Patent application title:

MODULAR WALL JUNCTIONS BRACKET SYSTEMS AND METHODS

Publication number:

US20260110170A1

Publication date:
Application number:

19/364,704

Filed date:

2025-10-21

Smart Summary: Modular wall junction bracket systems help install interior walls easily. They use special brackets to connect wall frames to a central guide, which keeps everything stable and secure. The guide has features that allow for adjustments, making it easier to set the walls at different angles during installation. This design improves flexibility and efficiency when building walls in different spaces. Overall, it makes the process of constructing modular walls simpler and more reliable. 🚀 TL;DR

Abstract:

Various embodiments provide modular wall junction bracket systems and methods for installing interior modular walls. They may utilize a plurality of frame rail brackets to connect corresponding frame rails to a central installation guide, forming a base for modular walls. The installation guide serves as a structural junction, anchoring the wall setup to the building's floor, ensuring stability and security. The installation guide features a sequence of registration structures, potentially accompanied by moveable connectors, to loosely secure the system yet still provide the adjustability to permit customized angular arrangements during the initial alignment process. This system enhances flexibility, security, and efficiency in constructing modular interior walls in various spaces within a building or any environment.

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Classification:

E04B1/2403 »  CPC main

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal Connection details of the elongated load-supporting parts

E04B2001/2415 »  CPC further

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal; Connection details of the elongated load-supporting parts Brackets, gussets, joining plates

E04B1/24 IPC

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons the supporting parts consisting of metal

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Ser. No. 63/710,002 , filed Oct. 21,2024, the entire content of which is incorporated herein by reference in its entirety.

BACKGROUND

1. Field of the Application

The present application relates to modular wall junction bracket systems and methods for interior wall installation. Specifically, the application relates to bracket systems and methods using at least two frame rail brackets that each engage with both a respective frame rail and installation guide to facilitate and speed up the installation of walls by systematically and securely connecting various wall components together.

2. Description of the Related Art

Wall installation is a fundamental aspect of construction and interior design, integral to defining spaces, enhancing aesthetics, and ensuring structural integrity. The process involves erecting dividers or barriers within structures, aligning and securing various components such as frames, panels, and insulations to construct a robust and functional wall. Different materials and methodologies can be employed, ranging from traditional wood framing to modern modular systems, each bringing unique characteristics and benefits to the overall design and functionality of the space. The choice of materials, design approaches, and installation techniques significantly influences the wall's durability, appearance, and acoustic and thermal properties. Effective wall installation uses a harmonious balance of precision, creativity, and technical knowledge, ensuring that the resulting structures meet the requisite standards of quality and performance, while aligning with the overarching aesthetic and functional objectives of the space.

Traditional wall installation processes often present significant challenges, being notably tedious and fraught with complexities that make them time-consuming. A predominant issue lies in the need for meticulous alignment and the secure attachment of wall pieces, necessitating precision and attention to detail that contribute to the process's laborious nature.

Consequently, the inventors have recognized it would be desirable to provide innovation and improvement of current systems and methods—ones that prioritize simplifying and optimizing the installation process. An advantageous system would emphasize facilitating a smoother, more efficient alignment process, ensuring that each component is secured robustly, enhancing overall structural integrity and stability.

Furthermore, such systems and methods should promote enhanced connection amongst wall components, fostering a cohesive assembly process that minimizes errors, reduces installation time, and contributes to the overall reliability and durability of the installed walls. This would represent a significant advancement in wall installation methodologies, addressing prevailing issues and offering a more streamlined, effective approach to wall installation.

Therefore, the inventors have endeavored to develop modular wall junction bracket systems and methods, designed to enhance the installation process by ensuring a secure and stable assembly of wall components through the utilization of frame rails, brackets, and an installation guide, thereby enhancing efficiency and accuracy of the installation.

SUMMARY

The present disclosure relates to systems and methods for aligning longitudinally extending frame rails for installing a modular wall system in a building space, the system comprising at least two frame rail brackets, each of the frame rail brackets being configured for an attachment to a frame rail with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the frame rail. The attachment is configured at adjustable installment lengths along the modular frame rail bracket. An installation guide is used for mounting to an interior surface of the building space, the installation guide including at least two bracket connectors angularly displaced from one another. The installation guide enables the frame rail brackets to be configured at variable installment angles with respect to an axis of the installation guide that extends perpendicularly to the interior surface. Each of the frame rail brackets have a guide connector at an end thereof, each of the bracket connectors and the guide connectors being configured for connection to one another to secure the frame rail brackets to the installation guide for orienting the frame rail brackets at their variable installment angles to align the frame rails in a position for permanent securement thereafter during installation of the modular wall system.

In some embodiments, the installation guide incorporates at least two bracket connectors, each with distinct functionalities to optimize the installation process. Included in these connectors may be a fixed bracket connector, providing a reliable point of attachment. Accompanying the fixed bracket connector may be a movable bracket connector, designed to offer adaptability and customization in the installation process. Unlike the fixed counterpart, the movable bracket connector may be able to move between different angles relative to the fixed bracket connector. This movement may allow for the selection of any angle, or may provide for predefined angles. This distinct feature allows for the variation of the installment angle, granting the flexibility to accommodate diverse installation requirements and preferences, thereby enhancing the method or system's overall versatility and adaptability in wall construction and assembly.

