MODULAR WALL CONSTRUCTION AND METHOD OF MANUFACTURE AND CONSTRUCTION

Description

FIELD OF THE INVENTION

The present invention relates to a modular wall construction and method of manufacture and construction.

BACKGROUND

Currently, several methods and apparatuses exist for construction of walls. However, current solutions in the area pose challenges with construction of the walls, such that heavy equipment may be required to lift panels to an appropriate height necessary to interlock the individual panels to form a wall. Furthermore, large quantities of mechanical fasteners may be required. As such, there is a need for a new modular wall construction and method of manufacture and construction.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is a top plan view of an installation of a modular wall, according to one embodiment of the present invention;

FIG. 2 is a perspective view of a method for installing walls, according to one embodiment of the present invention;

FIG. 3 is a top plan view of a modular wall, according to one embodiment of the present invention;

FIG. 4 is a top plan view of a modular wall, according to another embodiment of the present invention;

FIG. 5 is a top plan view of a modular wall, according to another embodiment of the present invention;

FIG. 6 is a top plan view of a modular wall, according to another embodiment of the present invention;

FIG. 7A is a perspective view of a modular wall, according to one embodiment of the present invention;

FIG. 7B is a perspective view of a modular wall, according to another embodiment of the present invention;

FIG. 8A is a perspective view of a modular wall, according to one embodiment of the present invention;

FIG. 8B is a perspective view of a modular wall, according to one embodiment of the present invention;

FIG. 9A is a top plan view of a bracket, according to one embodiment of the present invention;

FIG. 9B is a perspective view of a bracket, according to one embodiment of the present invention;

FIG. 9C is a right-side view of a bracket, according to one embodiment of the present invention; and

FIG. 9D is a rear view of a bracket, according to one embodiment of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention now may be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout. Where possible, any terms expressed in the singular form herein are meant to also include the plural form and vice versa, unless explicitly stated otherwise. Also, as used herein, the term “a” and/or “an” shall mean “one or more,” even though the phrase “one or more” is also used herein. Furthermore, when it is said herein that something is “based on” something else, it may be based on one or more other things as well. In other words, unless expressly indicated otherwise, as used herein “based on” means “based at least in part on” or “based at least partially on.”

Additionally, certain terminology is used herein for convenience only and is not to be interpreted as a limitation on the embodiments described. For example, the words “top,” “bottom,” “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configurations as depicted in the figures. Indeed, the referenced components in the figures may be oriented in any direction, unless specified otherwise, the configurative terminology used herein should be understood as encompassing such variations. Like numbers refer to like elements.

Embodiments of the invention are directed to a modular wall construction and method of manufacture and construction. The modular wall construction provides a plurality of panels each comprising nesting features structured to interlock with adjacent panels. Once the nesting features of two adjacent panels are joined, the panels are secured to a structural support member using a bracket and fasteners. A damper may also be provided as an intermediary feature between the panels and the structural member. The present invention addresses several key limitations of current wall construction and methods for constructing said walls, including reducing the amount of heavy-duty equipment needed, such as hoists and cranes, and reducing the amount of labor involved in mounting panels by reducing the number of holes to be drilled and fasteners to be secured.

FIG. 1 illustrates a top plan view of an installation of a modular wall, according to one embodiment of the present invention. Wall 102 may be constructed in a variety of locations, including but not limited to sports fields, recreation facilities, residential real estate, commercial real estate, concert venues, water, areas prone to flooding, highways, or the like. FIG. 1 illustrates one non-limiting example of a location where wall 102 has been constructed and implemented along the perimeter of a sports field, such as to contain and enclose athletes and sports equipment within the sports field, prevent outsiders from entering the sports field, or provide a physical object whereby overcoming the object during a game may indicate an achievement in the game (e.g. a “home run” in baseball).

FIG. 2 illustrates a perspective view of method of installing walls, according to one embodiment of the present invention. As illustrated, a panel 106, 120, 126 may be installed adjacent to other panels 106 from a horizontal direction, such as to prevent the need to raise the panel 106, 120, 126 during an installation. In this way, the panel 106, 120, 126 may be supplied horizontally to an adjacent panel 106, 120, 126 such that the nesting features of panel 106, 120, 126 align with nesting features of the adjacent panel 106, 120, 126. In some embodiments, as panel 106, 120, 126 approaches the adjacent panel 106, 120, 126, the panel 106, 120, 126 may be rotated along the vertical axis of panel 106, 120, 126 prior to attaching to the adjacent panel 106, 120, 126, such that the nesting features of both the panel 106, 120, 126 and the adjacent panel are oriented and aligned in the optimal direction to interlock. Thereafter, brackets, fasteners, dampers, or the like, as will be discussed in greater detail below, are added to form a unified structure.

