Wall start for panel systems

A wall start panel for knock-down portable partition systems of the type having a plurality of panels, each having standard width posts interconnected by structural members in a spaced-apart relationship to define a standard panel width. The wall start panel includes at least one structural member and a standard width post having a unitary construction and including a connection port. The standard width post also has opposite side faces defining a standard post width therebetween. The wall start panel further includes a wall start post having a connection port and having opposite side faces defining a width therebetween substantially less than the standard post width. The structural member spans between and releasably interconnects the standard width and wall start posts in a spaced-apart relationship. The wall start panel has a substantially standard panel width, such that the wall start post can be secured to an existing wall without use of a trim piece to close off the wall start panel.

BACKGROUND OF THE INVENTION
 The present invention relates to office partition panel systems, and in
 particular to a wall start that connects a partition panel to an existing
 wall in an off-module configuration.
 The efficient use of building floor space is an ever-growing concern,
 particularly as building costs continue to escalate. Open office plans
 have been developed to reduce overall officing costs, and generally
 incorporate large, open floor spaces in buildings that are equipped with
 modular furniture systems which are readily reconfigurable to accommodate
 the ever changing needs of a specific user, as well as the divergent
 requirements of different tenants. One arrangement commonly used for
 furnishing open plans includes movable or portable partition panels that
 are detachably interconnected to partition off the open spaces into
 individual workstations and/or offices. Such partition panels have
 sufficient structural strength to receive hang-on furniture units, such as
 work surfaces, overhead cabinets, shelves, etc., and are generally known
 in the office furniture industry as "systems furniture." In addition, such
 partition panels have an acoustical, sound-absorbing configuration to
 promote a quiet, pleasant work environment.
 Numerous partition panel systems have been developed for dividing office
 workspaces into smaller areas. Partition panel systems, like those
 disclosed in U.S. Pat. No. 4,996,811, utilize prefabricated rectangular
 partition panel members that have a unitary rigid perimeter frame formed
 by top, bottom, and end channels that are welded to one another.
 Decorative cover panels are fastened to opposite sides of the perimeter
 frame. Each perimeter frame member has a rectangular shape and is
 fabricated and shipped as a single unit, often with the decorative cover
 panels pre-fastened to the frame. During installation, the prefabricated
 perimeter frame of each panel member is fastened to the perimeter frame of
 an adjacent panel member along the vertical edges thereof, either directly
 or by a separate fastener post. Each partition panel member includes two
 height adjustable feet or glides along the bottom edge of each panel
 member, with one glide being located adjacent each vertical panel edge.
 Since there are two vertical frame members at each panel joint, this type
 of panel construction results in structural redundancy. In addition, since
 each glide must be properly adjusted for height, this configuration
 requires adjustment of both glides at each panel joint during assembly.
 Furthermore, although longer panels typically have a lower cost per unit
 length, longer panels are difficult to handle, which places a practical
 limit on the size of the partition panel member that can be shipped and
 installed as a prefabricated unit.
 Other partition panel systems, like that disclosed in U.S. Pat. No.
 5,150,554, utilize prefabricated rectangular partition panel members
 having a unitary perimeter frame that attaches to a post member along each
 vertical panel edge. Although this type of design may have a single glide
 at each post, each panel-to-post connection has at least two vertical
 structural members. Since only a single vertical member is needed to
 provide support and height adjustment, this type of system has redundant
 structure. In addition, the rectangular partition panel members are
 manufactured and shipped as a unit, limiting the size of the partition
 panel members that can be used.
 Other office divider systems, like that disclosed in U.S. Pat. No.
 5,406,760, utilize vertical posts and horizontal beams wherein each post
 attaches to an adjacent post along adjacent vertical edges. Since each
 post is attached directly to an adjacent post, this configuration also has
 redundant vertical structural members and glides.
 Other office panel dividers, like that disclosed in U.S. Pat. Nos.
 5,287,666 and 5,219,406, have multiple posts and beams with connector
 members that hold a pair of beams to adjacent posts. This arrangement has
 two horizontal beams in a side-by-side relationship at each height
 location, and also has two vertical posts attached directly together in
 either a back-to-back or side-by-side relationship. Thus, there is
 redundancy in both the post and the beam structures. In addition,
 connector pieces are required to attach the beams to the posts.
