Abstract:
A kit, system, and method for use in interconnecting wall panel sections to subdivide interior spaces within a building. Included are components and methods to assemble multiple in-line wall panel sections and corners, as well as optional roof members, windows, and doors.

Description:
This application claims the benefit of provisional application Ser. No. 60/402,412 filed Aug. 9, 2002. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to modular wall structures for subdividing space within a building. More particularly, the present invention relates to structural elements for use in interconnecting adjacent wall panel sections, to kits and systems of modular wall structural elements, and to methods of using the structural elements to subdivide space within a building. 
     2. Description of the Background Art 
     A number of different systems, and related hardware, are known for subdividing space within an existing building. Examples of some of the known systems and related hardware include U.S. Pat. No. 4,784,552 to Rebentisch, U.S. Pat. No. 4,910,938 to McGee, U.S. Pat. No. 5,233,803 to Bockmiller, U.S. Pat. No. 5,287,675 to McGee, and U.S. Pat. No. 6,076,322 to D&#39;Andrea et al. 
     Rebentisch, U.S. Pat. No. 4,784,552, issued in 1988 and entitled “Nuts for Channeled Structural Members”, discloses a specialized Unistrut® nut that fits into a substantially C-shaped channel of a frame member. 
     McGee, U.S. Pat. No. 4,910,938, issued in 1990 and entitled “Wall Stud for Portable In-Plant Building”, discloses a two-piece wall stud for interconnecting adjacent panel members of an in-plant or portable building. First and second stud members fit together in telescoping engagement, and are attached to one another using threaded fasteners. The first and second stud members cooperate to clamp adjacent wall panels therebetween, thereby interconnecting the wall panels. 
     Bockmiller, U.S. Pat. No. 5,233,803, issued in 1993 and entitled “Framing Apparatus for Clean Room Wall System”, discloses an elongated structural member having opposed contact surfaces, which may be positioned between opposed ends of adjacent panels. The Bockmiller reference discloses a pair of channel members, which may be bolted together to clamp adjacent panel ends therebetween, interconnecting the wall panels. The structural member of Bockmiller also includes gaskets disposed in recesses therein. 
     McGee, U.S. Pat. No. 5,287,675, issued in 1994 and entitled “Wall Stud Assembly”, discloses a stud assembly for a wall of an in-plant or portable building. The wall includes interfitting wall stud assemblies and wall panels. The stud assembly of McGee includes first and second stud members, each of which is generally U-shaped in cross-section. In addition, a strut having a generally C-shaped cross-section is positioned longitudinally between the first and second stud members and affixed thereto. The flanges of one stud member are in spaced generally parallel relation to the flanges of the other stud member, to sandwich a wall panel therebetween. 
     D&#39;Andrea et al, U.S. Pat. No. 6,076,322, issued in 2000 and entitled “Wall Stud Assembly for use in Forming Prefabricated Partitions or Walls”, discloses a wall stud assembly used to form a prefabricated partition or wall assembled within the interior space of a warehouse, factory or other building structure. 
     The assembly of D&#39;Andrea includes a first elongate stud member and a second elongate stud member, each having a joining part. Each of the joining parts of the stud members includes a plurality of punched holes and extruded holes formed therein, to allow interconnecting fasteners to be applied to the stud member from either side of the stud assembly. 
     Although the known systems are usable for their intended purposes, a need still exists in the art for improved structural elements for interconnecting modular walls to subdivide building space. In particular, there is a need for improved structural elements which will enable a user to easily assemble components, which will provide for durable structures, and which will provide a pleasing appearance in a finished installation thereof. 
     SUMMARY OF THE INVENTION 
     The present invention provides a kit, system, and method for use in interconnecting wall panel sections, to subdivide interior space within a building. 
     In a first embodiment of the present invention, a kit of components is provided which is usable to interconnect adjacent in-line wall panel sections. 
     A kit of components according to this first embodiment includes a outside linear flashing unit and a inside linear flashing unit for spaced-apart placement between two adjacent wall sections, and for cooperating with selected fasteners to clamp end portions of the wall sections therebetween. 
     The outside linear flashing unit, according to the first embodiment, includes a backing plate and two spaced-apart side members integrally attached to the backing plate. Each of the side members includes a first side wall portion and a flange extending from the side wall portion. 
     In the above structure, the backing plate and the side members define an open channel therebetween which is adapted to slidably receive a threaded nut therein. The flanges of the side members extend inwardly toward one another from the side wall portions, to cover part of the open channel. 
