US 3381438 A
Description (OCR text may contain errors)
y 7, 1963 J. A. BOHNSACK 3 3MA38 REUSABLE WALL SYSTEM Filed Dec. 12, 1963 4 Sheets-Sheet 2 Amy 293 I NVENTOR.
JOHN A. BOHNSACK I BY WW 1 9 300 I ATTORNEY mmmm May 7, WW .J. A. momma-3mm REUSABLE WALL SYSTEM 4 Sheets-Sheet 5 Filed Dec. 12, 1963 INVENTOR.
JOHN A. BOHNSACK AT TORNE YS May 7, 1968 J. A. BOHNSACK REUSABLE WALL SYSTEM 4 Sheets-Sheet 4 Filed Dec. 12. 1963 2'8 240 as 207 ze z INVENTOR.
JOHN A BOHNSACK W ATTORNEYS United States Patent 3,381,438 REUSABLE WALL SYSTEM John A. Bohnsack, Cleveland Heights, Ohio, assignor to The E. F. Hauserman Company, Cleveland, Ohio, a corporation of Ohio Filed Dec. 12, 1963, Ser. No. 330,017 24 Claims. (Cl. 52-481) This invention relates generally as indicated to an interior wall system for use in commercial, industrial, institutional and apartment buildings and more particularly to a low-cost, metal movable wall system which can be manufactured through maximum use of mass production techniques and can eliminate the need for extensive engineering expenses heretofore required to determine exact building conditions and manufacturing requirements for more expensive movable wall systems.
Heretofore, interior space in commercial, industrial, and institutional buildings has been divided by use of one of two basic types of walls: fixed walls, more or less permanent in structure, made of various materials; or, movable partitions. The more commonly used fixed walls are made of plaster on gypsum block or lath. These perform well as sound barriers and can be installed at relatively low initial cost. Because they must be built at the job site, however, they delay the completion of new buildings and keep interior space out of use for lengthy periods when remodeling is required. When layout changes are required, fixed walls must be demolished, rubble carted away and new walls built. The resultant dirt and dust can cause malfunction of expensive office machinery and elevators with considerable expense and inconvenience to tenants and loss of rental to owners.
Movable metal partitions, heretofore employed, which are prefabricated off the job site, permit earlier Occupancy of buildings and earlier return on owners invest ment. Because they are demountable and movable, with completely reusable components, adapting space to changes in layout requirement is much less expensive, time consuming and inconvenient than is possible with fixed walls. High quality movable walls provide sound control equal to that of fixed walls.
Because metal movable walls have heretofore been manufactured to precise widths, heights and design variations required by specific building conditions, a considerable amount of engineering expense is incurred in determining exact building conditions and manufacturing requirements. This, plus the fact that maximum use of mass production techniques was not possible, resulted in prices for movable walls somewhat higher than for fixed walls. In many structures, where first cost of materials is a determining factor, movable metal walls have been found too expensive.
It is accordingly a principal object of the present invention to provide a movable, reusable, wall which can be manufactured through the maximum use of mass production techniques, eliminating the engineering expenses heretofore required to determine exact building conditions and manufacturing requirements, providing the sound control, appearance, flexibility and fire-safety qualities of much more expensive partition systems, at a cost competitive with permanent plaster walls.
A further principal object is the provision of a metal movable wall system which makes possible earlier occupancy of a building because of fast delivery of components for assembly at the job site.
Another important object is the provision of a panel component for such a reusable wall system consisting of durable, impact resistant steel completely covering a plaster 3,381,438 Patented May 7, 1968 board, gypsum or like core which can easily be cut on site to fit any condition.
A further object is the provision of such panel component which is readily adaptable to mass production methods and which has no lateral projections so that it may be stacked one on top of another on pallets for convenient storage and speedy delivery.
A still further object is the provision of a metal clad gypsum core panel having the metal faces thereof interfitted in a manner to facilitate the joining of such panels together as well as to the post construction of the present invention.
Still another object is the provision of a sturdy post construction which is perforated along its entire length to permit pipe and conduit to pass therethrough at any elevation so that the interior of the wall system may be utilized for a utility space not requiring utilities to be run through the floor or ceiling.
Yet another object is the provision of such panel and post construction wherein the panels may snap out and back into place whenever access to the utility space is needed and yet where the panels meet they will butt together snugly in a line single line joint.
A yet further object is the provision of an interior partition system, all of the components of which are reusable, and yet which has an extremely handsome appearance with such tight single line joints while still providing maximum access to utilities.
It is also an object to provide a reusable interior partition system comprised of thin flat metal clad gypsum or like insulating material panels which are themselves substantially laterally spaced to provide an interior insulating chamber while yet having a total wall thickness of approximately three inches, adaptable to greater widths where required.
Other objects and advantages of the present invention will become apparent as the following description proceeds.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but a few of the various ways in which the principles of the invention may be employed.
