Panel joints

Mid-wall panel joints for joining first and second upstanding wall panel members tightly together with their front surfaces in a common plane. A first embodiment utilizes a combination of spacer members and alignment plates fixed to the rear surfaces of the wall panel members, and an elongated joining member which has first and second columns of elongated slots. The spacer members on the first and second wall panel members extend through spacer head receiving portions of the elongated slots and the joining member is then downwardly advanced to a frictional locking position. A second embodiment utilizes spacer members and a split or divided elongated joining member, adjustably clamped together, which permits alignment of the front surfaces of the wall panel members in a common plane, notwithstanding the joining of wall panel members having different thickness dimensions.

BACKGROUND OF THE INVENTION 
1. Field of the Invention: 
The invention relates in general to panel joints, and more specifically to 
panel joints for joining two upstanding panel members tightly together 
with their front surfaces disposed in a common plane. 
2. Description of the Prior Art: 
In certain applications, wall panel members are required to be joined 
together to form a room or cubicle, with the joining hardware concealed. 
When the width of a wall exceeds a predetermined dimension, it is 
constructed of two or more in-line panels. The joints between the in-line 
panels must be tight, and they must remain tight during usage. The front 
surfaces of the in-line panels must be disposed in a common plane, and the 
composite wall must be flat without any bowing at the joint. Wall panels 
formed of wood or other non-metal panels, are relatively thick and heavy, 
and their surfaces may not be perfectly flat. The weight and non-flatness 
add to the problem of assembling panels with tight joints. Further, 
certain types of panels may vary slightly in thickness from panel to 
panel, which creates a very difficult joining problem as the slightest 
deviation in panel thickness is noticeable when two panels are joined 
in-line with concealed hardware. 
It would thus be desirable to provide new and improved panel joints for 
relatively large, heavy panels which enable the panels to be quickly and 
tightly joined in-line with the desired orientation of the front panel 
surfaces in a common plane. It would further be desirable to remove or 
reduce any bow or out-of-flatness condition of the panel members, 
especially at the critical joint area, without increasing assembly time. 
Still further, it would be desirable to provide a new and improved panel 
joint which will quickly enable the assembler to compensate for a 
difference in thickness of the panels to be joined. 
SUMMARY OF THE INVENTION 
Briefly, the present invention includes new and improved panel joints for 
joining relatively thick wall panel members, such as wood, or other 
non-metallic materials, in-line with concealed hardware. The joints are 
quickly and easily formed by an assembler located adjacent to the front 
sides of the panels. 
In a first embodiment, a new and improved joint is disclosed for use when 
the panel thickness dimensions will be substantially uniform from panel to 
panel. Metallic alignment plates and spacer members are fixed to the back 
surfaces of first and second wall panel members adjacent to the edges to 
be butted together, and the panel members are shipped to the job site, 
along with a single metallic joining member. The assembler positions the 
first and second wall panel members, such that the alignment plates, which 
extend outwardly from their associated panel towards the other panel, 
contact the rear surface of the other panel. The joining member has first 
and second columns of elongated openings or slots which engage the spacer 
members on the first and second panel members. The assembler then pounds 
the metallic joiner member vertically downward, which forces the joining 
member tightly against the alignment plates to remove any bow or waviness 
in the panels, and it forces the two adjoining edges tightly together by 
virtue of slots in one of the vertical columns which are angled or 
inclined slightly from the vertical. 
