Top adjustable temporary wall system

An extendable wall panel assembly includes a first wall panel and a first core that includes a first and second surface. A first edge joiner comprises a first male extension extending therefrom. A second edge joiner has a first female receiver disposed therein. A second wall panel is slidably coupled to the first and second wall panels and has a second core. A third edge joiner extends between a third surface and a fourth surface and has a second male extension extending therefrom. A fourth edge joiner has a second female receiver disposed therein. A coupling mechanism has a first channel disposed in the first wall panel receiving a first clamp bar therein. A first fastener receiver is coupled to the second wall panel and a fastener extend through the first fastener receiver and into the first clamp bar in the first channel.

CROSS-REFERENCE TO RELATED APPLICATION

This application is non-provisional application of U.S. Provisional Application No. 63/409,796, filed on Sep. 25, 2022, and U.S. Provisional Application No. 63/431,344, filed on Dec. 9, 2022. The entire disclosures of the above application are incorporated herein by reference.

FIELD

The present disclosure relates generally to wall systems and, more particularly, to wall systems that have panels that are vertically adjustable.

BACKGROUND

Temporary wall systems have been in use for many years for various purposes. Sometimes temporary walls are constructed from studs and drywall, then destroyed when done. Temporary wall systems may be used to separate an area under construction from an area being used. The temporary wall systems separate dirt and noise associated with a construction area from the portions of the structure that are still in use. Temporary wall systems can also be used to reduce the amount of floor area heated and cooled in a larger structure, while allowing expansion when needed.

Reusable temporary walls are used in many industries to reduce waste and cost. Reusable wall systems are easily installed and disassembled so they can be moved to a different location for reuse. Reusable temporary wall systems are typically formed at standard heights such as 8 feet. However, the known reusable temporary wall systems are incorporated into structures that have ceilings that vary in height. The tops of the reusable temporary walls may therefore not extend to the full ceiling height. An unfinished look and a gap to allow dust and noise from a work zone on the other side of the wall to reach the non-working side.

SUMMARY

The ability to provide a simplistic wall system that is aesthetically pleasing while providing a seal to prevent dust and dirt contamination is desirable.

In one aspect of the disclosure, an extendable wall panel assembly includes a first wall panel and a first core comprising a first surface and a second surface opposite the first surface. A first edge joiner extends between the first surface and the second surface. The first edge joiner comprises a first male extension extending therefrom. A second edge joiner extends between the first surface and the second surface parallel to the first edge joiner. The second edge joiner has a first female receiver disposed therein. A second wall panel is slidably coupled to the first wall panel and second wall panel and has a second core comprising a third surface and a fourth surface opposite the third surface. A third edge joiner extends between the third surface and the fourth surface. The third edge joiner has a second male extension extending therefrom. A fourth edge joiner extends between the third surface and the fourth surface parallel to the third edge joiner. The fourth edge joiner has a second female receiver disposed therein. A coupling mechanism has a first channel disposed in the first wall panel receiving a first clamp bar therein. A first fastener receiver is coupled to the second wall panel and a fastener extending through the first fastener receiver and into the first clamp bar in the first channel.

Implementations may include one or more of the following features. The extendable wall panel assembly where the first channel is formed in a slot tube. The first channel is integrally formed with the first edge joiner. The first fastener receiver is integrally formed with the third edge joiner. A third channel is integrally formed with the second edge joiner. The first fastener receiver may include a second channel disposed within the second wall panel. The coupling mechanism further may include a second fastener receiver disposed in the second channel for receiving a second fastener. The first clamp bar receives the first fastener and the second fastener. The first surface may include a first planar skin, the second surface may include a second planar skin, and where the first core is disposed between the first planar skin and the second planar skin. The first planar skin and the second planar skin are composed of polymer. The first core and the second core are composed of a high-density foam. The high-density foam is composed of expanded polystyrene. The first clamp bar may include a rectangular cross section. The first male extension of a first wall panel of the plurality of wall panels is inserted into the first female receiver of a second wall panel of the plurality of wall panels. The first wall panel may include a door disposed therethrough, said second panel may include a first vertical sub-panel portion, a second vertical sub-panel portion and a horizontal sub-panel portion extending between the first vertical sub-panel portion and the second vertical sub-panel portion, where a distance between the first vertical sub-panel portion and the second vertical sub-panel portion is greater than or equal to a width of the door, a plurality of filler panels extending between first vertical sub-panel portion and the second vertical sub-panel portion. The first vertical sub-panel portion may include a first vertical edge channel and the second vertical sub-panel portion may include a second vertical edge channel and a second vertical edge channel. The plurality of filler panels is at least partially received in the first vertical edge channel and the second vertical edge channel. A bottom filler panel is secured to the first vertical edge channel by a first latch secured to the bottom filler panel. A bottom filler panel is secured to the first vertical edge channel by a first latch and a second latch secured to the bottom filler panel.