In some embodiments, the installation guide encompasses a base body furnished with a fixed bracket connector securely attached thereto. This design exhibits a robust foundation for the installation process. Integrally, the installation guide is also characterized by a guide slot, which extends circumferentially in relation to the axis, promoting versatile adaptability. Complementing these features, the installation guide is further enhanced with the inclusion of a movable body, on which the movable bracket connector is firmly affixed. This movable body may be accommodated within the guide slot, a design that allows for its sliding reception, thereby facilitating the circumferential movement of the movable bracket connector between different positions and angles relative to the fixed bracket connector. This arrangement may provide a system or method that is both dynamic and precise, improving the flexibility and accuracy of the installation process.

In some embodiments, the installation guide may include at least two bracket registration structures, each associated with a corresponding bracket connector. These bracket registration structures may be precisely configured to actively engage an end of a frame rail bracket. According to various embodiments, this engagement process may facilitate the registration of the guide connector, aligning it seamlessly with the associated bracket connector. Through this configuration, the system or method may provide a harmonious and secure integration of the components, enhancing the reliability and stability of the installation. By facilitating a streamlined alignment and connection process, one or more embodiments may significantly contribute to the effectiveness and efficiency of the wall installation, reinforcing the overall structural integrity.

In some embodiments, each bracket registration structure within the system or method may include a pair of projections that extend upwardly from the installation guide. These projections may be strategically positioned to actively engage the end of the frame rail bracket, fostering a robust connection that underpins the system's stability and precision. According to one or more embodiments, the deliberate upward extension of these projections improves engagement effectiveness, ensuring that the brackets are securely anchored, enhancing the overall integrity of the wall installation.

In some embodiments, each frame rail bracket may have a projection on an end to provide a connection point. The projection may have a guide connector and be configured for receipt between the pair of projections for registration of the guide connector with the associated bracket connector to afford further stability and sturdiness.

In some embodiments, a bore may be disposed between the associated projections and each guide connector. Each pair of projections may be configured to guide alignment of each guide connector bore with the associated bracket connector bore to provide the registration. The system or method may further comprise at least two fasteners each for receipt in the bores when aligned to secure the frame rail brackets to the installation guide. This may enhance stability and afford a more robust connection between rail frames. Certain embodiments are not confined to using only bores, whereas other threaded fasteners or similar projections may be used to establish various connections. For example, a pin may be strategically positioned within the installation guide, extending into a corresponding hole in the rail frame bracket, forming a secure connection between the components.

In some embodiments, the installation guide includes at least two bracket registration structures each associated with a corresponding bracket connector. Each bracket registration structure may be configured to engage an end of a frame rail bracket for registration of the guide connector thereof with the associated bracket connector.

In some embodiments, each bracket registration structure may be a pair of projections extending upwardly from the installation guide for engaging the end of the frame rail bracket.

In some embodiments, each frame rail bracket may have a projection on its end. The projection may include a guide connector and be configured for receipt between the pair of projections for registration of the guide connector thereof with the associated bracket connector.

In some embodiments, each bracket connector may be a bore disposed between the associated projections and each guide connector. Each pair of projections may be configured to guide alignment of each guide connector bore with the associated bracket connector bore to provide said registration.

In some embodiments, at least two fasteners may each be intended for placement within aligned bores, ensuring the secure attachment of the frame rail brackets to the installation guide. These fasteners may aid in maintaining the structure's integrity, enabling a robust and reliable connection during the wall installation process.

In some embodiments, at least one of the frame rail brackets may be angled perpendicularly and configured to run parallel with an internal wall within the building space.

In some embodiments, the installation guide may incorporate a least one hole that is configured to receive a drive screw for permanent securement to the interior surface of the building space thereafter during installation of the modular wall system.

In some embodiments, the present invention includes a method for longitudinally extending frame rails for installing a modular wall system in a building space.

In some embodiments, the present invention includes a system for aligning longitudinally extending frame rails for installing a modular wall system in a building space at the juncture of a wall and a horizontal surface comprising a floor surface or ceiling surface, the system comprising at least a frame rail bracket system comprising at least a vertical frame rail bracket and a horizontal frame rail bracket. The vertical frame rail bracket being configured for attachment to a vertical frame rail for extending vertically along the wall with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the vertical frame rail. The horizontal frame rail bracket being configured for attachment to a horizontal frame rail for extending horizontally along the horizontal surface with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the horizontal frame rail. An installation guide for mounting to an interior surface of the building space and the installation guide comprising a bracket connector. The frame rail bracket system having a guide connector, each of the bracket connector and the guide connector being configured for connection to one another to secure the vertical and horizontal frame rail brackets to the installation guide for orienting the frame rail brackets at their vertical and horizontal orientations, respectively, to align the frame rails in a position for permanent securement thereafter during installation of the modular wall system.

