Patent Publication Number: US-11391044-B2

Title: Modular partition and fabrication thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority under the Paris Convention to Australian Patent Application no. AU2019903470 filed in Australia on Sep. 18, 2019, all contents of which are hereby expressly incorporated by reference. 
     FIELD OF THE INVENTION 
     The present invention relates to room or space divider devices or partitions. More particularly, it is a partition interconnection device for use as non-structural walls which extend between the floor and the ceiling of the room. 
     BACKGROUND 
     Buildings typically include large open areas which can be divided into smaller room spaces by any of a number of space divider and panel systems that have been developed. These space divider arrangements typically use upright space-dividing wall panels which connect together to subdivide the room area into a plurality of smaller workstations of desired size and configuration. Such panels, especially for office areas, are typically less than floor to ceiling height. Typically, a plurality of upright space dividing wall panels is used which serially connect together panels together. These systems use straight connectors, which are typically used as a separate piece to connect together serial panels together. Introduction of additional components such as straight connectors add to the inconvenient fabrication costs for the purpose extending panel length. 
     Other conventional panels for use in dividing space are instalment of solid panels. Such panel systems tend to be rather costly due to increased material used in the fabrication of the solid panels and are heavy and difficult to install. An example of partitioning system is described in U.S. Pat. No. 4,344,475. 
     Other existing panel systems typically include heavy, rigid frames made from frame members which are cut to a pre-measured length and permanently welded to one another. Additionally, the panel frames typically include a large number of additional components for attaching the panel frames to one another, and also for attaching the panel to the ceiling of the room space. The large amount of different parts increases both the cost and the difficulty of manufacturing and installing existing floor to ceiling panel systems. As a result of the complexity of the design of existing floor to ceiling wall panel systems, the installation and removal of the panel generally requires trained and experienced workers such that modifications to the configuration of the panel system cannot easily be made. An example of a rigid partitioning system is described in U.S. Pat. No. 5,642,593. 
     There is a long felt need to provide a wall panel system which includes a minimal number of components to serially connect the panels which is easy to install to a desired surface. 
     Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field. 
     SUMMARY 
     Problems to be Solved 
     It is an aim and objective of the present invention to provide an improved modular device for dividing room space. 
     It may be advantageous to provide a modular device with a corrugated portion for reinforcing the strength of the planar surfaces of the panel. 
     It may be an advantage to provide a modular device that can mate or connect serially with another corresponding modular device. 
     It may be an advantage to provide a further reinforcement material between the corrugation portion and the planar surfaces of the panel for increasing the rigidity of the panel. 
     It may be an advantage to provide a low cost settable polyurethane foam which can become solid between the corrugation portion and the planar surfaces of the panel. 
     It may be an advantage to provide a panel constructed from a substantial amount of recycled or recyclable materials. 
     It may be an advantage to provide a base plate for use on the panel for securing the panel to the floor or a platform or a flat surface. 
     It may be an advantage to provide a corner piece for changing the direction of the panel extension. 
     It may be an advantage to provide a complementary male terminal cap for rendering the last panel as a smooth rectangular piece. 
     It may be an advantage to provide a complementary female terminal cap for rendering the front panel as a smooth rectangular piece. 
     It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative. 
     Means for Solving the Problem 
     A first aspect of the present invention may relate to a modular device adapted for subdividing room space, the modular device may comprise a panel comprising a corrugated portion which may be positioned between a first planar surface and a second planar surface of the panel. The peaks of the corrugated portion may be in engagement with the first planar surface and the troughs of the corrugated portion may be in engagement with the second planar surface. The first planar surface and the second planar surface may each have a first end and a second end. The first and second ends of the first planar surface are respectively opposite relatively to the first and second ends of the second planar surface. The second planar surface may be parallel to the first planar surface and the corrugations may be parallel to the vertical axis of the panel. A concave female portion may be positioned along the vertical axis in the panel, wherein the concave female portion may be formed from at least: the first end of the first planar surface, the first end of the second planar surface, and a curved portion from the corrugated portion. A convex male portion may be positioned along the vertical axis of the panel, wherein the convex male portion may be positioned outside of the second end of the first planar surface and the second end of the second planar surface, wherein to extend the length of the panel, the convex male portion of a first panel may be adapted to engage with the concave female portion of a second panel. 
     Preferably, the modular device may further comprise a male cap, wherein the male cap may be adapted to cover the female portion of the last panel. 
     Preferably, the modular device may further comprise a corner portion, wherein the corner portion may comprise a female corner cap and an adjacent male part; wherein the female corner cap may be adapted to engage with the male portion of the front panel, wherein the adjacent male part may be adapted to engage with the female portion of the next panel; and wherein the adjacent male part may be extended outwardly from an outer surface of the female cap at an angle relative to the longitudinal axis of the length of the panel. 
