CA2075014A1 - Modular wall panel system - Google Patents
Modular wall panel systemInfo
- Publication number
- CA2075014A1 CA2075014A1 CA 2075014 CA2075014A CA2075014A1 CA 2075014 A1 CA2075014 A1 CA 2075014A1 CA 2075014 CA2075014 CA 2075014 CA 2075014 A CA2075014 A CA 2075014A CA 2075014 A1 CA2075014 A1 CA 2075014A1
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- Canada
- Prior art keywords
- rails
- wall
- spaced
- apart
- frame
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Abstract
MODULAR WALL PANEL SYSTEM
ABSTRACT OF THE DISCLOSURE
A modular wall panel system comprising generally rectangular panels, each of which is fabricated from vertical stiles and horizontal rails. The panels are adapted to be mounted together in a side-by-side relationship or stacked upon one another in a vertical relationship. When the panels are mounted together in a side-by-side relationship, the horizontal rails form a continuous, load bearing track along the length of the wall formed by the panels. Accessory components such as cabinets and work surfaces are mountable to the panels along the continuous load bearing track. The horizontal rails not only form a means for mounting accessory to the wall panels, but they also provide a means for joining adjacent wall panels. Also disclosed is a universal connector for use in joining wall modules to form a continuous wall. A frame member is also disclosed which allows two rail connectors to be used without interfering with one another.
ABSTRACT OF THE DISCLOSURE
A modular wall panel system comprising generally rectangular panels, each of which is fabricated from vertical stiles and horizontal rails. The panels are adapted to be mounted together in a side-by-side relationship or stacked upon one another in a vertical relationship. When the panels are mounted together in a side-by-side relationship, the horizontal rails form a continuous, load bearing track along the length of the wall formed by the panels. Accessory components such as cabinets and work surfaces are mountable to the panels along the continuous load bearing track. The horizontal rails not only form a means for mounting accessory to the wall panels, but they also provide a means for joining adjacent wall panels. Also disclosed is a universal connector for use in joining wall modules to form a continuous wall. A frame member is also disclosed which allows two rail connectors to be used without interfering with one another.
Description
MODULAR WALL PANEL ~YST~M
BACKGROUND OF T~E INVENTION
The present invention relate6 generally to frame systems and more particularly to frame~ used in modular wall panel systems.
The design of most modern inter~or work spaces, especially offices, mu6t possess the fundamental ability to adapt to change. Small changes must be responded to -- such as recognizing an employee's promotion -- as well as major changes -- such as adding employees. Because modern interior space designs must accommodate changing environments, the va6t majority of today's building interior spaces are designed using prefabricated modular wall panel systems. These modular systems allow work areas to be expanded, redesigned, or even eliminated at only a fraction of the cost associated with revamping non-modular designs. The fundamental bullding block of most modular wall panel systems is a generally rectangular frame comprised of horizontal rails and vertical stiles. Typically, the frames are joined in an end-to-end relationship thereby forming a continuous wall. The frame structure generally includes a raceway for routing wires, cables, or other utility services. Also, it is common for one or more hor$zontal rails to be accessible for engaging and supporting vertical loads such as writing surfaces, shelving, and the like.
A common drawback associated with prior art wall panel systems iB that the horizontal rails are noncontinuous acrofis adjoining frames. This typically occurs in frame designs where the horizontal rail terminates short of the end of the frame and the frame end portion is fitted with a peripheral trim member or the like. Consequently, when two frames are adjoined 207~014 in an end-to~end relationship, the horizontal rails are noncontinuous across the frame-to-frame interface. While this type of discontinuity may not be unduly restrictive in some applications, it reduces the number of locations whereby a load may be placed along the rail. Accordingly, in these types of wall panel systems the placement of accessories along the horizontal rail may be dictated more by the shortcomings inherent in the noncontinuous rail sy6tem than by the de6ires of the interior designer.
Additionally, although many wall panel sy6tem6 are fitted with a raceway to accommodate utilities, the raceway is typically confined to one dimension and accordingly, does not lend itself to routing utilities in two or three dimensions.
An ever present concern associated with designing, producing and installing wall panel 6ystems is that of containing cost. One major cost involves connectors and other hardware used to install wall panels. One approach to reducing hardware costs is to design a fastener which has universal applicability for adjoining wall panel frames regardless how, or at what angle, the wall panel frames are joined. It is also desirable to design a universal connector which will accommodate mounting a first wall panel frame anywhere along the horizontal rail of a second wall panel frame.
Accordingly, it i6 an object of this invention to provide a modular wall panel frame having three dimensional raceway capability.
It is a further object of this invention to provide a frame member for use in a modular wall panel sy6tem that provides a means for connecting adjacent frames to form a continuous wall and also provide a frame member which supports vertical loads.
It i6 still a further object of the present invention to provide a universal connector which is used to connect adjoining frames regardles~ of the relative angle between the two frames.
A further object of thi6 invention i8 to provide a universal connector which allows a first frame to be mounted along a second frame at a point intermediate the ends of the second frame.
Another object of the present invention i6 to provide a frame member, which when joined to other frame member~, provides a continuous horizontal rail across joined frame6.
~ ARY OF T~E INVENTION
In light of the foregoing object6, in one a6pect, the pre6ent invention provides a frame member for use in a modular wall panel 6ystem, the frame member including an elongated body having a first wall, second wall, and a connecting wall, the connecting wall extending between and connected to the first snd second walls to maintain the first and second wall6 in a fixed, 6paced-apart relationship to one another. The first and second walls define an inner surface and an outer surface and the first and second walls each include a free end where the free end6 of the first and second walls define an elongated entrance opening. The inner surface6 of the first and 6econd wall form a boundary of a rear zone and a forward zone. The inner 6urface6 of the fir6t and 6econd wall bounding the rear zone include means for engaging and retaining a first connector therebetween. The inner surface6 of the first and second wall bounding the forward zone include means for engaging and retaining a second connector therebetween. The ` 207~01~
inner 6urfaces of the first and second wall include means for maintaining the first and 6econd connectors in a spaced-apart relationship whereby when the first connector is disposed in the rear zone and the second connector is disposed in the forward zone, the first a~ld second connectors are free to move within their respective zones without interfering with one another.
Preferably, the outer surface of one of the first and second walls includes means for engaging and retaining a panel. The connecting wall of the frame member preferably includes a generally planar e~ternal surface for facilitating mounting the member to a support structure.
In a second aspect, the present invention provides a wall panel for u6e in a modular wall panel system. The wall panel includes first and 6econd spaced-apart horizontal frame members and first and 6econd spaced-apart vertical frame members wherein the fir6t and second horizontal frame members are each connected to a vertical frame member. Each frame member including an elongated body having a first wall, 6econd wall, and a connecting wall, the connecting wall extending between and connected to the first and second wallg to maintain the first and second walls in a fixed, spaced-apart relationship to one another. The first and second walls define an inner surface and an outer 6urface and the fir6t and second walls include a free end which defines an elongated entrance opening. The inner surfaces of the first and second walls form a boundary of a rear zone and a forward zone. The inner 6urfaces of the flr6t and ~econd wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner surfaces of the first and second wall bounding the forward zone include means for engaging and retaining a second connector therebetween. The inner surfaces of the first and second wall include means for maintaining the first and second connectors in a spaced-apart relationship whereby when the first connector is 207~01 4 disposed in the rear zone and the second connector i8 disposed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer surface of one of the first and second walls of each frame member includes means for engaging and retaining a panel. In a preferred embodiment, the connecting wall of each frame member include6 a generally planar external surface for facilitating mounting the frame mPmber6 to one another to form the wall panel.
