Patent Publication Number: US-2021180320-A1

Title: Plenum support for demountable wall system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/947,349, titled “PLENUM SUPPORT FOR DEMOUNTABLE WALL SYSTEM,” filed Dec. 12, 2019, the entire contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND 
     Demountable wall systems, and particularly demountable wall systems using glass panels, are used in both residential and commercial settings. Compared to traditional, fixed wall systems, demountable wall systems include panels (e.g., glass panels, metal panels, wood panels, composite panels, polymer panels, concrete panels, fabric-covered acoustic panels, gypsum, etc.) that can be unmounted, relocated, and reinstalled at new locations relatively quickly, and thus provide increased design flexibility. The panels are also often interchangeable such that the wall system can be customized to the particular needs of the setting (e.g., panels can be swapped for panels with different finishing options, different material properties, etc.). Due to their flexibility, demountable wall systems can be used for a variety of different purposes in their setting, including, but not limited to, sound control (acoustical protection), light and solar control, seismic control, safety, air and water resistance, thermal control, clean rooms, emergency egress and ingress, lockability (ability to lock rooms or spaces defined by the wall systems), etc. 
     Traditionally, demountable wall systems include a frame that is positioned within the area or setting to receive the wall system. The frame includes upper frame components, lower frame components, and/or side frame components depending on the particular shape or needs of the wall system. In some cases, the frame components may define a channel to receive the glass panel. These frame components may be attached using any suitable joining technique, including but not limited to right angles, other angles, mullion, butt joints, etc. The frame component includes a lip at the front of the channel, and to install the glass panel, the glass panel is pushed into the channel of the upper frame component such that the panel can clear the lip, and then the glass panel is lowered into the channel of the lower frame component. As such, the channel of the upper frame component must have a sufficient depth to both accommodate the lifting and lowering action and retaining the glass panel on the frame after installation. 
     Because the panels are often heavy and the installation requires relatively complex movements in a limited space, installation of the glass panels is not easy, and panels may become damaged if improperly installed. Likewise, uninstalling the panel can be relatively difficult to perform. 
     With suspended panels, lateral reinforcement may be necessary to provide the panels with structural integrity to withstand the weight of a user leaning against the panel or seismic events that may apply lateral pressure. Suspension of the panels from the ceiling also presents potential issues with regard to access and sound travel. Many traditional buildings include different equipment and machinery within the plenum, which can hinder installation of a panel from above. For clarity, the term “plenum” refers to any spaces between the drop ceiling and the slab of the upper floor (or the main ceiling), regardless of whether the space is designated for air circulation. Therefore, an adaptable solution is required to provide a user with the flexibility to install the panel from a variety of locations. Moreover, when a panel is installed from above, sound can travel over the panel and through the plenum. Existing ceiling tiles typically do not provide sufficient mitigation of this sound travel. As such, there is need for demountable wall systems with plenum support that provide the necessary reinforcement and mitigate sound travel. 
     Moreover, after installation, a gap may exist between a top of the glass panel and the base of the channel of the upper frame component, which may lead to substandard performance of the wall system (e.g., due to improper sealing, misaligned or angled panels, etc.). Traditional demountable wall systems are often unable to account for any variations in surfaces on which the system is mounted (e.g., warped or slated floors and/or walls, unlevel or non-parallel floors and/or ceilings, etc.). As such, there is a need for demountable wall systems that are easy to install and customize. 
     SUMMARY 
     According to certain embodiments, a method of anchoring a demountable wall system includes introducing a hub into a plenum between a main ceiling and a drop ceiling positioned below the main ceiling, pivoting a telescoping anchor member relative to the hub and to a target angle, extending the telescoping anchor member to an extended length sufficient to span from the hub to the drop ceiling at the target angle, and securing the telescoping anchor member. The telescoping anchor member may be secured at the extended length and the target angle so that the telescoping anchor member is anchored to the main ceiling and coupled for supporting a demountable wall panel on an underside of the drop ceiling. 