     Preferably, the angle may be 90° relative to the longitudinal axis of the length of the panel. 
     Preferably, the modular device may further comprise an elongated base plate adapted for attaching to a base of the panel, wherein the length of the elongated base plate may be shorter than the length of the base of the panel. 
     Preferably, the elongated base plate may have a first end and a second end, wherein the first end of the base plate may be adapted to engage with a first end of the base of the panel, wherein the female portion of the panel may be outside the first end of the base plate. 
     Preferably, the second end of the base plate may be adapted to engage with a second end of the base of the panel, wherein the male portion of the panel may be outside the second end of the base plate. 
     Preferably, the base plate may comprise a plurality of legs extending perpendicularly away from the longitudinal axis of the base plate, wherein each leg of the plurality of legs has a floor securing means. 
     Preferably, the panel may be constructed from at least one polymer selected from the group of: acrylonitrile butadiene styrene, polyethylene, polycarbonate, polyamide, high impact polystyrene, and polypropylene. 
     Preferably, the female portion may further comprise a securing means positioned in the female portion. 
     Preferably, the modular device may further comprise an elongate U bracket or U shaped bracket along the longitudinal axis of the panel, wherein a base of the U bracket may be mountable to the ceiling of room space, and wherein the arms of the U bracket may be adapted to secure with the top of the panel. 
     Preferably, the panel may be formed form at least one selected from the group of: extrusion, and injection moulding. 
     Preferably, the modular device may further comprise a panel reinforcement positioned between the first planar surface and the second planar surface, wherein the panel reinforcement may be polyurethane foam. 
     Preferably, the sinusoidal wavelength to amplitude ratio of the corrugation may be in the range of: 1:1 to 3:1. 
     Preferably, the sinusoidal wavelength to amplitude ratio of the corrugation may be 2:1. 
     Preferably, the height of the panel may be in the range of: 1 metre to 3 metres, the length of the panel may be in the range of: 1 metre to 4 metres, and the thickness of the panel may be in the range of: 20 millimetres to 80 millimetres. 
     Preferably, the height of the panel may be 1 metre, the length of the panel may be 2.4 metres, and the thickness of the panel may be 50 millimetres. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1A  illustrates a top view of a modular device in accordance with a first preferred embodiment of the present invention. 
         FIG. 1B  illustrates a perspective view of the modular device of  FIG. 1A . 
         FIG. 1C  illustrates a front view of the modular device of  FIG. 1B . 
         FIG. 2A  illustrates a top view of a corner portion for engaging with the modular device of  FIG. 1A . 
         FIG. 2B  illustrates a perspective view of the corner portion of  FIG. 2A . 
         FIG. 3A  illustrates a top view of the corner portion of  FIG. 2A  with the corner male portion engaged with a female portion of a modular device of  FIG. 1A  and the corner female portion engaged with a male portion of another modular device of  FIG. 1A . 
         FIG. 3B  illustrates a perspective view of  FIG. 3A . 
         FIG. 4A  illustrates a top view of a portion of the corrugated portion of the modular device of  FIG. 1A . 
         FIG. 4B  illustrates a perspective view of  FIG. 4A . 
         FIG. 5A  illustrates a top view of a male cap for engaging with a female portion of the modular device of  FIG. 1A . 
         FIG. 5B  illustrates a perspective view of  FIG. 5A . 
         FIG. 5C  illustrates a back view of  FIG. 5A . 
         FIG. 6A  illustrates a top view of a female cap for engaging with a male portion of the modular device of  FIG. 1A . 
         FIG. 6B  illustrates a perspective view of  FIG. 6A . 
         FIG. 6C  illustrates a front view of  FIG. 6A . 
         FIG. 7A  illustrates a modular device of  FIG. 1B  engaged with a base plate. 
         FIG. 7B  illustrates a bottom view of  FIG. 7A . 
         FIG. 8A  illustrates a top view of the base plate. 
         FIG. 8B  illustrates a perspective view of the base plate. 
         FIG. 9A  illustrates a top view of the end portions. 
         FIG. 9B  illustrates a perspective view of  FIG. 9A . 
         FIG. 9C  illustrates a back view of the  FIG. 9A . 
     
    
    
     DESCRIPTION OF THE INVENTION 
     Preferred embodiments of the invention will now be described with reference to the accompanying drawings and non-limiting examples. It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features. 