One general aspect includes an extendable wall panel assembly that also has a first wall panel that includes a first core including a first surface and a second surface opposite the first surface; a first edge joiner extending between the first surface and the second surface, the first edge joiner may include a first male extension extending therefrom; a second edge joiner extending between the first surface and the second surface parallel to the first edge joiner, the second edge joiner may include a first female receiver disposed therein, a first channel receiving a first clamp bar therein; a second channel receiving a second clamp bar therein. The assembly also includes a second wall panel slidably coupled to the first wall panel and second wall panel may include: a second core may include a third surface and a fourth surface opposite the third surface; a third edge joiner extending between the third surface and the fourth surface, the third edge joiner may include a second male extension extending therefrom; a fourth edge joiner extending between the third surface and the fourth surface parallel to the third edge joiner, the fourth edge joiner may include a second female receiver disposed therein; a third channel having a first fastener extending therethrough, said first fastener coupling the first clamp bar within the first channel; and a fourth channel having a second fastener extending therethrough, said second fastener coupling the second clamp bar within the second channel.

Implementations may include one or more of the following features. The extendable wall panel assembly may include a third fastener coupling the first clamp bar within the first channel and a fourth fastener coupling the second clamp bar within the first channel. The first fastener and the third fastener extend into the first channel through a first elongated slot through the first channel. The second fastener and the fourth fastener extend into the second channel through a second elongated slot through the first channel.

DETAILED DESCRIPTION

Referring now toFIGS.1A and1B, a front or finished-side view of a plurality of extendable wall panel assemblies10joined together to form a wall system12are illustrated. The “front” side provides a more finished look and is intended to be customer facing. However, the word front is meant as a reference to the more aesthetically pleasing side. Certainly, the back side may be customer-facing as well. The panel assemblies10each comprise and lower or front fixed panel10A and an upper or back extendable panel10B. The panel assemblies10are joined together and illustrated in an extended position. The leftmost upper panel (relative to the front side) is removed to illustrate the rear configuration. In use, the panel assemblies10are shipped assembled so that in a lowered position with the extendable panel10B in a downward position. The extendable panel10B may then be easily extended. The wall panel assemblies10, when assembled, rest on the floor at the floor line FL or within a channel or lower track16on the floor line FL. An upper edge of the wall panel assemblies10are fastened to the building structure or ceiling denoted by ceiling line CL directly or using a track (not illustrated).

The words fixed and extendable are used to denote the in-use positions while being installed. The wall panel assemblies10are transportable and intended to be used as temporary walls that are fixed during use. Once positioned, the fixed panels10A are into position and the extendable panels10B are moved vertically into position they are fixed until removal.

The adjacent panel assemblies10form joints as will be further described below. Seams14are formed at the joints when assembled. The seams14are hardly noticeable when the panels10are assembled when the same finishing materials are used. In this example, three fixed panel10As are joined together and therefore two seams14are shown. Two extendable panels10Bs are joined together at a joint that form the seam14. InFIG.1A, the front view is illustrated. The front view corresponds to the view that faces away from the enclosed area and may have a more finished look. In many examples, the panels are used for blocking a construction area. The front view illustrated inFIG.1Afaces outward while the rear view inFIG.1Bfaces the construction or blocked off area.

InFIG.1B, the extendable panels10B are partially extended. The amount of extension may vary based on the final use and the physical structure into which the wall systems will be formed. The height of fixed panels10A may vary. As well the height of the extendable panels10B may vary. Coupling mechanisms18also govern the amount of extendibility of the extendable panels10B of the wall panel assemblies10.

The coupling mechanisms18are hidden in the front view inFIG.1Aand at least partially hidden in the rear view ofFIG.1B. The fixed panels10A have a plurality of slot tubes20with elongated slots22that are recessed within each of the fixed panels10A. The slot tubes20, in this example are square tubes having a width W1. The slot tubes20may extend the entire height (length) of the fixed panels10A. Although the length maybe limited to about the length of the slots22. Slots22in the slot tubes have a width W2less than the width of the slot tubes20.

As will be described in more detail below, the extendable panels10B have fastener receivers26embedded therein. The fastener receivers26receive fasteners28and are described in greater detail below. The fastener receivers26may be formed in square bars30embedded within the extendable panels10B. Holes32in the extendable panels10B through the square bars30are used to secure a clamp bar36within the slot tube20by the fasteners28that are received within the holes32. The holes32allow the fasteners28to be recessed therein. A description of the clamp bar36will be provided in more detail below. The clamp bar36is received within the slot tube20. The clamp bar36has a width W3that is less than W1to allow the clamp bar36to move freely within the slot tube20when desired. In the fixed position, the fasteners28are tightened so that the clamp bar36is drawn or forced against the surface of the slot tube20having the slot22. To move the extendable panel10B, the fasteners28are loosened so that the clamp bar36is no longer secure. In this manner, the extendable panel10B may be raised and lowered and the secured into place.

