Wall panel assemblies

An acoustical wall assembly comprises at least two modular sound absorbing panels. Each panel includes a substantially flat body and a tongue extending substantially parallel to and spaced from one edge of the body so as to form a channel therebetween. The tongue is provided with a flange portion which extends from the tongue away from the channel. A first connector member having two side plates each extending into a corresponding channel of two modularly-aligned panels, and a second connecting member disposed between the tongues of the adjacent panels, are secured together so as to clamp the flange portions therebetween and secure the two panels together in a coplanar relationship.

This invention relates to panel assemblies and more particularly to panel 
assemblies of the modular type. 
Modular acoustical panel assemblies are well known for providing sound 
absorbing and attenuating walls and ceilings which are easy to construct 
and build with minimum effort and skill. In my copending applications Ser. 
No. 643,698 filed Dec. 23, 1975 now U.S. Pat. No. 4,038,796 and Ser. No. 
727,034 filed Sept. 27, 1976 now U.S. Pat. No. 4,074,489, I describe 
improved acoustical modular panel assemblies which are easily and quickly 
assembled and disassembled without the need for specially designed tools. 
The assemblies described in both applications include identical modular 
panels so that any two can be assembled together. In assembling the panels 
together to form a wall or ceiling, each panel is aligned and oriented 
with respect to an adjacent panel so that two side edges of the respective 
panels are in a confronting and spaced relationship. Each panel includes a 
substantially flat body and at least one tongue which extends along a side 
edge of the panel substantially parallel to and spaced from the body so as 
to form a channel therebetween which is open along one side of the panel. 
The panel assemblies include connector means for connecting the panels 
together in an acoustically tight fashion. In order to connect the panels 
together in a coplanar relation, the connector means includes two 
preferably U-shaped connector members which join together the two 
confronting side edges of two adjacent panels. Each connector member 
comprises two parallel side plates and a web or strap connected to and 
supporting the side plates. Each side plate of one connector member 
extends within a corresponding one of the channels of each panel where it 
makes a tight fit with the adjacent tongue and flat body. The other 
connector member is fitted between the two panels so its side plates 
extend between and make a tight fit with the adjacent tongues of the two 
adjoining panels. Various types of connector means are also described in 
both applications for connecting two adjacent panels so as to form a 
corner. 
Modular panels assembled in this manner have several advantages. For 
example, the assemblies have improved acoustical insulation and structural 
characteristics as well as the ability to easily accommodate doors and 
door frames. The use of identical modular panels enables the manufacturer 
to produce the panels more economically and makes the assembly of the 
panels easy. Finally, the use of the U-shaped connector members to connect 
adjacent panels provides not only a vertical load bearing column but also 
a raceway between panels for accommodating plumbing lines, electrical 
cable and the like. 
The assemblies of my copending applications also include means, in the form 
of floor channel members to reinforce the lower longitudinal edges of the 
panels, secure the joined panels to the floor and also to restrain the 
panel connector members against separating movement. The floor channel 
members are preferably in the form of U-shaped members adapted to receive 
the bottom longitudinal edges of the panels as well as the connector 
members in a close, preferably tight, fit. Similarly, ceiling or roof caps 
are provided in order to lock together the upper ends of the connector 
members as well as reinforce the upper margins of each of the panels. The 
floor channel members and roof caps thus provide reinforcement for the 
upper and lower longitudinal edges of the panels, and also prevent 
separating movement of the connector members. However, they also can 
provide some inconvenience when it may become necessary to replace a panel 
of an assembled wall, since the connector members cannot easily be removed 
until they are released from the floor channel members and roof caps. 
Further, a particular user of the assemblies may not wish to utilize the 
floor channels or roof caps, because, for example, he may not wish to 
permanently secure the floor channels to the floor or they may be 
undesirable purely for aesthetic reasons. Additionally, where the panel 
assemblies are used as ceiling panels, the assemblies may be more 
difficult to handle when installing or removing a ceiling since the 
U-shaped connecting members are held only by frictional engagement and may 
not be as securely attached as desired. 
Therefore, it is an object of the present invention to provide an improved 
modular panel assembly which includes many of the advantages of the 
modular panel assemblies of my copending applications Ser. Nos. 643,698 
and 727,034. 
