Solid-core wall system

• US 5,822,935 A
• Filed: 12/19/1996
• Issued: 10/20/1998
• Est. Priority Date: 12/19/1996
• Status: Expired due to Term

• Current Assignee: Steelcase Development Inc.
• Original Assignee: Steelcase Incorporated
• Inventors: Juhlin, Gary S., Houda, James D., Mitchell, Terry
• Primary Examiner(s): Kent, Christopher
• Assistant Examiner(s): CALLO, LAURA ANTOINETTE
• Application Number:
  US08/770,132
• Time in Patent Office: 670 Days
• Field of Search: 52/483.1, 52/489.1, 52/489.2, 52/781.3, 52/797.1, 52/796.1, 52/800.1, 52/801.1, 52/801.11, 52/238.1, 52/239, 52/506.09 , 52/475.1, 52/481.1, 52/481.2, 52/511, 52/764, 52/770, 52/771, 52/773, 52/775, 52/781, 52/241, 52/242, 52/243, 52/220.7, 52/733.2 , 52/731.5, 52/731.9
• US Class Current: 52/239
• CPC Class Codes: E04B 2/7411 Details for fire protection
• CPC Class Codes: E04B 2/7455 Glazing details
• CPC Class Codes: E04B 2002/7488 Details of wiring
• CPC Class Codes: E04B 2002/749 Partitions with screw-type jacks

Abstract

A reconfigurable wall system includes a solid-core wall which is comprised of a plurality of solid-core wall panels arranged in two adjacently abutting vertical layers. Each of the adjacently abutting layers of the solid-core wall comprises a plurality of solid-core panels arranged in edge-to-edge abutment. The abutting edges form vertical seams. The vertical seams in each of the layers of the solid-core wall are laterally offset from the seams in the adjacent layer to eliminate gaps through which light and sound can penetrate or leak. A plurality of vertical studs are disposed on opposite faces of the solid-core panel. Each of the studs is aligned with a stud on the opposite face of the solid-core wall, and a plurality of horizontally spaced apart fasteners extend through the solid-core wall and connect the aligned studs on opposite sides of the solid-core wall. A plurality of wall covering panels are mounted on the vertical studs. The reconfigurable wall system provides improved fire resistance and acoustical resistance and allows flexibility in the selection and replacement of wall covering panels.

Claims

1. A reconfigurable wall system comprising:

a structural solid-core wall including a plurality of solid-core panels arranged in two adjacent abutting layers, each layer comprising a plurality of said solid-core panels arranged in edge-to-edge abutment, the abutting edges of the panels forming vertical seams, the vertical seams in each of the layers being laterally offset from the seams in the adjacent layer;

a plurality of reinforcing vertical studs on opposite faces of the solid-core wall, each of the reinforcing vertical studs being aligned with another of said vertical studs on an opposing face of the solid-core wall and stiffening the structural solid-core wall, but terminating short of a lower edge of the solid-core panels, such that the solid-core panels support a weight of the wall system; and

a plurality of horizontally spaced apart fasteners which extend through the solid-core wall and which connect aligned pairs of the reinforcing vertical studs on opposite sides of the solid-core wall.

2. The reconfigurable wall system of claim 1, wherein the vertical studs include a base portion abutting the solid-core wall, web portions which extend from opposite sides of the base away from the solid-core wall, and laterally spaced apart flanged portions which extend from the webs and are disposed in a vertical plane spaced from the solid-core wall;

and

wall covering panels attached to the flange portion of the vertical studs.

3. The reconfigurable wall system of claim 2, wherein a section of the web portions and flange portions of the vertical studs are cut out to form a notch, and wherein the reconfigurable wall system further comprises a horizontally extending expressway channel mounted to the solid-core wall and extending through the notches in the vertical studs, whereby the expressway channel provides means for distributing power and communication cables through the wall system.

4. The reconfigurable wall system of claim 3 further comprising a glass transom extending from the top of the expressway channel.

5. The reconfigurable wall system defined in claim 2 wherein the reinforcing vertical studs include apertures, and wherein the wall covering panels include connectors arranged to frictionally engage the apertures with the wall covering panels spanning between horizontally adjacent ones of the reinforcing vertical studs.

6. The reconfigurable wall system defined in claim 5 wherein the connectors include interlocking clips that releasably but lockingly engage the apertures.

7. The reconfigurable wall system of claim 1 further comprising a floor track defining a channel in which the bottom edge of the solid-core wall is received.

8. The reconfigurable wall system of claim 1 further comprising a ceiling track and a core capture extrusion which is attached to the ceiling track and which includes a channel in which the upper edge of the solid-core wall is received.