     In some embodiments, the extending of the telescoping member may include sliding one portion of the telescoping anchor member relative to another portion of the telescoping anchor member. The extending of the telescoping anchor member may further include coupling an extension member to the telescoping anchor member. 
     In some embodiments, the method further includes securing sound-reducing material in the plenum to the telescoping anchor member. 
     In some embodiments, the method further includes coupling the hub to a frame for receiving the demountable wall panel such that, in an installed state, support is provided for the demountable wall panel through the frame, hub, and telescoping anchor member to the main ceiling. 
     In some embodiments, the telescoping anchor member includes a first telescoping anchor member. The method may further include pivoting a second telescoping anchor member and a third telescoping member relative to the hub and to either side of the first telescoping anchor member. 
     According to certain embodiments, a method for reducing sound travel over a demountable wall panel of a demountable wall system includes introducing sound-reducing material into a plenum between a main ceiling and a drop ceiling positioned below the main ceiling, and securing the sound-reducing material to an anchor member. The anchor member may extend within the plenum at a non-vertical angle to the main ceiling from a hub for supporting the demountable wall panel. 
     According to certain embodiments, a demountable wall system includes an anchoring system for supporting a demountable wall panel. The anchoring system may include a hub and a telescoping anchor member. The hub may be installable in a plenum between a main ceiling and a drop ceiling positioned below the main ceiling. The telescoping anchor member may be pivotally coupled with the hub and extendible to span between the hub and the main ceiling. 
     In some embodiments, the demountable wall system further includes the demountable wall panel. 
     In some embodiments, the demountable wall system further includes a frame and a bracket. The frame may define a channel for receiving an upper edge of the demountable wall panel. The bracket may be couplable with or included as part of the frame, positionable to extend through the drop ceiling, and couplable with or included as part of the hub. 
     In some embodiments, the demountable wall system may further include sound-reducing material coupled with and supported by the telescoping anchor member. 
     According to certain embodiments, a demountable wall system includes a sound-mitigation system. The sound-mitigation system may include a hub for supporting a demountable wall panel, an anchor, and a sound-reducing material. The hub may be positionable in a plenum between a main ceiling and a drop ceiling positioned below the main ceiling. The anchor member may be installable within the plenum in a position extending to the main ceiling from the hub at a non-vertical angle. The sound-reducing material may be secured to the anchor member. 
     In some embodiments, the sound-reducing member includes at least one of a ceiling tile, gypsum, foam, a receptacle containing insulation, sound-dampening material, sound-blocking material, or sound-absorbing material. 
     In some embodiments, the sound-reducing material is sized to span a length spanning between edges of the demountable wall panel. The sound-reducing material may be arranged in or across a path of travel over the demountable wall panel and provide a second barrier to supplement a first barrier provided by a ceiling panel of the drop ceiling. 
     In some embodiments, anchor member includes a telescoping anchor member pivotally coupled with the hub. The telescoping anchor member may be extendible to span between the hub and the main ceiling. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a plenum support system with an anchor in a retracted position, according to certain embodiments of the present invention. 
         FIG. 2  is a side view of the plenum support system of  FIG. 1  with the anchor in an extended and connected position. 
         FIG. 3  is a close-up view of the hub of the plenum support system of  FIG. 1 . 
         FIG. 4  is a close-up view of the hub of the plenum support system of  FIG. 1 . 
         FIG. 5  is a bottom view of the plenum support system of  FIG. 1  showing the sound reducing material in place and locations of various barrier positions. 
         FIG. 6  is a bottom view of the plenum support system of  FIG. 1  showing another anchor being used in place of the vertical support. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “left,” “right,” “front,” “back,” and “corners,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing. 
       FIGS. 1-5  illustrate an example of an improved system  100  for a plenum support for a demountable wall system. As best illustrated in  FIGS. 1-2 , in certain embodiments, the system  100  is installed in a plenum  102  between a main ceiling  104  and a drop ceiling  106 . The drop ceiling  106  is positioned below the main ceiling  104 . 