In general, each fixed panel10A and extendable panel10B has edge joiners on the vertically extending edges. A male edge joiner40M is one edge and a female edge joiner40F is on the other side of each panel10A,10B. When assembled, the male edge joiner40M is inserted into the female edge joiner40F of the respective fixed panel10A or extendable panel10B. In this example, the extendable panel10B and the fixed panel10A both have the male edge joiner40M located on the same edge of the panel. The female edge joiner40F has a female receiver on both the extendable panel10B and the fixed panel10A. The interaction of the male edge joiner40M end and the female edge joiner40F allow the extending panel to extend relative to adjacent extending panels.

In one example, the male edge joiner40M and the female edge joiner40F are formed from extruded aluminum with machining in certain areas. The female edge joiner40F forms a rectangular C-shaped or U-shaped channel that extends in the vertical direction when assembled. Likewise, the slot tubes20and the bar30may be extruded.

In this example, the wall panels10A and10B have two outer layers or skins458with a foam layer or core layer50therebetween. The core layer50is a low-density material to make the walls lighter. Examples of the core layer50include but are not limited to foam made from expanded polystyrene (EPS), isocyanurates, polyethylene and urethanes The outer layers or skins48may be planar and formed of acrylonitrile butadiene styrene (ABS) or another type of polymer, aluminum, paper or other materials. By forming the outer layer or skins48of plastic or aluminum, the outer layers or skins48become durable, washable and may be printed with graphics.

Referring now toFIGS.2A-2D, various views of the fixed panel10A are illustrated. The outer layer or skins48covers the female edge joiner40F and partially covers the male edge joiner40M and the other components of a panel10A. Adhesive may be applied to the skins48to stabilize the panel and hold the components together. Details of the male edge joiner40M and female edge joiner40F will be illustrated in further detail below.FIG.2Ais a front view of the fixed panel10A.FIG.2Bis a rear view of the fixed panel10A. The pair of slots22extend through the skin48and into a slot tube20that is secured within the fixed panel10A. A lubrication area52may be provided for placement of glide tape or other lubricating tape. The lubrication area52may comprise nylon, Teflon® or another lubricating component so that the panel10B when extending is not bound and moves freely. In a specific example, a strip or strips of glide tape are located at the back side of the fixed panel10A near the top edge. Glide tape may be used on various joining or facing surfaces to promote movement of the upper and lower panels.

FIG.2Cis top view of the fixed panel10A. The slot tubes20are illustrated as separate components from the edge joiners40M,40F. However, the slot tubes20and edge joiners40M,40F may be integrally formed in a monolithic structure with a common wall as described below.FIG.2Dis a side view of the fixed panel10A at the female edge joiner end. In one example the panel10A was constructed to be 90 inches tall and 48 inches wide. The male joiner40may have one or more channel openings54to facilitate assembly as described below.

Referring now toFIGS.3A-3D, various views of an extendable panel10B are illustrated. In this example, the front view, inFIG.3A, may have a lubrication area (e.g., glide tape) in various locations around the bottom edge and partially on the side edge to facilitate movement between the front of the extendable panel10B and the back of the fixed panel10A. In this example, two vertical lubrication areas56A,56B are disposed adjacent to the edges of the panel10B and a horizontal portion56C is disposed at the bottom of the panel between lubricating areas56CA and56B. As illustrated, the back of the fixed panel10A may have larger holes32than the holes58in the front of the extendable panel10B. The larger holes32in the back of the extendable panel10B may allow a screw head to be at least partially recessed therein. The holes58receive the shaft of the fastenersFIG.3Ais a front view of the extendable panel10B.FIG.3Bis a back view of the fixed panel10A.FIG.3Cis a top view of the fixed panel10A andFIG.3Dis a side view of the fixed panel10A at the female side.

As is best shown inFIG.3B, a horizontal slot60may be formed in an upper cross member62. The slot60may be used to receive a bracket or fastener for securing the wall panel assembly to a structure of the building.

FIGS.4A,4B and4Cshow respective front side and top views of the wall panel assembly10is shown in a minimum height condition. That is, the extendable panel10B is lowered to a position not extending above the top edge of the fixed panel10A. In the position illustrated inFIGS.4A-4C, the wall panel10B may be easily lifted to the positions illustrated below inFIGS.5A-5C.

FIG.4Dis an enlarged portion of the male edge joiner40having the channel opening54. In this example, the channel opening is a generally C-shaped slot having a first horizontal portion54A, a second horizontal portion54B and a vertical portion54C extending therebetween. InFIG.4Eis a top view of the fixed panel10A joined to the extendable panel10B. The extensions64M are protrusions that extend inward in the direction of the thickness from the outer walls of the female joiner40F. The extensions64are aligned opposite to each other collinearly, in this example.

During assembly the female edge joiner40of one panel may be brought to the male edge joiner40M of another panel or vice versa. The extensions64are aligned with one of the horizontal portions54A or54B. If the male edge joiner40M is being moved, the bottom horizontal portion54B may be aligned with the extension64. The extensions64positioned in the vertical portion54C as the panel assembly10being moved is lowered onto the stationary wall panel assembly. If the wall panel assembly with the female side is being moved, the extensions64are aligned with the upper channel portion54A so that as the end with the female joiner40M of the panel assembly is lowered, the extensions64are moved into the vertical portion54C. The extendable panels10B may not include channel opening to allow maximum flexibility in the panel positions.