In said annexed drawings:
FIG. 1 is a fragmentary elevation of a partition wall in accordance with the present invention;
FIG. 2 is an enlarged fragmentary horizontal section taken substantially on the line 2;.2 of FIG. 1;
FIG. 3 is a further enlarged horizontal detailed section of the vertical edge of the panel components of the present invention;
FIG. 4 is a fragmentary vertical section taken substantially on the line 4--4 of FIG. 1;
FIG. 5 is a horizontal section illustrating an exemplary three-way wall intersection;
FIG. 6 is a horizontal section illustrating an exemplary two-way wall intersection;
FIG. 7 is a horizontal section illustrating an end filler;
FIG. 8 is a fragmentary vertical section illustrating the manner of assembly of the panel components;
FIG. 9 is a fragmentary side elevation of one form of post construction that may be employed with the present invention;
FIG. 10 is a fragmentary end elevation of the post construction shown in FIG. 9 as seen from the right thereof;
FIG. 11 is an enlarged fragmentary horizontal section taken through such post with the panel components secured thereto;
FIG. 12 is a fragmentary horizontal section similar to FIG. 11 illustrating a further form of post construction in accordance with the present invention;
FIG. 13 is a fragmentary end elevation of such post construction as seen from the line 13-13 of FIG. 12; and
FIG. 14 is an enlarged fragmentary horizontal section illustrating a glass panel construction and the post accommodating such glass panels.
Referring now to the annexed drawings and more particularly to FIG. 1, there is illustrated in elevation a typical partition system construction in accordance with the present invention. Such partition construction may extend from the semifinished floor F to a finished ceiling C and comprises, reading from left to right, a solid panel 1, a frame post 2, solid panels 3, 4 and 5, a frame post 6, and a solid panel 7. Above the panels 3, 4 and 5, supported on a frame rail 8, are glass panels 9 and 10 separated by a glass frame or post 11. The term solid panel as employed throughout the present description refers not to the interior construction of the panel, which actually comprises two laterally spaced panel members having a substantial opening therebetween, but to the appearance of the panel to distinguish the same from a glass or transparent panel. A plinth or cove 13 extends along the base of the structure and a ceiling runner or frame 14 may extend along the top.
The construction of the solid panels may be seen more clearly in FIG. 2 wherein each of the panels 1, 3, 4, and 7 comprises laterally spaced panels 16 and 17, the detailed construction of which is illustrated more clearly in FIG. 3. The panels 1 and 7, which extend from the floor to the ceiling, may be as tall as 12 feet and the panels 3, 4 and 5 may be somewhat shorter depending upon the height of the glass transom formed by the panels 9 and thereabove. Since the laterally spaced panels of the solid panel constructions may be substantially identical in form except for variations in height and width, only one such panel will be described in detail.
Referring now to FIG. 3, it will be seen that the panel 17, for example, may comprise a gypsum or other plaster board type of insulating core 20, having a front metal face sheet 21 adhesively secured thereto as at 22, and extending laterally beyond the edge 23 of the gypsum core and bent as indicated at 24 to form an end flange 25 which extends normal to the planar face 26 of the face panel or sheet 21. The edge flange 25 is bent again at 28 to extend parallel to the face 26 and then flat folded at 29 back upon itself and finally bent at 30 to extend parallel and adjacent the edge flange 25. The sheet 21 thus terminates in a double thickness inwardly directed L-shape flange.
The inner or backup sheet of metal 32 is adhesively bonded at 33 to the back face of the gypsum or like material core 20 and extends slightly beyond the edge 23 of the core and is bent at 34 to extend parallel to the end face of the gypsum board and is bent again at 35 to extend parallel and adjacent the back surface of the front face or sheet 21 and is finally bent at 36 to form an end flange 37 terminating at 38 inside the folded portion 29 of the face panel 21. In this manner, the face and backup metal panels are interlocked together beyond the end or edge 23 of the gypsum core. It will be understood that the opposite vertical edge of the panel, as initially manufactured, will be identical in form to the edge illustrated in FIG. 3. The gypsum board or core 20 may be approximately of an inch in thickness while the front panel 21 may be 24 gauge steel (.0239) while the back panel is 28 gauge steel (.0149). Any adhesive may be utilized for bonding the front and back panel plates to the gypsum core, but it is preferred to employ a rubber contact type of adhesive with good metal adhesion, tack, strength and resilience properties. Although a neoprene type of adhesive is preferred, other types such as reclaimed rubber, butadiene-styrene, butyl polybutylene, buna-N or Thiokol may be used. Such panels, which consist of durable, impact resistant steel, completely covering a gypsum core, readily lend to automatic production techniques and reference may be had to the copending application of Marvin D. Merritt, entitled Apparatus and Method for Mannfacture of Building Panels, Ser. No. 330,015, filed Dec. 12, 1963, now Patent No. 3,344,503, for a method of fabricating such panels on a production line basis. It will be understood that other panel edge sectional configurations may be employed than that illustrated in FIG. 3. For example, the flange 37 may extend parallel to and adjacent the flange 25 with the edge thereof clinched in the flat folded portion.