In a second embodiment, a new and improved joint is disclosed for use when 
the panel thickness dimension may vary from panel to panel. Spacer members 
are fixed to the rear surfaces of first and second panel members, adjacent 
to the edges to be butted together. A metallic joining member is provided 
which has first and second portions or elements, which elements are 
clamped together to enable the joining member to function as a single 
member. Elongated slots are provided in each of the first and second 
elements. In a preferred embodiment, the spacers are fixed to one of the 
panel members through the elongated slots in one of the elements to 
slideably fix the joining member thereto for shipment. At the job site, 
the assembler places the first and second wall panels in position adjacent 
to one another and raises the joining member to allow the spacer members 
on the other panel to enter and be captured by the slots. The assembler 
then pounds the joining member vertically downward, to pull the adjacent 
edges tightly together. If the front surfaces of the two panels are in 
different planes due to the panels having slightly different thickness 
dimensions, the joining member is released by pounding it upwardly. The 
clamping means is loosened to permit the relative positions of the two 
elements of the joining member to be adjusted according to the variation 
in panel thickness. The clamping means is retightened and the panels are 
then reassembled.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
FIG. 1 is an elevational view of a panel joint 10 constructed according to 
the teachings of the invention, with FIG. 2 being an end view of joint 10, 
and FIG. 3, a plan view. Joint 10 is especially suitable for joining wall 
panel members which have a uniform thickness dimension from panel to 
panel, but which may have a slight bow or waviness viewed from an edge. 
Non-flat panels joined in-line with concealed hardware make an 
unattractive joint, if the panel surfaces are not aligned along the entire 
length of the joint. The joint of the present invention forces such 
alignment. 
More specifically, panel joint 10 is an in-line joint, as opposed to an 
angular joint, with joint 10 joining first and second upstanding wall 
panel members 12 and 14. Wall panel members 12 and 14 are relatively large 
and heavy panels, formed of a material such as wood, or a wood substitute. 
Panel members 12 and 14 form a wall, or a portion of a wall, such as a 
wall for a cubicle which may be used as the cab for an elevator car. Wall 
panel member 12 has front and rear major flat surfaces 16 and 18, 
respectively, top and bottom edges 20 and 22, respectively, and first and 
second vertically extending side edges 24 and 26, respectively, with the 
second side edge 26 also being referred to as an "adjacent" edge, because 
it is the edge to be butted against wall panel member 14. Wall panel 
member 14 has first and second major flat surfaces 28 and 30, 
respectively, top and bottom edges 32 and 34, respectively, and first and 
second vertically extending side edges 36 and 38, respectively, with the 
first side edge 36 also being referred to as an "adjacent" edge. Joint 10 
joins wall panel members 12 and 14 in-line with their front surfaces 16 
and 28 aligned in a common vertical plane. 
Joint 10 includes a plurality of metallic alignment plates 40 and 40' fixed 
in vertically spaced staggered relation to the rear surfaces 18 and 30, 
respectively, of the first and second wall panel members 12 and 14. The 
metallic alignment plates are fixed to the adjacent edges 26 and 36, with 
a portion of each alignment plate extending outwardly past the adjacent 
edge of the panel member it is fixed to, such that it overlaps and 
contacts the rear surface of the other panel member. Alignment plates 40 
and 40' alternate with one another such that there is no interference 
between them. Alignment plates 40 and 40' are preferably grouped to 
provide a plurality of pairs 42, with each pair 42 including an alignment 
plate 40 fixed to panel member 12, and an alignment plate 40' fixed to 
panel member 14. The alignment plates of each pair 42 are closely spaced, 
with a larger spacing between adjacent pairs. 
FIG. 4 is a perspective view of the uppermost pair 42 of alignment plates 
40 and 40' as they would appear during a step in the formation of joint 10 
shown in FIGS. 1, 2, and 3. FIG. 4 more clearly illustrates an exemplary 
construction of an alignment plate. Since alignment plates 40 and 40' may 
be of like construction, only alignment plate 40 will be described in 
detail. Alignment plate 40 is formed from a metallic plate or sheet, such 
as 0.188 inch thick steel. Alignment plate 40 has a generally elongated 
rectangular configuration which has a length dimension of about 6 inches, 
and a width dimension of about 2 inches. Plate 40 has first and second 
major flat opposed surfaces 44 and 46, respectively, with a plurality of 
holes formed therein which are countersunk on side 46. Imaginary center 
line 48 divides plate 40 into first and second halves 50 and 52, 
respectively, with the plurality of openings or holes being formed in the 
first half 50. Flat head screws 54 secure each alignment plate 40 to the 
rear surface 18 of the first wall panel member 12, with care being taken 
to ensure that the surface of each flat head screw 44 does not extend 
outwardly past the second major surface 46 of alignment plate 40. 