 Special bracket arrangements have been developed to connect partition panel
 systems to existing architectural walls and are commonly referred to as
 "wall starts." Available wall start brackets position the side edge of the
 partition panel some distance away from the architectural wall and may
 require specially fabricated and/or fitted cover panels and trim adjacent
 the architectural wall. Because the wall start bracket adds width that is
 not a multiple of a standard panel width, the resulting partition panel
 has an overall length that is non-standard. Consequently, the partition
 panel that is connected to the architectural wall and adjoining panels may
 be misaligned relative to the other partition panels in the system, making
 it difficult to integrate the non-standard panels with the other panels in
 the system to provide the desired workspace dimensions. Accordingly, there
 is a need for a wall start for a partition panel that provides a standard
 panel width, and also permits quick and easy connection to various types
 of existing dividers and walls, without requiring custom-fit cover panels
 and trim.
 SUMMARY OF THE PRESENT INVENTION
 One aspect of the present invention is to provide a wall start panel for
 knock-down portable partition systems of the type having a plurality of
 panels, each having standard width posts interconnected by structural
 members in a spaced-apart relationship to define a standard panel width.
 The wall start panel includes at least one structural member and a
 standard width post having a unitary construction and including a
 connection port. The standard width post also has opposite side faces
 defining a standard post width therebetween. The wall start panel further
 includes a wall start post having a connection port and having opposite
 side faces defining a width therebetween substantially less than the
 standard post width. The structural member spans between and releasably
 interconnects the standard width and wall start posts in a spaced-apart
 relationship. The wall start panel has a substantially standard panel
 width, such that the wall start post can be secured to an existing wall
 without use of a trim piece to close off the wall start panel.
 Another aspect of the present invention is a wall start panel for
 knock-down portable partition systems of the type having a plurality of
 standard width panels with standard width cover panels mounted thereon.
 The wall start panel includes a wall start frame defining a first side
 edge shaped for connection to an existing wall and an opposite side edge.
 A standard width cover panel is secured to the wall start frame and covers
 at least a portion of the same. The cover panel defines a side edge
 extending vertically adjacent the existing wall, such that a trim piece is
 not required along the side edge. The wall start frame includes a standard
 width post having upper and lower ends and having opposite side faces
 defining a standard post width therebetween. The standard width post also
 has at least two beam connection ports. The wall start frame further
 includes a wall start post configured to be secured to an existing wall
 and having at least two beam connection ports. Upper and lower beams
 extend generally horizontally between the standard width and wall start
 posts and releasably interconnect the posts adjacent the connection ports.
 The wall start post has opposite side faces defining a width therebetween
 substantially less than the standard post width, such that the wall start
 panel has a substantially standard width when secured to an existing wall.
 Another aspect of the present invention is a wall start post for knock-down
 portable partition systems of the type having a plurality of standard
 width panels including a wall start panel of the type having a standard
 width post and a pair of beams releasably connected to the standard width
 post. The standard width post has a unitary construction with opposite
 side faces defining a standard width post therebetween. The wall start
 post is shaped to secure the wall start partition panel to an existing
 wall, and has a first side face with at least two beam connection ports
 thereon for releasably connecting to the beams to form a wall start panel.
 A second side face of the wall start post is shaped to abut an existing
 wall. The side faces of the wall start post define a width therebetween
 that is substantially less than that of the standard width post, such that
 the wall start panel has a substantially standard width when the wall
 start post is secured to an existing wall.
 These and other features, objects, and advantages of the present invention
 will become apparent upon reading the following description thereof
 together with reference to the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
 For purposes of description herein, the terms "upper," "lower," "right,"
 "left," "rear," "front," "vertical," "horizontal," and derivatives thereof
 shall relate to the invention as oriented in FIG. 1. However, it is to be
 understood that the invention may assume various alternative orientations
 and step sequences, except where expressly specified to the contrary. It
 is also to be understood that the specific devices and processes
 illustrated in the attached drawings and described in the following
 specification are simply exemplary embodiments of the inventive concepts
 defined in the appended claims. Hence, specific dimensions and other
 physical characteristics relating to the embodiments disclosed herein are
 not to be considered as limiting, unless the claims expressly state
 otherwise.
