Patent Publication Number: US-11661736-B2

Title: Modular wall panels and system

Description:
CLAIM OF PRIORITY 
     This application is a continuation of co-pending U.S. patent application Ser. No. 16/242,742, filed Jan. 8, 2019, the content of which is incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to wall systems, and more particularly, to modular wall panel system frame components for assembling the exterior frames of a customizable wall system. 
     BACKGROUND 
     Temporary walls are needed in many settings, such as for events like exhibitions, trade shows, and festivals. Such temporary walls need to be easy to assemble and disassemble and also easy to transport. Current modular wall offerings are made of sheetrock or plywood and are therefore quite heavy and cumbersome to transport, often requiring multiple people or trips to transport to a site. This makes them difficult to use if there is only one person transporting and setting up the walls, or if there are many other items being transported as well, such as merchandise or supplies. Existing modular walls often require affixing one to another with hinges or connection hardware that requires tools to assemble or connect and disconnect. A person must therefore also transport tools for assembly, adding to the weight and bulk of materials being transported. Their cumbersome nature also makes existing wall panels difficult to alter once installed, such as updating, repositioning, and changing configurations. They are difficult to use and are limited in their functionality and customization. For instance, they may only attach a certain number of ways and do not stack on one another for height variation or extension. 
     What is needed therefore is a wall system that can be quickly and easily assembled and disassembled for ease of use. Lighter weight walls would also be beneficial to make transportation easier, but they still need to be structurally sound. These two aspects are at odds with one another. A fully customizable temporary wall system is still lacking in the art, and one which can be customized not only to size and configuration but aesthetically as well to a variety of different palates. 
     SUMMARY 
     A modular wall system and panels are disclosed which address the above needs. Specifically, the modular wall system and wall panels of the present invention are lightweight, being made of lightweight material and having a substantially hollow interior to provide even lighter construction. The construction is structurally sound despite this light weight, each wall panel including a frame made of a plurality of frame components collectively supporting the wall panel from within. Wall sheets are mounted to the frame on at least one side, but preferably both sides to sandwich the frame between wall sheets made of lightweight material. The frame components making up the frame themselves are substantially hollow, having a plurality of apertures extending therethrough to allow access to the interior of the wall panel. However, the frame components also include support ribs in the walls and may include at least one divider to separate the interior space of the frame component and provide additional structural support. Further support is provided by inserting cap(s) and/or connector(s) into the apertures of the frame components. 
     Because the frame components forming the frame of each wall panel include a plurality of apertures, each wall panel may be connected to any other wall panel through the apertures in their outer edges. For example, at least one bi-directional connector may be received in an aperture of one wall panel and an aperture of an adjacent wall panel. Any number of connectors may be used with the apertures in the frame components to connect adjacent wall panels. Planar connectors may also be used to bridge between adjacent wall panels, inserting into the apertures of adjacent wall panels while spanning over the outer surface of the panels. Caps may be inserted into unused apertures to conceal the openings for aesthetics. 
     The wall panels may come in any size, shape and dimension for increased customization to fit any size space and desired configuration. The wall panels may also include a feature, such as a window, door or other structure within the boundaries of the panel, such as to provide for designs, logos, indicia, backlighting, and other design features as may be desired. The lightweight yet structurally sound design of the wall panels allows them to be combined in any number of ways, including stacked vertically on one another and intersecting at 90° angles to form joining walls. No tools are necessary, as the caps and connectors are simply inserted to assemble and may be removed by pulling to release. 
     Because of these features, the modular wall panels and system as described herein provides numerous options for different aesthetics, easier and faster assembly and disassembly without the need for tools, and the ability to run cables through the interior of the wall panels and system for power, connectivity, lighting, Internet and the like without having to sacrifice aesthetics. They may be used for any type of wall where customization or temporary walls may be used, such as but not limited to office walls, cubicles, wall dividers, apartments, trade shows, art exhibits, fairs, festivals and events. 
     The modular wall panels and system, together with their particular features and advantages, will become more apparent from the following detailed description and with reference to the appended drawings. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is an isometric view of one exemplary embodiment of a modular wall panel of the present invention. 
         FIG.  2    is an exploded view of the modular wall panel of  FIG.  1   . 
         FIG.  3    is an isometric view of a second exemplary embodiment of a modular wall panel of the present invention. 
         FIG.  4    is an exploded view of the modular wall panel of  FIG.  3   . 
         FIG.  5    is an exploded view of an arrangement of frame components of another exemplary embodiment of the modular wall panel. 
         FIG.  6    is an exploded view of an arrangement of frame components of the modular wall panel of  FIG.  3   . 
         FIG.  7    is a top isometric view of an exemplary frame component as may be used in the modular wall panel. 
         FIG.  8    is a bottom isometric view of the frame component of  FIG.  7   . 
         FIG.  9    is a partial isometric view of one embodiment of the modular wall system of the present invention. 
         FIG.  10    is a partially exploded view of a portion of a modular wall system demonstrating connection of adjacent walls. 