The clamp bar36is shown received within the slot tube20and adjacent to the wall within the slot tube20closest to the extendable panel10B in a locked position. The slot tube20with the clamp bar36is directly adjacent to the female edge joiner40F. On the other end of the panel10A, the clamp bar36is adjacent to the male edge joiner40M is configured in in a similar manner.

Referring now toFIG.4F, the coupling mechanism18for the fixed panel10A and extendable panel10B is shown. In this example, the extendable panel10B has a solid frame portion or bar30that has a channel that is described as holes32/54therethrough. A head28A of the fastener may be countersunk into the bar30. The clamp bar36is drawn toward the head28A of the fastener28when the threads36A of the clamp bar36engage the threads28B of fastener28. By pulling the clamp bar36toward the head28A of the fastener28, the clamp force on the bar30inFIG.4Fis in the direction toward the back of the panel and thus the upper panel10B is held against the lower panel10A and the position is thereby maintained.

Referring now toFIGS.5A-5C, the extendable panel10B is illustrated at a maximum height relative to the fixed panel10A. The views illustrated inFIGS.5A-5Ccorrespond generally toFIGS.1A and1Bwith only one panel illustrated. Slots22illustrated inFIG.5Bextend through both the skin48and into slot tubes20. The fasteners28move vertically in the slots22and lock the extendable panel10B in place.

Referring now toFIGS.6A-6B, the fixed panel10A is illustrated with the skins48removed. A top tube70and a bottom tube72are illustrated, which are square in this example. Slot tubes20extend between the top tube70and bottom tube72in a vertical direction. The horizontal slot60is formed in the top tube70. Slots22are formed in the slot tubes20and are less than the width of the slot tubes20. Each of the female edge joiner40F and male edge joiner40M are directly adjacent to the slot tubes20on each edge of the panel10A. The slot tubes20are exposed so that the clamp bar36may be received therein during assembly as described in more detail below. The perimeter of the panel assembly has the top tube70and bottom tube72as well as a female edge joiner40F adjacent to the slot tube20as well as a male edge joiner40M adjacent to a slot tube20. The male edge joiner40M and female edge joiners40F are provided at respective vertical edges of the fixed panel10A.

Referring now toFIGS.7A-7Bthe extendable panel10B is illustrated. The extendable panel10B is formed in a similar manner to that described above with respect to the fixed panel10A. That is, the top panel10B has male edge joiners40M and female edge joiners40F disposed on opposite vertical edges. Lower frame solid bars30are directly adjacent to the male edge joiner40M and female edge joiner40F. Ultimately, the holes32,58that form channels66illustrated inFIG.1Bare drilled or formed into the upper frame solid bars30to receive fasteners therein. A top tube74and bottom76coupled to the upper frame solid bars30. The top tube74has the horizontal slot60. Two horizontal slots60may be provided, one on the front side and one on the rear side.

Referring now toFIG.8, a perspective view of the female edge joiner40F is shown. The female edge joiner40is essentially a C-shaped or U-shaped channel. Holes64A are at the position where the extensions64are attached. The extensions64may be welded, press fit, glued or screwed into the holes64A. The position of the holes64A is such that when two adjacent wall panels are assembled the extensions align with the channel openings54, and more specifically to the vertical portion54C to assist in securing the female edge joiner40F to the male edge joiner40M.

Referring now toFIGS.9A-9Ca perspective view, a side view, a bottom view of the male edge joiner40M is illustrated to show the details of the channel openings portions54A-54C. In one example the width of the openings were 0.5 inches. As is illustrated inFIG.9C, both the front and back side of the male joiner40M has a channel opening54. In this example, a total of four channel openings54are set forth.

Referring now toFIG.10, the top tubes70,74, bottom tubes72,76may be made of a rectangular, and more a specifically square hollow tube1010and sized to the proper dimension.

Referring now toFIGS.11A-11D, a respective view of the clamp bar36is illustrated. The clamp bar36has receiving openings1110for receiving the fasteners28. The size of the clamp bar36is sized to be received within the slot tubes20. That is, the inside of the slot tubes20is just larger than the width of the clamp bar36so that the clamp bar36may be moved within the slot tube20. The clamp bar36may also include an end opening1112disposed in an end of the clamp bar36. The openings1110and1112may be threaded.

Referring now toFIG.12, a perspective view of the foam or core layer50, a front view and an edge view of the foam core of an upper panel is illustrated. The upper panel10B is illustrated as a one-inch-thick foam panel having foil skin1210.

Referring now toFIGS.13A-13D, a respective perspective view, side view, an end view and a top view of the slot tube20are illustrated respectively. The slot tube20is essentially a square tube which, in this example, is a one-inch square tube that has channel1310. The slot22having a width of about 5/16″, in this example is used. The inside distance (length and width) of the slot tube20forms the channel1310that is sized to allow the clamp bar36to be received and move therein when the extendable wall panel10B is positioned. The width of the slot22allows the fasteners28to travel therein when positioning the extendable panel10B. The slot22may be made different lengths depending upon the desired position of the upper or extendable panel10B relative to the lower panel10A.

