

FIGS. 41-42

, the wall panel also can be attached to a permanent wall


494


. In this arrangement, a mounting plate


496


is disposed inside a channel-shaped cover


498


having a top wall


499


, similar to an end cover. A hanger bracket


70


, the cover


498


and mounting plate


496


are mounted on the permanent wall


494


with a plurality of fasteners. The wall panel is connected to the hanger bracket as described above, with a light seal


450


being inserted between the cover and the top cap of the adjacent panel.




The construction of the frame members and panel, as described above, is ideally suited for improved manufacturability of the wall panel. In particular, the method for making each vertical frame member includes providing a core member


28


, a hanger bracket


70


and a pair of sidewall members


34


, each having an edge portion


40


with an outer leg


118


having an outer surface. The hanger bracket


70


is attached to the outer surface


50


of the core member as discussed above.




Referring to

FIGS. 50-51

, the core member


28


and hanger bracket


70


are placed in a fixture


500


, which has a first surface


502


spaced apart from a second and third surface


504


,


505


. The fixture


500


is rotatably attached to supports


506


at each end of the fixture


500


. In this way, fixture surfaces can be provided on opposite sides of the same fixture for different frame members. The fixture is simply rotated so that the surfaces to be employed are accessible to the assembler.




As illustrated in

FIG. 51

, the core member


28


and hanger bracket


70


are positioned in the fixture such that an outer surface of the hanger bracket engages the first surface


502


. The sidewalls


34


are then inserted into the fixture


500


on opposite sides of the core member. The ends of the sidewalls and the ends of the core member are positioned relative to each other in the fixture using a locator pin as the outer leg


118


of the edge portions of the two sidewalls engage the second and third surfaces


504


,


505


of the fixture respectively. The core member, hanger bracket and sidewalls are clamped together in the fixture using a plurality of clamps


508


. The sidewalls are then attached to the core member with a plurality of fasteners, preferably staples. Alternatively, the sidewalls can also be bonded to the core member using a suitable adhesive, or bonded and mechanically fastened.




It should also be understood by one skilled in the art, that various aspects of the assembly process can be automated. For example, the hand clamps shown in

FIG. 51

can be replaced with pneumatically controlled clamps. Similarly, the fastening process can be automated, whereby the application of adhesive and stapling is done automatically.




By using a fixture as just described, the distance between the outer surface of the hanger bracket and the outer leg of each sidewall can be maintained as a relative constant with relatively tight tolerances. Thus, when two panels are installed end-to-end, the gap between adjacent opposing sidewalls will be maintained with tight tolerances so as to provide a uniform appearance when viewing a system of interconnected wall panels. In essence, the gap at each joint between adjacent panels is maintained as a relative constant. Moreover, this method of manufacture ensures that the slotted portion of the hanger bracket is always maintained a constant distance from the outer leg


118


of the sidewall edge portion. Thus, the user is ensured that components can be consistently installed on the hanger bracket without having to force the component past a protruding sidewall.




Another advantage of this method is realized when different thickness fabrics are installed on the panel. Typically, when a thicker fabric is installed on one panel, the fabric fills more of the gap between connected panels, and can therefore interfere with the installation of components on the hanger brackets, as well as creating a displeasing appearance as between adjacent joints. With the current construction, the distance between the first and second and third surfaces in the fixture can be altered to provide more or less distance between them so as to accommodate thicker or thinner fabrics respectively.




Referring to

FIG. 52

, a scanner


600


or caliper can be used to measure the thickness of the fabric


130


being installed and provide that data to a computer. The computer


602


employs logic and actuates a servo motor


604


that changes the relative distance between the first and second and third surfaces so as to provide a uniform gap between panels once the fabric is installed. It should be understood that actuators could alternatively be used to adjust the second and third surfaces relative to the first surface. In this way, the second surface could be spaced a greater distance from the first surface than the third surface is from the first surface so as to accommodate two different thickness fabrics on each side of the panel. For example, it may be desirable to employ a heavy thick fabric on the outside wall of a panel system forming a walkway which experiences a lot of abuse, while providing a thinner fabric, for reasons of color selection etc., on the inside wall of the system forming the workspace.




Another advantage is realized by using a wooden core member in each of the frame members in that the sidewalls can be attached extremely fast and inexpensively with staples, rather than by expensive welding or mechanical screw and bolt type fasteners.