Such panel, which constitutes the basic component of the present reusable wall system, having no lateral projections, can be stored on pallets, strapped thereto, and shipped in this manner directly from warehouses to the site of installation for on-site assembly. The panels unique steel and gypsum construction makes it possible to cut panels at the job site, by conventional hand saws, for example, to the exact height and width required. This then eliminates the costly pre-engineen'ng and manufacturing expenses necessary to produce panels to the exact measurement of building interiors.
Such panels 16 and 17, which form the solid panels 1, 3, 4, 5 and 7, are thus steel clad gypsum boards wherein the backup sheet interlocks with the face sheet in the manner shown more clearly in FIG. 3. Such panel will not warp and is not easily distorted and is not fragile. In fact, such panel sounds on contact much like a conventional plaster wall. The face sheet 21 may be prime coated and the backup sheet 32 may be flash coated, galvanized, or prime coated. The variation in thickness between the face and backup sheet bonded to the panel contributes to the soundproofness of the panel and a very high degree of sound control in the reusable wall systern.
Intermediate the frame posts 2 and 6, the panels 3, 4 and 5 may be joined in a tight single line joint illustrated at 40 and 41 by means of a special interior post construction indicated generally at 42 in FIG. 2. Such post construction 42 provides rigidity and support throughout the system and the panels 17 snap easily into place and are held thereby rigidly in a continuous grip along the entire preformed edge flange 25 of the face plate from floor to ceiling. Such zipper-type connection of the panel to the post serves to eliminate sound and light leaks, and assures a tight clean joint. Such post construction is illustrated in greater detail in FIGS. 8 through 11.
The frame members 2 and 6 may be identical in form to the frame members 8 and 11 and serve to frame glass panel units such as 9 and 10 as well as doors as hereinafter described. Such frames 2, etc., are in a sectional configuration similar to that of an I-beam having a web 45 and flanges 46 and 47. Thickened portions 48 and 49 connect the web with the respective flanges and each flange adjacent the thickened portion is provided with vertically extending ridges 50 and 51. The ridges 50 and 51 projecting inwardly from each flange provide grooves 52 and 53.
When utilized with the panels 16 and 17, spreaders 55 and 56 may be employed which are of a U-shape construction and the bight portions of which are held to the web 45 by suitable fasteners 57 such as the nut and bolt assemblies illustrated. The bight portions of each of the spreaders are secured in this manner to the Web 45 and extend between the enlarged portions 48 and 49. Each leg of the spreaders is bent inwardly as indicated at 53 and then inclined outwardly at 59 to terminate in inwardly directed flange 60 which resiliently bears against the inner face plate of the associated panel 17. The legs of the spreaders thus serve resiliently to separate the panels 16 and 17 holding the edges of the same against the edges of the flanges 46 and 47 in complete vertically continuous contact.
Referring to FIG. 4, the horizontal rail or frame 8 is identical in form to the vertical frames 2 and 6 and a spreader 62 may be employed secured to the web of the frame 8 by fastener 63 holding the panels 17 and 16 vertically spaced. The frames 2, 6, 8, etc., may be extruded aluminum shapes. Similarly, an extruded aluminum shape 65 having a central channel 66 therein may be secured between the flanges 67 and 68 of the horizontal frame 8. The glass pane 9 is supported in the channel 66 on insulating strips 69 and a metallic glazing element 70 is also provided having the curled top edges which resiliently engage the faces of the panel. Reference may be had to Bohnsack Patent No. 3,081,504, issued Mar. 19, 1963, and assigned to The E. F. Hauserman Company of Cleveland, Ohio, for a more clear disclosure of a glazing assembly which may be utilized with the present invention.
The legs 71 and 72 of the horizontal member 65 may be provided with latch portions 73 and 74 along the outer ends thereof which engage within the groove 52 formed by the ridges 53. In this manner, the member 65, which fits flush with the top of the flanges 67 and 68, may resiliently be snapped into place with the latch portions 73 and 74 on the legs thereof latching behind the ridges 50. It is noted that the legs will abut the thickened portions 48 and 49 of the frame 8 firmly supporting the member 65 and thus the glass pane 9.
As seen in FIG. 4, the bottom edge 77 of the frame 2 is supported a substantial distance above the floor F by means of fastener 78 passing through vertical slot 79 in stilt member 80 which includes two legs 31 and 82 supported on and fastened by screws 83 to floor runner 84. Such screws 83 pass through upstanding bent portions 85 of the runner on either side of central channel 86 having the rebent sides as indicated with fasteners 87 being provided through the bight portion thereof firmly to secure the runner to the floor F. Such runner includes horizontally extending portions terminating in upwardly bent flanges 88 which include downwardly and inwardly bent ridges 89 cooperating with the central channel to form retaining grooves for seals 90 and the like which may be provided on either or both sides of the central channel. Vinyl coves 92 and 93 may be provided completing the plinth construction. Accordingly, it will readily be appreciated that the vertical position of the frame 2 may readily be adjusted by means of the fastener 73 and the vertically elongated slot 79 connected between the web of the frame 2 and the stilt member 80.