         FIG.  11    is an isometric view of one embodiment of a cap as may be used with the modular wall panels and/or system. 
         FIG.  12    is an isometric view of a second embodiment of a cap and is also an embodiment of a planar connector. 
         FIG.  13    is an isometric view of a second embodiment of a planar connector, being L-shaped. 
         FIG.  14    is an isometric view of a third embodiment of a planar connector, being T-shaped. 
         FIG.  15    is an isometric view of an embodiment of a bi-directional connector. 
         FIG.  16    is an isometric, partially exploded view of another embodiment of a modular wall system of the present invention showing intersecting walls. 
         FIG.  17    is an exploded view of another embodiment of a modular wall panel showing a sub-assembly. 
         FIG.  18    is an isometric view of another embodiment of a wall system showing spaced apart wall panels. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     As shown in the accompanying drawings, the present invention is directed to modular wall panels and a wall system made thereof. The present modular wall panels and system are extremely lightweight. They provide minimal material and lightweight materials to increase mobility in the field for ease of transportation and use. The modular wall panels may be connected in any number of configurations as described in greater detail below to achieve a fully customizable system that a user can assemble to their own specifications. For example, the modular wall panels and system described herein may be used in a variety of settings, such as but not limited to office walls, cubicles, wall dividers, apartments, trade shows, art exhibits, fairs, festivals and events. The modular wall panels are also capable of having cables run through their interior, such as power cables for various lighting and devices, Internet, and other cables or wires as may be necessary for electronic connectivity and yet remain concealed for aesthetic purposes. The modular wall panels make for easy and customizable assembly, as well as quick disassembly, changing or updating as needs or desires dictate. 
     The modular wall panels described herein may be interoperable and used with any of the blocks, interfacing members, and floor panels as shown and described in U.S. Pat. Nos. D791885, D809162, D786586, D783731 and D800846, and U.S. patent application Ser. No. 29/640,623 and U.S. Ser. No. 15/954,391, all of which are incorporated by reference herein. 
     With reference now the Figures, the present invention is directed to modular wall panels  100  that may be connected to one another to form a modular and customizable wall system  200 . As shown in  FIGS.  1 - 2   , each modular wall panel  100  is composed of at least one wall sheet  150  secured to a frame  140  made up of a plurality of frame components  110 . The wall sheet  150  may be made of any lightweight material and may be flexible or rigid. For example, the wall sheet  150  may be made of materials such as but not limited to paper, fabric, wood, vinyl, fiberboard, fiberglass, fiberglass reinforced panel (FRP), styrofoam, polyvinyl chloride (PVC), expanded PVC, foam, polystyrene, polyurethane, polypropylene, acrylic, cardboard, carbon fiber, balsa, plastic, polymeric material, titanium, steel, stainless steel, magnesium, aluminum, zinc, carbon steel and metal alloys. In at least one embodiment, the wall panels  150  may be made of FRP which provides not only structural integrity in a lightweight material but is also fire retardant. In such embodiments, the wall panels  100  can be assembled into a wall system  200  that can act as a fire wall, such as may be useful in basements and garages where firewalls may be a desired safety precaution or mandated by building codes. The present wall system  200  can therefore be used to create a firewall to supplement existing walls without having to tear down and rebuild walls to code. 
     The material comprising the wall sheets  150  may be of any color, design, or combination thereof. For instance, the wall sheets  150  may be a solid color or may be a combination of colors in a pattern or design. Artwork, logos, branding indicia, and other markings may also be present on the wall sheets  150 . In some embodiments, the wall sheet  150  may include a feature  152 , such as depicted in  FIG.  9   . The feature  152  may be a window, door, mesh screen or other similar structure interrupting or differing from the surface of the wall sheet  150 . The feature  152  may be transparent, translucent or opaque. For instance, a transparent feature  152  such as a window may be useful in revealing items behind it (i.e., within the wall panel  100 ) such as lighting. Accordingly, in at least one embodiment, the feature  152  may be backlit with colored or white lights, such as LEDs, to create a lighting effect, ambiance or desired aesthetic. The feature  152  may be translucent or opaque so as to set off design elements, such as but not limited to logos for advertising or custom designs. The feature  152  may be made of the same or different material as the wall sheet  150 , such as acrylic, vinyl or other material. In other embodiments, the feature  152  may be an optical or display screen, such as an LCD or other similar screen suitable for displaying moving images thereon, and which may be touch-enabled for interactive display. The display screen feature  152  may be in electrical communication with a processor and/or computing device configured to receive, process and display visual information on the screen. It may also be in electrical communication with speakers to provide audio information as well, which may be presented simultaneously with the video. It may further be in electrical communication with the Internet, cloud, and/or a network such as available through WiFi, Bluetooth® or direct communication. 