     The inside linear flashing unit is provided for placement opposing the outside linear flashing unit, and for clamping edge portions of adjacent in-line wall panel sections therebetween. The inside linear flashing unit includes a center plate having a plurality of openings formed therethrough, and two spaced-apart side members integrally attached to the center plate. 
     Each of the side members of the inside linear flashing unit includes a side wall portion and a flange extending substantially transversely from the side wall portion. The flanges of the inside unit are situated substantially in the same plane, and extend away from the side wall portions in opposite directions. The flanges of the inside unit are provided for overlapping placement against selected surfaces of the adjacent wall panel sections. 
     Another embodiment of the invention provides a kit of components for use in joining adjacent corner wall sections together to form a corner wall seam. The corner wall seam kit includes an outside corner flashing unit and an inside corner flashing unit which cooperate to sandwich a pair of transversely oriented wall panel sections therebetween. 
     Another embodiment of the invention relates to a window frame interface member, which can be subdivided to form multiple window frame segments. The window frame segments can be situated surrounding a windowpane, and can then be joined together with L-brackets, to form a window structure that fits between wall panel sections. 
     Still another embodiment of the invention relates to a system including one or more linear wall seam assemblies, one or more corner seam assemblies, and one or more window interface members. 
     Accordingly, it is an object of the present invention to provide a method and kit of components usable with a plurality of wall panels to assemble a modular wall structure, which may be constructed inside of an existing building. 
     For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portion of a modular wall structure according to the present invention; 
         FIG. 2  is an exploded perspective view of an in-line wall seam assembly according to the present invention; 
         FIG. 3  is a cross-sectional view of the in-line wall seam assembly of  FIG. 2 ; 
         FIG. 4  is an exploded perspective view of a corner wall seam assembly according to the present invention; 
         FIG. 5  is a cross-sectional view of the corner wall seam assembly of  FIG. 4 ; 
         FIG. 6  is a front plan view of a window frame assembly according to the present invention, with an expanded cross-sectional detail view of a corner portion thereof shown in an insert; 
         FIG. 7  is a cross-sectional view of the frame assembly of  FIG. 6 , taken along the line  7 — 7  in  FIG. 6 ; and 
         FIG. 8  is an exploded perspective view, partially cut away, of the frame assembly of  FIG. 6 , also showing part of a windowpane. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to the drawings,  FIG. 1  shows a cut away perspective view of a modular building structure  10  according to an illustrative embodiment of the invention. 
     The modular building structure  10  consists primarily of a wall structure  15  and related hardware and subassemblies, as will be further explained herein. Space isolated by the wall structure  15  may function as an office, storeroom, shop area, or other use selected by a user. 
     The modular building structure  10  of  FIG. 1  includes two adjacent in-line wall panel sections  12 ,  14  interconnected by an in-line seam assembly  20 , and at least one window assembly  100  placed in an opening formed in one of the panel sections  12 . The modular building structure  10  also includes two adjacent wall panel corner sections  12 ,  13  interconnected by a corner scam assembly  60 . 
     The modular building structure  10  is preferred to include a conventional door frame and door assembly (not shown), and may also include a corrugated roof panel  150  to keep dust out of the space enclosed thereby. 
     Other optional components of the modular building structure  10  include upper wall flashing  152 , lower wall flashing  154 , and upper roof deck flashing  156 . 
     A modular building structure  10  according to the invention is not primarily intended to be free standing, or to form an exterior structure. Instead, the modular building structure  10  is primarily intended to be assembled indoors, to subdivide the existing space inside warehouse, assembly plant or other existing structure. 
     Alternatively, the materials according to the invention may be adapted to be used outdoors, to construct temporary or portable buildings. 
     In a first embodiment, the present invention provides a kit of components for use in constructing an in-line panel seam  20  to interconnect adjacent in-line wall panel sections  12 ,  14  in a modular building structure  10 . The kit of the first embodiment includes at least one outside linear flashing unit  22  and at least one inside linear flashing unit  24  ( FIGS. 2–3 ). Optionally, the kit may also include fasteners and/or a decorative cap  23  for placement in the inside linear flashing unit  24 , to cover the fastening hardware and shield it from view. 
     The Panel Sections 
     The wall panel units  12 ,  14  are not necessarily part of the present invention, although in one embodiment, the present invention encompasses a modular wall structure including a plurality of panel units  12 ,  14 . 
     The first and second wall panel units  12 ,  14  have a substantially identical structure and composition, with the exception of possible openings formed therein such as door or window openings. Accordingly, a discussion of the structure of the first wall panel unit  12  will be sufficient. 