In an additional aspect, the present invention provides a frame 6tructure for use with a modular wall panel system. The frame structure includes two 6paced-apart 6tiles, each stile having a front face and a rear face. The frame structure also includes first, second, third, and fourth rails, the first and second rails are spaced-apart and connected to the front face6 of each of the two 6tiles, wherein the first and second rail6 form a front pair of rail6. The third and fourth rails are spaced-apart and each connected to the rear face of each of the two 6tiles, the third and fourth rail6 forming a rear pair of rails, wherein the rear pair of rail6 are spaced-apart from the front pair of rails. The space between the two spaced-apart 6tiles creates a raceway along a first dimension, and the space between the front pair of rails creates a raceway along a second dimension, and the space between the rear pair of rails creates a raceway along the second dimension spaced-apart from the raceway created by the front pair of rails, and the space between the spaced-apart stiles in conjunction with the space between the front pair of rails in further conjunction with the space between the rear pair of rails creates a raceway along a third dimension whereby the first, second, and third dimensions are mutually orthogonal. In a preferred embodiment, the stiles and rails which make up the frame structure are màde from substantially the same type of frame member, each frame member including an elongated body having a first wall, ~econd wall, and a connecting wall, the connecting wall extending between and connected to the f ir8t and second walls to maintain the first and second walls in a fixed, spaced-apart relationship to one another. The first and second walls define an inner surface and an outer surface and the first and second walls each include a free end. The free ends of the fir6t and second walls define an elongated entrance opening.
The inner surface6 of the first and 6econd wall form a boundary of a rear zone and a forward zone. The inner surfaces of the fir6t and second wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner 6urfaces of the fir6t and 6econd wall bounding the forward zone include means for engaging and retaining a 6econd connector therebetween. The inner surface6 of the first and second wall include mean6 for maintaining the fir6t and second connector6 in a spaced-apart relationship whereby when the first connector i6 disposed in the rear zone and the second connector i6 di6posed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer ~urface of one of the first and second walls of each frame member includes means for engaging and retaining a panel. The connecting wall of each frame member preferably includes a generally planar external surface for facilitating mounting said frame members to one another.
Preferably each of the stiles is made from two frame member6 fastened together 6uch that the generally planar external surfaces of the frame members are abutted.
Still in another aspect, the present invention provides a continuou6 rail frame structure for use in a modular wall panel ~ystem. The frame structure comprises two spaced-apart vertical stiles, each stile having a front face and first and second spaced-apart horizontal rails, each rail being ..
:-` 2075~14 connected to each one of the two ~paced-apart 6tiles. The horizontal rails are connected to the vertical fitiles such that each horizontal rail extend6 acros6 the face of each 6tile whereby when the horizontal rail6 of two frame structure6 are placed in an end-to-end relation6hip, the horizontal rails of each frame structure abut one another thereby forming a continuou6 horizontal rail acro66 the two frame structure6.
Preferably the vertical stiles of the frame 6tructure include a rear face, and preferably the frame ~tructure further includes third and fourth rail6, the fir6t and 6econd rails spaced-apart and each connected to the front faces of each of the two 6tile6, the fir6t and 6econd rail6 forming a front pair of rails. The third and fourth rails are 6paced-apart and each connected to the rear faces of each of the two 6tile6. The third and fourth rails forming a rear pair of rails wherein the rear pair of rails are 6paced-apart from the front pair of rail6. The 6pace between the two 6paced-apart stile~ create6 a raceway along a first dimension, and the 6pace between the front pair of rails creates a raceway along a 6econd dimen6ion, and the 6pace between the rear pair of rail6 create6 a raceway along the second dimen6ion which is 6paced-apart from the raceway created by the front pair of rail6, and the 6pace between the 6paced-apart stiles in conjunction with the 6pace between the front pair of rail6 in further conjunction with the cpace between the rear pair of rail6 creates a raceway along a third dimension whereby the first, second, and third dimensions are mutually orthogonal. Preferably, the stiles and rails are made from substantially the same type of frame member whsrein each frame member includes an elongated body having a fir6t wall, second wall and a connecting wall, the connecting wall extending between and connected to the fir6t and 6econd wall6 to maintain the fir6t and second walls in a fixed, 6paced-apart relationship to one another. The first and 6econd wall6 define an inner 6urface and an outer 6urface. The fir6t and 6econd wall~ each - 207~0~4 include a free end which defines an elongated entrance opening.
The inner surfaces of the first and second wall form a boundary of a rear zone and a forward zone wherein the inner surfaces of the first and second wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner surfaces of the first and second wall bounding the forward zone include mean~ for engaging and retaining a second connector therebetween. The inner surfaces of the first and second wall include mea~s for maintaining the first and second connectors in a spaced-apart relationship whereby when the first connector i~ disposed in the rear zone and the second connector i8 disposed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer surface of one of the first and second walls of each frame member includes means for engaging and retaining a panel and, the connecting wall of each frame member preferably includes a generally planar external surface for facilitating mounting the frame members to one another. Preferably each stile includes two frame members fastened together 6uch that the generally planar external surfaces of the frame members are in a face-to-face relationship.
Still, in a further aspect, the pre6ent invention provides a universal connector for use in connecting two or more frame members together, the frame members of the type having spaced-apart inner surfaces. The universal connector includes a first lnserting end, a second inserting end~ and means for pivotally connecting said first inserting end with said second inserting end. Each inserting end include~ an expanding means for expanding the respectively as~ociated inserting end. When the inserting end is di~posed between the spaced-apart inner surface~ of a frame member and when the expanding means on each of the inserting ends is actuated, the expanding means frictionally engages tne spaced-apart inner surfaces of its 2~7501~
g respective frame member thereby connecting two frame members together. Each expanding means preferably includes a cam member pivotally connected to its respectively associated inserting end. The cam member preferably includes a pin for pivotally connecting the cam to its reRpective inserting end, whereln each pin is adapted to rotate its cam, thereby engaging the cam against the spaced-apart inner surfaces of the associated frame member. The pin preferably comprises a screw.
~RIEF DESCRIPTION OF TnE DRAWING~
Figure 1 is an isometric view of an interior office layout constructed from the modular wall panels of the present invention.
Figure 2 is a isometric view of an interconnection of frame portions of the modular wall panels of the present invention.
Figure 3 is an end view of the wall panel of the present invention.
Figure 4 is an isometric view of a partial portion of an insert for use on the wall panel of the present invention.
Figure 5 is an isometric view of a partial portion of a kick panel for use on the wall panel of the preEent invention.
Figure 6 is a top cross-sectional view of the wall panel of the present invention taken substantially along line 6-6 of Figure 3.
Figure 7 i6 an i~ometric view of a load bearing connector for use in the wall panel 6ystem of the present invention.
Figure 8 is a cross-sectional view of a preferred embodiment of a horizontal frame member of the pre~ent invention.
Figure 9 i8 a front cross-sectional view of the wall panel of the present invention taken substantially along line 9-9 of Figure 3.
Figure 10 i6 an exploded view of two wall panel frames of the present invention adjoined in an end-to-end relationship.
Figure 11 is an isometric view of the universal connector of the present invention.
Figure 12 is an expanded view of portions of two adjoining wall panel frames.
Figure 13 is a top view of two adjoining wall panel frames taken substantially along lines 13-13 of Figure 12.
Figure 14 is a cross-sectional view of the combination of horizontal rail and universal connector taken substantially along line~ 14-14 of Figure 12.
Figure 15 is a cross-sectional view of the combination of horizontal rail and universal connector taken ~ub6tantially along lines 15-15 of Figure 12.
Figure 16 is a top view of the universal connector of the present invention as it is used to connect 3 wall panels of the present invention.