 The reference numeral 1 (FIG. 1) generally designates a wall start for
 knock-down portable partition systems embodying the present invention,
 which is particularly designed for use in open office plans and other
 similar settings and environments. In the illustrated example, the wall
 start 1 includes a knock-down portable partition panel 2 for partition
 systems of the type having a plurality of standard width panels 3. The
 partition panel 2 has a first side edge 4 connectable to an existing wall
 5 in an off-module configuration. The partition panel 2 also includes an
 opposite side edge 6 that can be connected to a standard width panel 3.
 The partition panel 2 includes a rigid panel frame 7 having a central
 portion 8. At least one cover panel 20 is connected to the rigid panel
 frame 7 and covers at least a portion of the central portion 8 of the
 rigid panel frame 7.
 With further reference to FIG. 2, the rigid panel frame 7 includes a
 standard width post 9 having a unitary construction with opposite side
 faces 10 defining a standard post width "W1" therebetween. The opposite
 side faces 10 have at least two beam connection ports 11. The rigid panel
 frame 7 also includes a wall start post 12 having first and second
 opposite side faces 13 and 14 defining a width "W2" therebetween. Width
 "W2" is substantially less than the standard post width "W1," such that
 the opposite side edge 6 is spaced-apart from the existing wall 5 at
 substantially a standard panel width. The first side face 13 of the wall
 start post 12 has at least two beam connection ports 11. Upper and lower
 beams 15 extend generally horizontally between the standard width and wall
 start posts 9 and 12 and releasably interconnect the posts adjacent the
 connection ports 11. The second side face 14 of the wall start post 12
 defines the first side edge 4 of the partition panel 2. The side face 14
 has at least a portion defining a contour corresponding to the existing
 wall 5. The wall start post 12 further includes at least one wall
 connector such as upper, intermediate, or lower hooked brackets 16-18
 (FIG. 2), described in more detail below. Alternatively, the connector may
 comprise an architectural wall connector bracket 19 (FIGS. 3 and 4) or
 other suitable connector. The wall connector brackets secure the wall
 start post 12 to the existing wall 5 in an off-module configuration
 without requiring additional trim, spacers, or other specially made
 hardware.
 Examples of standard width posts 9 and beams 15 are described in detail in
 the above-identified U.S. Pat. Nos. 6,009,675; 5,899,035; 6,098,358;
 6,058,667, and and hence, will not be described in detail herein. With
 reference to FIG. 2, beams 15 are constructed from tubular steel and
 include quick-disconnect connectors, such as wedges 21. The wedges 21 are
 rotatably mounted on the beams 15. Each beam connection port 11 includes
 four vertical slots 22 (see also FIG. 6) that receive hooks located on the
 ends of the beams 15. Wedge 21 is then rotated to engage opening 24,
 thereby ensuring that hooks 23 remain engaged with slots 22. Utility
 troughs 25 extend between the posts 9 and/or 12, and receive lay-in
 wiring. Utility troughs 25 also provide for mounting of power receptacles
 26 and/or communications receptacles 27. Wall start posts 9 and 12 each
 utilize the same connecting arrangement for cover panels, beams, utility
 troughs, and related components, such that additional, specially
 fabricated cover panels, trim, or other components are not required.
 The standard width posts 9 have front faces 28 with a vertical row of
 openings, such as slots 29, that receive hooks of hang-on accessory units
 (not shown), such as binder bins, worksurfaces, and the like.
 Clip-receiving openings 30 receive clips 31 of cover panels 20 for support
 of the cover panels. Base cover 32 includes integrally formed upper and
 lower clips 33 and 34 that are received in upper and lower openings 35 and
 36 to removably secure the base cover 32 along the base of the partition.
 A top cap 37 includes a plurality of clips 38 that secure the top cap 37
 along upper edge 39 of cover panels 20. Posts 9 and 12 each include a
 glide 40 for supporting the post on an existing floor surface 41. Each
 glide 40 includes a threaded portion 42 (FIG. 6) that is received in a
 threaded plate 43 adjacent the lower end of the post. As best seen in FIG.
 14, wall start post 12 includes a vertical row of slots 60 located at the
 corner formed by the junction of the second opposite side face 14 and
 front faces 28. Slots 60 are positioned directly adjacent the existing
 wall when the wall start post 12 is in the installed position.