In FIG. 5, there is illustrated an examplary three-way intersection between a solid panel unit 95 and a relatively narrow solid panel 96 which terminates on one side in a glass panel 97 and on the other side in a door jamb 98. An extruded aluminum shape 99 is employed to join the panels 95 and 96 and such shape comprises a center web portion 100 having three alternately directed dove-tail channels therein with the two outermost channels 101 and 102 providing grooves for reception of elongated seals 103 which may be provided on either or both sides of the central channel. A series of vertically spaced screws or the like S may be provided firmly to secure the member 99 to the panel 104 of the relatively narrow solid panel 96, such fastener passing through the central outwardly directed dove-tail channel in the back or web 100. The member 99 laterally terminates in flanges 105 and 106 which cooperate with legs 107 and 108, respectively, which extend from the backs of the outer edges of the side channels 101 and 102 to receive the panel components 109 and of the panel 95. Such legs 107 and 108 are rebent along the outer edges thereof as indicated at 111 and are yieldable firmly resiliently to secure the panels 109 and 110 between the legs 105, 111 and 108, 106, respectively. In this manner, the member 99 serves 6 as a spreader properly to hold and space the panels 109 and 110.
Frame posts 113 and 114 are provided at the ends of the relatively narrow panel 96 and spreaders 115 and 116 secured to the webs thereof serve laterally to space and firmly to hold the panels 117 and 104 of such relatively narrow panel. A glazing channel member 118 is secured to the frame vertical 113, such being identical in form to the glazing horizontal member 65 shown in FIG. 4. The glass pane 119 may be held centrally in the channel 120 by glazing elements 121. The legs '122 and 123 of the glazing member 118 are latched to the frame vertical 113 as indicated. A door jamb member 125 is similarly secured to the frame vertical 114. Such door jamb member is provided with legs 126 and 127 which latch behind the vertical ridges 128 and 129 in the frame member 114 firmly to hold the door jamb member in place. Such door jamb member is provided with an L-shape channel 130 adapted to receive a resilient door stop 1.31.
It will be appreciated that instead of a door jamb unit 125, a similar extruded shape may be provided not having the L-shape flange 130 to provide a finished end construction. Also, instead of the frame posts 113 and 114, utilized with the glazing or door frame construction, posts such as shown at 42 may be provided for a continuous solid panel construction.
Referring now to FIG. 6, there is illustrated a two-way or corner intersection between two solid panel units. Such corner structure may be accomplished by extruded aluminum members illustrated generally at and 136 which hold the panels 137 and 138 of one panel 139 properly laterally spaced and in proper relation to the panels 140 and 141 of the second or intersecting panel 142. The member 135 includes the exposed corner portions 143 and 144 which extend normal to each other and join at the corner 145. The other edges of the portions 143 and 144 terminate in relatively short inwardly bent portions 146 and 147 which bear against the exterior plates or faces of the panels 140 and 138, respectively. Extending inwardly from the normal portions 143 and 144 are legs 148 and 149, each of which include two obtuse bends and terminate in flange portions 150 and 151 which have on the inner ends thereof L-shaped projections 152 and 153, the short legs of which bear against the inner faces or sheets of the panels 146 and 138, respectively. The legs 150 and 151 include inward extensions 155 and 156 which mate with the grooves formed by zig-zag bends 157 and 158 at the cornersof legs 159 and 160 of the inner corner member 136. Such legs terminate in inwardly directed flanges which abut against the outer portions of the legs 148 and 149 thus seating and properly securing the members 135 and 136 together.
The member 136 includes three outwardly directed legs 162, 163 and 164 with the legs 162 and 164 being normal to each other and the leg 163 bisecting the angle therebetween. The center leg 163 is bifurcated as indicated at 165 and the two legs thus formed 166 and 167 will be exposed and form the inside of the corner construction. Such legs 166 and 167 extend parallel to the legs 162 and 164, respectively. Each of the legs terminates in an inwardly directed projection adapted to bear against the panels 141 and 137 securing the same therebetween.
FIG. 7 illustrates another use of the extruded shape 99 as an end filler wherein a solid panel 170 abuts against a wall W and the laterally spaced panels 171 and 172 thereof may be enclosed between the legs 173, 174 and 175, 176, respectively. Fasteners 178 may be employed to secure the member 99 to the wall and additional fasteners 179 and 180 may also be employed adjacent the vertical edges thereof better to secure the member 99 to the wall W. Seals 181 may be provided in the dove-tail channels On either or both sides of the center fasteners 178 to provide a soundproof joint between the wall and the panel 170. Since the panel components 171 and 172 may be cut to fit at the installation site, and then inserted into 7 the projecting legs of the member 99, a high degree of accuracy in the precise cuts of the panel components of the panel 170 is not required. The legs of the member 99 will conceal the cut end of the panel components.