-- 207~014 Figure 17 i6 an i60metric view of two wall panel frames of the present invention 6tacked in vertical relation.
Figure 18 i8 a cross-sectional view of the wall panel frame taken substantially along lines 18-18 of Figure 17.
Figure 19 is a front view of the rail and ~tile interconnection taken 6ubstantially along lines 19-19 of Figure 18.
Figure 20 is a side view of the wall panel system of the present invention showing a work surface engaged in and supported by a horizontal rail.
DET~IL~D D~SCRIPTION OF T~F PReEERRED EMBODIM~NTS
Now referring to Figure l, wall panel sy6tem 30 i8 comprised of a plurality of generally rectangular modular wall panels 32. Each wall panel 32 includes a plurality of horizontal rails 34-42 which are adapted to engage and support various accessories such as cabinet 44, shelf unit 46, and work surface 48.
Now referring to Figures l and 2, each wall panel 32 comprise6 frame structure 50. Frame structure 50 ifi comprised of a plurality of horizontal rails 34-42 and two vertical stile6 52, 54. Each horizontal rail 34-42 is fastened to a front face 56, 58 of each re~pective vertical stile 52, 54. Similarly, horizontal rails 60-68 are arranged along the rear faces 70, 72 of vertical ctilec 52, 54 respectively. When horizontal rails 36-42 ant 62-68 are arranged along respective faces 56, 58 and 70, 72 of vertical stiles 52, 54, frame structure 50 functions to service two adjoining work 6paces.
2~75014 One important aspect of the present invention relates to the ability of frame structure 50 to form a three dimensional raceway for accommodating the passage of wire, cables, utilities or the li~e. Thi6 three-way raceway capability i6 best understood by referencing Figure 2. For example, because horizontal rails 36-42 are spaced-apart from horizontal rails 62~68, cable 74 is able to traverse frame structure 50 along the Y dimension. The space created between spaced-apart horizontal ralls 34-42 creates a raceway along an X
dimension. Accordingly, cable 76 i~ free to traverse frame structure 50 along the X dimension. A raceway is created through frame structure 50 along a Z dimension by virtue of the fact that the raceway along the X dimension and the raceway along the Y dimension intersect one another thereby forming a raceway along the Z dimen6ion. The above illustrated three dimensional raceway capability forms an important aspect of the present invention. Unlike prior art systems which utilize a single dimensional raceway (which typically travels along the lower portion of the wall panel) frame ~tructure 50 of the present invention allows increased flexibility of cable and utility routing through the wall panel system of the present invention.
Now referring to Figures 3-9, frame 50, which forms part of modular wall panel 32, can be used by itself or can be used with any number of insert6 78-88. Although insert6 78-88 can be used to fill the opening (exemplified at 90) between two vertically-spaced horizontal rails, they may also be used to bridge the opening between two horizontal rails. For exa~ple, insert 82 is designed to bridge gap 90 between vertically offset horizontal rail~ 40, 42 thereby creating a concealed raceway along the X axi6. This provides a means for routing cable 76 through frame 50 along the X dimension and al60 for concealing it~ presence. Inserts 78-88 are made from a full range of materials, colors, and finishe6 and are preferably interchange-able. For example, in6erts 78-88 may be comprised of painted or powder-coated steel, fabric, sound deadening material, wood and glass (including mirrors, fro6ted, colored glass, etc.).
Special function materiAls and finishes uch as marker in~erts, static and chemical re6istant flnishe6, radio frequency 6hielding insert6, etc. may also be used.
In6erts 78-88 preferably snap into place without the use of tools. Preferably this is accomplished by designing in6erts (see Figure 4) with an insert attaching finger 92 which is adapted to frictionally engage an outer surface of horizontal rail 42. By fitting each insert with a plurality of inserts attaching finger6 92, the panels 82 may be installed and removed without the use of tools. Each modular wall 32 preferably includes kick panel 94. Kick panel 94 primarily 6erves to conceal adju6tment leg 96. Kick panel 94 also act6 to "dress"
or visually frame the lower portion of each wall panel. Each kick panel 94 (exemplified in Figure 5) is fitted with a plurality of kick panel attaching fingers 98. Kick panel attaching fingers 98 are adapted to matingly engage with an inner surface of a horizontal rail thereby firmly securing kick panel 94 in place. As was di6cus6ed in conj ction with inserts 78-88, kick panel 94 is adapted to be installed and removed without the use of tool6.
End trim panel 100 (6ee Figure 6) i6 adapted to cover the terminal end of a modular wall panel. Each end trim panel 100 i6 fitted with an end trim engaging finger 102 which is sdspted to be received in and retained by an inner surface 104 of stile 52.
Load bearing connector 106 (6ee Figure 3) is adapted to support vertical loads (such as accessories) which are placed '. :
207501~
on horizontal rails 60-68. Gne embodiment of load bearing connector 106 i6 shown in Figure 7. In this embodiment, body portion 112 separates rail engaging end 108 from load engaging end 110. Rail engaging end 108 i8 designed to be inserted through opening 114 of horizontal rail 40 (see Figure 3). Once rail engaging end 108 i6 in6erted through opening 114 of horizontal rail 40, load bearing connector 106 is rotated 90 degrees thereby positively engaging rail engaging end 108 against an inner ~urface 126 of horizontal rail 40. Any number of accessorie6 44-48 can be attached to connector 106 by way of threaded aperture 116 or any other conventional fastening technique.
In a preferred embodiment, horizontal rails 36-42 and 60-68 are comprised of frame member 118 as 6et out in Figure 8. Frame member 118 i8 comprised of an elongated body having a fir~t wall 120, a second wall 122 and a connecting wall 124.
First and 6econd wall6 120, 124 define an inner surface 126 and an outer surface 128. Wall6 120, 122 include free end6 130, 132 respectively which define entrance opening 114. Inner surface 126 of wall6 120, 122 form6 a boundary of rear zone 134 and forward zone 136. One function of forward zone 136 i6 to engage and support load bearing connector 106. Rear zone 134 is preferably used to cooperate with universal connector 144 for joining two modular wall panels together. The function and u6e of universal connector 144 will be disclo6ed in conjunction with Figures 9-15. Outer 6urface 128 of frame member 118 i6 used to support insert attaching finger 92 of insert 82 as was previously discussed in conjunction with Figure 4.
First wall 120 and second wall 122 are both fitted with cusp portion 138, 140 re6pectively. Each cusp 138, 140 acts to separate a connector residing in forward zone 136 from a connector residing in rearward zone 134. This separation is an 207~014 important aspect to the present invention in that two connectors may reside side-by-side each in a respective zone and each are free to move within their respective zone without referriDg to one another. For example, if universal connector 144 of Figure 11 were placed in rear zone 134 of frame member 118 and load bearing connector 106 were placed in forward zone 136 of frame member 118, they each would be free to move laterally within their zone (along the length of fr~ne member 118), without interfering with one another. Thus, it is seen that any accessories 44-48 supported by a load bearing connector, may be slid along their respective horizontal rail 118 without interfering with any universal connectors residing in rear zone 134. This has the distinct advantage of not requiring that any connectors 106, 144 be removed before relocating a connector within its respective zone. Connecting wall 124 of frame member 118 preferably includes generally planar external surface 142 for facilitating mounting frame member 118 to a support structure (such as vertical stile 52).