     The wall panels  100  may be of any shape, such as but not limited to square and rectangular. They may also be any size and dimension. The particular shape, size and dimension of each wall panel  100  may be based, at least in part, on the geometry and/or size of the frame  140  which supports it. For example, a modular wall panel  100  may have a generally rectangular configuration and may be about 4 ft by 8 ft, as in  FIGS.  1  and  2   , or may be about 1 ft by 8 ft as in  FIGS.  3  and  4   . These are non-limiting examples for illustrative purposes only. The dimensions of the modular wall panels  100  may vary in increments of 1 foot, 6 inches, or other suitable increment as permitted by the shape and size of the frame components  110 . 
     In forming the wall panel  100 , wall sheets  150  are affixed to a face of the frame  140 . For instance, as seen in  FIG.  2   , a first wall sheet  150   a  is affixed to a first face  141  of a frame  140 , and a second wall sheet  150   b  is affixed to a second face  142  of the frame  140 . Similarly, in  FIG.  4   , a narrower first wall sheet  150   a ′ is affixed to a first face  141  of a frame  140 ′, and a second wall sheet  150   b ′ is affixed to a second face  142  of the frame  140 ′ to form a narrower wall panel  100 ′. The wall sheets  150   a ,  150   b  may be affixed to the face of the frame  140  by any means, such as but not limited to by rivets, screws, bolts, adhesive, welding, hook and loop fasteners, and combinations thereof. Accordingly, the wall sheets  150   a ,  150   b  may be affixed to the face of the frame  140  by permanent or selective fastening. In at least one embodiment, the wall sheets  150   a ,  150   b  are permanently affixed to the frame  140  such as at a manufacturer&#39;s facility and are provided to end users as wall panels  100 . In other embodiments, the frame  140  and wall sheets  150   a ,  150   b  may be provided separately to the end user and the end user may assemble the wall panel  100  to their own liking in the field, which may be changed later if desired. 
     Different types of wall sheets  150   a ,  150   b , such as of different materials or different configurations, may be affixed to the different faces  141 ,  142  of the frame  140 . In other embodiments, the wall sheets  150   a ,  150   b  on either side of the frame  140  may be of the same type. In some embodiments, multiple wall sheets  150  may be affixed to the same face  141 ,  142  of the frame  140 , such as when combining multiple smaller wall sheets  150  to fill a frame  140 . Multiple wall sheets  150  of a size smaller than the frame  140  to which they are affixed may be used to provide different colors, designs, or create patterns across the entire wall panel  100  when assembled. When the wall sheets  150   a ,  150   b  are affixed to both sides of the frame  140 , the resulting wall panel  100  is hollow inside. This hollow interior may be filled with foam or insulating material to convey insulating properties to the wall panel  100 . The hollow interior of the wall panel  100  is also adapted for receiving and conveying cables  220  therethrough, as shown in  FIG.  10   . Such cables  220  may be any type of cable or wire, such as for electrical power, Internet or ethernet cables, sound or audio-visual cables and the like. The wall panel  100  therefore hides cables  220  that may be needed for lights, sound systems, and other devices that may be used in proximity to the space formed by the wall panels  100  and/or system  200 . Utility boxes for plumbing, networking and power, such as outlet boxes and the like, may also be mounted to an interior surface of a wall sheet  150  or to the frame  140  within the hollow formed in the wall panel  100  between wall sheets  150   a ,  150   b . The connecting plumbing, networking, and power cables, including grounding wires, may be run to the utility box through the frame  140  such as through or between frame components  110  as described below. 
     With reference to  FIGS.  2  and  4 - 6   , the wall panel  100  includes a frame  140  made up of a plurality of frame components  110 . As indicated above, the frame  140  forms the skeleton of the wall panel  100 , providing the structural support for the wall sheets  150  attached thereto. The frame  140  may be any shape, such as but not limited to rectangular, square, triangular, and others. The frame  140  may also have any configuration, such as intersecting in a radial or grid configuration which may traverse at least a portion of the wall panel  100  and provide support to central portions of the wall sheets  150 . Portions of the frame  140  may also form a sub-assembly  143  as shown in  FIG.  17    configured to support a feature  152 , such as a window, door or screen within a wall sheet  150 , as discussed above. In such embodiments, the sub-assembly  143  may have a shape or configuration corresponding to at least a portion of the feature  152 . The feature  152  and sub-assembly  143  may be located anywhere on the wall panel  100 , though in some embodiments the feature(s)  152  need not be supported by a sub-assembly  143 . When present, the sub-assembly  143  may be connected to the remainder of the frame  140  or may be separate from the rest of the frame  140 . In at least one embodiment, the frame  140  preferably forms the perimeter, or at least a portion of the perimeter, of each wall panel  100 . For instance, the frame  140 ′ in  FIG.  4    forms the entire perimeter of the wall panel  100 ′. In other embodiments, as in  FIG.  2   , the frame  140  forms only the corners of the wall panel  100 . 