Referring now toFIGS.14A-C, a perspective view of the solid bar30is illustrated. These may be used as the upper frame solid bars30illustrated inFIG.7B. The holes33,58that form the channels66are formed therethrough and are space apart to align with the openings1110. The channels66receive the fasteners28and may be drilled or formed therethrough.

During assembly, the core layer50, the solid bars30for the upper panel and the joiners40F,40M may be laid out and covered with an outer layer or skin48to hold the assembly together. The same procedure may be used to form the lower panel10A. However, the upper frame solid bars30are replaced with the slot tube20. After assembly, the skin48over the slot of the slot tube20may be opened by a routing type process. The panel10A may be laid out horizontally and the clamp bar may be inserted from the top with the holes32,58and channels66in the clamp bar36aligned with the slots22. The extendable panel10B frame may be positioned so that the holes that extend therethrough are aligned with the openings1110in the clamp bar36so that the fasteners28may be received in the clamp bar36. That is, each clamp bar36at each end of the panel10A may have two fasteners that are coupled thereto. The assembled wall panel assembly12may be shipped in a position where the extendable panel10B is in the lowermost position.

Referring now toFIG.15, a partial cutaway view of a male edge joiner inserted into a female edge joiner is set forth. In this example, a female edge joiner has an inward extension, one of which is shown. In a constructed embodiment, two inward extensions are provided. The extensions may be formed directly in the material of the female edge joiner or as separate component, such as rivet or another type of fastener that extends inward into the female edge joiner. The male edge joiner has a cutaway portion that has a horizontal part. The inward extension or extensions align with the horizontal part of the cutaway portion during the initial phase of assembly. Then, the vertical part of the cutaway portion or channel engages the inward extension. In this example, the female edge joiner and the panel associated with the female edge joiner is lifted so that the inward extension aligns with the horizontal part of the cutaway portion. Horizontal motion of the panel having the female edge joiner part allows the inward extension to move horizontally within the horizontal part of the cutaway portion until the end of the horizontal part is reached. At this point, the female edge joiner fully is coupled to the male edge joiner. The panel with the female edge joiner is lowered into position on the floor and the inward extension moves downward in the vertical part. This allows the wall panels to be maintained and not come apart.

Referring now toFIGS.15and16as well asFIG.4D, the channel opening54is illustrated. The channel opening54, as described above are C-shaped. The channel opening54is formed in and through a surface of the male edge joiner40M. Each side of the male edge joiner40M (toward the front and rear of the panel when assembled) have a male edge joiner40M. In this example, four channel openings54are used on each male edge joiner. However, more or fewer channel openings54may be used. In this example, two channel opening portions54A,54B and two inward extensions64are provided at one location on the male edge joiner40M. The inward extensions64extend inward from the female edge joiner40F and engage the channel opening portion54A or54B and54C during assembly. Because the portions54A,54B of the channel opening54is in the curved portion, as the male edge joiner40A is inserted into the female edge joiner40F, the inward extension64is received in one of the horizontal portions54A,54B. The horizontal portions54A,54B are separated by a vertical portion54C of the channel opening.

During assembly, the panel10A with the female edge joiner40F may be received in the uppermost horizontal portion54A, inserted, then slid downward by moving the panel10A downward within the vertical portion54C of the channel portion54. That is, the inward extension64moves from the horizontal portion54A to which it is moved into the vertical portion54C. Assembly may also take place by lifting the panel with the male edge joiner40M and inserting the inward extension64into the vertical portion54C at the lowest extent of the channel opening54and horizontally moving the male edge joiner40M into the female edge joiner40F where the vertical portion54C may be engaged with the inward extension of the female edge joiner40F in the channel opening.

The wall panel assembly10may be shipped having the extendable panel10B in a completely retracted position as illustrated inFIGS.4A-4BC. The fasteners28may secure the clamp bars36into the slot tubes20to prevent movement. Upon loosening the fasteners28at the clamp bars36, the upper panel10B with the male edge joiner40M and female edge joiner40F may be positioned into place in the desired height as shown inFIGS.5A-5C. Once the height is secured by fasteners28an adjacent panel may be aligned and coupled together. Some of the male edge joiner features such the C-shaped channel openings54and the extensions64on the female edge joiners40F may be used. Securing the height of the upper panels10B may be performed before or after the panels are secured to an adjacent panel.

Referring now toFIG.17, the building structure having a ceiling line CL, a floor line FL and two wall lines WL are illustrated. In this example, a plurality of wall panel assemblies10are used to form the wall system12. In this example, a female starter trim panel18A is illustrated in the left side of the illustration. A male starter panel1910is illustrated on the right side of the wall system12. Because of various structural limitations, the larger width wall panel assemblies10may not entirely fit. Therefore, the starter trim panels1810and/or1910may be used on one or either side of the wall system to accommodate and completely seal the wall system12in place. A single door panel assembly2210having a fixed panel2210A and an extendable panel2210B is set forth. A door2212provides access to the space beyond the wall system12. Further details of the trim panel assemblies and the door assembly are provided below.