Joint 10 additionally includes a plurality of spacer members 60 and 60' 
fixed in vertically spaced relation to the rear surfaces 18 and 30, 
respectively, of the first and second wall panel members 12 and 14, along 
their adjacent edges 26 and 36, respectively. In a preferred embodiment, 
spacer members 60 and 60' are located at like vertical positions, with 
spacer member 60 preferably being located between panel edge 26 and an 
imaginary vertical line 61 which interconnects the left hand edges of 
alignment plates 40, as viewed in FIG. 4. In like manner, spacer member 
60' is preferably located between panel edge 36 and an imaginary vertical 
line 63 which interconnects the right hand edges of alignment plates 40'. 
Since spacer members 60 and 60' may be of like construction, only spacer 
member 60 will be described in detail. More specifically, spacer member 60 
is a metallic member which includes a smooth, round shank portion 62 
having a predetermined diameter, such as about 0.5 inch, and a length 
dimension in the direction of the longitudinal axis 64 which is slightly 
greater, i.e., about 0.005 inch greater, than the thickness dimension of 
the alignment plates 40 plus the thickness dimension of a metallic joining 
member to be hereinafter described. Spacer member 60 further includes a 
smooth round head portion 66 having a predetermined diameter which is 
larger than the diameter of shank portion 62, such as about 0.75 inch, and 
a length dimension of about 0.125 inch. Instead of the shank 62 and head 
66 joining at right angles relative to one another such that the underside 
of the head forms a flange, an angled or tapered cam surface 68 is 
provided between shank 62 and head 66. Cam surface 68 defines a 
predetermined angle with shank 62, such as an angle of about 25.degree.. 
The longitudinal length of cam surface 68, i.e., measured along the 
longitudinal axis 64 of spacer member 60, is about 0.25 inch. 
Spacer member 60 is secured to the back surface 18 of panel member 12 via 
suitable fastener means. As illustrated, spacer member 60 may have an 
opening coaxial with its longitudinal axis 64 for receiving a screw 70. A 
pilot opening may be pre-drilled in panel member 18 to accurately locate 
and guide screw 64. Spacer members 60 are attached to the back surface 18 
of wall panel member 12 with the centers of the spacer members all being 
located on a common vertical imaginary line spaced a predetermined 
dimension from the adjacent edge of the wall panel member. 
Joint 10 is completed by a joining member 80, best shown in FIG. 6. FIG. 6 
is a fragmentary, perspective view of joint 10, after the completion 
thereof. Joining member 80 is formed from an elongated metallic plate 
member 82, such as a steel plate, having first and second major opposed 
flat surfaces 84 and 86, respectively. Plate member 82 further includes 
upper and lower ends, with reference to the view shown in FIG. 6, such as 
upper end 88, and a longitudinal axis or center line 90 which extends 
between its ends. Plate member 82 also has firt and second side edges 92 
and 94, respectively. As illustrated, plate member 82 may be bent adjacent 
to side edges 92 and 94 to provide leg portions 96 and 98 which extend 
vertically outward from major side or surface 86. Leg portions 96 and 98 
function to stiffen the elongated joining member 80, and may be omitted if 
plate member 82 is formed from steel plate which has the required 
mechanical characteristics without additional stiffening. A metallic block 
member (not shown) may be welded adjacent to the upper end of the metallic 
joining member, for use in hammering the joining member 80 into, or out 
of, its frictional locking position to be hereinafter described. The 
length dimension of joining member 80 is selected such that the joining 
member will not extend below the bottom edges of the panel members, after 
the joining member 80 is disposed in its locking position. 