Referring now to FIG. 8, there is illustrated still another use of the extruded aluminum member 99 and that is as the ceiling runner or channel 1 1. The ceiling channel may be secured to the ceiling C by means of suitable fasteners 183 extending through the center dove-tail channel thereof and again seals may be provided on either or both sides of such fasteners as indicated at 184 in the channels provided therefor. The downwardly projecting legs 185, 186, 137 and 188 serve to confine and properly space the upper ends of panel components 189 and 1% of a solid panel unit in which the panels extend to the ceiling. In this manner, the function of the legs is exactly the same as shown in FIGS. 5 and 7. The rebent latch portions 192 and 193 on the ends of the inner legs 186 and 187, respectively, while serving inwardly to confine the tops of the panel components 189 and 1%, may also serve to latch and engage post extension 194 which telescopes within the post 42 and projects upwardly therefrom. Such post is provided with horizontally elongated dimples 195 and 196 which snap into the latch portions 192 and 193 as the post is projected between the legs 186 and 187. It is also noted that the configuration of the inner legs 186 and 137 providing the latch portions '2 and 193, which extend slightly below the edges 198 and 19*) of the outer legs 185 and 186, facilitates the insertion of the panel components 189 and 19%. Such a construction which provides an interior clearance permits the panel components to be inclined outwardly for insertion as indicated for the panel 189 in FIG. 8 and then pivoted in the direction of the arrow at the bottom as shown at 280 and vertically lifted to the sung fit between the legs as indicated for the panel component 1%. Such movement of the panel also secures the 53 1116 in a vertically continuous zipper tight single line connection to the post 42.
Accordingly, while the outer legs 135 and 138 are in a vertical plane, the inner legs 1% and 157 are bent in the zigzag manner indicated to afford such clearance for installation of the panel components. At the proximal end of the legs 136 and 187 as indicated at 261, such legs are spaced from the outer leg approximately the width of the panel. The legs then extend inclined inwardly for a substantial distance and then terminate in the reverse bend forming the outer latch tips 192 and 196 thereon. The innermost part of the reverse bend forming such latch portions is again spaced from the outer leg a distance equal to the approximate width of the panel component and is substantially below the edges 19% and 199 of such outer legs. The latching inner legs of the ceiling channel may also be employed to secure the top channel frame of the glass panels 9 and 18 which will, of course, have u'pw'ardly projecting legs interlatching with the inner legs of the ceiling channel.
Referring now more particularly to FIGS. 9, 1G and 11 in addition to FIG. 8, the inner or interior post construction 42 which provides the primary rigidity of the wall is comprised of two vertically continuous members 264 and 205 which are spaced apart and yet secured together to form a rectangular section vertical post. Since such post members are identical in form, only the member 284 will be described in detail. Such member comprises a rolled shape which is vertically continuous having a central shallow channel 207 therein and is folded at 208 and 269 beyond such channel to enclose the flat folded flanges or legs 2'16 and 2 11 of outer vertical member 213. The legs of the vertical 264 are then flat folded back upon themselves as indicated at 214 and 2'15 to extend outwardly and are then bent at 216 and 217 to extend inwardly and then bent again at 218 and 219 to form vertically extending outwardly directed flanges 2'28 and 221. Such flanges are provided with vertically extending laterally inwardly o u directed beads 222 and 223 which serve to rigidity the same.
At the bends 218 and 219, the flanges are lanced as indicated at 224 in equal vertically spaced intermittent sections and the portions of the flanges 220 and 221 thus freed from the body of the vertical 204 are bent diagonally outwardly as indicated at 226 in FIG. 10, then bent at 227 to extend parallel to the unlanced portion of the flange 2211, then bent again at 228 to extend diagonally back to the unlanced portion of the flange 221 therebelow as indicated at 229. The formation of such diagonal bracing facilitated by the lancing of the flanges may occur throughout the height of the vertical on 6 to 7 inch centers. The vertically extending beads 222 and 223 of the flanges will be flattened at the center of the diagonally extending bracing thus provided as indicated at 239, such portion extending parallel to the unlanced portion of the flange 22 1. The corresponding flange of the vertical 205 will similarly be lanced and bent to form such diagonal bracing and the adjoining parallel juxtaposed portions 230 may then be spot welded together as indicated at 231. In this manner, the verticals 2M and 2% are securely joined together and yet the lattice work formed by the diagonally bent and joined flanges leaves a substantially unobstructed space between the members 204 and 2115 of the vertical. For example, as seen in FIG. 10, 233, 234, 235, 236, etc., all represent open spaces between the members of the vertical whereby electrical wiring conduit and the like may readily pass through the posts.
The outer verticals 213, the folded outwardly directed legs 2'18 and 211 of which are clinched or secured during the roll forming operation to the members 204 and 20 5, are bent to conform to the central channel 207 in each of the main vertical members and the central portion thereof may include an outwardly directed shallow channel indicated at Mt). The legs of the vertical 213 are bent outwardly at the fiat folds 2 14 and 215 of the main verticals and terminate in curved outwardly directed J-shape latching portions 241 and 242 which terminate in inwardly inclined latching flanges 243 and 244.