Referring now toFIGS.18A-18D, a female starter panel1810is illustrated. The female starter panel1810is used when the female side is directly against an adjacent wall. The female starter panel1810is shown having an extendable portion1812and a fixed portion1814. The fixed portion1814and the extendable portion1812are configured in the manner described above relative to the slot tubes20and the edge joiners40F. That is, rather than separate components, the slot tubes20′ and the female joiner40A are integrally formed in an integrated monolithic structure. Because the slot tube20′ and the female edge joiner40F′ are integrally formed, they have a common wall therebetween as is best illustrated inFIG.8B. The female starter panel1810also have compliant material1820extending from the upper portion1812and the lower portion1814. The compliant material1820may be cut to size to fill the gap between the wall system2512and the existing structure. That is, the amount the compliant material1820extends from the female edge joiner40F may vary. In one example, the compliant material1820extends about six inches from the female edge joiner but may be trimmed to size as desired. The compliant material1820may be foam, foam rubber or other material suitable to form a seal with the adjacent wall or building structure.

The compliant material1820is disposed in a compliant material receiver1822that is also integrally formed with the slot tube20′ and the female edge joiner40F′. It should be noted that the slot tube20′ and the female edge joiner40F may be integrated together and used in any of the examples set forth above. That is, the receivers1822may be eliminated if the integrated slot tube20′ and female edge joiner are integrated in one of the examples set forth above.

Referring now toFIGS.19A-19E, a male starter panel1910is set forth. The male starter panel1910has the slot tube20′ and the edge joiner40M″ formed as an integral structure. Compliant material1820similar to that illustrated above may be formed in a compliant material receiver1922. That is, the compliant material receiver1922may be used to receive one or more pieces of compliant material1820to accommodate any gaps on the female side of the wall system12. The male edge joiners40M″ insert in a female edge joiner. The male starter panel1910includes an extendable portion1912and a stationary portion1914. The slot22is formed with in the slot tube20″ which is integrally formed with the male edge joiner40M.

Referring now toFIGS.20A and20B, an edge joiner2010used for outside corners of a wall system is illustrated. In this example, the corner is 90° however other angles may be formed in a similar manner. The edge joiner2010has a male portion2012on a stationary side of the edge joiner2010and a male portion2014on the extendable portion of the edge joiner2010. A female portion2016, having extensions2018, is formed on the stationary side while the female portion2020is formed on the extendable portion. The system operates in a similar manner to that described above in that a fastener2028may extend into a fastener receiver2030to secure the extendable portion relative to the fixed portion.

Referring now toFIGS.21A and21B, an inside corner assembly2110is illustrated having a male portion2112and a female portion2114on a fixed portion2116. On a movable portion2118, a male portion2120and a female portion2122are formed. A fastener2128is received in a fastener receiver2130in the stationary portion2116. The assembly of the corners is similar in that the extensions2134engage the channel opening portions54A or54B and54C.

Referring now toFIGS.22A and22B, a wall panel assembly2210having a door2212built therein is illustrated. The fixed wall panel2210A is formed in a similar manner to the fixed wall panels10A described above but includes a door opening and a door coupled thereto. The extendable panel2210B has a plurality of removable filler panels2220coupled thereto. The filler panels2220are removably coupled as will be described in more detail below. The filler panels2220extend between vertical sub-portions2222of the extendable panel2210B. A horizontal sub-panel portion2224extends between the vertical sub-panel portions2222. Slot tubes with slots22may be used in a similar manner as well as the fasteners28for fixing the extendable panel2210B.

Referring now toFIG.22C, a cross sectional perspective view of the removable panels2220is illustrated. In this example, a female channel on each side of the vertical sub-panel portions2222are vertical edge channels2240. The female-channel vertical edge channels2240receives male joiners2242formed at each end of the removable panel2220(or the panel themselves without joiners2242illustrated inFIGS.24A and24Bbelow).

Referring now also toFIG.22D, the removable panels2220may also have a recess2244thereunder. The bottom filler panel2220may be retained in place by a latch2250. The latch2250has a latch body2252and a handle2254that moves a latch panel2256into and out of a recess2258of the channel2240. Although only one latch2250is illustrated, a latch2250may be disposed at each end of the filler panel2220and configured in a similar way. As the extendable panel2210B is lowered, filler panels2220that are blocking the opening of the door2212the bottom filler panel may be removed and the latch or latches2250may be reinstalled. The filler panels2220may be slid to the bottom of the extendable panel2210B and removed, one by one until the door opening is clear. That is, the bottom filler panel changes as the lowermost filler panel is removed. Because the filler panels2220are made of the same materials as the panels2210A,2210B, they are light and can be easily moved and removed.