In some embodiments, the frame rail bracket system is a one-piece structure comprising the vertical frame rail bracket and the horizontal frame rail bracket formed together as one-piece in an L-shape.

Other aspects, features, and advantages of the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

An exemplary embodiment will now be described with reference to the accompanying drawings, in which:

FIG. 1 shows the insertion of a frame rail bracket into a frame rail.

FIG. 2 illustrates an initial setup before the frame rails are secured and aligned along the floor space.

FIG. 3 shows the rail frames, positioned and anchored to the installation guide, configured to be secured to the floor space.

FIG. 4 illustrates another embodiment and shows an initial setup before the frame rails are secured and aligned along the wall and floor space.

FIG. 5 relates to the FIG. 4 embodiment and shows the rail frames, positioned and anchored to the installation guide, configured to be secured to the wall and floor space.

FIG. 6A-6D shows examples of circular installation guides paired with swivel connectors.

FIG. 7A-7B shows an example of a modular wall junctions bracket system that is secured using an installation guide, one fixed frame rail bracket configuration, and two frame rail bracket configurations joined via swivel connectors.

FIG. 8 shows examples of modular wall junctions bracket systems with two-and three-way connections with a variety of angular capabilities, corner markers, and corner marker frameworks.

DETAILED DESCRIPTION OF DRAWINGS AND ILLUSTRATED EMBODIMENTS

One or more embodiments of the present invention account for enhanced efficiency and simplified assembly in wall installations. Various embodiments ensure a secure, stable connection among wall components, utilizing a strategic combination of frame rails, connectors, and guides, thereby minimizing the necessity for exhaustive precision and thorough attention to detail.

The present application discloses systems and methods for constructing interior walls using modular wall junction brackets. FIG. 1 shows the insertion of a frame rail bracket 102 into a frame rail 104. The interior wall construction need not be office related, but can be any setting, including residential, factory, educational, or otherwise. Such settings may include both indoor and outdoor spaces as well, highlighting the system's adaptability in various environments. This adaptability to both indoor and outdoor applications is facilitated by the modular nature of the wall junction brackets. They can be designed to withstand different environmental conditions, making them suitable for outdoor use where they might be exposed to weather elements. The ability to quickly assemble and disassemble these structures aligns well with the dynamic needs of various settings, from temporary event spaces to permanent installations in homes or educational institutions.

Modular walls typically have frames supporting panels of a variety of styles. Such panels may be wood, frameless glass (or another translucent or transparent material), framed glass, gypsum, fiberboard, canvas exterior, metal, etc. Such panels can also be functional components, like a whiteboard, display screen, etc. The types of modular walls and panels thereof is not limiting, and the examples mentioned herein are exemplary only. For context, the present application incorporates by reference the following co-owned applications, including for teachings regarding the general features and installation steps for modular wall systems and the individual wall panels thereof: U.S. Provisional Application Nos. 63/347,742; 63/328,756; 63/338,274; 63/327,389; 63/470,037; U.S. Non-Provisional application Nos. Ser. No. 18/129,681 (U.S. Pat. No. 12,410,611); Ser. No. 18/127,617 (U.S. Published Application No. US 2023/0323662); Ser. No. 18/766,606 (U.S. Published Application No. US 2024/0360666); Ser. No. 18/143,478 (U.S. Published Application No. US 2023/0358036); Ser. No. 18/203,175 (U.S. Published Application No. US 2023/0392372); Ser. No. 18/677,128 (U.S. Published Application No. US 2024/0417973); and International Application Nos. PCT/US2023/016648 (PCT Published Application No. WO2023/196143); PCT/US2023/016640 (PCT Published Application No. WO2023/196142); PCT/US2023/021053 (PCT Published Application No. WO2023/215511); PCT/US2023/023844 (PCT Published Application No. WO 2023/235301); PCT/US2024/031414 (PCT Published Application No. WO 2024/249483).