Figure 9 discloses a preferred embodiment of frame structure 50 wherein each horizontal rail 40, 42 extends acrosg the full face 56, 58 of its respective stile 52, 54. By constructing frame member 50 in this way, horizontal rail~ 40, 42 abut adjacent horizontal rails 41, 43 of adjacent frame 51 (abutment shown at 47, 49 respectively). By constructing the frames in this manner, the horizontal rails form a continuous, load bearing track along the length of a wall formed by a plurality of frames 50, 51. This continuous track permits tremendous defiign flexibility in that accessories 44-48 can be 00untet at any horizontal location along a wall formed by the panels. Thus, it is easily seen, in contrast to the prior art, that the beginning and end demarcations of adjoining wall panels 47, 49 have no bearing on the placement of accessories 44-48 along a wall constructed from the wall panel system of the present invention.
207~014 Now referring to Figure 10, universal connector 144 is used to fasten adjacent frames 50, 51 in order to construct the wall panel system of the present invention. Universal connectors 144 are adapted to engage the rear zone portions 134 (see Figure 8) of abutting horizontal rails (exemplified at 429 43) thereby joining abutting frames 50, 51.
Now referring to Figure 11, universal connector 144 is comprised of first and second inserting ends 146, 148 2nd hinge 150. Hinge 150 pivotally connects inserting ends 146, 14~. Each inserting end 146, 148 include6 an opening 152 wherein rotatable cam 154 i~ housed. Rotatable cam 154 i8 pinned in place by way of screw 156. By rotating screw 156, rotatable cam 154 can be made to completely retract 153 within opening 152. Rotating cam 154 can be made to translate from its fully retracted position 153 (totally contained within opening 152) to its fully extended position 151 by simply rotating screw 156 through 90 degrees.
Now referring to Figures 12-15, when it is desired to connect two frames 50, 51 in an end-to-end relationship, frames 50, 51 are placed in an end-to-end abutting relationship, as 6hown in Figure 12, and univer~al connector 144 is passed through opening 114 and through forward zone 136 of two abutting horizontal rails 42, 43 and inserted into rear zone 134 portion of rail~ 42, 43. Screw 156 is then rotated ~0 degree~ thereby translating cam 154 into its maximum extension position (see Figure 14) whereby it frictionally engages inner surface 126 of rear zone 134. This frictional engagement positively locks universal connector 144 between abutting horizontal rails 42, 43 thereby forming a secure attachment between adjacent frames 50, 51.
Although our discussion until now has confined the use of load bearing connector 106 to forward zone 136 of horizontal rail member 43 (see Figure 3) and the use of universal connector 144 has been limited to rear zone 134 of horizontal rail member 43 (see Figure 14), it is contemplated within the present invention that universal connector 144 may operate from either forward zone 136 or rear zone 134 of horizontal rail member 43. The type of application where this would be favorable is disclosed in Figure 16. In Figure 16, there is depicted a top view of an intersection between three adjacent frames 50, 51, and 53. Frames 50, 51 are joined end-to-end by universal connector 144 in the same method that was di6cusged previously in conjunction with FigureR 10-15.
Frame 53 i6 attached to frames 50, 51 by disposing universal connectors 144 and 144 in the forward zones 136 of horizontal rail6 41, 42 and 39, 43 respectively. Because connector 144 is confined to the rear zone 134 of horizontal rails 42 and 43, it cannot interfere with the portions of universal connectors 144 and 144 which are confined to the forward zones 136 of horizontal rails 42 and 43. Accordingly, frame 53 i6 free to be located laterally 158 anywhere along the wall segment comprised of frames 50, 51. It is even possible to locate frame 53 across end wall joint 160 because of the continuous, non-interrupted, nature in which horizontal rails 42, 43 are joined. Thus, it is seen that end wall ~oints 160 do not hinder the placement of return frame 53 even if it falls directly on end wall joint 160. Accordingly, end wall joint 160 has no bearing on the placement or arrangement of accessories 44-48 or intersecting wall 53. Thus, the wall panel system of the present invention offers an interior de6igner maximum flexibility in the design of interior-space systems.
Now referring to Figure 17, in the same manner in which it has been ~hown that frames 50, 51 can be placed in an edge-to-edge relationship to form a continuous wall, they likewise can be stacked one on top another in the manner shown : ~:
in Figure 17. This vertical stacking capability gives sn interior designer extra flexibility in design~ng an interior ofice space. In a preferred embodiment, the vertical stiles (exemplified at 55 in Figure 18) are fabricated from the identical material used for fabricating horizontal rails 36-42 and 60-68. Stiles 55 are preferably fabricated from two horizontal rail "type" members wherein their generally planar external surfaces 166, 168 abut. By fabricating s~ile 55 in this manner, universal connectors 144 can be used to attach ver~ically stacked frames 50, 51 to one another in the same manner the universal connectors are used to adjoin frames 50, 51 in an end~to-end relationship. Thus, it has been demonstrated that universal connector 144 is indeed universal in its ability to attach modular frame sections together. This applies attaching vertically 6tacked frames, attaching frames in an end-to-end relationship, and attaching frames in the manner depicted in Figure 16.
Now referring to Figures 18 and 19, it i6 preferred that horizontal rail 43 is attached to vertical stile 55 by way of threaded fastener 170 and T-nut 172. It is also contemplated that load bearing fastener 106 can be directly used, or easily modified, to attach vertical stile 55 and horizontal rail 43.
Now referring to Figure 20, work surface 48 is supported from forward zone 136 of horizontal rail 43. Work surface 48 inclute6 rail engaging finger 172 for positively enga8ing inner 6urface 126 of forward zone 136. For heavier loads where the load support design 6hown in Figure 20 i8 unsafe, load bearing connector 106 as depicted in Figure 7, i6 used.
The foregoing detailed description show6 that the preferred embodiments of the present invention are well suited to fulfill the objects of the invention. It is recognized that ~7~01~
those skilled in the art may make various modification6 or additions to the preferred embodiments chosen here to illustrate the present invention, without departing from the spirit of the present invention. For example, it is contemplated that various materials may be used to construct the horizontal and vertical frame members of the present invention. Such materials include plastics, steel, high density foams and the like. Accordingly, it is to be understood that the subject matter sought to be afforded protection hereby should be deemed to extend to the subject matter defined in the appended claims, including all fair equivalents thereof.
BACKGROUND OF T~E INVENTION
The present invention relate6 generally to frame systems and more particularly to frame~ used in modular wall panel systems.
The design of most modern inter~or work spaces, especially offices, mu6t possess the fundamental ability to adapt to change. Small changes must be responded to -- such as recognizing an employee's promotion -- as well as major changes -- such as adding employees. Because modern interior space designs must accommodate changing environments, the va6t majority of today's building interior spaces are designed using prefabricated modular wall panel systems. These modular systems allow work areas to be expanded, redesigned, or even eliminated at only a fraction of the cost associated with revamping non-modular designs. The fundamental bullding block of most modular wall panel systems is a generally rectangular frame comprised of horizontal rails and vertical stiles. Typically, the frames are joined in an end-to-end relationship thereby forming a continuous wall. The frame structure generally includes a raceway for routing wires, cables, or other utility services. Also, it is common for one or more hor$zontal rails to be accessible for engaging and supporting vertical loads such as writing surfaces, shelving, and the like.
A common drawback associated with prior art wall panel systems iB that the horizontal rails are noncontinuous acrofis adjoining frames. This typically occurs in frame designs where the horizontal rail terminates short of the end of the frame and the frame end portion is fitted with a peripheral trim member or the like. Consequently, when two frames are adjoined 207~014 in an end-to~end relationship, the horizontal rails are noncontinuous across the frame-to-frame interface. While this type of discontinuity may not be unduly restrictive in some applications, it reduces the number of locations whereby a load may be placed along the rail. Accordingly, in these types of wall panel systems the placement of accessories along the horizontal rail may be dictated more by the shortcomings inherent in the noncontinuous rail sy6tem than by the de6ires of the interior designer.