 If width "W2" of wall start post 12 is one-half width "W1" of standard
 width post 9, standard width post 9 will be positioned at a standard panel
 width from the existing wall. The illustrated wall start post 12 includes
 vertical slots 60 on front faces 28 adjacent second side face 14 of post
 12. Because slots 60 have the same width as slots 29, width "W2" of wall
 start post 12 is slightly greater than one-half width "W1" of a standard
 width post 9. Accordingly, although standard width post 9 is not precisely
 positioned at a standard panel width because width "W2" is about one-half
 width "W1", panel misalignment or "creep" due to the wall start is
 substantially eliminated.
 In contrast to prior systems having two side-by-side vertical frame members
 that are directly interconnected, standard width post 9 has a unitary
 construction with beams interconnected to the same post 9 on opposite side
 faces. Similarly, wall start post 12 may also have a unitary construction
 with a first side face 13 providing beam connection ports 11, and a second
 side face 14 that closely fits against and abuts the existing wall. Posts
 9 and 12 have a tubular steel construction with a quadrilateral plan
 shape.
 With reference to FIG. 12, each wall start post 12 includes at least one
 bracket 44 with a horizontally extending tab portion 45 and a vertical leg
 46 that is welded or otherwise secured to the post 12. Threaded fasteners
 48 secure either an architectural wall connector bracket 19 (FIGS. 4-7) or
 an intermediate hooked bracket 17 (FIGS. 8-11) to the horizontal tab 45.
 Wall start post 12 includes a plurality of openings 58 that permit routing
 of power and/or communications cabling through post 12 and the existing
 wall. With further reference to FIGS. 13 and 14, each architectural wall
 connector bracket 19 includes an elongated slot 49 that receives threaded
 fastener 48. First opposite side face 13 of post 12 includes a clearance
 opening 50, such that vertical leg 46 of bracket 44 can be welded to the
 inner surface of the second opposite side face 14 of post 12, with tab 45
 extending horizontally through opening 50. Architectural wall connector
 bracket 19 is generally L-shaped and includes a horizontal leg 51 and
 vertical leg 52. Vertical leg 52 includes a pair of clearance holes 53
 that receive a conventional anchor bolt or other conventional fastener for
 securing connector bracket 19 to an existing wall, such as an
 architectural wall, or other type of wall capable of receiving fasteners
 for securing bracket 19. Slot 49 permits bracket 19 to be slid
 horizontally in the direction of the arrow "A" (FIG. 14) to account for
 variations in the surface contour of the existing wall and permit vertical
 positioning of post 12. After adjustment of the bracket 19 to the proper
 position, threaded fastener 18 secures bracket 19 to the threaded opening
 47 of bracket 44. The second opposite side face 14 has a large,
 rectangular clearance opening 54 permitting vertical leg 52 of connector
 bracket 19 to pass through second side face 14 as required to secure
 bracket 19 to an existing wall, while accounting for variations in the
 contour of the wall surface. A plurality of brackets 44 and connector
 brackets 19 are provided for securing the wall start post 12 to an
 existing architectural wall or other wall. The wall start post 12
 illustrated in FIGS. 4-7 has upper, intermediate, and lower brackets 19.
 However, the number of brackets required can be varied, depending upon the
 height of the partition system 1 and wall start post 12, or other factors
 relating to the particular application.
 In another preferred embodiment (not shown), clearance holes are provided
 in wall start post 12. Conventional fasteners extend through the clearance
 holes and secure post 12 directly to an architectural wall. Suitable
 fasteners for anchoring to dry wall, concrete block, or the like are
 selected depending on the construction of the existing wall. This
 arrangement replaces the connector bracket 19 described above.
 Another type of existing wall 55, illustrated in FIG. 2, includes a
 plurality of horizontal frame members 56 having horizontal rows of slots
 57. An example of an existing wall 55 of the type illustrated in FIG. 2 is
 described in detail in U.S. Pat. No. 5,802,789, the entire contents of
 which are hereby incorporated by reference. To configure wall start post
 12 for use with the existing wall 55, a plurality of brackets 44 are
 welded to the wall start post 12 in a similar manner as described above,
 except that brackets 44 are positioned at heights corresponding to the
 horizontal rows of slots 57 in the existing wall 55.