It can now be seen that the curved portions 241 and 242 which extend vertically continuously and are parallel are designed to fit the inwardly directed groove 245 in the lateral edges of each of the panel components 16 and 17 which are formed by the interlocked front and back facing plates which clad the gypsum core 20. (See FIG. 3.) In this manner, the ]-shape or bulb projections of the outer vertical 213 cooperate with the folded edge 29 of the front face plate 21 which restricts the opening of the groove 245 firmly to hold the panel component edge to the post construction. The curved portions 241 and 242 are thus wedged within the groove and the terminal inclined flanges 243 and 24 4 bear against the fold 29 restricting the groove 245 in each of the panel components. Accordingly, as illustrated in FIG. 11, the J-shape portions 24 1 and 24-2 exert a substantial force on the fold edge 2 tending to push the panel 17 on the right to the left and conversely the panel on the left to the right so that the flanges 25 are brought into tight butting relationship with each other and forced securely against the outwardly projecting portion 240 in the center of the outer vertical 213.
Referring back again now to FIG. 8, it can be seen that the panel 139 can readily be installed in the post 42 by inserting the same first in the receptive ceiling channel legs and 186 and aligning the groove 245 in the edge thereof with the formed latching portion 242 and the panel 18) may then simply be driven into tight engagement by moving the same in the direction of the arrow 2190. When the panels are thus assembled, only the fine line joint will appear and the entire post construction 42 is completely hidden, and yet provides a st rdy interior support for such panel components. It is noted that the center of the post is completely open permitting conduit to extend vertically therewithin, but since the space he tween the partition panel components 16 and 17 is also completely open, such post space will not normally be needed for utilities. The center of the post may be filled with an insulating material such as PJF. board further to ensure a sound and fireproof joint between the panel components. Such insulation may be placed in the post prior to erection. Holes can be made by push-ing an object through the insulation, cutting or pushing it out. The insulation material improves the sound transmission loss of the partition and slightly minimizes heat transfer. In a fire endurance rated wall, the post cavity may be filled with gypsum mix. Gypsum board may be placed on each side of the post and the panel cavity may be packed with insulation.
In FIGS. 12 and 13, there is illustrated an alternative form of interior post construction made of only two components 250 and 251 instead of the four components illustrated in the post of FIG. 11. Each component includes respective web portions 252 and 253 which may be provided with vertically spaced enlarged circular apertures 254- for the running of electrical conduit, utilities and the like through the wall. Such members 250 and 251 may be allochirally identical in form and readily interfit and may be secured together to form a rigid and firm box post construction. The member 251 is bent at 255 and 256 to extend generally in the plane of the partition and is bent again at 257 and 25S and folded flat upon itself and then bent at 259 and 260 to extend outwardly at 261 and 262 to form the verticallycontinuous bulb curved I-shape latch portions 263 and 264 which terminate in inwardly inclined flanges 265 and 266.
The member 250 is folded at 263 and 269 and then flat folded back upon itself at 270 and 271 and is then again folded at 272 and 273 to extend outwardly of the post to form lateral flanges 274 and 275 which are then folded into the curved bulb I-shape latch portions 276 and 277 which terminate in the inwardly inclined flanges 279 and 280. Each of the members 250 and 251 thus includes a double thickness section extending longitudinally of the panel wherein the member is folded back upon itself and such portions may be provided with outwardly extending identations as indicated at 282. The members 250 and 251 may simply be snapped together into interlatching engagement and, if desired, they may be spot welded firmly to provide a rigid post construction.
The vertically continuous J-shape latching portions 276, 263, 277 and 264 will function in the same manner as the similar latching portions provided by the outer vertical member 213 in the post construction 42 illustrated in FIG. 11. The indentations 282 in the members 250 and 251 may serve the same purpose as the shallow channel or indentation 240 in the outer vertical 213 by providing a positive stop for the folded over inwardly directed flange on the outer face 21 of each of the panel components. In this manner, the panel outer faces will be horizontally aligned producing the single fine line joint 40 therebetween. It can now be seen that such interior post constructions afford a rigid firm support for the panel components and yet in no way hinder electrical wiring or utilities passing through the wall. Such post construction cooperating with the unique panel having the interlocked face plates forming the inwardly directed latching channel with the restricted opening permits the panel components quickly and easily to be attached thereto and removed therefrom without damaging the panels. The spring pressure exerted by the continuous latching members of the post draws adjacent panels into a continuous tight butting joint and further draws the panels inwardly against the rigid portion of the post.