FIG. 1 illustrates an initial setup environment 10 in which a frame rail bracket 102 can be inserted into a corresponding frame rail 104. The frame rail bracket 102 and frame rail 104 may be of aluminum or steel, but may also be made of other metals, or any other material suitable for mounting a modular wall section, e.g., rigid plastics, composites, with options for either temporary or permanent mounting. The internal structure of the frame rail 104 is formed to permit the frame rail bracket 102 to seamlessly attach to the corresponding frame rail 104. The attachment may be configured at adjustable installment lengths along the modular frame rail bracket. In some embodiments, the frame rail 104 is designed with internal channels that facilitate a sliding action of the frame rail bracket 102. As the bracket is moved into place, it “rides” along these channels. This action is not merely a sliding movement but is purposefully designed so that as the frame rail bracket 102 moves, it creates a frictional interaction with the sides of the channels of the frame rail 104. This interaction is calibrated: as the frame rail bracket 102 is pushed further into the channel, it begins to exert a greater force against the channel walls of the frame rail 104. This force is a result of the frame rail bracket's 102 structural design, which may include slightly angled or textured surfaces intended to “bite” into the material of the channels of the frame rail 104. As a result of this biting action, a friction lock is created. This lock serves as a temporary holding mechanism, keeping the frame rail bracket 102 securely in place within the frame rail 104 without the immediate need for additional fasteners. The inherent tension generated by this friction fit provides a robust hold, ensuring that the frame rail bracket 102 maintains its position even under varying stress conditions. This feature is particularly advantageous during the construction process, as it allows for adjustments to be made before the final securement is applied, enhancing both the installation efficiency and the structural integrity of the assembled framework. Additionally, this allows the modular frame rail bracket and frame rail to be attached at adjustable lengths, enabling custom angles and lengths on the fly and reducing the need for machine-fitted pieces that are fit to specific lengths. This adjustability also eliminates the need for the frame rail bracket and frame rails to be stamped and finished on both sides beforehand, allowing them to be secured directly to the floor and through one another once the desired length is set. Nevertheless, frame rails with their corresponding brackets may also come pre-assembled or be assembled at the installation site. Utilizing a bracket such as the frame rail bracket 102 depicted in FIG. 1, affords flexibility and customizability to permit different angular frame rail 104 arrangements.

The frame rail bracket 102 is also configured to engage with the installation guide 100 by establishing a connection via a guide connector 103 and frame rail bracket shoulders 88 and 90. The installation guide 100 includes at least two or more upwardly extending registration structures 101 that stick out from their base 105 and permit a passive registration with respective frame rail bracket shoulders 88 and 90 of a corresponding frame rail bracket 102. The passive registration design allows the frame rail bracket 102 to be loosely secured while maintaining the ability to adjust its desired angular position. This enables a provisional attachment of the frame rail bracket 102 to the installation guide 100, a process that does not initially require tight fastening or the use of specialized tools. According to one or more non-limiting embodiments, this loose engagement may be helpful during the preliminary stages of assembly, where adjustments and alignments may be frequently necessary. The frame rail bracket 102 and the installation guide's 100 design is such that, despite being only creating an initial loose attachment, it remains sufficiently stable to prevent dislocation or detachment under nominal conditions.

The installation guide 100 may contain any number of registration structures 101 that may engage with any number of frame rail brackets 102. The engagement with the registration structures 101 sets the variable installation angle for the frame rail 104. For example, in FIGS. 2 and 3, four registrations structures 101 are in 90 degree pairs, so two rails 104 can be easily aligned at 90 degree increments (e.g., 90, 180, 270 degrees). According to different embodiments, the angular increments may be different. For example, an embodiment with 60 degree increments using six structures 101 will provide rail-to-rail angles of 60, 120, 170, 180, 240, and/or 300 degrees. Any angular increment can be used (e.g., 10, 30, 45, 120, etc.). In the illustrated embodiment, all increments are the same 90 degrees. However, according to other embodiments, the angular increments may be heterogenous (e.g., a mixture of 45 and 90 degree increments around a 360 degree perimeter of the guide 100. This variability in installment angles not only allows for custom modular wall designs in any environment but also permits direct engagement with the floor without the need for an intermediate bracket or similar support. Additionally, the modular frame rail bracket can be formed in various custom shapes and sizes, allowing different angles and arrangements for attachment on the installation guide to meet the specific needs of the custom wall arrangement.

Once registered, the frame rail bracket 102 may be secured in place using a screw or another type of fastener by establishing a connection between the guide connector 103 and one of the ancillary installation guide bores 98. Moreover, the bottom of the installation guide 100 may be outfitted with a range of adhesive mechanisms, such as Velcro, tape, or the like. For example, such adhesive mechanisms may be used for the initial registration of the installation guide 100 with the floor, offering both secure and flexible attachment during the installation process. Once installation is complete, the installation guide 100 may then be anchored to the floor space via a fastener such as a drive screw or another type of fastener using the primary installation guide bore 86.

Once the temporary structure is set in place, a user may insert two screws or any form of fasteners within frame rail ports 92 and 94. As the user turns the screw, frame rail bracket 102 travels up the screw threads while the end of the screw engages with the bottom of frame rail 104. Eventually, frame rail bracket 102 is bound against the flanges and the screw will be friction bound within the frame rail's internal channel. This effectively further reinforces the friction-based locking along the channels of the frame rail 104 and creates a binding mechanism for secure attachment. The placement of two screws within frame rail ports 92 and 94 can optionally occur near the final stage of assembly, facilitating adjustments towards the completion of setup, or earlier in the process if necessary. However, if inserted before final adjustments, the screws may be loosened (or not fully tightened) to allow for subsequent alignment modifications. Lastly, the frame rail bracket slot 96 may afford the user the ability to permanently anchor the frame rail bracket 102 along with its respective frame rail 104 to the floor space using fasteners-usually in the form of anchor screws. At any time, if additional securing is needed, self-tapping screw (e.g., wood or concrete depending on the subflooring) can be driven into the extrusion of frame rail 104 from above. At times a through-hole might need to be drilled into the extrusion of frame rail 104 prior to anchoring to the floor. In the same manner, the frame rail ports 92 and 94 of frame rail bracket 102 can be opened as to allow a self-tapping screw to anchor both the frame rail bracket 102 and frame rail 104 to the floor surface.