Additionally, although many wall panel sy6tem6 are fitted with a raceway to accommodate utilities, the raceway is typically confined to one dimension and accordingly, does not lend itself to routing utilities in two or three dimensions.
An ever present concern associated with designing, producing and installing wall panel 6ystems is that of containing cost. One major cost involves connectors and other hardware used to install wall panels. One approach to reducing hardware costs is to design a fastener which has universal applicability for adjoining wall panel frames regardless how, or at what angle, the wall panel frames are joined. It is also desirable to design a universal connector which will accommodate mounting a first wall panel frame anywhere along the horizontal rail of a second wall panel frame.
Accordingly, it i6 an object of this invention to provide a modular wall panel frame having three dimensional raceway capability.
It is a further object of this invention to provide a frame member for use in a modular wall panel sy6tem that provides a means for connecting adjacent frames to form a continuous wall and also provide a frame member which supports vertical loads.
It i6 still a further object of the present invention to provide a universal connector which is used to connect adjoining frames regardles~ of the relative angle between the two frames.
A further object of thi6 invention i8 to provide a universal connector which allows a first frame to be mounted along a second frame at a point intermediate the ends of the second frame.
Another object of the present invention i6 to provide a frame member, which when joined to other frame member~, provides a continuous horizontal rail across joined frame6.
~ ARY OF T~E INVENTION
In light of the foregoing object6, in one a6pect, the pre6ent invention provides a frame member for use in a modular wall panel 6ystem, the frame member including an elongated body having a first wall, second wall, and a connecting wall, the connecting wall extending between and connected to the first snd second walls to maintain the first and second wall6 in a fixed, 6paced-apart relationship to one another. The first and second walls define an inner surface and an outer surface and the first and second walls each include a free end where the free end6 of the first and second walls define an elongated entrance opening. The inner surface6 of the first and 6econd wall form a boundary of a rear zone and a forward zone. The inner 6urface6 of the fir6t and 6econd wall bounding the rear zone include means for engaging and retaining a first connector therebetween. The inner surface6 of the first and second wall bounding the forward zone include means for engaging and retaining a second connector therebetween. The ` 207~01~
inner 6urfaces of the first and second wall include means for maintaining the first and 6econd connectors in a spaced-apart relationship whereby when the first connector is disposed in the rear zone and the second connector is disposed in the forward zone, the first a~ld second connectors are free to move within their respective zones without interfering with one another.
Preferably, the outer surface of one of the first and second walls includes means for engaging and retaining a panel. The connecting wall of the frame member preferably includes a generally planar e~ternal surface for facilitating mounting the member to a support structure.
In a second aspect, the present invention provides a wall panel for u6e in a modular wall panel system. The wall panel includes first and 6econd spaced-apart horizontal frame members and first and 6econd spaced-apart vertical frame members wherein the fir6t and second horizontal frame members are each connected to a vertical frame member. Each frame member including an elongated body having a first wall, 6econd wall, and a connecting wall, the connecting wall extending between and connected to the first and second wallg to maintain the first and second walls in a fixed, spaced-apart relationship to one another. The first and second walls define an inner surface and an outer 6urface and the fir6t and second walls include a free end which defines an elongated entrance opening. The inner surfaces of the first and second walls form a boundary of a rear zone and a forward zone. The inner 6urfaces of the flr6t and ~econd wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner surfaces of the first and second wall bounding the forward zone include means for engaging and retaining a second connector therebetween. The inner surfaces of the first and second wall include means for maintaining the first and second connectors in a spaced-apart relationship whereby when the first connector is 207~01 4 disposed in the rear zone and the second connector i8 disposed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer surface of one of the first and second walls of each frame member includes means for engaging and retaining a panel. In a preferred embodiment, the connecting wall of each frame member include6 a generally planar external surface for facilitating mounting the frame mPmber6 to one another to form the wall panel.
In an additional aspect, the present invention provides a frame 6tructure for use with a modular wall panel system. The frame structure includes two 6paced-apart 6tiles, each stile having a front face and a rear face. The frame structure also includes first, second, third, and fourth rails, the first and second rails are spaced-apart and connected to the front face6 of each of the two 6tiles, wherein the first and second rail6 form a front pair of rail6. The third and fourth rails are spaced-apart and each connected to the rear face of each of the two 6tiles, the third and fourth rail6 forming a rear pair of rails, wherein the rear pair of rail6 are spaced-apart from the front pair of rails. The space between the two spaced-apart 6tiles creates a raceway along a first dimension, and the space between the front pair of rails creates a raceway along a second dimension, and the space between the rear pair of rails creates a raceway along the second dimension spaced-apart from the raceway created by the front pair of rails, and the space between the spaced-apart stiles in conjunction with the space between the front pair of rails in further conjunction with the space between the rear pair of rails creates a raceway along a third dimension whereby the first, second, and third dimensions are mutually orthogonal. In a preferred embodiment, the stiles and rails which make up the frame structure are màde from substantially the same type of frame member, each frame member including an elongated body having a first wall, ~econd wall, and a connecting wall, the connecting wall extending between and connected to the f ir8t and second walls to maintain the first and second walls in a fixed, spaced-apart relationship to one another. The first and second walls define an inner surface and an outer surface and the first and second walls each include a free end. The free ends of the fir6t and second walls define an elongated entrance opening.
The inner surface6 of the first and 6econd wall form a boundary of a rear zone and a forward zone. The inner surfaces of the fir6t and second wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner 6urfaces of the fir6t and 6econd wall bounding the forward zone include means for engaging and retaining a 6econd connector therebetween. The inner surface6 of the first and second wall include mean6 for maintaining the fir6t and second connector6 in a spaced-apart relationship whereby when the first connector i6 disposed in the rear zone and the second connector i6 di6posed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer ~urface of one of the first and second walls of each frame member includes means for engaging and retaining a panel. The connecting wall of each frame member preferably includes a generally planar external surface for facilitating mounting said frame members to one another.
Preferably each of the stiles is made from two frame member6 fastened together 6uch that the generally planar external surfaces of the frame members are abutted.
Still in another aspect, the present invention provides a continuou6 rail frame structure for use in a modular wall panel ~ystem. The frame structure comprises two spaced-apart vertical stiles, each stile having a front face and first and second spaced-apart horizontal rails, each rail being ..
:-` 2075~14 connected to each one of the two ~paced-apart 6tiles. The horizontal rails are connected to the vertical fitiles such that each horizontal rail extend6 acros6 the face of each 6tile whereby when the horizontal rail6 of two frame structure6 are placed in an end-to-end relation6hip, the horizontal rails of each frame structure abut one another thereby forming a continuou6 horizontal rail acro66 the two frame structure6.
Preferably the vertical stiles of the frame 6tructure include a rear face, and preferably the frame ~tructure further includes third and fourth rail6, the fir6t and 6econd rails spaced-apart and each connected to the front faces of each of the two 6tile6, the fir6t and 6econd rail6 forming a front pair of rails. The third and fourth rails are 6paced-apart and each connected to the rear faces of each of the two 6tile6. The third and fourth rails forming a rear pair of rails wherein the rear pair of rails are 6paced-apart from the front pair of rail6. The 6pace between the two 6paced-apart stile~ create6 a raceway along a first dimension, and the 6pace between the front pair of rails creates a raceway along a 6econd dimen6ion, and the 6pace between the rear pair of rail6 create6 a raceway along the second dimen6ion which is 6paced-apart from the raceway created by the front pair of rail6, and the 6pace between the 6paced-apart stiles in conjunction with the 6pace between the front pair of rail6 in further conjunction with the cpace between the rear pair of rail6 creates a raceway along a third dimension whereby the first, second, and third dimensions are mutually orthogonal. Preferably, the stiles and rails are made from substantially the same type of frame member whsrein each frame member includes an elongated body having a fir6t wall, second wall and a connecting wall, the connecting wall extending between and connected to the fir6t and 6econd wall6 to maintain the fir6t and second walls in a fixed, 6paced-apart relationship to one another. The first and 6econd wall6 define an inner 6urface and an outer 6urface. The fir6t and 6econd wall~ each - 207~0~4 include a free end which defines an elongated entrance opening.