     Any placement or configuration of the frame  140  within the wall panel  100  is contemplated herein. For example, the various frame components  110  that make up the frame  140  may each be contiguous with and touching the next adjacent frame component  110 , as in  FIG.  4   . In other embodiments, only some of the frame components  110  may be touching one another, as in  FIG.  2   . In some embodiments, some of the frame components  110  may be spaced apart from one another, also as shown in  FIG.  2   . In still other embodiments, all the frame components  110  may be spaced apart from one another. It should be appreciated that the frame  140  may be formed even when frame components  110  are not contiguous and touching one another. Indeed, the frame components  110  need not be secured or connected to one another to form the frame  140 . All that is needed is that they form a support for the wall sheet(s)  150  to affix to. In some embodiments, the frame  140  may be assembled by arranging the frame components  110  on a jig where they “float” until a wall sheet  150  is secured to them, fixing them in place. In such embodiments, complete wall panels  100  may be provided to the end user in the field for assembling into a wall system  200  in the field, as described below. In other embodiments, the frame components  110  may be connected to one another, such as by adhesive, welding, screws, hinges, hook and loop fasteners, and other types of fastening mechanisms, to secure the frame  140  before the wall sheet(s)  150  is affixed thereto. In these embodiments, the frame  140  and walls sheets  150  may be provided to the end user for assembly in the field. 
     The frame components  110  used in the frame  140  may be any combination of several types but they all have certain elements in common. For instance, and with reference to  FIGS.  7 - 8   , the frame components  110  have several wall components  111 , such as a first face wall  112  and opposite second face wall  114  that are spaced apart from one another. In at least one embodiment, the first and second face walls  112 ,  114  are parallel to one another, though in other embodiments they may be other than parallel. Each frame component  110  also includes a first end  116  and second end  118  located at opposite terminal ends of the face walls  112 ,  114 . The ends  116 ,  118  may be a solid wall, an open space, or a combination thereof. An outer surface  120  spans between the first and second face walls  112 ,  114 , such as extending transversely between corresponding edges of the first and second face walls  112 ,  114 . In at least one embodiment, the outer surface  120  also extends between the first and second ends  116 ,  118 . Accordingly, the outer surface  120  may connect to corresponding edges of the face walls  112 ,  114  and the ends  116 ,  118  to cover an entire surface of the frame component  110 . An inner surface  122  similarly spans between corresponding edges of the first and second face walls  112 ,  114  opposite from the outer surface  120 . In at least one embodiment, the inner surface  122  may be open to the interior of the frame component  110 , as shown in  FIG.  8   . In other embodiments, the inner surface  122  may be at least partially solid, as is the outer surface  120 . Accordingly, the outer and inner surfaces  120 ,  122 , face walls  112 ,  114  and ends  116 ,  118  form the boundaries of the frame components  110 . Each frame component  110  may measure any dimension, such as but not limited to 12 inches wide (distance from first end  116  to second end  118 ), 3 inches deep (distance from first face wall  112  to second face wall  114 ), and 3 inches high (distance from outer surface  120  to inner surface  122 ). 
     In at least one embodiment, as can be appreciated from  FIGS.  7  and  8   , the outer surface  120  may extend beyond or over hang the first and second face walls  112 ,  114  by an amount sufficient to accommodate the wall sheet  150 . For instance, the overhang amount may be about the same distance as the thickness of the wall sheet  150  to be affixed to the corresponding face wall  112 ,  114  that forms the corresponding face  141 ,  142  of the frame  140  when assembled. By way of example, and not to be limiting, the amount of overhang of the outer surface  120  may be in the range of 0.1-0.11 inches at either face wall  112 ,  114 . 
     The outer surface  120  includes at least one outer aperture  130  formed therein and spaced apart from one another, as shown in  FIG.  7   . Each outer aperture(s)  130  has a size and shape large enough to receive and accommodate at least a portion of an insert  155  therein, described in further detail below. For instance, the outer aperture(s)  130  may be square, rectangular, circular, ovoid, or asymmetrically shaped as would correspond with a matching insert  155 . In at least one embodiment the outer aperture(s)  130  may measure in the range of 0.5 to 4 inches and may be about 2 inches squared in at least one embodiment. There may be any number of outer aperture(s)  130  in each frame component  110 , such as one, three, four, five, ten and twelve as some non-limiting examples. In one embodiment, each frame component  110  may have four outer apertures  130  formed in the outer surface  120 . 
     Similarly, the inner surface  122  includes at least one inner aperture  131  formed therein and spaced apart from one another, as shown in  FIG.  8   . Each inner aperture(s)  131  also has a size and shape large enough to receive and accommodate at least a portion of an insert  155  therein. In at least one embodiment, each inner aperture  131  is aligned with a corresponding outer aperture  130 , forming a passage  128  therebetween. Accordingly, there are preferably the same number of inner apertures  131  as there are outer apertures  130 . In at least one embodiment, each corresponding inner and outer aperture  131 ,  130  may be substantially the same size, shape and dimension. However, in other embodiments the inner aperture(s)  131  may be larger than the corresponding outer aperture(s)  130 . 