In some embodiments, the interaction between the frame rail bracket 102 and the internal structure of the rail frame 104 is engineered to enhance securement. This is achieved through a mechanism that allows the two components to engage more intimately, for example, through a “snap-in-place” feature. When the frame rail bracket 102 is aligned with the rail frame 104, specific elements of their structures—such as protrusions on one component and corresponding recesses on the other—may interlock. This engagement is facilitated by the inherent elasticity or designed flexibility of the materials involved, allowing one piece to temporarily deform and then snap back into its original shape once it is correctly positioned within the other. This snapping action not only simplifies the assembly process, allowing for quick and efficient installation, but also significantly strengthens the connection between the two components. Once engaged, the rail frame bracket 102 and rail frame 102 form a robust unit, less susceptible to vibrations or accidental dislodgment. This secure fit is particularly critical in modular construction, where the stability of the components can directly impact the overall integrity of the structure. The “snap-in-place” feature, therefore, contributes both to the ease of assembly and the long-term durability of the construction.

FIG. 2 illustrates an initial setup environment 10 in which two frame rail brackets 102 and 106, inserted within their corresponding frame rails, 104 and 108 respectively. The frame rail brackets 102 and 106 may passively register with their corresponding registration structures 101 in order to form the initial foundation of a modular wall structure. The guide connectors 103 of each frame rail bracket 102 and 106 may then be secured via a fastener 112 with a respective ancillary installation guide bore 98. In some embodiments, bore 98 can be tapped in order to receive fastener 112.

FIG. 3 illustrates a configuration setup environment 20 in which a set of two frame rail brackets 102 and 106 are passively registered with corresponding registration structures 101 and secured in place using guide connector fastener 112 which may be in the form of a screw or another type of fastener. These guide connector fasteners 112 are threaded (and may be generally short in length) as to set the frame rail bracket 102 to the installation guide 100, which in turn, is anchored to the floor via the drive screw 110. In the alternative, these guide connector fasteners 112 may also be made of concrete for building floors, plastic, etc. Each guide connector fastener 112 is normally secured in place typically after the final adjustments are made. Once the guide connector fasteners 112 are secured, the frame rail brackets 102 and 106 may hold the frame rails 104 and 108 in place if they have been fastened into place via their frame rail ports 92 and 94. Afterwards, a modular wall can then be installed and held in place via the configured setup environment 20. The installation guide 100 further afford a temporary engagement with the floor using an adhesive, however, the installation guide 100 may then be completely secured to the floor surface via a drive screw 110 or another type of fastener via the primary installation guide bore 86.

In some embodiments, a laser alignment tool may be utilized to determine the strategic placement of the installation guide 100 within the floor space. Essentially, this allows a user to quickly determine the optimal location for the installation guide 100, facilitating a quicker transition to the measuring process. Subsequently, the user can then confirm and adjust the specific layout and placement of additional structures such as the floor tracks and brackets, wall track and brackets, ceiling track and brackets, etc. Specifically, this tool may project highly visible laser lines onto the floor, which can be either straight or at specific angles, depending on the requirements of the modular construction. With the laser lines as a reference, the user can determine the exact location for the installation guide 100 with high precision. This level of accuracy ensures that the modular wall components will align correctly during the later stages of assembly. The laser alignment tool not only increases the precision of placement but also speeds up the process, as it eliminates the need for traditional, more time-consuming measurement methods. Initially, the installation guide 100 may be temporarily affixed to the floor with an adhesive that allows for repositioning. Thus, by employing the laser alignment tool, the user can make on-the-fly adjustments to the position of the installation guide 100, which may be beneficial in situations where structural elements or floor irregularities present a challenge. The immediate visual feedback from the laser lines enables quick decisions and adjustments, ensuring that the installation guide 100 is optimally positioned before proceeding with the securement process. This technological aid can be particularly useful in complex installations, where multiple installation guides are to be positioned at various points across a large area, or where the alignment of the guides aids the structural integrity and aesthetic outcome of the finished construction. Final securement is then achieved by inserting a drive screw 110, or an alternative fastening device, through the primary installation guide bore 86, as illustrated in FIG. 3.

FIG. 4 illustrates an initial setup environment 10 for another embodiment, in which a pre-assembled frame rail bracket system 115 comprising a horizontal frame rail bracket 102 and a vertical frame rail bracket 116. In the illustrated embodiment, the frame rail bracket system 115 is configured as one piece (i.e., an integrally formed bracket) comprising a horizontal frame rail bracket 102 and a vertical frame rail bracket 116 formed together as one-piece in an L-shape that can register with the registration structures 101. The installation guide 100 and its corresponding registration structures 101, allow for multiple rail brackets to intersect and register. The horizontal frame rail bracket 102 engages with a corresponding horizontal frame rail 104, as described above, and a vertical frame rail bracket 116 engages with a corresponding vertical frame rail 114. In some embodiments, the frame rail bracket system 115 is configured as two separate pieces engaged with one another (i.e., interlocked in place), where the installation guide 100 allows for multiple rail brackets 102, 116 to intersect and register with the registration structures 101—as shown in the other figures.