The inner surfaces of the first and second wall form a boundary of a rear zone and a forward zone wherein the inner surfaces of the first and second wall bounding the rear zone include means for engaging and retaining a first connector therebetween and the inner surfaces of the first and second wall bounding the forward zone include mean~ for engaging and retaining a second connector therebetween. The inner surfaces of the first and second wall include mea~s for maintaining the first and second connectors in a spaced-apart relationship whereby when the first connector i~ disposed in the rear zone and the second connector i8 disposed in the forward zone, the first and second connectors are free to move within their respective zones without interfering with one another. Preferably, the outer surface of one of the first and second walls of each frame member includes means for engaging and retaining a panel and, the connecting wall of each frame member preferably includes a generally planar external surface for facilitating mounting the frame members to one another. Preferably each stile includes two frame members fastened together 6uch that the generally planar external surfaces of the frame members are in a face-to-face relationship.
Still, in a further aspect, the pre6ent invention provides a universal connector for use in connecting two or more frame members together, the frame members of the type having spaced-apart inner surfaces. The universal connector includes a first lnserting end, a second inserting end~ and means for pivotally connecting said first inserting end with said second inserting end. Each inserting end include~ an expanding means for expanding the respectively as~ociated inserting end. When the inserting end is di~posed between the spaced-apart inner surface~ of a frame member and when the expanding means on each of the inserting ends is actuated, the expanding means frictionally engages tne spaced-apart inner surfaces of its 2~7501~
g respective frame member thereby connecting two frame members together. Each expanding means preferably includes a cam member pivotally connected to its respectively associated inserting end. The cam member preferably includes a pin for pivotally connecting the cam to its reRpective inserting end, whereln each pin is adapted to rotate its cam, thereby engaging the cam against the spaced-apart inner surfaces of the associated frame member. The pin preferably comprises a screw.
~RIEF DESCRIPTION OF TnE DRAWING~
Figure 1 is an isometric view of an interior office layout constructed from the modular wall panels of the present invention.
Figure 2 is a isometric view of an interconnection of frame portions of the modular wall panels of the present invention.
Figure 3 is an end view of the wall panel of the present invention.
Figure 4 is an isometric view of a partial portion of an insert for use on the wall panel of the present invention.
Figure 5 is an isometric view of a partial portion of a kick panel for use on the wall panel of the preEent invention.
Figure 6 is a top cross-sectional view of the wall panel of the present invention taken substantially along line 6-6 of Figure 3.
Figure 7 i6 an i~ometric view of a load bearing connector for use in the wall panel 6ystem of the present invention.
Figure 8 is a cross-sectional view of a preferred embodiment of a horizontal frame member of the pre~ent invention.
Figure 9 i8 a front cross-sectional view of the wall panel of the present invention taken substantially along line 9-9 of Figure 3.
Figure 10 i6 an exploded view of two wall panel frames of the present invention adjoined in an end-to-end relationship.
Figure 11 is an isometric view of the universal connector of the present invention.
Figure 12 is an expanded view of portions of two adjoining wall panel frames.
Figure 13 is a top view of two adjoining wall panel frames taken substantially along lines 13-13 of Figure 12.
Figure 14 is a cross-sectional view of the combination of horizontal rail and universal connector taken substantially along line~ 14-14 of Figure 12.
Figure 15 is a cross-sectional view of the combination of horizontal rail and universal connector taken ~ub6tantially along lines 15-15 of Figure 12.
Figure 16 is a top view of the universal connector of the present invention as it is used to connect 3 wall panels of the present invention.
-- 207~014 Figure 17 i6 an i60metric view of two wall panel frames of the present invention 6tacked in vertical relation.
Figure 18 i8 a cross-sectional view of the wall panel frame taken substantially along lines 18-18 of Figure 17.
Figure 19 is a front view of the rail and ~tile interconnection taken 6ubstantially along lines 19-19 of Figure 18.
Figure 20 is a side view of the wall panel system of the present invention showing a work surface engaged in and supported by a horizontal rail.
DET~IL~D D~SCRIPTION OF T~F PReEERRED EMBODIM~NTS
Now referring to Figure l, wall panel sy6tem 30 i8 comprised of a plurality of generally rectangular modular wall panels 32. Each wall panel 32 includes a plurality of horizontal rails 34-42 which are adapted to engage and support various accessories such as cabinet 44, shelf unit 46, and work surface 48.
Now referring to Figures l and 2, each wall panel 32 comprise6 frame structure 50. Frame structure 50 ifi comprised of a plurality of horizontal rails 34-42 and two vertical stile6 52, 54. Each horizontal rail 34-42 is fastened to a front face 56, 58 of each re~pective vertical stile 52, 54. Similarly, horizontal rails 60-68 are arranged along the rear faces 70, 72 of vertical ctilec 52, 54 respectively. When horizontal rails 36-42 ant 62-68 are arranged along respective faces 56, 58 and 70, 72 of vertical stiles 52, 54, frame structure 50 functions to service two adjoining work 6paces.
2~75014 One important aspect of the present invention relates to the ability of frame structure 50 to form a three dimensional raceway for accommodating the passage of wire, cables, utilities or the li~e. Thi6 three-way raceway capability i6 best understood by referencing Figure 2. For example, because horizontal rails 36-42 are spaced-apart from horizontal rails 62~68, cable 74 is able to traverse frame structure 50 along the Y dimension. The space created between spaced-apart horizontal ralls 34-42 creates a raceway along an X
dimension. Accordingly, cable 76 i~ free to traverse frame structure 50 along the X dimension. A raceway is created through frame structure 50 along a Z dimension by virtue of the fact that the raceway along the X dimension and the raceway along the Y dimension intersect one another thereby forming a raceway along the Z dimen6ion. The above illustrated three dimensional raceway capability forms an important aspect of the present invention. Unlike prior art systems which utilize a single dimensional raceway (which typically travels along the lower portion of the wall panel) frame ~tructure 50 of the present invention allows increased flexibility of cable and utility routing through the wall panel system of the present invention.
Now referring to Figures 3-9, frame 50, which forms part of modular wall panel 32, can be used by itself or can be used with any number of insert6 78-88. Although insert6 78-88 can be used to fill the opening (exemplified at 90) between two vertically-spaced horizontal rails, they may also be used to bridge the opening between two horizontal rails. For exa~ple, insert 82 is designed to bridge gap 90 between vertically offset horizontal rail~ 40, 42 thereby creating a concealed raceway along the X axi6. This provides a means for routing cable 76 through frame 50 along the X dimension and al60 for concealing it~ presence. Inserts 78-88 are made from a full range of materials, colors, and finishe6 and are preferably interchange-able. For example, in6erts 78-88 may be comprised of painted or powder-coated steel, fabric, sound deadening material, wood and glass (including mirrors, fro6ted, colored glass, etc.).
Special function materiAls and finishes uch as marker in~erts, static and chemical re6istant flnishe6, radio frequency 6hielding insert6, etc. may also be used.