Referring now to FIGS. 8, 9 and 10, a special base clip indicated generally at 285 may be provided securely latching the vertical construction to the floor runner 84. Such clip includes a main upstanding U-shaped portion 286 and latch portions 287 and 288 on either side thereof,
each of which includes inner latching fingers 289 and 290 which terminate in upwardly and outwardly extending tangs 291 and 292, respectively, which are adapted to engage the inner surfaces of the inclined Walls or legs of the center dove-tail channel 86 of the floor runner 84. The center portion 286 fits snugly within such center dovetail channel of the runner. The latching portions 287 and 288 also include hook-shape latches 293 and 294, each of which terminate in inwardly directed tangs 295 and 296 engaging the outer faces of the vertical members 204 and 205, respectively. In this manner, the spring clips 285 are secured both to the lower end of the vertical and to the floor runner 84 and serve normally to latch the vertical in place. However, it will be appreciated that the vertical can then readily be moved or adjusted along the floor and ceiling runners to be placed in the desired position.
As indicated in FIG. 8, the panels 189 and 190 may stop short of the floor and may not provide sufiicient backup for the vinyl base or cove 93. This condition may then require a snap-on inner steel base 298 having a bottom inwardly curved configuration 299 terminating in an upwardly extending flange edge 300 which will wedge between the bottom of the runner 34 and the floor F holding it in place with the top edge tight against the wall. The vinyl base or cove 93 may then be positioned flush against the snap-on inner steel base 298 which covers the bottom edge of the panel. The snap-on inner steel base 293 also improves the sound transmission loss of the partition.
Referring now to FIG. 14, for a full height glass panel 302, the posts provided therefor may be reinforced as indicated. Such posts comprise the basic glass or door frame members 303 and 304 which are in the sectional configuration of an I-beam having the relatively thin webs 305 and 306, respectively. Glazing members 307, 308, 309 and 310, each having the central vertically extending glazing channel therein, are snapped into the posts with the legs 311 and 312 of each snapping behind the vertically extending ridges 313 and 314 to secure the glazing member in place. The metallic glazing elements 315 snap within the respective channels having the inwardly folded edges which bear against the faces of the pane 302 centering and maintaining the glass panel properly posi tioned. Vertical reinforcing elements 316, 317 and 318, 319 may be secured to the webs 305 and 306 of the posts 303 and 304, respectively. Each reinforcing member comprises laterally spaced channel portions 320 and 321, the inner legs of which are connected by a bridge 322 forming a central outwardly directed channel surrounding the central glazing channel in each of the glazing members 307 through 310. Vertically spaced screws 324 and 325 passing through the backs of the lateral channels 320 and 321 may be employed to secure the reinforcing members to the central web of the post member. Accordingly, the frame post construction can readily be reinforced to accommodate full height glass panels of considerable thickness and the aluminum shapes used in such glass wall may be shipped to the job in length and fabricated by carpenters in units to receive the glass panes. Accordingly, no pro-engineering or fabrication is required even for the full height glass panel. In this manner, no field measurements or shop drawings are required and the reusable partition system can be erected from architects drawings or from customers sketches.
It can now be seen that there is provided an economical reusable wall system utilizing a minimum number of parts. The basic panel component comprises a steel clad gypsum core, the backup sheet of which interlocks with the face sheet to form a restricted opening inwardly directed groove at the vertical edges of the panel which cooperates with the unique inner or concealed post con struction enabling the panels readily to be assembled to such posts forming only a tight single line joint therebetween.
Shelving, cabinets, etc., may be attached directly to the wall panel components with toggle bolts and no additional reinforcing is required in the wall unless the loading of such items is abnormal. Pictures may be hung on the panel components, but no drilled holes are required. Using ordinary metal picture hooks and small wire nails, such may be driven into the wall in exactly the same manner as any plastered wall. If the hooks or nails are removed, the holes may be spackled and repainted to look like new. With independent steel and gypsum panels held securely in place by the continuous grip of the post, and sealed at ceiling, floor and end walls against leaks, there is provided the kind of privacy and sound control normally afforded only by a gypsum block wall which is plastered on both sides. For example, sound originating on one side of the wall of the present invention is reduced by 43 decibels on the other, such loss can be increased to 50 decibels with minor modification to the partition components, while the sound transmission rating of a typical three inch thick gypsum block wall, plastered on both sides, is 39 decibels. Since the partition system of the present invention is composed of completely incombustible components, adequate fire safety is provided and by the addition of interior insulating materials may easily be adapted to provide a full one hour rating where required.
Since the basic metal clad gypsum or like insulating board panel component can readily be cut with ordinary hand-held carpenter tools, it can be seen that the parts of the system when at the assembly site can readily be fabricated into a complete reusable wall system without precise measurements, working drawings, and the preengineering normally required in metal interior partition systems.
Other modes of applying the principle of the invention may be employed, change being made as regards the details described, provided the features stated in any of the following claims or the equivalent of such be employed.
1, therefore, particularly point out and distinctly claim as my invention:
1. In combination, a post construction for interior partition systems comprising a vertical, and a pair of vertically extending allochiral J-sh-aped latching projections extending laterally from said vertical; panels each comprising an insulating core, front and back face sheets bonded to said core, said sheets extending beyond the edges of said core and cooperating to form vertically extending latching edge channels coextensive with said projections, the adjacent edge channels of said panels being latched to one projection of each pair and thus secured to said post construction.