The frame rail bracket system 115 via the vertical frame rail bracket 116 can then engage with a vertical frame rail 114 that is perpendicular to a wall space to align the modular wall with the interior wall space of the room. The T screw 105 and T nut 107 work in tandem in order to secure the frame rail bracket system 115. Specifically, the T nut 107 has a width that is thin enough to fit into the track of a vertical frame rail bracket 116 and vertical frame rail 114, however, when rotated via the T screw 105—it locks in place since the length is longer than the width and the rotating action due to the corners, dimensionally “expand” into the space under the T shaped ledge preventing it from pulling out while drawing the assembly together. The installation guide 100 then engages with the frame rail bracket system 115 in order to hold the temporary structure in place. This thus enhances alignment in a manner similar to the prior embodiment, but in the context of a connection at a floor-wall junction (or a ceiling wall junction). The installation guide in FIGS. 4 and 5 therefore provides for proper alignment between the vertical and horizontal rail members 104, 114, including ensuring the horizontal frame rail 104 is at the correct installment angle (90° as shown) to the vertical frame rail 114 and the wall.

FIG. 5 illustrates a configuration setup environment 20 in which a frame rail bracket system 115 is engaged with a corresponding vertical frame rail 114. The frame rail bracket system 115 engages with the corresponding horizontal frame rail 104 in order to form a corner junction with the interior wall of the building space. The frame rail bracket system 115 passively registers with corresponding registration structures 101 and is further secured via the guide connector 103 and a guide connector fastener 112. Next, a drive screw 110 may engage with a guide connector 103 in order to establish a stable and secure modular wall junction within the building space. Alternatively, installation guide 100 may be fastened to the ground using drive screw 110, then the frame rail bracket system 115 may be attached to installation guide 100 by a guide connector fastener 112 (e.g., threaded screw), which is permissible since the clearance opening 112 in the frame rail bracket system 115 allows the drive screw 110 to be placed and secured first. Such an alternative arrangement permits the frame rail bracket system 115 to be removed or repositioned since the installation guide 100 can be installed first to ensure proper measurements and approval prior to the installation of more expensive components.

FIG. 6A-6D show an installation guide 140 including at least one fixed base connector 121 and one or more swivel connectors 134, which are moveably entrapped connectors in which the entrapment shape is predicated by the movement range useful to form various multi-angled intersections. The shape of the swivel connectors 134 is not limiting, and any body shape providing for circumferential/angular movement of the swivel connectors 134 relative to the fixed base connector 121 may be used. The circular installation guide 140 includes at least one primary installation guide bore 86 that may take the form of various shapes and/or sizes to afford optimal securement to the floor of the building space. The primary installation guide bore 86 is configured to engage with a corresponding fastener that will permanently secure the installation guide 140 to the floor. Further, the installation guide 140 includes a series of ancillary installation guide bores 98 that can take the form of various shapes and sizes to secure the frame rail brackets 102 to the installation guide 140. The installation guide 140 may also include a plurality of registration points 126, 128, 130, and 132 that permit a passive registration with a plurality of corresponding frame rail brackets 102 in order to establish the connection junctions for the modular walls. The swivel connector 134 provides an ancillary securement point and a plurality of registration points 128, 130. The swivel connector 134 may be removed by a user to afford further customizability and flexibility when positioning a frame rail. Additionally, the swivel connector 134 may optionally slide along the open area of the circular installation guide to permit various angular arrangements based on user preference when constructing the modular wall junctions for the building space.

FIG. 7A-7B show a modular wall junctions bracket system 142 for connecting three frame rails 104. The frame rails 104 are secured to the brackets 102 using two frame rail port screws 145 and 146. This securement is described above in FIG. 1. The frame rail brackets 102 are then joined to an installation guide 144 that provides attachment via a fixed connector and one or more optional swivel connectors 134. Each swivel connector 134 includes at least one installation guide bore 98, which is a protrusion (registration structure). The swivel connectors 134 also utilize their exterior shape for registration, leveraging their form and the nature of being an inserted element. As shown in FIG. 7A-7B, one of the rail bracket connection points is integrated into the guide base of the guide 144, while the other two rail bracket connection points are provided by the swivel connectors 134. Further, as depicted in FIG. 7B, the connection with the installation guide 144 is secured using guide connector fasteners 112, which can be used to secure a fixed frame rail bracket 102 and the frame rail brackets 102 that have been joined via the swivel connectors 134. The swivel connectors 134 afford greater flexibility and customizability when laying the modular wall junctions bracket system onto the floor and designing the interior modular wall space. Further, the installation guide 144 may include “gear” registrations permitting any number of angles (e.g., in predefined increments of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, and/or 10 degrees, in other common increments (e.g., 10, 22.5, 30, 45, 60, 90 degrees)) of rotation for the swivel connectors 134. These registrations could also be replaced by markings to accommodate the most common angles utilized. Once configured and laid onto the floor, the modular wall junctions bracket system is then secured via a connection between the primary installation guide bore 86 and a fastener such as a screw or pin that holds the modular wall junctions bracket system into place. The frame rail bracket 102 may then be secured via the installation guide bore 98 that permits the connection of the bracket notch with a fastener (i.e., partial pin).

