Patent Publication Number: US-4546590-A

Title: Partition wall system and components therefor

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to modular partition panels and, more particularly, to modular panels which are made from metal sheets having opposed end portions folded inwardly into uniquely configured connector members. 
     2. Background Discussion 
     Self service warehouses (so-called &#34;Ministorage&#34; warehouses) have a number of individual storage units in which the users store property. The structure of these warehouses varies substantially: for example, the floors may be concrete or of wood; ceiling height may be 8 ft., 10 ft., 12 ft., etc.; available floor space and geometry may be regular, irregular, small, large, etc. Each customer also requires a storage unit of a particular size to meet his or her individual requirements. Ideally the storage units would be modular so that as customer requirements change, old storage units could be disassembled and new ones erected to satisfy the present customer requirements. Such storage units should be safe, secure, inexpensive to purchase, and easy to install and disassemble. 
     SUMMARY OF THE INVENTION 
     The present invention provides an inexpensive, modular partition system of panels that are strong, durable, and easy to connect together, or disassemble, and that provide a wide range of storage unit sizes. Panels are ordered from the factory to meet the height specifications for any given installation. These panels are formed in accordance with the invention to develop particular edge configurations which facilitate the joining together of adjacent panels in assembling the partition system of the invention. As will be more fully appreciated upon reading the complete specification, no on-site cutting of the panel is required because any two panels may be joined together by either an overlapping type connection or an abutting type connection. No special training is necessary to install or disassemble the panels. The storage units made from these panels are both safe and secure. 
     The panels are preferably made from metal sheets such as galvanized steel with corrugated ribs in the sheets that strengthen the panel. The rough edges of the metal sheet could be a hazard since, if contacted, they could damage property such as upholstered furniture being stored or could injure the user. Opposed end portions of the metal sheet including these rough edges are folded inwardly to provide the unique connector members. Each connector member has three generally flat, rectangular segments. The first segment extends inwardly toward the center line of the sheet and is generally parallel to the back of the sheet and spaced therefrom a distance which is about equal to or slightly greater than the thickness of the sheet. The space between the first segment and the back of the sheet provides a female element in the connector member. The second segment is integral with the first segment along a common line which is generally parallel to the center line of the sheet. This second segment extends outwardly from the first segment, away from the sheet and generally perpendicular to the sheet. This second segment provides a stop element in the connector member. The third segment is integral with the second segment along a common line which is generally parallel to the center line of the sheet and spaced apart from the line along which the first and second segments are joined together. The third segment extends inwardly toward the center line of the sheet and is generally parallel to the back of the sheet. This third segment provides a male element in the connector member having a leading edge which is one of the rough edges of the sheet. The first and third segments are of about equal width, generally having a width ranging between about 1/4 and about 3/4 inches. The second segment is wider than the first and third segments. Its width ranges between about 1.0 and about 17/8 inches. The length of each segment is equal to that of the sheet. 
     The connector members are the key to the partition system and provide the main advantages of this invention, one such advantage being that the rough edges of the sheet are covered when two panels are connected together to form a wall of the storage unit. In the abutting type connection, one male element matingly engages a female element in another connector member, thus enclosing the rough edge within the female element. In the overlapping type connection, an enclosure is formed by overlapping portions of the panels and other rough edges are disposed within this enclosure. Another advantage of the present invention is that the pointed tips of the screws or other means used to connect the panels together, which would normally protrude from the wall of the storage unit on one side or the other, are hidden, at least partially, by the connector member. Other advantages of the present invention are that the panels are readily manufactured, and provide a very versatile partition system for making storage units of different sizes which are safe, secure, and inexpensive to purchase, install, and disassemble. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     A better understanding of the present invention may be had from a consideration of the following detailed description, taken in conjunction with the accompanying drawing in which: 
     FIG. 1 is a perspective view of two sides of a storage unit made from the panels of this invention. 
     FIG. 2 is a plan view of the corrugated metal sheet from which a panel of this invention is made. 
     FIG. 3 is a perspective view of one of the panels of this invention. 
     FIG. 4 is an enlarged cross-sectional view taken along line 4--4 of FIG. 1. 
     FIG. 5 is an enlarged fragmentary view, similar to FIG. 4, showing an alternate way of fastening together the panels of this invention. 
     FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 1. 
     FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 1. 
     FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 1. 
     FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 1 illustrating one type of connection for the tops of the panels. 
     FIG. 10 is a elevational view showing one alternative type of connection for the top of the panels. 
     FIG. 11 is an elevational view showing a second alternative type of connection for the tops of the panels. 