     In certain embodiments, as illustrated  FIGS. 1-4 , the system  100  includes at least one hub  116 , which is capable of supporting the demountable wall panel  108 . The hub  116  may be positioned within the plenum  102  (i.e., between the main ceiling  104  and the drop ceiling  106 ). While the system  100  is illustrated in  FIGS. 1-2  with one hub  116 , the system  100  may include multiple hubs  116 . In some embodiments, the hub  116  may include flanges  140  extending from a main body  142  of the hub  116 . The flanges  140  may be integrally formed with the main body  142  of the hub  116 . Alternatively, the flanges  140  may be formed as separate pieces from the main body  142  of the hub  116  and fastened to the main body  142  of the hub  116 . Moreover, the hub  116  may include other parts, for example, but not limited to, a bracket  114  and/or a frame  110  (discussed in further detail below). 
     In certain embodiments, as illustrated in  FIGS. 1-2 and 4 , the system  100  includes at least one anchor member  118  positioned within the plenum  102 . The anchor member  118  may be coupled with the hub  116 , as illustrated in  FIGS. 1-2 and 4 . The anchor member  118  may include an end member  144  coupled to an end of the anchor member  118 . The end member  144  may be coupled to the end of the anchor member  118  by any conventional means, including, but not limited to, snap fit connection, threaded connection, hinge, or any other suitable means. Alternatively, the end member  144  may be formed integrally with the anchor member  118 . In some embodiments, the anchor member  118  is pivotably coupled to the hub  116  at a pivot point  120 , thereby allowing the anchor member  118  to pivot relative to the hub  116 . The anchor member  118  may be coupled to the flange  140  of the hub  116 . The anchor member  118  may be coupled to the hub  116  via any pivotable means, including but not limited to, pivots, a hinge mechanism, or any other suitable connection means. In certain embodiments, the anchor member  118  is pivoted to a position such that an angle is formed with respect to the drop ceiling  106 . The anchor member  118  may be pivoted in the direction of arrow  122  such that the angle is a target angle, wherein the anchor member  118  is optimally positioned to maximize efficiency of the system  100  and minimize the amount of sound travel within the plenum  102 . In addition to maximizing efficiency of the system for purposes of acoustics, the anchor could be pivotable to maximize the structural integrity of the system or to accommodate other items in the plenum. As illustrated in  FIGS. 1-2 and 4 , the system  100  may include multiple anchor members  118  coupled to opposite sides of the hub  116 . The anchor members  118  may be independently movable with respect to one another. Alternatively, the anchor members  118  may be simultaneously adjustable such that the anchor members  118  can be adjusted uniformly. 
     In certain embodiments, as illustrated in  FIGS. 1-2 , the anchor member  118  comprises a first portion  124  and a second portion  126 . The anchor member  118  may be telescopically adjustable such that the first portion  124  and the second portion  126  may slide with respect to one another along the direction of arrow  128  to adjust the length of the anchor member  118 . For example, the first portion  124  may slide within the second portion  126 , or, alternatively, the second portion  126  may slide within the first portion  124 . In some embodiments, the anchor members have a retracted position, wherein the first portion  124  is fully retracted within the second portion  126 , and an extended position, wherein the second portion  126  is fully extended with respect to the first portion  124 . In certain embodiments, additional extensions or portions may be coupled to the anchor members  118  to further extend their length (similar to the concept of extenders for curtain rods, etc.). The additional extensions may be included with the original anchor members  118  or may be added as needed for particularly long distances. The anchor member  118  may be locked in a plurality of positions between the retracted position and the extended position. When the anchor member  118  has been adjusted to the desired length, an end of the second portion  126  may be coupled to a mount  130  secured to the main ceiling  104 . In order to facilitate fastening a fastening means may be incorporated into the mount  130 . As examples, any suitable permanent or non-permanent fastening means that apply mechanical, electromechanical, piezoelectric, vacuum, magnetic, and/or friction force to join the mount  130  to the main ceiling  104  may be used. Examples of mechanical fastening means include, but are not limited to, snap-fit, hook and loop, snaps, clasps, nuts and bolts, screws, pins and rivets, cams, and ratchets. Examples of vacuum fasteners may include, but are not limited to, suction cups and the like. Examples of magnetic fasteners may include, but are not limited to, hidden fasteners that can be turned through application of a magnetic field (such as those described in http://swissinvis.com/products/). Examples of additional fastening means may include, but are not limited to, gravity, crimping, welding, soldering, brazing, taping, gluing cementing riveting, magnets, electromagnets, camming, spring closures, snap-fit, hinges, friction lock systems, hook and loop fasteners, dual lock fasteners, zippers, clinching thermodynamic materials, elastic materials, wedge locking the use of other adhesives, or various other fastening mechanisms. 