     The passage  128  formed between each corresponding outer and inner aperture  130 ,  131  is dimensioned to receive and also selectively restrain an insert  155  therein. For instance, the frame component  110  may include at least one component wall  111  disposed between the outer and inner surfaces  120 ,  122  and spaced apart from the ends  116 ,  118 . Such component walls may be a divider(s)  126  which separate adjacent passages  128 , as best shown in  FIG.  8   . Accordingly, the divider(s)  126  may have the same height as the rest of the frame component  110 . The divider(s)  126  and other component walls  111 , such as the interior-facing sides of the face walls  112 ,  114  and ends  116 ,  118 , if walls. The divider(s)  126  may have the same or similar thickness as the other component walls  111 , such as in the range of about 0.07-0.15 inches. In at least one embodiment, the divider(s)  126  may be thicker or thinner than the outer component walls  111 . For instance, the outer component walls  111  may have a thickness in the range of 0.06-0.1 inches. These are a few non-limiting examples for illustrative purposes only. 
     The frame components  110  may include at least one support rib  124  extending outwardly from a wall  111  or divider  126  in which they are formed. As such, they provide structural support to the corresponding wall  111  or divider  126 , and therefore to the wall panel  100  overall. They may also provide frictional engagement with an insert  155  placed within a passage  128  into which a support rib  124  extends. Accordingly, in at least one example the support ribs  124  may extend longitudinally along the interior wall surfaces of the frame component  110 , such as between the outer and inner surfaces  120 ,  122 , to be aligned with the direction of insertion and removal of inserts  155  therein. In other examples, however, at least some of the support ribs  124  may extend along the interior wall surfaces of the frame component  110  between adjacent walls which may be other than longitudinal. There may also be different types of support ribs  124 . For example, and as depicted in  FIG.  8   , the frame component  110  may include support ribs  124   a  that extend the entire height of the component walls  111  such as the interior surface of the face walls  112 ,  114 . These full support ribs  124   a  may have a uniform thickness or dimension or may have a varying thickness along its length. Some support ribs  124   b  may be a partial rib that extends only a fraction of the height of the frame component  110 . These partial support ribs  124   b  may be tapered, as depicted, or may have a uniform dimension throughout. Other support ribs  124   c  may span between walls, such as between one side of a divider  126  and the underside of the outer surface  120  as shown in  FIG.  8   . As such, the support ribs  124   c  may be fins, fans, or other geometric structure to reinforce a junction of walls and provide further support. These are a few non-limiting examples. 
     As shown in  FIGS.  7 - 8  and  10   , the outer surface  120  may also include at least one countersunk portion  132  associated with an outer aperture  130 . For example, a countersunk portion  132  may be disposed along at least a portion of the perimeter of an outer aperture  130 , such as surrounding a corner(s) of the outer aperture  130  or fully or partially surrounding the outer aperture  130 . The countersunk portion  132  is dimensioned to receive a portion of the insert  155  therein. For example, the insert  155  may be a cap  160  having at least one lug portion  162  extending from a cover  166 , as described below. The countersunk portion  132  may be dimensioned to receive the cover  166  when the lug portion  162  is received within the corresponding outer aperture  130 . In at least one embodiment, the countersunk portion  132  has depth similar in dimension to the thickness of the cover  166 , such as but not limited to about 0.075 inches. It may also have a lateral dimension similar to that of the cover  166 , which may be wider than the outer aperture  130  into which it is inserted. Accordingly, in at least one embodiment, the countersunk portion  132  provides a planar fit of the cap  160  into the outer aperture  130  such that the cover  166  is substantially co-planar with the surrounding outer surface  120  of the frame component  110  when the cap  160  is placed fully within the outer aperture  130  and passage  128 . 
     As mentioned previously, there may be many varieties of frame components  110 . For example, the frame component may be a combination frame component  110   a , as illustrated in  FIGS.  7  and  8   . Angled frame components  110   a  have one end  118  that is substantially perpendicular to the outer and inner surfaces  120 ,  122 , and one end  116 ′ that is angled relative to the outer and inner surfaces  120 ,  122 . Accordingly, each face wall  112 ,  114  may have an angled end. The angled end  116 ′ may be at any oblique angle relative to the outer and inner surfaces  120 ,  122 , such as in the range of 10°-80°. In at least one embodiment, the angled end  116 ′ is at a 45° angle relative to the outer surface  120 . Two angled frame components  110   a  may be joined together at their angled ends  116 ′ to form a corner of a frame  140 , as depicted in  FIG.  5   . 
     Other frame components  110   b  have both ends  116 ,  118  that are substantially perpendicular to the outer and inner surfaces  120 ,  122 . The straight ends  116 ,  118  may be substantially perpendicular in that some slight deviation from 90° may be tolerated and still considered straight, such as to allow for drafting between adjacent frame components  110   b . These straight frame components  110   b  may be used to extend the frame  140  in any direction, as shown in  FIG.  5   . Other frame components  110   c  have both ends  116 ′,  118 ′ that are angled relative to the outer and inner surfaces  120 ,  122 , as depicted in  FIG.  6   . The angled ends  116 ′,  118 ′ may have the same angle or different angles from one another. In at least one embodiment, both angled ends  116 ′,  118 ′ are about 45° relative to the outer surface  120 . Such angled frame components  110   c  may be used to form an end of a frame  140  that is intended to be as narrow as the width of a single frame component, as shown in  FIG.  6   . 