     FIG. 12 is a cross-sectional view taken along line 12--12 of FIG. 1. 
     FIG. 13 is a cross-sectional view taken along line 13--13 of FIG. 1. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows several panels 10 of this invention connected together to form two sides of a storage unit 12. These panels 10, referred to as standard panels 10, have nominal dimensions of 8 ft.×11/2 ft., with novel connector members 14 (FIG. 3) along opposed sides of the panels which extend outwardly from 1 to 2 inches, preferably about 11/2 inches, from the back of the body 16 of the panel. 
     As illustrated in FIG. 3, each connector member 14 has a lip 18, a female element 20 in the lip 18, a stop element 22, and a male element 24. The lip 18, stop element 22, and male element 24 are integral with each other. The leading end 26 of the male element is the rough edge of the sheet material 28 (FIG. 2) from which the panel is made. As will be apparent from the following discussion, this rough edge 26 is not exposed when panels are connected to form a wall using either an abutting type connection (FIG. 4) or an overlapping type connection (FIG. 6). As shown in FIG. 2, each of the panels is made from a generally rectangular sheet 28 of metal such as steel having a thickness ranging between about 0.016 and about 0.030 inch. Generally, this sheet 28 is between about one and about 21/2 feet wide and between about 8 and about 12 feet long, with the length depending on the size of the storage units being constructed. The sheet is corrugated to provide ribs 30 in the body of the panel which are generally at right angles to the edges 26 of the sheet. Each connector member is formed from an end portion 32 of the sheet by folding this end portion about three spaced-apart lines 33, 34, and 35 which are parallel to each other and to the center line 36 of the sheet. This end portion 32 will usually be along the longer dimension of the sheet. 
     In one particular embodiment, the first fold line 33 is 11/2 inches from the edge 26 of the sheet. The second line 34 is 11/4 inches from the edge 26 of the sheet. Thus distance between the first and second lines 33 and 34 is 1/4 inch. The third line 35 is also 1/4 inch from the edge 26. The distance between the second and third lines 34 and 35 is about one inch. 
     The end portion 32 of the sheet is folded using conventional equipment. Specifically, the lip 18 is formed by inwardly folding the end portion 32 of the sheet (FIG. 2) about the first line 33 towards the center line 36 through a bend of about 180° and outwardly folding the end portion about the second line 34 away from the body 16 of the panel through a bend of about 90°. This lip 18 has a smooth, rounded edge 38 which is as long (high) as the body of the panel and a generally flat segment 40 between this edge 38 and the bend about the second line 34. The flat segment 40 is as long as the body of the panel and has a width of about 1/4 inch, the distance between lines 33 and 34. It is also generally parallel to the body 16 of the panel and is spaced from the body a distance which is about equal to or slightly greater than the thickness of the sheet 28. This spacing provides a cavity 42 which is part of the female element 20. This cavity 42 terminates at one end at a bight 43 opposite the edge 38, and it terminates at its other end at an opening 44 which runs along the length of the body of the panel. This opening 44 is adapted to receive a male member of another panel. The top and bottom of the cavity 42 are open. 
     The stop element 22 is formed by inwardly folding the end portion 32 of the sheet about the third line 35 towards the center line 36 through a bend of about 90°. This stop element 22 has one smooth, rounded edge 46 at the opening 44 in the cavity. This edge 46 has a length which is equal to the length of the body of the panel and a bight 48 opposite this edge on the opposed side of the sheet. Another smooth, rounded edge 50 is provided upon folding the end portion 32 about the line 35. This edge 50 also has a length equal to the length of the body of the panel and a bight 52 opposite it on the opposed side of the sheet. The stop element 22 also has a gnerally flat, rectangular segment 54 between the lines 34 and 35. The length of this segment is equal to the length of the body of the panel and its width is about one inch, the distance between lines 34 and 35. It is generally perpendicular to the body of the panel. 
     The male element 24 is formed when the end portion 32 of the sheet is bent about the third line 35. It also has a generally flat, rectangular segment 56 which has a length equal to the length of the body of the panel and a width equal to about 1/4 inch, the distance between line 35 and the rough edge 26 of the sheet. As mentioned above, this rough edge 26 of the sheet constitutes the leading edge of the male element which is inserted into the cavity of another connector member. 