Referring now toFIGS.23A-23D, a double door panel assembly2310is illustrated. The double door panel assembly2310has two doors2312. A fixed portion2310A has an extendable portion2310B that extends therefrom. In the example set forth inFIGS.22and23, because the ceiling height or the coupling height of the extendable panels2210B and2310B are unknown, the removable panels2220and the removable panels2320may be removed from the bottom so that from the front view, there are no gaps in the system. As the extendable panels2210B and2310B are lowered, the panels2220and2320may be removed from the bottom up to provide a complete closure.

Referring back toFIGS.23A-23D, the double door assembly2310may be formed of two halves joined together at a joiner2330. The joiner2330includes a nail portion2332and a female portion2334.

Referring now toFIGS.24A-24B, an alternate style of filler panel2410is set forth. In this example, the wall panel assembly2210having the fixed panel2210A and2210B are formed the same as that set forth inFIGS.22A-22C. However, the panels are formed of a thin plastic material and stamped metal having a face2412and flanges2414. The latch2250is ultimately used to engage the panel2410proximate the flange2414. The latch2450may be configured similar to the latch2250described above. The latches2250have the latch body2252and the handle2254used for removing the latch from the female channel2240. It should be noted that inFIGS.22-24, the fasteners28are used to secure the clamp bar (not shown) relative to the slots22.

Referring now toFIGS.25,26A and26B, an adjustable trim cover assembly2520is provided that allows for coarse and fine vertical adjustability for the wall system2512. This is accomplished using a trim cover2530that is adjustably mounted to upper portion of the wall panel10. A trim cover2530is vertically moved and secured in place, creating a pressure seal. The trim cover2530is coupled to an adjustment mechanism2560that moves a telescoping extension2542vertically to allow the wall system2512to look finished at various ceiling heights.

InFIG.25, a plurality of assembled wall panels2510are illustrated to form a wall system2512. The wall panels2510have seams2514that are formed at joints between adjacent wall panels10. The wall panels10may be various sizes. In a commercial example, the lengths may be standardized such as 4 feet, 8 feet, and 16 feet, although another length can be used. The seams2514may also vary in length. For example, 2 foot to 16 foot high panels may be used.

In the present example, separate male and female joiners are illustrated that are used for joining the wall panels. The joiners are mostly concealed inFIG.25. However, inFIGS.28A,28B, the joiners will be described in further detail.

InFIGS.25,26A and26B, an adjustable trim cover assembly2520may adjust vertically so that the adjustable trim cover assembly2520may be disposed against a ceiling of the building. A corner trim cover2522is also illustrated to complete the finished look of the adjustable trim cover assembly2520of two adjacent panels2510. The adjustable trim cover assembly2520may be formed of aluminum or another material. Likewise, the corner trim cover2522may also be formed of the same material as the adjustable trim cover assembly2520or a different material. The formation of the corner of two walls will be described in further detail below.

Referring now toFIGS.27A and27B, the adjustable trim cover assembly2520is illustrated having a trim cover2530having a finished surface2524. The finished surface2524is placed toward the side customers or the public view. The rear side2526illustrated inFIG.27Ais the cordoned off or construction area. The vertical height of the trim cover is adjustable to accommodate different ceiling heights of a building as indicated by arrows2528. The trim cover2530may have a horizontal top plate2532and a flange2534formed therein. The horizontal top plate2532extends parallel to the ceiling CL and is perpendicular to the trim cover2530in the present example. The flange2534may also be formed in the trim cover2530. The flange2534, as will be described in more detail below, may have a plurality of holes for receiving a screw or fastener.

The horizontal top plate2532may have a closed cell foam seal2536between the ceiling CL and the horizontal top plate2532to further increase the sealing of the system. The closed cell foam may be a thickness to allow accommodation of locally uneven ceilings. Dust and noise transfer between sides of the wall is reduced by providing a closed cell foam seal between the horizontal top plate and the ceiling.

A post mount plate2540is coupled to an adjustable extension2542, which in this example is a square tube that is adjustably received into a receiving channel2550within the wall panels2510. As will be described inFIG.28, the receiving channel2550may be disposed in a joiner that is used for coupling two adjacent wall panels10together. The adjustable extension2542has a plurality of horizontally disposed receiving holes2552for coarse adjustment of the height of the trim cover. A rough adjustment block or coarse adjustment plate2554is inserted into one of the receiving channels2550to roughly adjust the height of the trim cover2530relative to the ceiling CL. The adjustment mechanism2560has a fine adjustment screw1562or tensioner that is moved or rotated to adjust the height of the adjustable extension2542and thus the horizontal top plate2532of the trim cover2530into the desired position. The adjustment mechanism2560has the threaded fastener or fine adjustment screw2562that moves relative to the coarse adjustment block2554in the vertical direction. By rotating the fine adjustment screw2562, movement relative to rough adjustment block is performed. The fine adjustment screw2562moves the adjustable extension2542into and out of the receiving channel2550, which, in turn, causes the trim cover2530to move in the direction illustrated by the arrows2528. A retaining nut2564is disposed on the fine adjustment screw2562and may be used to rotate the screw2562.