Another object of the present invention is to provide an improved modular 
panel assembly in which the connecting members used to join adjacent 
panels are secured from separating movement without the need for floor 
channels or roof capss, so that a panel can be easily replaced without 
requiring disassembly or removal of several other panels from the panel 
assembly. 
And another object of the present invention is to provide an improved 
modular panel assembly of the type described having a relatively improved 
structural connection between any two adjacent panels. 
These and other objects are achieved by a panel assembly comprising at 
least two modular panels of the type including a substantially flat body 
and a tongue extending substantially parallel to and spaced from one edge 
of the body so as to form a channel therebetween. The tongue is provided 
with a flange portion which extends from the tongue away from the channel. 
The two panels are connected together by connecting means comprising first 
and second connector members so that the panels are in a substantially 
coplanar relationship. The first connector member has two side plates, 
each of which extend into a corresponding channel of the two aligned 
panels, and the second connector member is disposed between the tongues of 
the adjacent panels. Releasable means secure the first and second 
connectors together so as to clamp therebetween the flange portions of 
adjacent panels.

Also, for convenience of illustration, the thickness of the panels is 
exaggerated in the drawings. In practice, for example, the panels may 
measure 4 feet wide, 8 feet high and either 2 or 4 inches thick. 
Referring now to FIGS. 1-4, the illustrated assembly comprises at least two 
sound absorbing and attenuating panels 10 each including a pair of flat 
plates 12A and 12B mounted in a parallel and spaced relationship with 
respect to each other so as to form a substantially flat body. While both 
of the plates may be perforated (so as to render it transparent to sound) 
or solid, in the preferred embodiment one of the plates 12A and 12B is 
perforated and the other plate is not perforated. As shown in FIG. 2, the 
top and bottom longitudinal edges of the two plates of each panel are 
secured together by stiffeners 14A and 14B. Each stiffener has a pair of 
side flanges 16 which are secured to the inside surfaces of plates 12A and 
12B and end flanges 18 which extend transversely to and are spaced from 
the side flanges so as to provide a relief (not shown) at each corner of 
the stiffener. Each plate 12A is provided with right angled side 
extensions 20 which, in the embodiments of FIGS. 1-4 and 7, are secured to 
the end flanges 18 of stiffeners 14A and 14B and serve as the side edges 
of the panel so as to enclose the space between plates 12A and 12B. The 
space is filled with a suitable sound absorbing material 22 such as glass 
fibers or a plastic foam. The other plate 12B is preferably formed with 
right angle side extensions 24, hereinafter referred to as "tongues 24." 
In the embodiments described in FIGS. 1-4 and 7, each tongue extends along 
the entire side edge of the panel and is spaced from the adjacent side 
extension 20 so as to form a channel 26 therebetween (see FIGS. 4 and 7) 
which is preferably open along one side of the panel, in this case along 
the side formed by plate 12A. Where one of the plates 12A and 12B is 
perforated, the channel 26 preferably is open on the side of the 
perforated plate. 
To the extent described these panels are identical to those described in my 
prior copending applications Ser. Nos. 643,698 and 727,034. In accordance 
with the present invention, the panels are preferably modified so that 
each tongue 24 is provided with an outwardly-turned flange portion 28, 
each of the latter being of a predetermined width and extending 
substantially perpendicular to the tongue of which it is a part. 
Additionally an improved connecting means is employed for connecting two 
adjacent panels in a coplanar relationship. The connecting means generally 
comprises inner and outer channel-shaped connector members 30 and 32. 
Inner member 30 is preferably essentially the same as the outer U-shaped 
connector member described in my copending applications Ser. Nos. 643,698 
and 727,034. Specifically, inner channel member 30 has two, parallel, 
spaced-apart side plates 34 and a strap or web portion 36 connected to and 
supporting the side plates at a right angle thereto. Each channel member 
30 preferably extends the full height of the panels. The two adjacent 
panels 10 to be connected together are spaced from one another so that the 
side plates 34 of the channel member 30 extend into corresponding ones of 
the channels 26 at the confronting side edges of the two panels. Each side 
plate 34 makes a snug, preferably tight, fit with the tongues 24 and 
extensions 20 of the two panels and when the side plates 34 are properly 
positioned in the channels, the web portion 36 is preferably flush with or 
coplanar with the outer surfaces of the plates 12A of the two panels as 
well as in contact with the flange portions 28 of the tongues. The web 
portion 36 of the connector member 30 is modified from the connector shown 
and described in my copending applications Ser. Nos. 643,698 and 727,034 
so as to include at least one and preferably a plurality of apertures 40 
which are located substantially centrally between side plates 34 and are 
longitudinally spaced from one another. The web portion 36 is dimensioned 
so that when connector member 30 is connecting two panels together a space 
is provided between the flange portions 28 which is sized to allow the 
threaded portion of a bolt 42 to extend through the aperture 40 between 
the flange portions 28. 