     In certain embodiments, as illustrated in  FIGS. 3-4 , the system  100  may include components for installing and/or supporting a demountable wall panel  108 . For example, the system  100  may include a frame  110  for receiving the demountable wall panel  108 . The frame  110  may further comprise a channel  112  capable of receiving an upper edge of the demountable wall panel  108 . In some embodiments, as illustrated in  FIGS. 3-4  the channel  112  has a rectangular cross-section. However, the channel  112  may be any suitable shape to accommodate the upper edge of the demountable wall panel  108 . 
     In certain embodiments, as illustrated in  FIGS. 3-4 , the system  100  includes a bracket  114 . The bracket  114  may be coupled to the frame  110  by any of the conventional means described above, for example, but not limited to, crimping welding soldering brazing, taping, gluing, cementing, riveting, magnets, electromagnets, camming spring closures, snap-fit, hinges, friction lock systems, hook and loop fasteners, dual lock fasteners, zippers, clinching, thermodynamic materials, elastic materials, wedge locking, the use of other adhesives, or various other fastening mechanisms. Alternatively, the bracket  114  may be integrally formed with the frame  110 . Moreover, the bracket  114  may be coupled to the hub  116 . The bracket  114  may be coupled to the hub  116  by any conventional fastening means previously described, for example, but not limited to, screw thread, welding, bolts, or any other suitable fastening means. Alternatively, the bracket  114  may be integrally formed with the hub  116 . In some embodiments, the system  100  includes one bracket  114 ; however, multiple fasteners  114  may be used. 
     In certain embodiments, as illustrated in  FIGS. 1-2 , the system includes a vertical support  132 . The vertical support  132  may be coupled at a first end to the main ceiling  104  and at a second end to the bracket  114 . While the vertical support  132  is illustrated in  FIGS. 1-2  as a threaded rod, the vertical support  132  may be another suitable support member, such as a rod, strip, angle, wire, cable, chain, or strap. Moreover, the first end of the vertical support  132  may be secured to the main ceiling  104  by any suitable fastening means. As examples, any suitable permanent or non-permanent fastening means that apply mechanical, electromechanical, piezoelectric, vacuum, magnetic, and/or friction force to join the first end of the vertical support to the main ceiling  104  may be used. Examples of mechanical fastening means include, but are not limited to, snap-fit, hook and loop, snaps, clasps, nuts and bolts, screws, pins and rivets, cams, and ratchets. Examples of vacuum fasteners may include, but are not limited to, suction cups and the like. Examples of magnetic fasteners may include, but are not limited to, hidden fasteners that can be turned through application of a magnetic field (such as those described in http://swissinvis.com/products/). Examples of additional fastening means may include, but are not limited to, gravity, crimping, welding, soldering, brazing, taping, gluing, cementing, riveting, magnets, electromagnets, camming, spring closures, snap-fit, hinges, friction lock systems, hook and loop fasteners, dual lock fasteners, zippers, clinching, thermodynamic materials, elastic materials, wedge locking, the use of other adhesives, or various other fastening mechanisms. Similarly, the second end of the vertical support  132  may be secured to the bracket by any of the above fastening means. 