FIGS. 3-6 illustrate top plan views of a modular wall, according to some embodiments of the present invention. The panel 106, 120, 126 may be a panel defined by features or members with substantially constant cross-sections, such that the method of manufacturing the panel 106, 120, 126 may be through extrusion (e.g., “profile extrusion”). The panel 106, 120, 126 may be comprised of any number of materials, including, but not limited to: vinyl, PVC, polyethylene, polycarbonate, carbon fiber, composites, wood, wood-plastic composites, or the like. The panel 106, 120, 126 may also comprise a plurality of layers of material, such that the outer layer(s) are a different material and/or color and/or texture than the inner layer(s). For example, the outer visible layer of the panel 106, 120, 126 may comprise a visible aesthetic material dissimilar from the non-visible inner layers of the panel 106, 120, 126, such as to promote a certain aesthetic, and/or weathering capabilities. The outer layer(s) may be co-extruded alongside the other layers, or the outer layer(s) may be applied after the extrusion process of the inner layer(s) is complete. Typical outer layers may comprise polymers such as vinyl, PVC, polyethylene, or the like, or the outer layers may comprise pressure-adhesive or heat-applied films and/or foils. It shall also be considered that panel 106, 120, 126 may be configured with an external texture such as an embossing pattern or layer which may be applied during or after the extrusion process of the inner layer.

Each panel 106, 120, 126 comprises an inner nesting feature 111 and an outer nesting feature 112. The panel 106, 120, 126 define a first side comprising an inner nesting feature 111, and an opposite second side comprising an outer nesting feature 112. The inner and outer nesting features 111, 112 are structured such that a curved portion with a radius R1 of the inner nesting feature 111 is sized to fit within the curved portion with radius R2 of the outer nesting feature 112. In this way, multiple panels 106, 120, 126 may be positioned adjacent one another and the inner nesting feature 111 of a first panel fits within the outer nesting feature 112 of an adjacent second panel. The curvature of the inner and outer nesting features 111, 112 are seated or “nested” such that lateral movement along the horizontal direction of panel 106, 120, 126 is reduced or eliminated once an inner nesting feature 111 of a first panel is inserted into an outer nesting feature 112 of a second panel. It shall be noted that the assembly may still be capable of vertical movement until additional components are added, as will be described in detail below.

The panels 106, 120, 126 may be mechanically coupled to structural members 108 using brackets 114. The structural members 108 may be a length of support material such as plywood, lumber, engineered wood, metal, composites, or the like. Structural members 108 may be intermittently positioned horizontal members such as 4×6 or 2×4 lumber positioned horizontally at various heights interposed and secured between vertical structural posts (not pictured). The structural members 108 provide a rigid material to which the panels 106, 120, 126 are affixed using brackets 114.

Referring now to FIGS. 9A-9D, FIGS. 9A-9D depict one embodiment of a bracket 114. Brackets 114 are comprised of formed metal, such as steel, aluminum, stainless steel, steel or aluminum alloys, and may be treated or coated with any number of surface treatments such as anodizing, plating, paint, or powder coating. In other embodiments, brackets 114 may be comprised of material such as plastic or composite.

Furthermore, brackets 114 are configured with holes and/or slots capable of passing the screw or bolt portion of fasteners 118 while also being small enough to prevent the washer, screw/bolt head, or nut portion of fasteners 118. In this way, brackets 114 when tightened using fasteners 118 securely couple and affix panels 106 to structural members 108 by applying pressure and force to brackets 114 by converting the torque on the threads of the screw or bolt portions of fasteners 118 into linear force sufficient to secure brackets to structural members 108.

The bracket 114 includes a base 152, a front tab 162, a rear tab 164, and an interconnecting member 166. The front tab 162, a rear tab 164, and the interconnecting member 166 form a u-shaped hook 158 which is connected to an edge of the base 152. The hook 158 creates a gap 160 between the rear tab 164 and the front tab 162. The gap 160 is dimensioned to receive inner and outer nesting features 111, 112 of panels 106 and overlaps and partially fills the inner radius defined by R1 of the inner nesting feature 111 and surround or overlap outer edge of outer nesting feature 112, thus capturing both the inner nesting feature 111 and outer nesting feature 112.

The base 152 also includes an aperture 154. The aperture 154 permit fastener 118, such as a screw, a pin, a dowel, or a nail, to be inserted therethrough and secure the bracket 114 to the structural members 108.