A plurality of first elongated slots or openings 100 are provided on one 
side of longitudinal center line 90, and a plurality of second elongated 
slots or openings 102 are provided on the other side of center line 90. 
The longitudinal axes of the first slots 100 are vertically oriented, and 
the longitudinal axes of the second slots 102 are inclined such that the 
upper end 104 of each slot 102 is closer to the longitudinal center line 
90 than the lower end 106 of the slot. 
The longitudinal axes of the first slots 100 are all located on imaginary 
line 108, which is parallel to and spaced from the longitudinal center 
line 90. The second elongated slots 102 have centers which are all located 
on an imaginary line 110 which is parallel to and spaced from longitudinal 
center line 90. Unlike slots 100, however, the longitudinal axes 112 of 
slots 102 are not vertically oriented, but they are slightly inclined, 
such as by an angle of about 4.degree. from the vertical line 110. 
Slots 100 and 102 each have an enlarged first portion at its lower end, a 
second portion which has parallel side, which starts at its upper end, and 
a third portion in the form of a tapered transition which extends between 
the enlarged first portion and the second portion. For example, slot 102 
has an enlarged first portion 114 at its lower end 106, a second portion 
116 starting at its upper end 104, which portion has parallel sides, and a 
tapered intermediate transition or third portion 118 which starts at the 
enlarged first portion 114 and tapers inwardly to the second portion 116. 
Enlarged portion 114 is constructed such that its lower end is in the form 
of a half circle, with the transition 118 extending from the ends of the 
half circle to the second portion 116. The diameter of the half circles is 
selected such that the head portion of the spacer member 60' will extend 
therethrough without interference. 
Referring again to FIG. 4, the first step in forming joint 10 is 
illustrated. The assembler uprights the panel members 12 and 14 in 
approximately the position they will assume when they are assembled. For 
ease in positioning the alignment plates 40 and 40' properly, panel 
members 12 and 14 may initially be angled slightly such that they provide 
an angle slightly less than 180.degree., with the assembler being located 
on this side of the angle. When the adjoining edges 26 and 36 are just 
about touching, the assembler straightens the panels to cause the angle to 
swing to 180.degree., which will bring the alignment plates 40 and 40' 
against the rear surfaces 30 and 18, respectively, of the panel members, 
as shown in FIG. 5. Joining member 80 is then placed in position such that 
the spacer members 60 and 60' enter the enlarged portions of the elongated 
slots 100 and 102, respectively, and are captured thereby. The assembler 
then strikes the top edge of the joining member 80, or the special block 
provided for this purpose, with a hammer, forcing the joining member 80 
into a downwardly displaced frictional locking position, as shown in FIG. 
6. 
As joining member 80 is forced vertically downward, the tapered transitions 
of slots 100 and 102 make it easy to capture the spacer members 40 and 40' 
in the slots, even when the panel members are bowed. Continued downward 
movement of joining member 80 results in the narrowing taper of transition 
118 camming the joining member 80 into tight engagement with the alignment 
plates 40 and 40'. Joining member 80, being straight and flat, cams 
tightly against the alignment plates, forcing the alignment plates 40 and 
40' into a common plane. Since surfaces 44 of the alignment plates, and 
thus the rear surfaces 18 and 30 of the panel members are all in a common 
plane, especially in the joint area, their front surfaces 16 and 28 are 
forced into a common plane at the joint area, with no mismatch or step. 
Continued downward movement of joining member 80 to its final locking 
position causes the adjoining edges of the panel members 12 and 14 to be 
drawn tightly together due to the inclined slots 102 acting upon the 
spacer members 60', to move wall panel member 14 tightly against wall 
panel member 16. 