     Shown in  FIG. 3 , panel section  12  has an insulating foam core  15  with a covering skin  17 ,  19  respectively, glued or otherwise attached to the foam core  15  on each of the opposed sides thereof. The skin  17 ,  19  is formed from a strong, durable material such as metal or a tough, strong and non-brittle plastic. This type of paneling material is known and is commercially available. 
     The Linear Panel Connectors 
     The present invention relates to a linear panel fastening structure, including components for use in interconnecting adjacent in-line wall panel sections, such as those shown at  12  and  14  in  FIG. 3 . 
     A linear panel fastening structure according to the embodiment of  FIGS. 2–3  includes an elongated outside linear flashing unit and an elongated inside linear flashing unit. The linear flashing units are provided for spaced-apart placement between two adjacent wall sections, and for cooperating with selected fasteners to clamp end portions of the wall sections therebetween. 
     The Outside Linear Flashing Unit 
     The outside linear flashing unit  22 , according to the first embodiment, includes a generally flat backing plate  28  having opposed edge portions  30 ,  32  for overlapping placement against selected surfaces of the adjacent wall panel sections  12 ,  14 . 
     The outside linear flashing unit  22  also includes two spaced apart side members  34 ,  36  integrally attached to and extending away from the backing plate. 
     In the embodiment of  FIG. 3 , each of the side members  34 ,  36  has a respective first side wall portion  31 ,  33 , a second side wall portion  35 ,  37  which is substantially parallel to the first side wall portion, and a respective lip flange  38 ,  39  extending substantially transversely inwardly and away from the first side wall portion. 
     In the above structure, the backing plate  28  and the side members  34 ,  36  define an open channel  40  therebetween which is adapted to slidably receive a threaded nut  41  therein. As shown, the nut  41  includes a main body having a threaded opening formed therein, and a spring connected to one side of the main body. When the nut  41  is disposed in the open channel  40 , outer edges of the main body engage the flanges  38 ,  39  and the spring engages the backing plate  28 , such that the nut is normally maintained in place within the channel by the force of the spring. The nut  41  may be selectively moved by pressing the main body to compress the spring, and sliding the nut to a different position. A nut sold by the UNISTRUT® corporation, and as described in U.S. Pat. No. 4,784,552 is suitable for use with the outside linear flashing unit  22  hereof, and such nuts are commercially available from the UNISTRUT® corporation of Wayne, Mich. The disclosure of U.S. Pat. No. 4,784,552 is hereby incorporated by reference. The lip flanges  38 ,  39  extend inwardly toward one another from the respective first side wall portions  31 ,  33 , to cover part of the open channel  40 , and to permit trapping of the nut  41  therein. 
     The Inside Linear Flashing Unit 
     The inside linear flashing unit  24  is provided for placement opposing the outside linear flashing unit and for cooperating with the outside linear flashing unit  22  to clamp edge portions of the adjacent wall panel sections  12 ,  14  therebetween. In the depicted embodiment, the inside linear flashing unit  24  includes a center plate  50  having a plurality of openings  51 ,  52  formed therethrough, and two spaced apart side members  53 ,  54  integrally attached to and extending away from the center plate. As shown, the openings  51 ,  52  are elongated and spaced from each other in the longitudinal direction of the center plate  50 . 
     Each of the respective side members  53 ,  54  of the inside linear flashing unit  24  includes a respective side wall portion  55 ,  56  and a respective flange  58 ,  59  integrally connected to, and extending substantially transversely away from the respective side wall portion. 
     The flanges  58 ,  59  of the inside linear flashing unit  24  extend away from the side wall portions  55 ,  56  in opposite directions, and are situated substantially in the same plane. The flanges  58 ,  59  of the inside linear flashing unit are provided for overlapping placement against selected surfaces of the adjacent wall panel sections  12 ,  14 . 
     Optionally, each of the side wall portions  55 ,  56  may have a cutout groove  57  formed therein to receive a detent boss  29  of the cap  23 , as will be discussed further herein. 
     It will be seen from a review of  FIGS. 2 and 3  that when joining adjacent in-line wall panel sections  12 ,  14  together using the inside linear and outside flashing units  22 ,  24  hereof, the outside linear flashing unit  22  is placed between and touching the panel ends with the flanges  30 ,  32  covering end portions of the panel sections. Then, a suitable number of UNISTRUT® nuts  41  are placed sideways inside of the channel  40 , and the nuts are then rotated 90 degrees so that they fit behind the opposed flanges  38 ,  39  of the side members  34 ,  36 . 