The upper and lower frame members are made in a similar manner, except that the first fixture surface


620


engages the core member rather than the hanger bracket as shown in

FIGS. 53-54

. The sidewall members are installed so that the outer legs


118


engage the second and third fixture surfaces


622


,


623


respectively. The bracket and mounting strip are installed on the outer surface of the lower core member with mechanical fasteners. The groove


33


positioned along the bottom of the bottom core member allows space for ends of a tool locator which positions the bracket and mounting strip relative to the bottom of the panel.




A method is also provided to assemble the wall panel. The method includes providing a plurality of fixtures


512


having horizontal surfaces


514


and vertical surfaces


516


. The fixtures


512


are arranged in a rectangular configuration on a bed


522


, as shown in

FIGS. 55-56

. A pedestal support


524


extends upwardly from the bed in the middle of the fixture arrangement. Each fixture is provided with a clamp


520


. Adhesive is applied to the inner surface of one of the wall members around its edge. The wall member is then placed on the horizontal surface


514


of the fixtures with the inner surface facing upward. The pedestal support


524


supports the outer surface of the wall member. The four frame members, i.e., the vertical frame members


14


and the upper and lower frame members


16


,


18


, are placed in the fixtures such that the sidewalls


34


,


36


,


38


of each frame engage the fixture surfaces oriented around the panel. The sidewalls of the upper frame member are pinched together and inserted between the upwardly extending sidewalls


68


of the vertical frame members and then released so that the sidewalls overlap. Similarly, the outwardly extending sidewalls


38


of the lower frame member are overlapped with the exposed core of the vertical frame members


550


. The vertical surfaces


516


of the fixture are magnetized with magnets


521


to attract and hold the frame members to the vertical surfaces


516


.




A partition member


140


, with adhesive applied to the mounting flange


142


, is then installed at each end of the panel by bonding the mounting flange to the inner surface


122


, of the wall member. The boundary flange


144


extends away from the wall member to form the vertical channel


108


. Because the partition member is preferably made of cardboard, it can be easily installed by bonding rather than be welding or mechanically fastening as would typically be required for metal or wood partitions.




Adhesive is applied to both sides of the honeycomb filler member


150


and it is disposed inside the frame on the inner surface


122


of the wall member


120


. The filler member


150


substantially fills the space between the upper and lower frame members and between the two partition members. In a preferred embodiment, an outlet box


270


is mounted to a hardboard base plate with a fastener. The base plate is adhesively bonded to the inner surface


122


of the wall member. One of a portion of the partition member or filler material is removed to allow the outlet box to be installed on the inside of the frame. The outlet box can be installed between the partition members, or such that one side of the box is aligned with the partition member to thereby provide a wall defining the inner surface of the vertical channel. The conduit


276


connecting the outlet box to the power system is disposed in the vertical channel and extends through the space between the bottom core member and the vertical core member.




Adhesive is applied around the edges of the inner surface


122


of the second wall member. The wall member


120


is positioned in the recess formed on a second side of the frame by the edge portions of the sidewalls. When an outlet box has been installed on the first wall member, a hole is cut in the second wall member so as to be substantially aligned with the outlet box once the second wall member is installed. The two wall members and frame are clamped together and to the fixtures. A staple gun, preferably a dual action staple gun


640


accessing both sides of the panel simultaneously, as shown in

FIG. 56

, is used to mechanically fasten the two wall members to the four frame members, and in particular, to staple through the wall member and sidewall member and into the core member. Fasteners are also installed in the overlapping portions of the upwardly extending vertical sidewalls, the sidewalls of the upper frame member and the wall member, as described above. As described above, it should be understood that various aspects of this assembly process could be automated. For example, the clamping could be pneumatically controlled, and the positioning of the wall members, filler member, partition members and frame members could be automated.




Because the core members are preferably made out of wood, the wall members can be easily and cheaply secured to the frame. This construction avoids the use of expensive and time consuming welding operations and/or the use of expensive screw and bolt type fasteners.




The support leg is installed by press fitting the upper portion of the leg into the opening between the bracket and core member. The foot member is attached to the leg member.