The bracket 114 may comprise insertion features 156 positioned adjacent to base 152, structured for insertion into structural members 108. In some embodiments, the insertion features 156 may include one or more triangular teeth. In the present embodiment of FIG. 9A-9D, bracket 114 comprises four insertion features 156. However, in alternate embodiments insertion features 156 may comprise one triangular tooth, two triangular teeth, three triangular teeth, four triangular or any number of triangular teeth. However, it shall be recognized that the insertion features 156 may have any form suitable for engaging structural members 108.

Referring back to FIG. 3, in some embodiments of the invention, the modular wall may be assembled such that a damper 110 is interposed between one or more elements of panel 106, 120, 126 (such as the outer nesting feature 112, as pictured in FIG. 3) and structural members 108. The damper 110 may comprise a rubber material, polymer, or gel sufficient to decelerate the panel 106, 120, 126 prior to the panel 106, 120, 126 impacting structural members 108 in the event of an external collision with the panel 106, 120, 126. In this way, the panels 106, 120, 126 may avoid unnecessary fracture or breakage, as damper 110 will absorb and/or displace the force of an impact to the surrounding structural members 108. Furthermore, the addition of the damper 110 creates mechanical flexural properties to panel 106, 120, 126, such that a forceable impact to panel 106, 120, 126 by individuals like humans and animals, will result in minimized injuries or health consequences to said individuals.

A void is formed as a result of the enclosed area between the panel 106, 120, 126, and the first and second sides of the panel 106, 120, 126, the brackets 114, the structural member 108, and in some embodiments, the damper 110. It shall be appreciated that in some embodiments of the invention not depicted graphically, the aforementioned void may be filled with a material such as foam, wood, rubber, or the like, in order to provide additional dampening or strengthening properties.

Fasteners 118 secure bracket 114 and the adjacent panels 106 to structural members 108. Fasteners 118 may be any configuration of hex bolts, machine screws, shoulder bolts, screws, washers, lock washers, nuts, locknuts, nails, pins, dowels, and so forth capable of securing brackets 114 to structural members 108. In some embodiments of the invention, structural members 108 may be pre-drilled with holes to accept fasteners 118. In other embodiments of the invention, fasteners 118 may be configured with self-drilling features such that holes may not be required to be pre-drilled into structural members 108.

When viewing from a top plan view such as FIG. 3, panel 106 comprises an approximately linear first member 105. A second member 107 and third member 109 each extend perpendicularly from the opposing ends of the first member to form the first and seconds sides of panel 106, and an inner nesting feature 111 is positioned at the end of the second member 107, and an outer nesting feature 112 is positioned at the end of the third member 109. Dimension h1 represents the overall height of the panel 106, 120, 126, which is between 1 and 5 inches, preferably 2 ¼ inches. Dimension w1 represents the width of the exposed portion of panel 106, 120, 126 once installed, which is between 10 and 14 inches, preferably 11 15/16 inches.

FIG. 4-5 illustrate a top plan view of a modular wall, according to another embodiment of the present invention. The panel 120 is a panel of alternate geometry to panel 106, and it shall be noted that other elements such as brackets 114, damper 110, and structural member 108 previously described in other embodiments may be structured to function similarly to those in the present embodiment, and as such may not be discussed with as much detail hereinafter.

The panel 120, when viewing from a top plan view, comprises a linear member 121 extending from a first side to a second side, the linear member 121 defining a curvature at each end. First extending member 122 extends from a first intermediate point of the linear member 121 at an angle A from the linear member 121 to the first side, while second extending member 124 extends at an angle B (approximately 90 degrees in relation to extending member 122) from a second intermediate point of the linear member 121 to the second side.

First extending member 122 comprises an outer nesting feature 112 at the end of first trust member 122, whereas second extending member 124 comprises an inner nesting feature 111 at the end of second extending member 124. Dimension h2 represents the overall height of panel 120, which is between 1 and 5 inches, preferably 3 inches. Dimension w2 represents the width of the exposed portion of panel 120 once installed, which is between 10 and 14 inches, preferably 11 15/16 inches.

As illustrated in FIG. 5, the panel 120 may be structured with a lap feature on the end of the linear member 121 such that at least a portion of the lap feature 121 on a first side of a first panel 120 is positioned behind a corresponding portion of the linear member 121 on the adjacent second side of a second panel 120 when the first and second panels 120 are positioned adjacent one another. It shall be appreciated that the lap feature 121, although depicted in FIG. 5 as a feature of panel 120, may similarly be adapted to panel 126.

FIG. 6 illustrates a top plan view of a modular wall, according to another embodiment of the present invention. The panel 126 is a panel of alternate geometry to the panels 106, 120 and it shall be noted that other elements such as brackets 114, damper 110, and structural member 108 previously described in other embodiments may be structured to function similarly to those in the present embodiment, and as such may not be discussed with as much detail hereinafter.