In contrast to FIG. 1-3 where the angle is fixed at 90° (or 180°), in FIGS. 6 and 7 or similar embodiments, the user can choose any angular arrangement they want by moving the swivel connections 134 capable of gliding along a defined circumferential pathway. The unique design of these swivel connections 134 allows for a smooth and continuous range of motion, thereby enabling the user to set the walls at any desired angle beyond the fixed positions of 90° or 180° degrees, providing a versatile solution for creating customized building space layouts.

FIG. 8 shows examples of the modular wall junctions bracket systems with two-and three-way connections with a variety of angular capabilities and corner markers. The frame rail bracket 102 intersects with an installation guide 140 (circular embodiment). Since the installation guide 140 is circular shaped, this affords various angular capabilities such as 120°, 135°, and 150° angles, and can be used as an alternative to the guide 100. The modular wall junctions bracket system further incorporates corner marker frameworks 154, 166, and 172 as well as variously shaped corner markers 150, 152, 156, 160, 162, 164, 170, and 174. The variously shaped corner markers 150, 152, 156, 160, 162, 164, 170, and 174 may be crafted based on the distinctly preferred angles to form a specific corner junction that fits the desired interior modular wall junctions. The exterior corner marker frameworks 154, 166, and 172 are also fitted to craft the preferred corner junctions and may include a variety of frame trim members as depicted in exterior corner marker frameworks 166 and 172. The frame trim members are equipped with latches to facilitate end-to-end junctions, also providing coverage for the spaces between vertical members. Additionally, the interior sections can accommodate corner marker frameworks 158 and 168, enabling latching for stacked internal vertical members. The corner marker frameworks and corner markers (i.e., slotted walls) are vertical extrusions, which run from floor to ceiling forming a finished corner. This setup enables the creation of more complex corners and junctions for the desired wall space.

The foregoing embodiments have been provided solely to illustrate the structural and functional principles of the present invention and are not intended to be limiting. To the contrary, the present invention includes all substitutions, modifications, alterations and equivalents within the spirit and scope of the following claims.

Claims

What is claimed is:

1. A system for aligning longitudinally extending frame rails for installing a modular wall system in a building space, the system comprising:

at least two frame rail brackets, each of the frame rail brackets being configured for attachment to a frame rail with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the frame rail;

an installation guide for mounting to an interior surface of the building space, the installation guide including at least two bracket connectors angularly displaced from one another;

wherein the installation guide enables the frame rail brackets to be configured at variable installment angles with respect to an axis of the installation guide that extends perpendicularly to the interior surface;

each of the frame rail brackets having a guide connector at an end thereof,

each of the bracket connectors and the guide connectors being configured for connection to one another to secure the frame rail brackets to the installation guide for orienting the frame rail brackets at their variable installment angles to align the frame rails in a position for permanent securement thereafter during installation of the modular wall system.

2. The system according to claim 1, wherein the at least two bracket connectors of the installation guide includes a fixed bracket connector and a movable bracket connector, the movable bracket connector being movable circumferentially with respect to the axis to vary the installment angle.

3. The system according to claim 2, wherein the installation guide comprises a base body with the fixed bracket connector fixed thereto and a guide slot extending circumferentially with respect to the axis,

the installation guide further comprising a movable body with the movable bracket connector fixed thereto, the movable body being slidably received in the guide slot to provide for circumferential movement of the movable bracket connector with respect to the axis.

4. The system according to claim 1, wherein the installation guide includes at least two bracket registration structures each associated with a corresponding bracket connector, each bracket registration structure being configured to engage an end of a frame rail bracket for registration of the guide connector thereof with the associated bracket connector.

5. The system according to claim 4, wherein each bracket registration structure is a pair of projections extending upwardly from the installation guide for engaging the end of the frame rail bracket.

6. The system according to claim 5, wherein each frame rail bracket has a projection on an end thereof, the projection having the guide connector and being configured for receipt between the pair of projections for registration of the guide connector thereof with the associated bracket connector.

7. The system according to claim 6, wherein each bracket connector is a bore disposed between the associated projections and each guide connector is a bore, wherein each pair of projections is configured to guide alignment of each guide connector bore with the associated bracket connector bore to provide said registration.

wherein the system further comprises at least two fasteners each for receipt in the bores when aligned to secure the frame rail brackets to the installation guide.