     Then, the inside linear flashing unit  24  is slid between the panel sections  12 ,  14  with the flanges  58 ,  59  partially covering end portions of the panels. A bolt  11  is then inserted through each opening  51 ,  52  in the inside linear flashing unit, and is threadably installed in the nut  41 . The bolt  11  is then tightened to draw the inside and outside flashing units  22 ,  24  toward one another, and to clamp the ends of the wall panels  12 ,  14  therebetween, thereby connecting them. 
     The Cap 
     The cap  23  is an optional member for use with the inside linear flashing unit  24 . The cap  23  is substantially U-shaped in cross-section, as shown. The cap  23  is integrally formed from a plastic material, and includes a main crosspiece  25  and two side pieces  26 ,  27  extending transversely outwardly from opposite sides of the main crosspiece. Optionally, the side pieces  26 ,  27  may have detent bosses  29  formed thereon, to fit into the cutout grooves  57  of the inside linear flashing unit, and to resiliently engage the cap therein. 
     The cap  23  fits into the inside linear flashing unit  24  to cover the holes and fasteners therein, and to present a more ornamental and decorative appearance than would otherwise be the case. The cap  23  can be made in different colors to match any selected decor. 
     The Corner Connectors 
     The present invention also relates to a corner fastening structure  60  ( FIGS. 4–5 ), including components for use in interconnecting adjacent wall panel corner sections  12 ,  13 . 
     A corner fastening structure  60  according to the embodiment of  FIGS. 4–5  includes an elongated outside corner flashing unit  62  and an elongated inside corner flashing unit  64 . The corner flashing units  62 ,  64  are provided for spaced-apart placement between two adjacent perpendicular wall sections  12 ,  13 , and for cooperating with selected fasteners to clamp end portions of the perpendicular wall sections therebetween. 
     The Outside Corner Flashing Unit 
     The outside corner flashing unit  62  includes an outside corner portion  63  having a substantially L-shaped cross sectional shape, including a first part  65  and a second part  66  integrally formed with the first part and transversely attached thereto. Each of the first and second parts  65 ,  66  of the outside corner portion  63  includes an outer edge portion  67 ,  68 , respectively, for overlapping placement against selected surfaces of the perpendicular wall panel sections  12 ,  13 . 
     The outside corner flashing unit  62  also includes a pair of spaced apart stop plates  70 ,  72  integrally attached to the first and second parts  65 ,  66 , respectively, of the outside corner portion  63 . As seen in  FIG. 5 , the stop plates  70 ,  72  are perpendicular to one another, and contact the ends of the panel sections  12 ,  13  in the completed installation. Each of the stop plates  70 ,  72  has an inwardly extending flange  71 ,  73  integrally formed therewith, as shown. 
     The outside corner flashing unit  62  further includes a bridge plate  74  integrally formed with, and interconnecting the stop plates  70 ,  72 . The bridge plate is disposed substantially at a 45 degree angle with respect to the stop plates  70 ,  72 , as shown. 
     The outside corner flashing unit still further includes two substantially parallel spaced apart webs  76 ,  78  integrally attached to and extending between the bridge plate  74  and the flanges  71 ,  73  at the inner ends of the stop plates. 
     The bridge plate  74  and the webs  76 ,  78  define an open channel  75  therebetween, adapted to slidably receive a threaded nut  41  therein. The flanges  71 ,  73  extend toward one another, from the inner ends of the stop plates  70 ,  72 , to cover part of the open channel  75 . 
     Inside Corner Flashing Unit 
     The inside corner flashing unit  64  is provided for placement opposing the outside corner flashing unit  60 , and for clamping edge portions of the adjacent wall corner panel sections  12 ,  13  therebetween. 
     The inside corner flashing unit  64  includes a center plate  80 , having a plurality of openings  81  formed therethrough, and two spaced apart side members  82 ,  84  integrally attached to and extending away from the center plate  80 . 
     Each of the side members  82 ,  84  has a respective side wall portion  83 ,  85  and flange  86 ,  88  extending substantially transversely from the side wall portion. The flanges  86 ,  88  of the inside corner flashing unit  64  are substantially perpendicular to one another, and are provided for overlapping placement against selected surfaces of the adjacent corner wall panel sections  12 ,  13 . 