The panel 126, when viewing from a top plan view, comprises a first linear member 127 extending from a first side to a second side, the linear member 127 defining a curvature at each end. The first extending member 130 comprises a second linear member 134 and a third linear member 136. The second linear member 134 extends from an intermediate point of the first linear member 127 in a substantially perpendicular direction from the first linear member 127. The third linear member 136 is positioned at the end of second linear member 134 and extends in a substantially perpendicular direction relative to second linear member 134 to the first side defined by the first end of first linear member 127.

The second extending member 132 comprises a fourth linear member 138 and a fifth linear member 140. The fourth linear member 138 extends from an intermediate point of the first linear member 127 in a substantially perpendicular direction from the first linear member 127. The fifth linear member 140 is positioned at the end of the fourth linear member 138 and extends in a substantially perpendicular direction relative to the fourth linear member 138 to the second side defined by the second end of the first linear member 127.

The first extending member 130 comprises an inner nesting feature 111 at the end of the first trust member 130, whereas the second extending member 132 comprises an outer nesting feature 112 at the end of the second extending member 132. Dimension h3 represents the overall height of panel 126, which is between 1 and 5 inches, preferably 3 inches. Dimension w3 represents the width of the exposed portion of panel 126 once installed, which is between 10and 14 inches, preferably 11 15/16 inches.

FIG. 7A-7B illustrate perspective views of a modular wall during wall installation, according to some embodiments of the present invention. As previously described, the structural members 108 may be a length of support material such as plywood, lumber, engineered wood, metal, composites, or the like. In the embodiment illustrated in FIG. 7A, the structural members 108 are constructed of lumber defined by a substantially rectangular cross-section. The structural members 108 may be “2×4” lumber, or lumber of any suitable nominal dimensions, and each of the three structural members 108 are intermittently positioned at various heights interposed and secured between vertical structural posts 142. The three structural members 108 are intermittently positioned at various heights interposed and secured between vertical structural posts 142, although other embodiments are contemplated where fewer than three or more than three structural members 108 are interposed and secured between vertical structural posts 142.

In the embodiment illustrated in FIG. 7B, structural members 108 are constructed of a U-shape channel preferably comprised of a metal such as aluminum, steel, galvanized steel, stainless steel, or the like. However, it shall be appreciated that the structural member 108 may take numerous configurations such as C-shaped channel, hollow tubing of rectangular or square cross section, solid tubing of rectangular or square cross section, an L-shaped channel, square bar, or round bar.

The structural member 108 may comprise a plurality of apertures structured to accept the fasteners 118, or in some embodiments the structural member 108 may require drilling or punching of apertures into structural member 108 to accept the fasteners 118.

The structural posts 142 may be wood, plastic, metal such as steel, galvanized steel, stainless steel, aluminum, and so forth. The structural posts 142 may be cylindrical tubular members with substantially circular cross-sectional geometry of the outer diameter of the structural posts 142. To aid in cost reduction, transportation, and/or manufacturability, the structural posts 142 may comprise an inner diameter and a constant cross-sectional wall-thickness, such as to create a hollow void within the structural posts 142. Although the structural posts 142 are depicted in FIG. 7 as cylindrical tubular members, it shall be appreciated that a number of alternate configurations of the structural posts 142 is possible, such as hollow square tubing, wooden posts of square or circular cross-section, metal I-beams, U-channels, C-channels, and so forth.

The structural posts 142 are secured to the surface 150 by placing the structural posts 142 in a vertical orientation, within a hole in the surface 150, and pouring cementitious material 146 in the hole. The cementitious material 146 is then allowed to dry, thereafter creating a rigid coupling between the structural posts 142 and the surface 150. The cementitious material may be asphalt, concrete, cement, concrete alternatives such as composites, rubbers, and so forth. The surface 150 may be any number of surfaces, including but not limited to grass, dirt, sand, concrete, asphalt, cement, rubber, metal, or the like. Although the cementitious material 146 is shown in FIG. 7, it shall be appreciated that in some embodiments, cementitious material 146 may not be necessary, and as such the structural posts 142 may be inserted directly into the hole in surface 150. Furthermore, it shall be appreciated that in other embodiments not depicted graphically, the structural posts 142 may comprise a flanged portion with a plurality of apertures structured to accept bolts such as lag-bolts, anchor-bolts, or the like. In such an embodiment, the structural posts 142 may be fastened and secured to the cementitious material 146 or directly to the surface 150.

While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of, and not restrictive on, the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.