     In an embodiment of the present invention, as illustrated in  FIGS. 1A to 1C ,  FIG. 1A  shows a top view of a modular device  10  according to a preferred embodiment of the present invention. The modular device  10  may be adapted for subdividing room space. The modular device  10  may comprise a panel  12 . The panel  12  may be elongated. The panel  12  may comprise a corrugated portion  14  which may be positioned between a first planar surface  16  and a second planar surface  18  of the panel  12 . The peaks  20  of the corrugated portion  14  may be in engagement with the first planar surface  16  and the troughs  22  of the corrugated portion  14  may be in engagement with the second planar surface  18 . The first planar surface  16  and the second planar surface  18  may each have a first end  24 ,  25  and a second end  26 ,  27 . The first  24  and second ends  25  of the first planar surface  16  are respectively opposite relatively to the first  26  and second ends  27  of the second planar surface  18 . The first end of the first planar surface  24  may be opposite relatively to the first end of the second planar surface  25 , and the second end of the first planar surface  26  may be opposite relatively to the second end of the second planar surface  27 . The second planar surface  18  may be parallel to the first planar surface  16 , where in the corrugations  14  may run parallel to the vertical axis of the panel  12 . 
     A female portion  28  may be positioned along the vertical axis in the panel  12 . The first planar surface  16  and the second planar surface  18  may each have a certain thickness. The first planar surface  16  may comprise an outer planar surface and an inner planar surface, and the second planar surface  18  may comprise an outer planar surface and an inner planar surface. The female portion  28  may be formed from at least: the first end of the first inner planar surface  35 , the first end of the second inner planar surface  37 , and a curved portion  30  from the corrugated portion  14 . The female portion  28  may have a concave profile. 
     A male portion  32  may be positioned along the vertical axis of the panel  12 , wherein the male portion  32  may be positioned outside of the second end of the first planar surface  26  and the second end of the second planar surface  27 . The male portion  32  may have a convex profile outside of the second ends of the first planar and second planar surfaces. For extending the length of the panel  12 , the convex male portion  32  of a first panel  12  may be adapted to engage with the concave female portion  28  of a second panel  12 . The first side of the male portion  34  may be engaged with a first side of the female portion  35 , and a second side of the male portion  36  may be engaged with a second side of the female portion  37 . Engagement of the convex male portion  32  and the concave female portion  32  may be such that the outer surface of the first planar surface of the second panel may be flush with the outer surface of the first planar surface of the first panel. Similarly, the outer surface of the second planar surface of the second panel may be flush with the outer surface of the second planar surface of the first panel. It may be preferred that the outer surface of the first planar surface  16  and the outer surface of the second planar surface  18  may be smooth. As illustrated in  FIGS. 4A and 4B , the modular device  10  may have corrugated spaces  40  between the corrugation portion  14  and the first and second planar surfaces  16 ,  18 . As shown in  FIGS. 1B and 1C , the modular device  10  may also have top portion  42  and a bottom portion  44 . 
     As illustrated in  FIG. 5A to 5C , to terminate the panel length of the last panel which has an open female portion  28 , the concave female portion  28  may be covered by a male cap  50 . The male cap  50  may have a first side  55 , a second side  57 , and a curved portion  58 . The first side of the male portion  55  may be engaged with a first side of the female portion  35 , the second side of the male portion  57  may be engaged with a second side of the female portion  37 , and the curved male cap portion  58  may be engaged with a curved portion of the female portion  30 . The male cap  50  may have a vertical plate  59  which may cover the concave opening of the female portion  28 . As also shown in  FIGS. 9A and 9C , the vertical plate  59  may have an upper end  52  and a lower end  54  for covering the upper part of the modular device  42  and the lower part of the modular device  44  respectively. The vertical plate  59  may also have a plurality of fasteners along the vertical axis of the vertical plate  59  for securing the vertical plate  59  with a solid material enclosed by a first side  55 , a second side  57 , a curved portion  58  and the vertical plate  59 . 
     As illustrated in  FIGS. 2A and 2B , the modular device  10  may further comprise a corner portion  60 , wherein the corner portion  60  may comprise a female corner cap  61  and an adjacent male part  62 . The female corner cap  61  may be adapted to engage with a male portion  32  of a panel  12 , wherein the adjacent male part  62  may be adapted to engage with the female portion of another panel  12 . The adjacent male part  62  may extend outwardly from an outer surface of the female cap  61  at an angle relative to the longitudinal axis of the length of the panel  12 . It may be preferred that for a corner, the angle may be 90° relative to the longitudinal axis of the length of the panel  12 . Engagement of the corner portion  60  with two panels  12  are illustrated in  FIGS. 3A and 3B . The female corner cap  61  may have a first side  65  for engaging with a first side of male portion  34  of the panel  12  and the female cap  61  may have a second side  67  for engaging with a second side of male portion  36  of the panel  12 . The adjacent male part  62  may have a first side  64  for engaging with a first side of the female portion  35  of the panel  12  and the adjacent male part  62  may have a second side  66  for engaging with a second side of the female portion  37  of the panel  12 . The female corner cap  61  may have space  63 , in which it may be filled with a structurally reinforcing material such as a polyurethane foam. It may be appreciated that any type of structurally reinforcing material can be used. 