The outer connector member 32 of the embodiment shown in FIGS. 1-4 is 
similar to the batten described in Canadian Patent No. 1,007,991, issued 
Apr. 5, 1977 to Oliver C. Eckel. Specifically, the outer connector member 
32 is essentially U-shaped, having two oppositely disposed, parallel, 
spaced-apart side plates 44, each of which are integrally connected at 
right angles to an opposite edge of a strap or web portion 46. The edges 
of the side plates opposite the web portion 46 are formed with inwardly 
directed lips 48 so as to provide a space 50 therebetween. Member 32 
preferably extends the full height of the panels and is filled with sound 
absorbing material 52, which bears against the side plates 44 and web 
portion 46 and is resilient when compressed. One or more flat retaining 
plates 54 are provided, each having a substantially centrally-located 
threaded hole 56 and dimensioned so that each can be inserted diagonally 
in the space 50 between the lips 48, into the interior of the connector 
member, pressed against the material 52 and reoriented so that the side 
edges of the retaining plate are biased into contact with the lips 48 by 
the resilient material 52. The connector member 32 is dimensioned so as to 
snugly fit between the tongues 24 of adjacent panels so that the lips 48 
contact the flange portions 28 of adjacent panels, while the web portion 
46 is substantially flush or coplanar with the plates 12B of the two 
panels. When plate 54 is positioned between the panels, its threaded hole 
56 is aligned with aperture 40 of the inner connector member 30, so that 
bolt 42 extending through the aperture 40 and between the flange portions 
28 of the panels 10 can be screwed into the aperture 56 and thus draw 
retaining plate 54 and connector member 32 toward connector member 30 and 
flanges 28. The connection formed by the inner and outer channel members 
30 and 32 essentially secures each tongue 24 between the side plates 34 
and 44 of the outer and inner connector members, respectively, and clamps 
its flange portions 28 between the lips of the outer connector member 32 
and the web portion 36 of the inner connector member 30. By securing the 
bolt 42 to the retaining plate 54 a vertical post or column is provided 
for structurally supporting the two adjacent modular panels 10 in a 
coplanar relationship which is more rigid and secure than the 
corresponding structure of the panel assemblies disclosed in my aforesaid 
copending applications. 
In a modified form of the present invention shown and described in FIGS. 5 
and 6, the panels 10A are made identical to panels 10, except that the 
side extensions 20A of the plates 12A only extend about half the width of 
the panel from one side of the panel and the tongues 24A together with 
their flange portions 28 formed by the plates 12B extend only about half 
the width of the panel from the opposite side of the panel. The side 
extensions 20A are preferably not secured to the upper and lower stiffener 
members 14A and 14B but are made flexible toward and away from the 
resilient material 22, with the extensions being made at an angle slightly 
greater than 90.degree. with respect to the frontal portion of the plate 
12A, i.e., so that the side extension of one panel converges toward the 
confronting side extension of the adjacent panel, for reasons which will 
become more apparent hereinafter. The channel 26A formed between the 
tongues and the side edges of the body is actually formed by the tongue 
and the resilient material 22 of the panel. Two adjacent panels 10A are 
connected together by utilizing connector members 30A and 32A identical to 
those previously described except that the side plates of both members are 
dimensioned to extend only half the width of each panel when two adjacent 
panels are connected together. Specifically, the side plates of inner 
connector member 30A extend into the channels 26A of the two adjacent 
panels, making a snug and preferably a tight fit with the tongues 24 and 
the resilient material 22, while the outer connector member 32A extends 
between the tongues so that the side plates 44 and lips 48 make contact 
with the confronting tongues 24A and the flange portions 28 respectively. 