In the embodiment of the invention shown in FIGS. 1-6, the thickness 
dimensions of the wall panel members were assumed to be substantially 
uniform from panel to panel, such that when the rear surfaces of the panel 
members are straightened and aligned in a common plane by the alignment 
plates and joining member, the front surfaces will also be automatically 
aligned in a common plane. Certain types of wall panel members, however, 
may have a slight variation in panel thickness dimension from panel to 
panel. FIGS. 7 and 8 are fragmentary, perspective view of a panel joint 
120 constructed according to another embodiment of the invention, which 
may be used to align the front surfaces of two in-line panel members in a 
common plane, notwithstanding a difference in their thickness dimensions. 
In general, the major differences between this embodiment of the invention 
and the embodiment of FIGS. 1-6 is the elimination of the alignment plates 
40 and 40', and the dividing of the joining member 80 into first and 
second parts or elements along the longitudinal centerline 90. The first 
and second parts or elements of the joining member are adjustably clamped 
after the elements are adjusted relative to one another to accommodate the 
specific thickness dimensions of the wall panel members to be butted 
together and joined. Components in FIGS. 7 and 8 which may be the same as 
those in FIGS. 1-6 will be given like reference numerals, and will not be 
described again in detail. 
More specifically, joint 120 includes a joining member 80' having first and 
second separate portions 82' and 82" with each portion having a 
substantially U-shaped cross-sectional configuration wherein portion 82' 
includes spaced leg portions 96' and 122, and a flat connecting bight 
portion 124. Portion 82" includes spaced leg portions 124 and 94', and a 
flat connecting bight portion 126. Leg portions 122 and 124 have aligned 
openings therein when the side surfaces of these leg portions are butted 
together, with additional aligned openings being vertically spaced at 
predetermined intervals. One of the openings of the aligned pairs is 
horizontally elongated, such as the horizontally elongated slot or opening 
128 shown in leg portion 122. Suitable adjustable clamping or fastener 
means 130 link the two portions via the aligned openings, such as a nut 
132, bolt 134, and lock washer 136. 
The elongated slots in the flat bight portions of the two elements of the 
joining member 80' may be the same as in the embodiment set forth in FIGS. 
1-6; or, as illustrated in FIG. 7, slot 100 may be modified to provide a 
slot 100' which as no enlarged portion and no tapered transition. The fact 
that this embodiment of the invention does not utilize the alignment 
plates of the first embodiment makes it possible to assemble the joining 
member 80' with panel member 16 at the factory, and thus one of the panel 
members and joining member 80' may be shipped as a unit. This has the 
advantage in that all elements of the joint are fixed to the panel members 
for shipment, precluding the loss of any of the essential joint elements. 
If the slots in both joint elements are identical to those in the 
embodiment of FIGS. 1-6, the spacer members would also be the same as in 
the first embodiment. However, if the modified slots 100' are used, then a 
spacer member 140 would be used, instead of spacer member 60. Spacer 
member 140 includes a shank and head portion, but it does not have the 
tapered transition of spacer member 60. Spacer members 140 are inserted 
through slot 100' and then fastened to the rear of wall panel member 12, 
to capture joining member 80' but with sufficient clearance to allow it to 
move in a snug but slideable relation. 
As illustrated in FIG. 7, joining member 80' is shipped to the job site 
with the first and second portions being initially set to join two panel 
members having the same thickness dimension. If it is found by the 
assembler in the field that panel member 14 is not as thick as panel 
member 12, or it is thicker than panel member 12, the assembler loosens 
the plurality of fastener means and adjusts the relative positions of the 
first and second portions or elements 82' and 82" to accommodate the 
difference in thickness. The fastener means is then retightened. This 
adjustment step may be accomplished with, or without panel member 14 
connected to panel member 12, depending upon the easiest approach 
considering the space available to the assembler. Similar to the first 
embodiment, when joining means 80' is hammered downwardly to its 
frictional locking position, panel 14 will be cammed tightly against 
joining member 80' due to the taper or cam on the spacers 60' and the 
tapered portion of the slots 102, and the adjacent edges of the wall panel 
members 12 and 14 will be drawn tightly together due to the inclined slots 
102 and spacer members 60'.