     Multiple frame components  110 , including any number and combination of the various types discussed above, as may be needed to form a frame  140  of the desired size and/or configuration. The frame components  110  are arranged with their outer surfaces  120  facing away from one another and their inner surfaces  122  facing toward each other, such that the outer apertures  130  are the most exteriorly facing portions of the frame components  110 , as shown in  FIGS.  1 - 6  and  10   . These outer apertures  130  may provide access into the interior of the wall panel  100  once assembled. 
     As mentioned previously, the wall panel  100  may also include at least one insert  155  configured to be inserted into an outer aperture  130  of a frame component  110 . In at least one embodiment, the insert  155  may be a cap  160  that is configured to cover and/or conceal the outer aperture  130  when inserted therein. As shown in  FIGS.  9  and  10   , the cap  160  includes at least one lug portion  162  that is configured to be received and retrained within a passage  128  of a frame component  110 . Accordingly, the lug portion  162  may be similarly sized and shaped to an outer aperture  130  so as to pass therethrough and a corresponding passage  128  so as to fit within the passage  128 . Support ribs  124  extending into the passage  128  may contact the lug portion  162  of the cap  160  when inserted therein, providing increased engagement with the lug portion  162  such as frictional engagement for a tighter or more restrained fit. For instance, the lug portion  162  may measure in the range of 0.1-2.0 inches squared and may be about 1 inch squared in at least one embodiment. It should be appreciated that the lug portion  162 , as with the outer aperture  130 , need not be square but can be rectangular, circular, ovoid, triangular or other shape. In addition, the lug portion  162  may have a smooth surface or may have ridges, grooves or other elements for increasing the grip or engagement between the lug portion  162  and the passage  128 . The lug portion  162  may be the same length, longer or shorter than the passage  128  in which it is retained. For example, in at least one embodiment, the lug portion  162  may have a height in the range of 0.01-1.0 inches and may be about 0.6 inches in at least one embodiment. The lug portion  162  may be solid or hollow throughout, providing more or less rigidity or flexibility as may be required. The lug portion  162  may include some slight angling, such as less than 1°, to allow for drafting or a frictional fit with outer aperture  130  and/or passage  128 , though this is not necessary. 
     The cap  160  also includes a cover  166  dimensioned to be at least as, though preferably larger than, the size of an outer aperture  130 . Accordingly, the lug portion  162  may be inserted through the outer aperture  130  and into the corresponding passage  128  up until the point the cover  166  stops against the outer surface  120  surrounding the outer aperture  130 . As explained above, the cover  166  may be correspondingly dimensioned to a countersunk portion  132  around the outer aperture  130  so as to cover or conceal the outer aperture  130  in a substantially planar manner. Indeed, the cover  166  may be flush with the outer surface  120  surrounding the outer aperture  130  when the cover  166  is fully within the countersunk portion  132  and the cap  160  is fully seated. Accordingly, the cover  166  may extend past the outer aperture  130  by a predetermined distance which may correspond with the countersunk portion  132 , such as by a distance in the range of 0.05-0.5 inches and may be about 0.22 inches in at least one embodiment. When desired, the cap  160  may be removed from the passage  128  and outer aperture  130 . 
     The cap  160  may come in many varieties. For example, it may be a single cap  160   a  as shown in  FIG.  11   , which includes a single lug portion  162  extending from the cover  166 , and which is intended to fill in and conceal a single outer aperture  130 . However, in some embodiments a single cap  160   a  may have a single lug portion  162  but an extended cover  166  to cover more than one outer aperture  130  despite only one outer aperture  130  being filled. The cap  160  may also be a double cap  160   b , as shown in  FIG.  12   , which includes a plurality of lug portions, such as a first lug portion  162  and a second lug portion  164  spaced apart from one another and both extending from the cover  166 . Accordingly, the cover  166  may have a longer dimension in a double cap  160   b  than a single cap  160   a . In a double cap  160   b , each lug portion  162 ,  164  is dimensioned to be received and retained within different and adjacent ones of outer apertures  130 . Accordingly, more than one outer aperture  130  may be covered or concealed with a double cap  160   b . The distance between the first and second lug portions  162 ,  164  is therefore the same distance that separates adjacent outer apertures  130 . In further embodiments, the cap  160  may be a triple, quadruple, etc., adding an additional lug portion for each additional outer aperture  130  to be concealed. It should be appreciated that with a double cap  160   b  or more, or with a single cap  160   a  having an extended cover  166 , the cover  166  may exceed the boundaries of a countersunk portion  132  at an outer aperture  130 . Accordingly, the cover  166  may not sit flush or co-planar with the outer surface  120  of the frame component  110  when a larger cap  160   b  spanning multiple outer apertures  130  is used. 