     Using the Corner Flashing Units 
     It will be seen from a review of  FIGS. 4 and 5  that when joining adjacent corner wall panel sections  12 ,  13  together using the inside and outside corner flashing units  62 ,  64  hereof, the outside corner flashing unit  62  is placed between and touching the panel ends with the stop members  70 ,  72  touching end portions of the panel sections, and with the flanges  67 ,  68  overlapping the outside end surfaces of the panels. Then, a suitable number of UNISTRUT® nuts  41  are placed sideways inside of the channel  75 , and the nuts are then rotated 90 degrees so that they fit behind the opposed flanges  71 ,  73  of the stop members  70 ,  72 . 
     Then, the inside linear flashing unit  24  is slid into the corner recess defined between the panel sections  12 ,  13  with the flanges  86 ,  88  partially covering side edge portions of the panels. A screw, bolt or other threaded fastener  111  is then inserted through each opening  81  in the inside corner flashing unit, and is threadably installed in the nut  41 . The fastener  111  is then tightened to draw the inside and outside flashing units  62 ,  64  toward one another, and to clamp the ends of the wall panels  12 ,  13  therebetween, thereby connecting them. 
     The Window Frame Interface Member 
     Referring now to  FIGS. 6–8 , it will be seen that the present invention also encompasses an elongated window frame interface member  90  for forming into a plurality of window frame segments, such as those shown at  92 ,  94  in  FIG. 8 . The window frame segments thus formed are intended for placement surrounding a relatively thin windowpane  95  or other thin panel, in a window opening formed in a relatively thick wall panel section  12 . 
     A window frame interface member  90 , according to the present invention, includes a generally flattened elongated sill bridge section  96 , and two spaced apart pane supports  97 ,  98  attached to the sill bridge section  96  and extending substantially transversely therefrom. The pane supports  97 ,  98  are substantially parallel to one another, and are spaced inwardly from the outer side edges of the sill bridge section  96 . 
     The window frame interface member  90  also includes two spaced apart parallel side braces  102 ,  104 , attached to the outer side edges of the sill bridge section  96  and extending substantially transversely therefrom, in a direction substantially opposite the pane supports  97 ,  98 . 
     Each of the side braces  102 ,  104  of the window frame interface member  90  has a respective truncated ledge  103 ,  105  extending inwardly thereon. The truncated ledges  103 ,  105  are substantially coplanar with one another, and they are substantially parallel to, and spaced apart from the sill bridge section  96 . The truncated ledges  103 ,  105  cooperate with the sill bridge section  96  to define respective slots  106 ,  108  therebetween, at opposite sides of the sill bridge section. The slots  106 ,  108  are situated at a surface of the window frame interface member  90  opposite the pane supports  97 ,  98  and near the junctions of the sill bridge section  96  and the side braces  102 ,  104 . 
     In use, the window frame interface member  90  is subdivided into frame segments  92 ,  94  by cutting therethrough at a 45 degree angle, so that each end of each section slopes outwardly as it moves from the pane supports  97 ,  98  into and through the side braces  102 ,  104 . This results in the frame segments  92 ,  94  having a peripheral outline somewhat similar to the angled ends on sections of a wooden picture frame, as seen from a vantage point similar to that shown in  FIG. 6 . Four of these segments may then be joined together to surround a translucent glass or plastic windowpane  95 , with a flexible rubber or elastomeric seal  99  therebetween. 
     At the junction of each abutting pair of frame segment ends, an L-bracket  106  is used to interconnect the segments together. The L-bracket  106  has two legs  108 ,  110 . Each leg  108 ,  110  of the L-bracket has a threaded hole  112  formed therethrough to receive a threaded fastener, such as a bolt or alien screw  114 . Each leg  108 ,  110  of the L-bracket  106  fits slidably into the slots  106 ,  108  defined between a pair of the truncated ledges  103 ,  105  and the sill bridge section  96  of a frame segment, as shown in  FIG. 8 . When the L-bracket  106  has been slidably installed in each of the slots of two abutting frame segments  92 ,  94 , the frame segments are moved together until they are contacting one another, and then each of the fasteners  114  is tightened inwardly in the L-bracket until it contacts the sill bridge section. Further tightening of the fasteners  114  forces the L-bracket  106  into interfering contact with the truncated ledges  103 ,  105 . This effectively locks the frame segments together. The completed window assembly  100  may be placed in between upper and lower panel sections. 
     Although the present invention has been described herein with respect to a limited number of presently preferred embodiments, the foregoing description is intended to be illustrative, and not restrictive. Those skilled in the art will realize that many modifications of the preferred embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.