8. The system according to claim 2, wherein the installation guide includes at least two bracket registration structures each associated with a corresponding bracket connector, each bracket registration structure being configured to engage an end of a frame rail bracket for registration of the guide connector thereof with the associated bracket connector.

9. The system according to claim 8, wherein each bracket registration structure is a pair of projections extending upwardly from the installation guide for engaging the end of the frame rail bracket.

10. The system according to claim 9, wherein each frame rail bracket has a projection on an end thereof, the projection having the guide connector and being configured for receipt between the pair of projections for registration of the guide connector thereof with the associated bracket connector.

11. The system according to claim 10, wherein each bracket connector is a bore disposed between the associated projections and each guide connector is a bore, wherein each pair of projections is configured to guide alignment of each guide connector bore with the associated bracket connector bore to provide said registration.

wherein the system further comprises at least two fasteners each for receipt in the bores when aligned to secure the frame rail brackets to the installation guide.

12. The system of claim 1, wherein the installation guide includes at least one hole being configured to receive a fastener for permanent securement to the interior surface of the building space thereafter installation of the modular wall backet system.

13. The system of claim 1, wherein the attachment between the frame rail bracket and respective frame rail includes an insertion of the frame frail bracket into a channel of the corresponding frame rail.

14. The system according to claim 1, wherein each of the frame rail brackets are configured to be attached to a frame rail at adjustable installment lengths of the frame rail bracket.

15. A method for aligning longitudinally extending frame rails for installing a modular wall system in a building space, the method comprising the steps of:

connecting at least two frame rail brackets, each of the frame rail brackets being configured for attachment to a frame rail with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the frame rail;

securing the at least two frame rail brackets to an installation guide for mounting to an interior surface of the building space, the installation guide including at least two bracket connectors angularly displaced from one another for enabling the frame rail brackets to be configured at variable installment angles with respect to an axis of the installation guide that extends perpendicularly to the interior surface;

wherein each of the frame rail brackets has a guide connector at an end thereof,

connecting each of the bracket connectors and the guide connectors to one another to secure the frame rail brackets to their respective installation guide for orienting the frame rail brackets at their variable installment angle to align the frame rails in a position for permanent securement thereafter during installation of the modular wall system.

16. The method according to claim 15, wherein the at least two bracket connectors of the installation guide include a fixed bracket connector and a movable bracket connector, the movable bracket connector being movable circumferentially with respect to the axis to vary the installment angle.

17. The method according to claim 15, wherein the installation guide comprises a base body with the fixed bracket connector fixed thereto and a guide slot extending circumferentially with respect to the axis, the method including securing the base body to the interior surface of the building space;

the installation guide further comprising a movable body with the movable bracket connector fixed thereto, the movable body being slidably received in the guide slot to provide for circumferential movement of the movable bracket connector with respect to the axis.

18. The method according to claim 15, wherein the installation guide includes at least two bracket registration structures each associated with a corresponding bracket connector, each bracket registration structure being engaged with an end of a frame rail bracket for registration of the guide connector thereof with the associated bracket connector during the connecting.

19. The method according to claim 16, wherein the installation guide includes at least two bracket registration structures each associated with a corresponding bracket connector, each bracket registration structure being engaged with an end of a frame rail bracket for registration of the guide connector thereof with the associated bracket connector during the connecting.

20. The method of claim 15, wherein the installation guide includes at least one hole that receives a drive screw fastener for permanent securement to the interior surface of the building space during installation of the modular wall backet system, the method further comprising inserting the drive screw fastener through each of the at least one hole for permanent securement.

21. The method of claim 15, wherein the attachment between the frame rail bracket and respective frame rail includes an insertion of the frame frail bracket into a channel of the corresponding frame rail.

22. The method of claim 15, further comprising the attachment of the frame rail brackets to the frame rails, which includes adjusting the installment length of each frame rail of the frame rail bracket.

23. A system for aligning longitudinally extending frame rails for installing a modular wall system in a building space at the juncture of a wall and a horizontal surface comprising a floor surface or ceiling surface, the system comprising:

a frame rail bracket system comprising a vertical frame rail bracket and a horizontal frame rail bracket, the vertical frame rail bracket being configured for attachment to a vertical frame rail for extending vertically along the wall with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the vertical frame rail, the horizontal frame rail bracket being configured for attachment to a horizontal frame rail for extending horizontally along the horizontal surface with a portion of the bracket extending outwardly therefrom in a longitudinal direction of the horizontal frame rail;

an installation guide for mounting to an interior surface of the building space, the installation guide comprising a bracket connector;

the frame rail bracket system having a guide connector,

each of the bracket connector and the guide connector being configured for connection to one another to secure the vertical and horizontal frame rail brackets to the installation guide for orienting the frame rail brackets at their vertical and horizontal orientations, respectively, to align the frame rails in a position for permanent securement thereafter during installation of the modular wall system.

24. The system of claim 23, wherein the frame rail bracket system is a one-piece structure comprising the vertical frame rail bracket and the horizontal frame rail bracket formed together as one-piece in an L-shape.

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