     The caps  160  may be used to conceal the outer apertures  130  and any combination of single and multiple caps  160  may be used on a wall panel  100 . However, it is not necessary to fill and/or conceal all the outer apertures  130 . In at least one embodiment, at least some of the outer apertures  130  may remain open for access to cables or the interior of the wall panel  100 . The caps  160  also provide further support to the frame components  110 , and therefore the frame  140 , when they are inserted into the outer apertures  130 . Accordingly, the caps  160  may help prevent the wall panel  100  from tipping over or falling. In particular, a double cap  160   b  may be useful along the bottom of a wall panel  100  to help it stand up since the double cap  160   b  does not countersink into the frame components  110 . They may also be used at the top side of the wall panel  100  where they are not as likely to be visible. 
     The present invention is also directed to a wall system  200  that includes a plurality of wall panels  100  as described above connected to one another with one or more connectors  210 . The wall system  200  may be assembled in the field by connecting wall panels  100  together laterally and/or vertically to cover any space or height desired. With reference to  FIGS.  9 ,  10  and  16   , the wall system  200  may include any number, combination and configuration of wall panels  100  as discussed above. The wall panels  100  may be connected to adjacent wall panels  100  at their respective outer surfaces  120 . Specifically, the wall system  200  includes at least one connector  210  configured to selectively connect adjacent wall panels  100  through the frame components  110 . The connector  210  is another type of insert  155  configured to be received by an outer aperture  130  of a frame component  110 . Each connector  210  includes a first lug portion  212  configured to be received and retained in an outer aperture  130  and/or passage  128  of one wall panel  100  and a second lug portion  214  configured to be received and retained in an outer aperture  130  and/or passage  128  of an adjacent wall panel  100 . Each lug portion  212 ,  214  of a connector  210  is similar to the lug portions  162 ,  164  of the caps  160  discussed above. Any number of connectors  210  may be used to connect adjacent wall panels  100  to one another, and they may interact with at least some of the frame components  110  and at least some of the outer apertures  130  thereof. 
     There are multiple types of connectors  210 . For example, the connector may be a bi-directional connector  210   a  as shown in  FIGS.  10  and  15   . The bi-directional connector  210   a  has a flange  218  along at least a portion thereof. In at least one embodiment, the flange  218  extends substantially around the circumference or perimeter of the bi-directional connector  210   a . First and second lug portions  212 ,  214  extend from opposite sides of the flange  218 . Each of the first and second lug portions  212 ,  214  are dimensioned to fit and be selectively retained within a different outer aperture  130  on different wall panels  100 . The flange  218  between the lug portions  212 ,  214  may be at least the dimensions of an outer aperture  130  of a frame component  110 . In at least one embodiment, the flange  218  may be dimensioned to correspond with a countersunk portion  132  associated with an outer aperture  130  of a frame component  110 . Accordingly, the flange  218  may be received within a countersunk portion  132  of at least one, if not both, wall panels  100  being joined together with the bi-directional connector  210   a . Accordingly, the bi-directional connector  210   a  provides a tight fit between adjacent wall panels  100 , forming only a very thin seam. This increases the structural integrity of the wall system  200  as well as the aesthetics. 
     Another type of connector is a planar connector  210   b , an example of which is shown in  FIGS.  10  and  12   . The planar connector  210   b  includes a plurality of lug portions, such as first and second lug portions  212 ,  214  as described above, but which extend from the same side of a cover  216 . Indeed, the double cap  160   b  discussed above may also function as a planar connector  210   b . When acting as a connector, one lug portion  212  of the planar connector  210   b  is received within a frame component  110 , such as an outer aperture  130 , of one wall panel  100 , and the other lug portion  214  of the planar connector  210   b  is received within a frame component  110  or outer aperture  130  of an adjacent wall panel  100 . The planar connector  210   b  may have two, three, four, or more lug portions  212  all extending from the same or common side of a cover  216 . Accordingly, the size of the cover  216  will increase with additional lug portions  212  present. 
     The planar connector  210   b  may come in various configurations. For example, the planar connector  210   b  may be linear in shape, with the length of the connector  210   b  dictated by the number of lug portions  212  it contains. In other examples, the planar connector may have an intersecting configuration to accommodate intersecting or transversely connecting wall panels  100 , such as an L-shaped connector  210   c  shown in  FIG.  13    and a T-shaped connector  210   d  shown in  FIG.  14   . The L-shaped connector  210   c  may have at least three lug portions  212 ,  214 ,  215  extending from a common side of a cover  216 ′, each spaced apart from one another and configured to fit within a different outer aperture  130 , at least two of which are on different frame components  110  of different wall panels  100 . Similarly, the T-shaped connector  210   d  may have at least four lug portions  212 ,  214 ,  215 ,  217  each extending from a common side of a cover  216 ″, each spaced apart from one another and configured to fit within a different outer aperture  130 , at least two of which are on different frame components  110  of different wall panels  100 . Any leg of the L-shaped connector  210   c  or T-shaped connector  210   d  may be longer if it has additional lug portions. 