     In some embodiments, as best shown in  FIG. 6 , the vertical support  132  may be replaced with an additional anchor member  118 . For example, the system  100  may include three anchor members  118  that are each pivoted with respect to the hub  116 . In this arrangement, one anchor member  118  may be oriented in a vertical position and mounted to the main ceiling  104  at a location approximately vertical of the hub  116 , while the remaining two anchor members  118  extend from opposite sides of the vertical anchor member  118  and positioned at an angle with respect to the vertical anchor member  118 . 
     In certain embodiments, the system  100  includes a sound reducing material  134  secured to the anchor member  118  and extending within the plenum  102 . The sound reducing material  134  may be formed of any suitable material for reducing sounds, for example, but not limited to, ceiling tile, gypsum, foam, a receptacle containing insulation, sound-dampening material, sound-blocking material, or any other suitable sound-absorbing material. The sound reducing material  134  may be supported by one or more anchor members  118  such that the sound reducing material  134  overlays the anchor members. Alternatively or additionally, the sound reducing material  134  may be received into notches, channels, vises, clamps, or any other suitable features formed within the anchor members  118 , fastened or adhered to one or more of the anchor members  118 , or wrapped around one or more of the anchor members  118 . Where the sound reducing material  134  is wrapped around one or more anchor members  118 , the sound reducing material  134  may be attached to itself through any suitable means of attachment, for example, but not limited to, hook and loop (or other additional fastening means previously identified), adhesive, thread, staples, or any other means appropriate for the material used. The sound reducing material  134  may also be formed with, or connected to, sleeves, hooks, or rings that slide over, or attach to, one or more anchor members  118 . Alternatively or additionally, any of the foregoing methods of attachment may be used to attach the sound reducing material  134  to the main ceiling or the drop ceiling or ribs (not shown) connecting anchor members  118 . 
     In certain embodiments, as illustrated in  FIG. 5 , the system  100  is adjustable to various barrier positions  138 A-E along a path of travel  136 . In other words, sound or noise may travel from one side of the demountable wall  108  to an opposite side of the demountable wall  108  along the path of travel  136 . The system  100  may be adjusted to a first barrier position  138 A wherein the anchor member  118  and the sound reducing material  134  are positioned approximately horizontal such that the anchor member  118  and the sound reducing material  134  lie approximately parallel to the drop ceiling  106  on a first side of the hub  116 . In a second barrier position  138 B, the system  100  may be adjusted such that the anchor member  118  and the sound reducing material  134  are positioned at angle with respect to the drop ceiling  106  on the first side of the hub  116 . In a third barrier position  138 C, the system  100  may be adjusted such that the anchor member  118  and the sound reducing material  134  are positioned approximately vertical and lie approximately parallel to the vertical support  132 . In a fourth barrier position  138 D, the system  100  may be positioned similar to the second barrier position  138 B, wherein the anchor member  118  and the sound reducing material  134  are positioned at angle with respect to the drop ceiling  106 . However, in the fourth barrier position  138 D the anchor member  118  and the sound reducing material  134  are positioned on a second side opposite the first side of the hub  116 . Similarly, in a fifth barrier position  138 E, the system  100  may be positioned similar to the first barrier position  138 A, wherein the anchor member  118  and the sound reducing material  134 , are positioned approximately horizontal and approximately parallel to the drop ceiling  106 . However, in the fifth barrier position  138 A the anchor member  118  and the sound reducing material  134  are positioned on the second side of the hub  116 . While the sound reducing material  134  is illustrated in  FIG. 5  at the barrier position  138 D, the sound reducing material  134  may be positioned at any one or more of the barrier positions  138 A-E. Although the barrier positions  138 A-E are shown at discrete angular positions that are symmetric with respect to the vertical axis of the 180° path of travel  136 , the angles at which the sound reducing material  134  may be positioned are continuous throughout the 180° path of travel  136 , and more than one layer of sound reducing material  134  may be used on the same or both sides of the hub  116 . Where sound reducing material  134  is used on both sides of the hub  116 , they need not be placed at angles that are symmetric with respect to the vertical axis of the 180° path of travel  136 . 
     The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention, nor the claims that follow.