     Similar to the female cap  61  of the female corner cap  60 , there may a terminal female cap  80  as illustrated in  FIGS. 6A to 6C . The terminal female cap  80  may be used for capping the male portion  32  of the front panel  12 . The terminal female cap  80  may have a first side  85  for engaging with a first side of the male portion  34  of the front panel  12  and a second side  87  for engaging with a second side of the male portion  36  of the front panel  12 . The peak of the concave female cap  61  may be in communication with the vertical plate  81  of the terminal female cap  80 . There may be gaps  84  formed between the curve of the concave female cap, the outer surface of the terminal female cap and the vertical plate  81 . The gaps  84  may be filled with a structurally reinforcing material which may also be polyurethane foam. 
     As shown in  FIGS. 8A and 8B , there may be provided an elongated base plate  90 , which may be adapted for attaching to a base of the panel  12 . The plate  90  may be constructed of a lightweight metal or alloy. Preferably, the plate  90  may be constructed of aluminium. The attachment may be a fastener  98  to secure the material  40  filled between the corrugation portion with the elongated base plate  90 . The elongated base plate  90  may comprise a plurality of legs  96 . The plurality of legs  96  may extend perpendicularly away from the longitudinal axis of the base plate  90 . The legs  96  may be adapted for engaging a floor or platform of the room. Each leg  96  of the plurality of legs may have a surface engagement means  99  for securing each leg to the floor or platform or a surface. The surface engagement means  99  may be a fastener. 
     As shown in  FIGS. 7A and 7B , the length of the elongated base plate  90  may be shorter than the length of the base of the panel  12 . The elongated base plate  90  may have a female proximal end  92  and a male proximal end  94 , wherein the female proximal end of the base plate  92  may be adapted to engage with a female proximal end of the base of the panel  12 , wherein the female portion  28  of the panel  12  may be outside of the female proximal end  92  of the elongate base plate  90 . The male proximal end  94  of the base plate  94  may be adapted to engage with a male proximal end of the base of the panel  12 , wherein the male portion  32  of the panel  12  may be outside of the male proximal end  94  of the elongate base plate  90 . 
     The panel may be constructed from at least one polymer selected from the group of: acrylonitrile butadiene styrene, polyethylene, polycarbonate, polyamide, high impact polystyrene, and polypropylene. The panel may be formed from at least one selected from the group of: extrusion, and injection moulding. 
     In another embodiment of the present invention, the module device  10  may further comprise an elongate U bracket along the longitudinal axis of the panel  12  (not shown). The base of the U bracket may be mountable to the ceiling of room space, and wherein the arms of the U bracket may be adapted to secure with the top portion of the panel  42 . The top portion of the panel  42  may be secured by sliding the top portion to the U bracket. 
     In another embodiment of the present invention, the corrugation of the corrugated portion  14  may have a sinusoidal wavelength to amplitude ratio in the range of: 1:1 to 3:1. Preferably, the sinusoidal wavelength to amplitude ratio of about 2:1. 
     In another embodiment of the present invention, the height of the panel  12  may be in the range of: 1 metre to 3 metres, the length of the panel  12  may be in the range of: 1 metre to 4 metres, and the thickness of the panel may be in the range of: 20 millimetres to 80 millimetres. Preferably, the height of the panel  12  may be 1 metre, the length of the panel  12  is 2.4 metres, and the thickness of the panel is 50 millimetres. 
     When additional panels are engaging with the parts, the connection between the male and female portions may be glued for extra reinforcement. Once the glue is dried, it may be appreciated that the dried glue may not be level with the surface of the panel  12 . The dried glue may be sanded such that the glued panels are level. The advantage of this modular device may be that it is significantly easier and cheaper to erect compared to conventional non-structural walls, which may be of gyprock and timber supports. 
     In further embodiments, the empty void space  40  between the corrugations of the panel may be backfilled with a non-structural filler agent such as expandable styrene foam. The non-structural filler may include materials that are flame retardant, fire retardant and/or noise absorbing. 
     Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms, in keeping with the broad principles and the spirit of the invention described herein. 
     The present invention and the described preferred embodiments specifically include at least one feature that is industrial applicable.