2. The combination set forth in claim 1 wherein each projection includes a resilient free edge directed toward the other projection of each pair operative firmly to force said panels together into tight butting engagement with each other and into engagement with said vertical.
3. The combination set forth in claim 2 including L- shaped flanges on said panels forming the outer walls of said edge channels adapted to engage the free edges of said projections.
4. The combination set forth in claim 3 wherein said insulating core of each panel comprises a gypsum board having the front and back face sheets adhesively bonded thereto, said front face sheets being thicker than said back face sheets.
5. The combination set forth in claim 1 wherein said vertical comprises a vertically extending box section with a pair of said vertically extending latching projections extending from opposite sides thereof.
6. The combination set forth in claim 1 wherein said vertical is a box section comprised of interconnected channels, said projections comprising the shaped edges of said channels.
7. The combination set forth in claim 6 wherein said channels include overlapped flat folded portions with said shaped edges projecting from said overlapped portions to form said pair of J-shaped latching projections.
8. The combination set forth in claim 5 including two pairs of J-shaped latching projections each comprising the shaped edges of a unitary vertical member, each channel of said box section vertical having one of said unitary vertical members secured thereto to provide a pair of said I-shaped latching projections on opposite sides of said box section vertical.
9. The combination set forth in claim 8 wherein said unitary vertical members are secured in clinch folded portions of said channels.
10. The combination set forth in claim 5 including two pairs of J-shaped latching projections projecting from opposite sides of said vertical, the laterally corresponding projection of each pair comprising the shaped edges of two channels interconnected to form said box section vertical.
11. The combination set forth in claim 1 wherein said latching edge channels have a folded flange restricting the opening thereof and engaging the resilient free edge of the respective J-shaped latching projection.
12. The combination set forth in claim 11 wherein the side of the J-shaped latching projection opposite the resilient free edge thereof tightly engages the side of the respective latching edge channel opposite said folded flange and is held thereagainst by the resilience of said free edge.
13. A post construction for interior partition systems comprising a box section vertical, a pair of allochiral I-shaped latching projections extending laterally from said vertical adapted to snap within vertical latching grooves of panels to be joined thereto, said box section vertical including laterally spaced channels having longitudinally directed edge flanges, lattice means interconnecting said flanges to form said box section vertical, said flanges being lanced vertically intermittently and bent, and means joining the respective bent portions of said flanges to interconnect said channels forming said box section vertical.
14. A post construction for interior partition systems comprising a box section vertical, a pair of allochiral J-shaped latching projections extending laterally from said vertical adapted to snap within vertical latching grooves of panels to be joined thereto, said projections comprising the shaped edges of two channels interconnected to form said box section vertical, said two channels each including laterally spaced flat folded portions forming the lateral walls of said box section vertical, and the corresponding fiat folded portions of each channel lying laterally adjacent each other and being secured together to form latenal walls having four times the thickness of the channel backs.
15. A post construction as set forth in claim 14 wherein the backs of said channels are apertured to provide openings through said post construction for utilities and the like.
16. A panel for interior partitions and the like comprising an insulating core, a metal face sheet bonded to one side of said core, a metal back-up sheet bonded to the other side of said core, said face and back-up sheets both extending beyond the lateral edges of said core and being interlocked to form vertical channels at both lateral edges of such panel, each opening away from said face sheet, such vertical channels each being provided with a restricted opening formed by an inwardly directed latching flange on the outer edge of such channels.
17. A panel as set forth in claim 16 wherein said back-up sheet is bent to enclose the lateral edges of said core at each side of said panel and cooperates with said face sheet to form said channels.
18. A panel as set forth in claim 17 wherein said face sheet extends coextensively with a rebent portion of said back-up sheet to form the interior wall of said channels.
19. A panel as set forth in claim 18 wherein said face sheet is bent to form the exterior wall of said channels, and terminates in said inwardly directed latching flange.
20. A panel as set forth in claim 19 wherein said latching flange is formed by a folded edge of said face sheet.
21. A panel as set forth in claim 20' wherein said latching flange comprises a flat folded portion of the edge of said face sheet which extends substantially in the plane of said back-up sheet.
22. A panel as set forth in claim 16 wherein said insulating core comprises a gypsum board with said face and back-up sheets being adhesively bonded thereto.
23. A panel as set forth in claim 16 wherein said face and back-up sheets are of different thickness.
24. A panel as set forth in claim 16 wherein said face sheet is a thickness on the order of .0239 inch while said back-up sheet is a thickness on the order of .0149 inch.
References Cited UNITED STATES PATENTS Fink 287-18936 Kemp 52-619 Rizzolo 52-493 Pollack et a1. 52-481 Wagner 52-731 Johnson 52-481 X Greulich 52-622 X Johnson 52-398 X Slowinski 52-574 HENRY C. SUTHERLAND, Primary Examiner. 15 FRANK L. ABBOTT, RICHARD W. COOKE, In,
G. W. HORNADAY, Assistant Examiners.