 With reference to FIGS. 16-19, lower bracket 18 includes a retainer plate
 64 and an upper hooked member 62 that is slidably connected to a lower
 hooked member 63. Upper hooked member 62 includes a pair of hooks 65 that
 are oriented in a first horizontal direction, and lower hooked member 63
 has a pair of hooks 66 that are oriented in an opposite horizontal
 direction. A connector, such as rivet 67, extends through a circular
 opening 68 in upper hooked member 62 and through an elongated slot 69 in
 lower hooked member 63 to slidably interconnect upper and lower hooked
 members 62 and 63. Upper and lower hooked members 62 and 63 each have an
 elongated slot 70 with a radiused end 71. During installation of lower
 hooked member 63, upper hooked member 62 is shifted sideways relative to
 lower hooked member 63 (opposite the arrow "B", FIG. 19) to the position
 "C" shown in phantom (FIG. 19). In position "C", hooks 65 are positioned
 substantially above, and aligned with, hooks 66, such that the hooks 65
 and 66 can be inserted into the horizontal slots 57 of a horizontal frame
 member 56 of the wall 55 illustrated in FIG. 2. Upper hooked member 62 is
 then shifted horizontally in the direction of the arrow "B" (FIG. 19),
 thereby locking hooks 65 and 66 into the slots 57. The glide 40 is then
 inserted into the elongated slot 70, and retainer plate 64 is secured to
 threaded openings 72 of lower hooked member 63 by means of conventional
 threaded fasteners 73 extending through clearance openings 74 in plate 64.
 Retainer plate 64 has a radiused cutout 75 that forms a circular opening
 76 (FIG. 17) with the radiused cutouts 71 of upper and lower hooked
 members 62 and 63 when installed. Radiused cutouts 71 and 75 fit snugly
 around the glide 40 (FIG. 16), yet provide sufficient clearance to permit
 the glide 40 to be vertically adjusted for support of the wall start post
 12. Preferably, lower hooked member 63 has a plate 77 (FIG. 18) welded, or
 otherwise secured thereto, to provide additional material for forming
 threads 72. Openings 74 in retainer plate 64 are preferably slotted to
 permit retainer plate 64 to be adjustably secured to upper and lower
 hooked members 62 and 63, thereby providing a secure connection to the
 glide 40.
 Upper hooked bracket 16 and intermediate hooked bracket 17 are
 substantially similar and are illustrated in FIGS. 20 and 21. Hooked
 brackets 16 and 17 include a lower hooked plate member 80 and upper hooked
 plate member 81. Lower hooked member 80 includes an elongated slot 82, and
 upper hooked member 81 includes a clearance opening 83. A rivet or other
 suitable connector 84 extends through elongated slot 82 and clearance
 opening 83 to slidably interconnect lower and upper hooked members 80 and
 81. During installation, upper hooked member 81 is first shifted in the
 direction of the arrow "E" (FIG. 20) relative to lower hooked member 80,
 such that the hooks 85 in upper hooked member 81 are positioned
 substantially above, and aligned with, the hooks 86 of lower hooked member
 80 in the position "D" (FIG. 20). Hooks 85 and 86 are then inserted into
 horizontal slots 57 of horizontal frame members 56 of an existing wall 55
 (FIG. 2). The upper hooked member 81 is then shifted opposite arrow "E"
 relative to the lower hooked member 80 (FIG. 20), thereby locking the
 bracket 16 (or 17) to the horizontal slots 57. A conventional threaded
 fastener or bolt 87 (FIG. 15) is then inserted through the slotted opening
 88 in the upper and lower hooked members 81 and 80 and into the threaded
 opening 47 of a bracket 44 at either the upper or intermediate positions.
 Opening 88 is preferably elongated to permit horizontal adjustment of post
 12. When post 12 is properly positioned, threaded fastener 87 is
 tightened, thereby securing post 12 to existing wall 55.
 After securing the wall start post 12 to the existing architectural wall of
 FIG. 3 or to the existing divider or wall 55 of FIG. 2, beams 15 and a
 standard width post 9 are assembled to the wall start post 12 to form a
 wall start panel frame. One or more standard width panels 3 (FIG. 1) can
 then be assembled to wall panel frame 7 in an adjoining relationship
 thereto as required for a particular installation.
 It will become apparent to those skilled in the art that various
 modifications to the preferred embodiment of the invention as described
 herein can be made without departing from the spirit or scope of the
 invention as defined by the appended claims.