The barrier sheet is disposed on both sides of the wall panel, and is either adhesively or mechanically attached to the wall member or the frame members. Alternatively, the barrier sheet can be wrapped around the edge portions of the sidewall members underneath the decorative sheet, which secures the barrier sheet to the wall panel, as shown in FIG.


47


A.




Next, the decorative sheets are installed by disposing a sheet on each side of the panel and attaching the strip to the edge portion of each side wall as described above, including the steps of tucking the excess fabric corner patch located at the corners into the edge portion channel and inserting a flexible corner block into each corner to secure the fabric in the channel.




It should be understood that all of the aforementioned steps of manufacture can be interchanged without departing from the spirit and scope of the invention. As such, it is intended that the foregoing order of steps be regarded as illustrative rather than limiting.




Additional steps can be included to accessorize the panel. For example, a top cap typically is installed on each panel. In addition, the power distribution system can be installed by attaching the power distribution server, including the receptacle modules and harnesses, to the bracket on the bottom of the lower frame member. In addition, the base cover can be installed on the mounting strip to conceal and protect the power distribution system. The base cover is installed by securing the two side walls to the mounting strip attached to the bottom of the lower frame member.




When assembled in a system of panels, the horizontal channel formed along the top and bottom of the panels provides the user with an ideal and easy to access space for storing and routing cables and wires, such as communication and data lines. Moreover, the vertical channels in each panel allow the user to easily rout wires and cables from the top of the panel to the bottom. In addition, the vertical channels provide a ready-made space for routing electrical conduit from the outlet mounted in the panel to the base of the panel and the attached power distribution system.




Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.