The bolt 42 and retaining plate 54 are used to secure the connector 
members together and clamp the tongues 24A and flange portions 28 
therebetween. Once the inner and outer connecting members secure two 
adjacent panels together, a recess is formed which is sized to receive a 
third connector member 30B. The latter may be identical to the inner 
connecting member 30A and thus includes the side plates 34 and web portion 
36; preferably, however, connector member 30B lacks a hole like that one 
in connector member 30A for bolt 42. Since the extensions 20A are made at 
an angle slightly greater than 90.degree. with respect to the side plates 
12A, insertion of third connector member 30B between the two panels 
results in the side plates 34 biasing the side extensions of the adjacent 
panels away from one another against the material 22. This results in a 
snug, preferably tight, fit between the connector member 30B and the side 
extensions 20A. In position, the side plates of connector 30B 
substantially abut the member 30A while the web portion 36 is 
substantially coplanar with panel 12A. Similarly, the web portion 36 of 
connector member 32A is substantially coplanar with plates 12B. 
The embodiment of FIGS. 5 and 6 provides the advantage that the hollow 
column thus formed by connector 30B hides the bolt 42 from view, making 
the appearance of the panel aesthetically more pleasing. Secondly, panels 
10A can be made twice the thickness of panels 10 while employing the same 
sized connecting members. Thirdly, the hollow column formed by the third 
connecting member 30B and web portion 36 of the inner connecting member 
30A can easily function as a raceway for electrical cables, piping or the 
like. In such a situation, although not shown, where building codes 
require it, the bolts 42 can be countersunk with respect to the web 
portion 34 of connector 30A so that the heads of the bolts are 
substantially flush with the web portion. 
A further modified form of the present invention is shown in FIG. 7. In 
this embodiment, each aperture 40 of the web portion 36C of the inner 
connector member 30C is provided with a threaded insert 58 which is welded 
or otherwise secured in place, and the outer connecting member 32B is 
replaced by the member 32A. The insert is provided with a width dimension 
larger than the space provided between the flange portions 28 when two 
adjacent panels are connected together. The member 32B is similar to the 
inner connector member of my copending applications Ser. Nos. 643,698 and 
727,034, with member 32B including side plates 60 oppositely disposed and 
parallel to one another and integrally joined at right angles to a web 
portion 62. The web portion 62 is provided with apertures 64 which 
correspond to threaded inserts 58, so that when the side plates 34 of 
connector member 30C are inserted in the respective channels 26 of 
adjacent panels and connecting member 32B is inserted between the tongues 
24 of adjacent panels, the bolt 42A can be inserted through each aperture 
64 between flange portions 28 and screwed into the corresponding threaded 
insert 58. In this manner, the side plates 60 of connector 32B clamp the 
flange portions 28 of the adjacent panels against the web portion 36C of 
connecting member 30C, the web portion 62 is substantially flush with the 
plates 12B of the adjacent panel and the web portion 36C is substantially 
flush with plates 12A. 
The assembly thus described provides a modular wall and/or ceiling assembly 
which has relatively improved acoustical insulation and structural 
properties without the need for floor and ceiling channel or cap 
connecting members. Further, with respect to the embodiments shown in 
FIGS. 5 and 7 the joints can easily accommodate water and heating pipes, 
electrical cable and the like through the raceway provided. Further, the 
assembly utilizes identical panels for both wall and ceiling structures. 
Additionally, by dimensioning each of the panels 10 to that of the size of 
a standard door frame and doors, a door frame and door can easily be 
substituted for one of the panels, thus making it easy to adapt the 
assembly to present construction demands. Also the plates 12A and 12B, as 
well as the stiffeners may be made of metal and connected together by spot 
welding or rivets. Alternatively, they may be made of plastic materials 
and locked together by a cement or suitable fasteners or ultrasonic 
welding. 
Obviously, certain changes may be made in the above apparatus without 
departing from the scope of the invention herein involved. Thus, for 
example, the tongues 24 of adjacent panels may not extend the full length 
of the panels 10 but instead may be slotted so as to form two or more 
smaller tongues spaced along the edge of the panel. Other possible changes 
are to use means other than the resilient sound absorbing material 52 to 
hold the retaininer plates 54 in place when they are not attached to bolts 
42, and not filling or only partially filling connector member 32 with 
insulation 52 so as to allow a portion of the interior space of the 
connector member to function as a raceway. Still other changes will be 
obvious to persons skilled in the art. Therefore, it is intended that all 
matter contained in the above description and shown in the accompanying 
drawings shall be interpreted in an illustrative and not in a limiting 
sense. 
It is to be understood that as used in the appended claims, the term "wall 
assembly" denotes either a wall or ceiling or floor.