In6erts 78-88 preferably snap into place without the use of tools. Preferably this is accomplished by designing in6erts (see Figure 4) with an insert attaching finger 92 which is adapted to frictionally engage an outer surface of horizontal rail 42. By fitting each insert with a plurality of inserts attaching finger6 92, the panels 82 may be installed and removed without the use of tools. Each modular wall 32 preferably includes kick panel 94. Kick panel 94 primarily 6erves to conceal adju6tment leg 96. Kick panel 94 also act6 to "dress"
or visually frame the lower portion of each wall panel. Each kick panel 94 (exemplified in Figure 5) is fitted with a plurality of kick panel attaching fingers 98. Kick panel attaching fingers 98 are adapted to matingly engage with an inner surface of a horizontal rail thereby firmly securing kick panel 94 in place. As was di6cus6ed in conj ction with inserts 78-88, kick panel 94 is adapted to be installed and removed without the use of tool6.
End trim panel 100 (6ee Figure 6) i6 adapted to cover the terminal end of a modular wall panel. Each end trim panel 100 i6 fitted with an end trim engaging finger 102 which is sdspted to be received in and retained by an inner surface 104 of stile 52.
Load bearing connector 106 (6ee Figure 3) is adapted to support vertical loads (such as accessories) which are placed '. :
207501~
on horizontal rails 60-68. Gne embodiment of load bearing connector 106 i6 shown in Figure 7. In this embodiment, body portion 112 separates rail engaging end 108 from load engaging end 110. Rail engaging end 108 i8 designed to be inserted through opening 114 of horizontal rail 40 (see Figure 3). Once rail engaging end 108 i6 in6erted through opening 114 of horizontal rail 40, load bearing connector 106 is rotated 90 degrees thereby positively engaging rail engaging end 108 against an inner ~urface 126 of horizontal rail 40. Any number of accessorie6 44-48 can be attached to connector 106 by way of threaded aperture 116 or any other conventional fastening technique.
In a preferred embodiment, horizontal rails 36-42 and 60-68 are comprised of frame member 118 as 6et out in Figure 8. Frame member 118 i8 comprised of an elongated body having a fir~t wall 120, a second wall 122 and a connecting wall 124.
First and 6econd wall6 120, 124 define an inner surface 126 and an outer surface 128. Wall6 120, 122 include free end6 130, 132 respectively which define entrance opening 114. Inner surface 126 of wall6 120, 122 form6 a boundary of rear zone 134 and forward zone 136. One function of forward zone 136 i6 to engage and support load bearing connector 106. Rear zone 134 is preferably used to cooperate with universal connector 144 for joining two modular wall panels together. The function and u6e of universal connector 144 will be disclo6ed in conjunction with Figures 9-15. Outer 6urface 128 of frame member 118 i6 used to support insert attaching finger 92 of insert 82 as was previously discussed in conjunction with Figure 4.
First wall 120 and second wall 122 are both fitted with cusp portion 138, 140 re6pectively. Each cusp 138, 140 acts to separate a connector residing in forward zone 136 from a connector residing in rearward zone 134. This separation is an 207~014 important aspect to the present invention in that two connectors may reside side-by-side each in a respective zone and each are free to move within their respective zone without referriDg to one another. For example, if universal connector 144 of Figure 11 were placed in rear zone 134 of frame member 118 and load bearing connector 106 were placed in forward zone 136 of frame member 118, they each would be free to move laterally within their zone (along the length of fr~ne member 118), without interfering with one another. Thus, it is seen that any accessories 44-48 supported by a load bearing connector, may be slid along their respective horizontal rail 118 without interfering with any universal connectors residing in rear zone 134. This has the distinct advantage of not requiring that any connectors 106, 144 be removed before relocating a connector within its respective zone. Connecting wall 124 of frame member 118 preferably includes generally planar external surface 142 for facilitating mounting frame member 118 to a support structure (such as vertical stile 52).
Figure 9 discloses a preferred embodiment of frame structure 50 wherein each horizontal rail 40, 42 extends acrosg the full face 56, 58 of its respective stile 52, 54. By constructing frame member 50 in this way, horizontal rail~ 40, 42 abut adjacent horizontal rails 41, 43 of adjacent frame 51 (abutment shown at 47, 49 respectively). By constructing the frames in this manner, the horizontal rails form a continuous, load bearing track along the length of a wall formed by a plurality of frames 50, 51. This continuous track permits tremendous defiign flexibility in that accessories 44-48 can be 00untet at any horizontal location along a wall formed by the panels. Thus, it is easily seen, in contrast to the prior art, that the beginning and end demarcations of adjoining wall panels 47, 49 have no bearing on the placement of accessories 44-48 along a wall constructed from the wall panel system of the present invention.
207~014 Now referring to Figure 10, universal connector 144 is used to fasten adjacent frames 50, 51 in order to construct the wall panel system of the present invention. Universal connectors 144 are adapted to engage the rear zone portions 134 (see Figure 8) of abutting horizontal rails (exemplified at 429 43) thereby joining abutting frames 50, 51.
Now referring to Figure 11, universal connector 144 is comprised of first and second inserting ends 146, 148 2nd hinge 150. Hinge 150 pivotally connects inserting ends 146, 14~. Each inserting end 146, 148 include6 an opening 152 wherein rotatable cam 154 i~ housed. Rotatable cam 154 i8 pinned in place by way of screw 156. By rotating screw 156, rotatable cam 154 can be made to completely retract 153 within opening 152. Rotating cam 154 can be made to translate from its fully retracted position 153 (totally contained within opening 152) to its fully extended position 151 by simply rotating screw 156 through 90 degrees.
Now referring to Figures 12-15, when it is desired to connect two frames 50, 51 in an end-to-end relationship, frames 50, 51 are placed in an end-to-end abutting relationship, as 6hown in Figure 12, and univer~al connector 144 is passed through opening 114 and through forward zone 136 of two abutting horizontal rails 42, 43 and inserted into rear zone 134 portion of rail~ 42, 43. Screw 156 is then rotated ~0 degree~ thereby translating cam 154 into its maximum extension position (see Figure 14) whereby it frictionally engages inner surface 126 of rear zone 134. This frictional engagement positively locks universal connector 144 between abutting horizontal rails 42, 43 thereby forming a secure attachment between adjacent frames 50, 51.
Although our discussion until now has confined the use of load bearing connector 106 to forward zone 136 of horizontal rail member 43 (see Figure 3) and the use of universal connector 144 has been limited to rear zone 134 of horizontal rail member 43 (see Figure 14), it is contemplated within the present invention that universal connector 144 may operate from either forward zone 136 or rear zone 134 of horizontal rail member 43. The type of application where this would be favorable is disclosed in Figure 16. In Figure 16, there is depicted a top view of an intersection between three adjacent frames 50, 51, and 53. Frames 50, 51 are joined end-to-end by universal connector 144 in the same method that was di6cusged previously in conjunction with FigureR 10-15.
Frame 53 i6 attached to frames 50, 51 by disposing universal connectors 144 and 144 in the forward zones 136 of horizontal rail6 41, 42 and 39, 43 respectively. Because connector 144 is confined to the rear zone 134 of horizontal rails 42 and 43, it cannot interfere with the portions of universal connectors 144 and 144 which are confined to the forward zones 136 of horizontal rails 42 and 43. Accordingly, frame 53 i6 free to be located laterally 158 anywhere along the wall segment comprised of frames 50, 51. It is even possible to locate frame 53 across end wall joint 160 because of the continuous, non-interrupted, nature in which horizontal rails 42, 43 are joined. Thus, it is seen that end wall ~oints 160 do not hinder the placement of return frame 53 even if it falls directly on end wall joint 160. Accordingly, end wall joint 160 has no bearing on the placement or arrangement of accessories 44-48 or intersecting wall 53. Thus, the wall panel system of the present invention offers an interior de6igner maximum flexibility in the design of interior-space systems.