Claims
  • 1. A wall panel comprising:a rectangular frame comprising a pair of spaced apart, generally parallel vertical side frame members, and spaced apart generally parallel horizontal lower and upper frame members, said horizontal frame members connected to said vertical side frame members at opposite ends thereof to form said rectangular frame, each of said frame members having a length and comprising a core member and a pair of separate sidewalls attached to opposite sides of said core member, said sidewalls running substantially the length of each frame member; a pair of sheetlike wall members each having an inner surface attached to the sidewalls of said frame members on opposite sides of the frame; a thin decorative sheet covering an outer surface of each wall member.
  • 2. The invention of claim 1 wherein said core members are made of wood.
  • 3. The invention of claim 1 further comprising a thin barrier sheet disposed between said wall member and said decorative sheet on each side of said wall panel.
  • 4. The invention of claim 1 wherein each of said sidewalls comprises a substantially flat leg portion attached to said core member and an edge portion extending laterally outward from said leg portion, said edge portions of said sidewalls forming a shallow recess on each of said opposite sides of the panel, each of said recesses having a bottom surface defined by an outer surface of the leg portion; said wall members substantially filling said recesses on opposite sides of said frame.
  • 5. The invention of claim 1 further comprising a filler member disposed between said wall members and extending between said horizontal frame members.
  • 6. The invention of claim 4 wherein said sidewalls on said upper horizontal frame member extend upwardly from the upper frame core member, said sidewalls and an upper surface of the upper core member forming a substantially horizontal channel.
  • 7. The invention of claim 6 further comprising a top cap releasably secured to said upper frame member, said top cap covering said horizontal channel.
  • 8. The invention of claim 7 wherein said sidewalls on said upper frame member further comprise an inwardly facing ridge, and wherein said top cap has a pair of downwardly facing flange members, each of said flange members having an elongated ribbed portion, said ribbed portion engaging said ridge so as to releasably secure said top cap to said frame member.
  • 9. The invention of claim 6 wherein said sidewalls on each of said vertical side frame members extend upwardly past a top end of the side frame member core member, said upwardly extending side walls of said side frame members overlap and attach to the upwardly extending sidewalls of said upper frame member.
  • 10. The invention of claim 9 wherein said sidewalls on said lower horizontal frame member extend outwardly past the opposite ends of said lower frame member core member, said sidewalls overlap and attach to a bottom portion of said vertical side frame members.
  • 11. The invention of claim 6 further comprising a vertical channel communicating with said horizontal channel and a bottom portion of said panel.
  • 12. The invention of claim 11 wherein at least one of said ends of said upper frame member core member is spaced apart from an inner surface of one of said side frame member core members to form an opening, said vertical channel communicating with said opening, and wherein said vertical channel is defined by an inner surface of said side frame member core member and a spaced apart partition member extending between said upper and lower horizontal frame members.
  • 13. The invention of claim 12 further comprising a brace member extending between a top end of said side frame member core member and the upper surface of said upper frame member core member, said brace member having an opening aligned with the opening formed between the side frame member core member and the upper frame member core member so as to provide access to the vertical channel.
  • 14. The invention of claim 12 wherein said vertical channel comprises a first vertical channel positioned along a first end of the panel and further comprising a second vertical channel substantially similar to the first vertical channel positioned on an opposite end of the panel, said second vertical channel defined by an inner surface of the side core member adjacent said opposite end and a spaced apart second partition member extending between the upper and lower frame members.
  • 15. The invention of claim 14 further comprising a filler member disposed between said wall members, said filler member extending between said upper and lower horizontal frame members and between said partition members.
  • 16. The invention of claim 4 wherein each of said edge portions comprises a C-shaped channel having an inner and outer leg connected by a surface member, said channel opening inwardly away from the outer surface of the wall member, said inner leg extending laterally outwardly in a perpendicular relationship from said leg portion of said side wall to define said recess, said surface member lying in substantially the same plane as the outer surface of said wall member.
  • 17. The invention of claim 16 wherein said decorative sheets are attached to the outer leg of said sidewalls on each side of the frame.
  • 18. The invention of claim 17 further comprising a strip secured to an edge of said decorative sheet, said strip comprising a hook member engaging said outer leg.
  • 19. The invention of claim 18 wherein said strip is bonded to said decorative sheet.
  • 20. The invention of claim 18 wherein said strip is sewn to said decorative sheet.
  • 21. The invention of claim 20 wherein said strip further comprises a second hook opposite said first hook, said second hook adapted to receive a tool member whereby said decorative sheet is attached to said C-shaped channel by using said tool to dispose said first hook on said inner leg.
  • 22. The invention of claim 18 wherein said decorative sheet comprises a plurality of corners and a corner patch extending outwardly from each of said plurality of corners of the sheet, said corner patches disposed in the edge portion channel, and a flexible corner block disposed in the edge portion channel over said corner patch to secure the decorative sheet in the edge portion channel.
  • 23. The invention of claim 1 wherein said vertical side frame members further comprise a hanger bracket attached to an outer surface of said side frame member core member, said hanger bracket having a plurality of slots arranged along a length thereof.
  • 24. The invention of claim 23 wherein said hanger bracket comprises a pair of channels extending along the length thereof.
  • 25. The invention of claim 1 further comprising a support leg secured to the bottom of each vertical side frame member, said support leg adapted to support the wall panel on a floor in a spaced apart relationship with the floor, and further comprising a base cover attached to and extending downwardly from the lower frame member, said cover defining a horizontal channel.