     To assemble the wall system  200 , two wall panels  100  are joined together along their outer surfaces  120  of the frame components  110  of their frames  140 , such as shown in  FIGS.  10    and  16 . These adjacent panels may be joined to one another by sandwiching a bi-directional connector  210   a  therebetween. Specifically, a first lug portion  212  of the connector  210   a  is inserted into an outer aperture  130  of one wall panel  100  and the opposite second lug portion  214  is inserted into an outer aperture  130  of another wall panel  100  brought adjacent to the first. The flange  218  of the bi-directional connector  210   a  is disposed between the joining frames  140 , and in at least one embodiment may sit at least partially in the countersunk portions  132  of adjacent outer apertures  130  being joined. 
     Adjacent wall panels  100  may also be connected by bridging a planar connector  210   b  across the panels  100  exterior to the outer surfaces  120  of the frames  140 . To accomplish this, the first lug portion  212  is inserted into an outer aperture  130  of one wall panel and the second lug portion  214  is inserted into an outer aperture  130  of an adjacent wall panel  100 , as shown in  FIG.  10   . In some embodiments, the wall system  200 ′ may include intersecting panels  100 , as in  FIG.  16   , or transversely connecting panels  100  where one or more wall panels  100  terminates at another transverse wall panel  100  such as in a T-shaped configuration. In either of these additional embodiments, the wall panels  100  may be at an angle relative to one another, such as but not limited to 90°, and may be connected with an L-shaped connector  210   c , T-shaped connector  210   d , or linear planar connector  210   b  having two or three lug portions by inserting a centrally-located lug portion into the outer aperture  130  at the intersection of the wall panels  100  and the remaining lug portions into their corresponding adjacent outer apertures  130  of the wall panels  100 , such as shown in  FIG.  16   . The planar connectors  210   b ,  201   c ,  210   d  may be inserted into outer apertures  130  located along the top surfaces of the wall panels  100  to hide them from view and/or along the bottom surfaces of the wall panels  100  to provide additional support to the wall system  200 ′ and keep the wall system  200 ′ from tipping over. 
     In still other embodiments, the insert  155  may include a spacer  230 , such as shown in  FIG.  18   , which may be used to assemble a spaced apart configuration of wall system  200 ″. The spacer  230  may be similar to a lug portion  162 ,  212  of a cap  160  or connector  210  as described above but differs in length. The spacer  230  may therefore also be configured to be received and retained within an outer aperture  130  and/or passage  128  of a frame component  110  but has a length longer than that of the lug portion  162 ,  212  of a cap  160  or connector  210 . In at least one embodiment, the spacer  230  may be longer than the length of the passage  128 . The spacer  230  is configured to connect different wall panels  100  and hold them in a spaced apart relation to one another, rather than contacting or abutting one another. In some embodiments, the spacer  230  may be a rod, bar or other similarly elongate member such as shown in  FIG.  18   . Such embodiments may be particularly useful in creating larger spaces between wall panels  100  within an system  200 ″. In other embodiments, however, the spacer  230  may be planar connector  210   b ,  210   c ,  210   d  having at least some lug portions  212 ,  214 , etc. spaced further apart than the spacing of outer apertures  130  in adjoining frame components  110  such that proximate wall panels  100  may be connected despite a small space maintained between them. The same may be accomplished by a bi-directional connector  210   a  having longer lug portions  212 ,  214  on either side of the flange  218  such that the entire length of the lug portions  212 ,  214  do not fit within the passage  128 . In such above manners, wall systems  200 ,  200 ′,  200 ″ may be built to any size, shape, configuration as desired and is therefore entirely customizable. 
     Cables  220  may be run through the frame components  110  between adjacent wall panels  100 , such as through the outer apertures  130 , inner apertures  132  and passages  128 . The cables  220  may therefore also run through the bi-directional connectors  210   a  that join adjacent wall panels  100 . Of course, cables  220  may also be run between frame components  110 , such as when frame components  110  are not contiguous the cables  220  may be run in the space between. When all the cables  220  are run, any empty outer apertures  130  may be filled with a cap  160 , if desired, though not every outer aperture  130  needs to be capped. 
     The wall system  200 ,  200 ′,  200 ″ may also be easily disassembled when desired, such as at the end of event, to remodel office space, or to update the configuration or options of the system  200 ,  200 ′,  200 ″. To disassemble, the steps are simply reversed, with the wall panels  100  being able to be pulled away from the lug portions  212 ,  214  of the connectors  210 , the caps  160  and spacers  230  removed, and the cables  220  pulled back through. The components of the wall system  200  may be easily transported to another site for reassembly. 
     Since many modifications, variations and changes in detail can be made to the described preferred embodiments, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents. Now that the invention has been described,