Now referring to Figure 17, in the same manner in which it has been ~hown that frames 50, 51 can be placed in an edge-to-edge relationship to form a continuous wall, they likewise can be stacked one on top another in the manner shown : ~:
in Figure 17. This vertical stacking capability gives sn interior designer extra flexibility in design~ng an interior ofice space. In a preferred embodiment, the vertical stiles (exemplified at 55 in Figure 18) are fabricated from the identical material used for fabricating horizontal rails 36-42 and 60-68. Stiles 55 are preferably fabricated from two horizontal rail "type" members wherein their generally planar external surfaces 166, 168 abut. By fabricating s~ile 55 in this manner, universal connectors 144 can be used to attach ver~ically stacked frames 50, 51 to one another in the same manner the universal connectors are used to adjoin frames 50, 51 in an end~to-end relationship. Thus, it has been demonstrated that universal connector 144 is indeed universal in its ability to attach modular frame sections together. This applies attaching vertically 6tacked frames, attaching frames in an end-to-end relationship, and attaching frames in the manner depicted in Figure 16.
Now referring to Figures 18 and 19, it i6 preferred that horizontal rail 43 is attached to vertical stile 55 by way of threaded fastener 170 and T-nut 172. It is also contemplated that load bearing fastener 106 can be directly used, or easily modified, to attach vertical stile 55 and horizontal rail 43.
Now referring to Figure 20, work surface 48 is supported from forward zone 136 of horizontal rail 43. Work surface 48 inclute6 rail engaging finger 172 for positively enga8ing inner 6urface 126 of forward zone 136. For heavier loads where the load support design 6hown in Figure 20 i8 unsafe, load bearing connector 106 as depicted in Figure 7, i6 used.
The foregoing detailed description show6 that the preferred embodiments of the present invention are well suited to fulfill the objects of the invention. It is recognized that ~7~01~
those skilled in the art may make various modification6 or additions to the preferred embodiments chosen here to illustrate the present invention, without departing from the spirit of the present invention. For example, it is contemplated that various materials may be used to construct the horizontal and vertical frame members of the present invention. Such materials include plastics, steel, high density foams and the like. Accordingly, it is to be understood that the subject matter sought to be afforded protection hereby should be deemed to extend to the subject matter defined in the appended claims, including all fair equivalents thereof.
Claims (7)
1. A continuous rail frame structure for use in a modular wall panel system, comprising:
two spaced-apart vertical stiles, each stile having a front face, first and second spaced-apart horizontal rails, each said rail connected to each one of said two spaced-apart stiles, wherein each said rail extends across the face of each said stile, whereby, when the horizontal rails of a first and second one of said frame structures are placed in an end-to-end relationship, one of the horizontal rails of said first frame structure abuts one of the horizontal rails of said second frame structure thereby forming a continuous horizontal rail across said first and second frame structures.
two spaced-apart vertical stiles, each stile having a front face, first and second spaced-apart horizontal rails, each said rail connected to each one of said two spaced-apart stiles, wherein each said rail extends across the face of each said stile, whereby, when the horizontal rails of a first and second one of said frame structures are placed in an end-to-end relationship, one of the horizontal rails of said first frame structure abuts one of the horizontal rails of said second frame structure thereby forming a continuous horizontal rail across said first and second frame structures.
2. The continuous rail frame structure of claim 1, wherein each one of said two spaced-apart vertical stiles includes a rear face, and wherein said frame structure further includes third and fourth rails, said first and second rails spaced-apart and each connected to said front faces of each of said two stiles, said first and second rails forming a front pair of rails, wherein said third and fourth rails are spaced-apart and each connected to said rear faces of each of said two stiles, said third and fourth rails forming a rear pair of rails, and wherein said rear pair of rails are spaced-apart from said front pair of rails, whereby said space between said two spaced-apart stiles creates a raceway along a first dimension, and whereby said space between said front pair of rails creates a raceway along a second dimension, and whereby said space between said rear pair of rails creates a raceway along said second dimension spaced-apart from said raceway created by said front pair of rails, and whereby the space between said spaced-apart stiles in conjunction with the space between said front pair of rails in further conjunction with the space between said rear pair of rails creates a raceway along a third dimension whereby said first, second, and third dimensions are mutually orthogonal.
3. The frame structure of claim 2, wherein each said stile and rail is made from substantially the same type of frame member, each said frame member including, an elongated body having a first wall, second wall, and a connecting wall, said connecting wall extending between and connected to said first and second walls to maintain said first and second walls in a fixed, spaced-apart relationship to one another, wherein said first and second walls define an inner surface and an outer surface, said first and second walls each including a free end, said free ends of said first and second walls defining an elongated entrance opening, and wherein said inner surfaces of said first and second wall form a boundary of a rear zone and a forward zone, and wherein said inner surfaces of said first and second wall bounding said rear zone include means for engaging and retaining a first connector therebetween, and wherein said inner surfaces of said first and second wall bounding said forward zone include means for engaging and retaining a second connector therebetween, and wherein said inner surfaces of said first and second wall include means for maintaining said first and second connectors in a spaced-apart relationship, whereby when said first connector is disposed in said rear zone and said second connector is disposed in said forward zone, said first and second connectors are free to move within their respective zones without interfering with one another.
4. The frame structure of claim 3, wherein said outer surface of one of said first and second walls of each frame member includes means for engaging and retaining a panel.
5. The frame structure of claim 3, wherein said connecting wall of each frame member includes a generally planar external surface for facilitating mounting said frame members to one another.
6. The frame structure of claim 1, wherein each said stile includes two frame members fastened together.
7. The frame structure of claim 5, wherein each said stile includes two said frame members fastened together such that the generally planar external surfaces of said frame members are in a face-to-face relationship.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US73839691A | 1991-07-31 | 1991-07-31 | |
| US738,396 | 1991-07-31 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2075014A1 true CA2075014A1 (en) | 1993-02-01 |
Family
ID=24967824
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2075014 Abandoned CA2075014A1 (en) | 1991-07-31 | 1992-07-30 | Modular wall panel system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2075014A1 (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5852904A (en) | 1996-08-05 | 1998-12-29 | Haworth, Inc. | Panel arrangement |
| US6148567A (en) * | 1998-06-08 | 2000-11-21 | Haworth, Inc. | Wall panel system |
| US6557310B2 (en) | 2000-06-09 | 2003-05-06 | Smed International, Inc. | Interior space-dividing wall system |
| US6711871B2 (en) | 2000-05-03 | 2004-03-30 | Herman Miller, Inc. | Wall panel with off-module components |
| US6920727B2 (en) | 2001-02-14 | 2005-07-26 | Haworth, Inc. | Wall panel arrangement with accessory-supporting top cap |
-
1992
- 1992-07-30 CA CA 2075014 patent/CA2075014A1/en not_active Abandoned
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5852904A (en) | 1996-08-05 | 1998-12-29 | Haworth, Inc. | Panel arrangement |
| US6161347A (en) | 1996-08-05 | 2000-12-19 | Haworth, Inc. | Panel arrangement |
| US6658805B1 (en) | 1996-08-05 | 2003-12-09 | Haworth, Inc. | Panel arrangement |
| US6148567A (en) * | 1998-06-08 | 2000-11-21 | Haworth, Inc. | Wall panel system |
| US6711871B2 (en) | 2000-05-03 | 2004-03-30 | Herman Miller, Inc. | Wall panel with off-module components |
| US6557310B2 (en) | 2000-06-09 | 2003-05-06 | Smed International, Inc. | Interior space-dividing wall system |
| US6920727B2 (en) | 2001-02-14 | 2005-07-26 | Haworth, Inc. | Wall panel arrangement with accessory-supporting top cap |
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