  • 26. The invention of claim 25 further comprising a bracket attached to a bottom of said lower frame member, and a power distribution system secured to said bracket and disposed in said channel defined by said cover, said power distribution system comprising a power harness and a receptacle module adapted to receive an electrical plug, said harness adapted to be electrically connected with an electrical distribution system in an adjacent panel.
  • 27. The invention of claim 26 further comprising an electrical outlet box attached to one of said wall members between said upper and lower frame members, and an electrical conduit electrically connecting said outlet box with said harness.
  • 28. The invention of claim 25 further comprising a support bracket mounted to an inner surface of the vertical side core member, said support bracket having an opening, and said support leg comprising a shaft having a shoulder and a foot, said shaft received in said support bracket opening so that a bottom of said support bracket engages said shoulder, said foot threadably engaging said shaft so as to make the panel height adjustable.
  • 29. A wall panel comprising:a rectangular frame comprising a pair of spaced apart, generally parallel vertical side frame members, and spaced apart generally parallel horizontal lower and upper frame members, said horizontal frame members connected to said vertical side frame members at opposite ends thereof to form said rectangular frame, each of said frame members having a length and comprising a core member and a pair of separate sidewalls attached to opposite sides of said core member, said sidewalls running substantially the length of each frame member, each of said sidewalls having an edge portion, wherein said edge portions define an outwardly facing recess on each of said opposite sides of the panel; a sheetlike wall member received in each of said recesses on said opposite sides of the panel, each of said wall members having an inner surface attached to the sidewalls of said frame members on opposite sides of the frame.
  • 30. The invention of claim 29 further comprising a thin decorative sheet covering an outer surface of each wall member.
  • 31. The invention of claim 30 wherein said edge portion of said sidewall comprises a leg, wherein said decorative sheet is secured to said leg of said edge portion.
  • 32. The invention of claim 29 further comprising a filler member disposed between said wall members and extending between said upper and lower horizontal frame member members.
  • 33. The invention of claim 29 wherein said upper frame member core member comprises an upper surface, said sidewalls attached to said upper frame member core member extending upwardly from said upper frame member core member above said upper surface, wherein said sidewalls attached to said upper frame member core member and said upper surface form a horizontally extending channel.
  • 34. The invention of claim 29 wherein said rectangular frame has a interior and further comprising a vertical channel extending between said upper and lower horizontal frame members in said interior of said frame.
  • 35. The invention of claim 34 wherein said vertical channel is defined in part by an inner surface of at least one of said vertical side frame members, wherein said inner surface of said at least one of said vertical side frame members defines in part said interior of said frame.
  • 36. The invention of claim 35 wherein said vertical channel is further defined in part by a partition member extending between said upper and lower horizontal frame members.
  • 37. The invention of claim 35 wherein said vertical channel is further defined in part by said inner surfaces of said wall members.
  • 38. The invention of claim 33 wherein said horizontal channel formed by said upper frame member sidewalls and said upper surface of said upper frame member core member opens to a top of said panel, and further comprising a top cap attached to said upper frame member sidewalls, wherein said top cap closes said horizontal channel.
  • 39. The invention of claim 38 wherein said upper frame member sidewalls and said top cap are releasably attached to each other with a snap fit.
  • 40. The invention of claim 29 wherein said core members are wood.
  • 41. The invention of claim 40 wherein said sidewalls are attached to said core members with staples.
  • 42. The invention of claim 40 wherein said sidewalls are attached to said core members with adhesive.
  • 43. A wall panel comprising:a rectangular frame comprising a pair of spaced apart, generally parallel vertical side frame members, and spaced apart generally parallel horizontal lower and upper frame members, said horizontal frame members connected to said vertical side frame members at opposite ends thereof to form said rectangular frame having an interior, each of said frame members having a length, opposite side surfaces, an outer surface and an inner surface defining in part said interior of said frame; and a pair of sheet like wall members, each of said wall members having an inner surface attached to the side surfaces of said frame members on opposite sides of the frame; wherein said inner surface of one of said vertical side frame members and said inner surface of at least one of said wall members define in part a vertical channel, wherein said vertical channel extends between said upper and lower frame members.
  • 44. The invention of claim 43 wherein at least one of said side frame members comprise a core member and a pair of sidewalls attached to said core member, wherein said core member defines said inner surface of said side frame member that defines in part said vertical channel, and wherein said sidewalls define said side surfaces of said at least one side frame member.
  • 45. The invention of claim 43 wherein said inner surface of said other of said vertical side frame members and said inner surface of at least one of said wall members define in part a second vertical channel, wherein said second vertical channel extends between said upper and lower frame members.
  • 46. The invention of claim 43 wherein said upper and lower frame members have an opening formed therein, wherein said openings communicate with said vertical channel.
  • 47. The invention of claim 43 wherein said inner surface of said other of said vertical side frame members and said inner surfaces of said wall members define in part a second vertical channel, wherein said second vertical channel extends between said upper and lower frame members.
  • 48. The invention of claim 47 further comprising a pair of partition members extending between said upper and lower frame members, said partition members spaced from said inner surface of said side frame members and further defining said vertical channels.
  • 49. The invention of claim 48 further comprising a filler member extending horizontally between said partition members, extending vertically between said upper and lower frame members and extending laterally between said wall members.
Parent Case Info

This application is a divisional of U.S. patent application Ser. No. 08/864,459, filed May 28, 1997 now U.S. Pat. No. 6,167,665, which claims the benefit of U.S. Provisional Application No. 60/018,956, filed Jun. 7, 1996, the entire disclosures of which are hereby incorporated herein by reference.

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Provisional Applications (1)
Number Date Country
60/018956 Jun 1996 US