Referring now toFIGS.28A and28B, adjacent wall panels10form a joint2566as illustrated. The wall panels2510are formed with an outer skin2568on each of the wall surfaces. The skins2568may be formed of acrylonitrile butadiene styrene (ABS) or another type of polymer. The skins2568in a constructed example had a density of about 1.07 g/cm3+/−0.1. The skins2568in the constructed example are between 0.35 and 0.60 inches thick.

Between the skins2568is a high density foam core layer2570. The high density foam core layer2570, in constructed examples, had a density of about 2-4 lbs/ft3. In the present example, expanded polystyrene (EPS) was used, although other suitable materials may be used. Other examples include but are not limited to isocyanurates, polyethylene and urethanes. The thickness of the wall panel including the skins and foam core in the constructed example is about 1.070 inches. However, other thicknesses and relative thicknesses may be used.

The joints in this example are formed by a pair of extrusions. A male extension (male joiner2572) that is received by a female joiner2574to assist in maintaining the wall system2512in a predetermined position. Each end of the wall panel may have either a male joiner2572or a female joiner2574. A seamless look is created when two adjacent wall panels2510are assembled and the adjacent surfaces are nearly flush. The opening2576in the female joiner2574may be referred to as a receiver. The receiver or receiver end receives the male extension2578or male end of the wall panel10. The male extension2578is shaped to allow the panels to be easily assembled even though a slight misalignment occurs. The male extension2578may be referred to as a bullnose.

The joiners2572,2574are coupled to their respective panels with adhesive or fasteners. The male extension2578of one panel is received in the female opening2576or receiver of the adjacent panel. In the present example, the female opening2576in thickness about 0.75 inches. The remaining thickness of the wall panel2510corresponds to female hip on each side of the opening. The female opening2576extends a distance or depth to accommodate the male extension2578. The depth may be slightly larger than the male extension.

InFIG.28A,28B, joiners between two panels having different geometries as illustrated. InFIG.28A, longer lateral surfaces are illustrated in the male joiner2572. InFIG.28B, the receiving channel2550is in the female joiner2574.

Referring also now toFIGS.29,30A,30B,31,32A and32B, the adjustment mechanism2560is illustrated in further detail. As illustrated, the coarse adjustment plate2554may push against a load distribution plate2580as illustrated best inFIG.30Athrough the fine adjustment screw2562. The coarse adjustment plater is placed into a receiving hole2552to approximate the distance to the building structure. In this example the fine adjustment screw can accommodate smaller distances of or less than the distance between adjacent receiving holes2552. The load distribution plate2580in this example is rectangular. However, another shape may be used. The load distribution plate2580is placed adjacent to the telescoping tube or extension2542. However, the load distribution plate2580may also extend around or partially around the extension or telescoping tube. That is, an opening in the load distribution plate2580may receive the telescoping extension2542and allow the extension2542to move relative thereto. The load distribution plate2580may also be adjacent to the telescoping tube. InFIG.30BB, the load distribution plate2580′ may be circular and have a diameter that is about the panel depth. The diameter of the load distribution plate2580′ may be slightly greater than the panel depth, the panel depth or slightly smaller than the panel depth. The load distribution plate2580,2581′, in any example, distributes the load from the fine adjustment screw2562across the thickness or depth of the wall panel2510. By moving the fine adjustment screw2562, the threads2562A force the coarse adjustment plate up2554or down which, in turn, forces the extension2542up or down. By moving the telescoping extension2542, the post mounting plate illustrated inFIGS.31and32, moves up and down which, in turn, moves the horizontal top plate of the trim cover vertically.

The post mount plate2540has a fastener surface2540A to receive fasteners2582that extend through the flange2534. The post mount plate2540extends wider than an opening between the flanges of two adjacent panels. A weld connection may bind the telescoping extension2542and the post mounting plate2540. Of course, other types of fasteners may form the joint between the post mount plate2540and the telescoping extension2542. When joined together, a portion of the post mount plate2540extends under the horizontal top plate2532. Thus, the post mount plate2540supports the horizontal top plate2532and thus the adjustable trim cover assembly2520to the flange2534. That is, the flange2534and the post mounting plate2540are directly adjacent so that they may be held together with the fasteners2582. This is best illustrated inFIG.32B.

Referring now toFIGS.33-35, the corner trim covers2522of two adjacent wall panels2510forming a corner are illustrated. The trim covers2522come together at a corner trim cover2522. A post mount plate2540at the corner is modified or trimmed at the job site or prior to the job site so that both trim covers at the corner are supported thereby. The adjustment mechanism2560is disposed at a corner adjacent to one of the walls. The adjustment mechanism2560thus can change the height of the trim cover in both portions of the corner. A removed piece of the post mount plate is illustrated. The gap between the trim covers is covered by the corner trim cover2522.

InFIG.35, an alternate corner trim cover2522′ is illustrated. A corner post2584engages tabs2586couple to and engage the top of the post2584. The tabs2586hold trim cover2522′ to the desired position to enclose the corner. The foam seals2536inFIG.35are directly adjacent and thus the corner is also sealed between the ceiling and trim covers.