     As best illustrated in FIG. 4, two different panels 10a and 10b having essentially identical connector members 14a and 14b are joined together by simply bringing the female and male elements of the connector members 14 into mating engagement with each other. This is referred to as the abutting type connection. As viewed in FIG. 4, the male element 24b of the right-hand panel 10b is inserted into the opening 44a in the cavity 42a of the female element 20a of the left-hand panel 10a and the male element 24a of the left-hand panel 10a is inserted into the opening 44b in the cavity 42b of the female element 20b of the right-hand panel 10b. The stop elements 22a and 22b abut each other, with the respective edges 46a and 46b of the stop elements nestled, respectively, in the bights 52b and 52a. The rough ends 26a and 26b are received, respectively, within the cavities 42b and 42a and are just about touching, respectively, the bights 43b and 43a. Thus, the ends 26a and 26b are covered so that they cannot cause damage or injury. 
     Preferably, the panels 10a and 10b are fastened to each other by such conventional means as self-drilling screws 58a. These screws are provided with tapered flutes (not shown) at their tips 60a which drill a hole into the metal as the screw is being forced against the surface of the metal by a power drill. The screws are inserted at several spaced-apart points along the length and on the front side of the lip of one of the connector members, for example, lip 18a. Upon insertion of the screw 58, the tip 60 of the screw passes through the front side of the lip 18a into the cavity 42a, through the male element 24b of the connector member 14b, and then through the underside of the lip 18a, protruding therefrom. The head 62a of the screw 58a abuts the front side of the lip 18a. The protruding tip 60a of the screw is hidden from view by the lip 18a and does not extend outwardly from the face of the panel. This reduces substantially the risk of anyone injuring themselves or damaging their clothing or items stored within the enclosure by snagging them against the tip 18a of the screw. 
     By virtue of this manner of fastening panels together, as particularly shown in FIGS. 4 and 7, for example, the pointed ends of the self-drilling screws 58 are behind the lip of the junction edge or, as in FIG. 6, within the box formed by the junction. Thus, they are out of the way and unlikely to cause any damage to goods stored in the storage unit or to injure anyone, since they are unlikely to be contacted. The rounded heads of the self-drilling screws are along the exposed surface of the joined-panel wall. This allows for easy disassembly of a wall when it is desired to move a wall or reconstruct a storage unit. However, it will be noted that the screws enter the panel junction from two opposite sides. Thus, a person having access to only one side of a wall (e.g., the user of a single storage unit) will not be able to disassemble a wall and thereby cannot gain unauthorized access to an adjacent storage unit. 
     An alternate way of fastening connector members 14c and 14d together is shown in FIG. 5. Here a dimple 64 is formed in the lip 18c of the connector member 14c using a conventional sheet metal punch having an oversized female die. The punch includes a male member which is manually movable into and out of the female die. With the male member withdrawn from the female die, the lip 18c, retaining the male element 24d of the connector member 14d, is placed between the male member and the female die of the punch. The male member is then depressed, forcing two opposed pieces 66 and 68 from the front side and back side of the lip 18c and one piece 70 from the male element 24d into the die. This forms the dimple 64 which consists of three hollow cones formed, respectively, from the pieces 66, 70, and 68. These cones 66, 70 and 68 are tightly jammed together so that the two connector members are secured to each other. A plurality of these dimples 64 can be readily formed in this manner along one or both junction edges of a pair of panels being joined, thus facilitating the assembly and construction of a panel wall. 
     As shown in FIG. 6, whenever the dimensions of the storage unit 12 require, two panels may be joined together to form a sidewall using an overlapping or telescoping type connection rather than the abutting type connection shown in FIG. 4. Thus, any size storage unit wall may be fashioned using standard panels without the need for cutting panels on site. Typically, the last panel to be joined in the wall being constructed is joined in overlapping fashion to accommodate the remaining dimensional space to the next adjacent intersecting wall. 
     As illustrated in FIG. 1, the respective connector members of the panels 14e and 14f of the panels 10e and 10f are attached employing this overlap connection. The desired width is obtained by moving these two standard panels relative to each other sideways. The male elements 24e and 24f of each of the connector members are parallel to the overlapping sections 72 and 74 of the body of the panels. With the male elements of the two connector members so positioned, one of them, for example 14f, is simply fastened to the back of the body of the other panel by means of self-drilling screws 76. Each screw is inserted through the face of the panel 10e into and through the male element 24f of the opposite panel 10f. The rough edges 26e and 26f of the male elements 24e and 24f, respectively, and the tips 76a of the screws extending through the male members are hidden in an enclosure formed by the opposed connector members 14e  and 14f and the overlapping sections 72 and 74 of the panels. Therefore, any danger of damage from contact with the rough edges or screw tips is avoided. 
     In accordance with an important feature of this invention, not only two, but three or four panels may be joined together along a common junction. Thus, for example, four different storage units would have a common point of connection. This is illustrated in FIG. 7 where the panels 10f, 10g, 10h and 10i are shown joined together. Two of the panels 10f and 10h are connected as illustrated in FIG. 3 except that screws are not immediately inserted into the lips 18f and 18h of these panels until the other two panels 10g and 10i have been placed in position. The panel 10g is placed against the face of the panel 10h so that its lip 18g overlaps and is at a right angle to the lip 18h of the panel 10h and the stop element 22g abuts the face of this panel 10h, with the edge 38h of the lip 18h nestled into the bight 48g in the connector member 14g. In a similar manner, the panel 10i is placed against the face of the panel 10g so that its connector member&#39;s lip 18i overlaps and is at a right angle to the lip 18f of the connector member of panel 10f and stop member 22i abuts the face of this panel 10f, with the edge 38f of the lip 14f being nestled into the bight 48i of the connector member 14i. Panels 10g and 10i are generally parallel to each other; however they are slightly offset with respect to each other a distance corresponding to the width of one lip, which is about three times the thickness of the sheet. 
     The panel 10g is fastened to the panels 10g and 10h by inserting several self-drilling screws 78 through the stop element 22g into the front side of the lip 18h, through the male element 24f of the connector member of panel 10g, and out the underside of lip 18h. The lip 18g forms an enclosure which partially hides the protruding tip of the screw 78a. This provides both esthetic and safety advantages. In like fashion several self-drilling screws are inserted through the stop element 22i through the front side of the lip 18f into and through the male element 24h, and out the underside of the lip 18f, securing together the panels 10i, 10g and 10h. The rough edges 26i and 26g, respectively, of the male elements 24i and 24g are exposed and, preferably, are covered with tape or other suitable protective means. This will reduce the risk of anyone injuring themselves or damaging their clothing or items stored in the storage unit by contacting these edges. 
     In accordance with another feature of this invention, as illustrated in FIG. 8, a starter wall panel 10j is provided by simply bending its lip 18j inwardly toward the stop element 22j through a bend of 90° and flattening it. This provides a stop plate 80 which has a step 82 in it equal to three times the thickness of the sheet 28. With the stop plate 80 abutting a wall, screws or ram nails 84 are inserted through the underside of this stop plate into the wall 86 to secure the panel to the wall. 
     The panels of this invention are connected at their tops by any one of several conventional means. Three typical connections are illustrated in FIGS. 9 through 11. In FIG. 1 the panels 10 are free standing and a U-shaped bracket 88 (FIG. 9) is placed over the tops of several adjoining panels. This bracket 88 has a generally horizontal piece 90 having at its opposed ends a generally vertical piece 92 which points downwardly and a clip piece 94 which also points downwardly and is biased inwardly. Thus, when the panel 10 is inserted between the pieces 92 and 94, the clip piece presses against the panel to hold the panel secure. In FIG. 10, a panel 10k is shown connected to a purlin or beam 96 by inserting a self-drilling screw 98 through the male member 24k of the panel into the beam. In FIG. 11, a panel 101 is shown connected to the underside of a beam or joist 100 by means of an L-shaped bracket 102. The foot 104 of the bracket is connected by a conventional wood screw 106 to the joist 100 and the leg 108 of the bracket is secured by self-drilling screws 110 which pass through a hole in the leg and through the face of the panel 101. 
     The bottom of the panel 10 is held in a U-shaped bracket 112 of the type illustrated in FIG. 12. This bracket includes a flat portion 114 which rests against, for example, a concrete floor 116 and a ram nail 118 is inserted through a hole in this flat portion into the floor. One side 120 of the bracket is slightly longer than the other side. 
     As shown in FIG. 1, the storage unit 12 may include a hinged door 124 and an overhead roll-up door 126. As illustrated in FIG. 13, conventional U-shaped channel members 128 receive within the channel 130 the connector members, for example the connector member 14g of the panel 10g. The doors 124 and 126 are secured by conventional means to these U-shaped members 128. 
     Transom panels 132 (FIG. 1) are provided which have the same general configuration as standard panels except they are shorter in length than the standard panel. These transom panels have connector members connected together as illustrated in FIG. 4 or FIG. 6. The unattached connector members of the transom panels are received in the channels of the U-shaped brackets 134. 
     Although there have been described above specific arrangements of modular panels having unique connector members in accordance with the invention for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention as defined in the annexed claims.