9. The reconfigurable wall system of claim 1 further comprising a floor track defining a channel in which the lower edge of the solid-core wall is received;

a ceiling track;

a core capture extrusion connected to the ceiling track and including a channel in which the upper edge of the solid-core wall is received; and

a plurality of wall covering panels attached to the vertical studs.

10. The reconfigurable wall system of claim 9, wherein the vertical studs include a base portion abutting the solid wall, web portions which extend from opposite sides of the base portion away from the solid wall, and laterally spaced apart flange portions which extend from the web portions and are disposed in a vertical plane spaced from the solid wall, a section of the web portions and flange portions of the vertical studs being cut out to form a notch;

and further comprising a horizontally extending expressway channel mounted to the solid wall and extending through the notches in the vertical studs, whereby the expressway channel provides means for distributing power and communication cables through the wall system.

11. The reconfigurable wall system of claim 10 wherein the expressway channel includes a center septum which divides the expressway channel into an upper channel and a lower channel, whereby power and communication cables are able to be distributed through separated channels.

12. The reconfigurable wall system defined in claim 1 wherein the reinforcing vertical studs include vertically extending slots, and wherein the fasteners extend through the slots.

13. The reconfigurable wall system defined in claim 1 wherein the solid-core panels include gypsum material.

14. A reconfigurable wall system comprising:

a load-bearing solid-core wall including a plurality of solid-core wall panels having opposing faces and laterally spaced apart edges, the solid-core wall panels being arranged in abutting wall layers with a face of each said solid-core wall panel in one of the wall layers abutting a face of adjacent ones of said solid-core wall panels in an adjacent wall layer, an edge of each said solid-core wall panel in each of the wall layers abutting an edge of an adjacent one of said solid-core wall panels in the same wall layer to form edge seams, the edge seams in each of said one wall layers being laterally spaced from the edge seams in the adjacent wall layer, whereby said solid-core wall panels in each said wall layer overlap the edge seams in the adjacent wall layer to create a stronger wall;

a plurality of vertically adjustable, reinforcing vertical studs disposed on opposite faces of the solid-core wall, each of the vertical studs being aligned with a vertical stud on the opposite side of the solid-core wall and having vertical slots therein;

a plurality of fasteners which extend through the solid-core wall and through the vertical slots to adjustably connect the aligned vertical studs on opposite sides of the solid-core wall; and

a plurality of wall covering panels mounted on the vertical studs.

15. The reconfigurable wall system of claim 14 wherein a section of the web portions and flange portions of the vertical studs are cut out to form a notch, and wherein the reconfigurable wall system further comprises a horizontally extending expressway channel mounted to the solid-core wall and extending through the notches in the vertical studs, whereby the expressway channel provides means for distributing power and communication cables through the wall system.

16. The reconfigurable wall system of claim 14 further comprising a floor track defining a channel in which the bottom edge of the solid-core wall is received.

17. The reconfigurable wall system of claim 14 further comprising a ceiling track and a core capture extrusion which is attached to the ceiling track and which includes a channel in which the upper edge of the solid-core wall is received.

18. The reconfigurable wall system of claim 14 further comprising a floor track defining a horizontal channel in which the lower edge of the solid-core wall is received;

a ceiling track;

a core capture extrusion defining a channel in which the upper edge of the solid-core wall is received; and

wherein the vertical studs include a base portion abutting the core wall, web portions which extend from opposite sides of the base away from the core wall, and laterally spaced apart flange portion which extend from the web portions and are disposed in a vertical plane spaced from the core wall, a section of the web portions and flange portions of the vertical studs being cut out to form a notch; and

wherein the reconfigurable wall system further comprises a horizontally extending expressway channel mounted to the core wall and extending through the notches in the vertical studs, whereby the expressway channel provides means for distributing power and communication cables through the wall system.

19. The reconfigurable wall system of claim 14 further comprising a glass transom extending from the top of the expressway channel.

20. The reconfigurable wall system defined in claim 14 wherein the reinforcing vertical studs include vertically extending slots, and wherein the fasteners extend through the slots.

21. The reconfigurable wall system defined in claim 14 wherein the reinforcing vertical studs include apertures, and wherein the wall covering panels include connectors arranged in a pattern to frictionally engage the apertures with the wall covering panels spanning between horizontally adjacent ones of the reinforcing vertical studs.

22. The reconfigurable wall system defined in claim 21 wherein the connectors include interlocking clips that releasably but lockingly engage the apertures.

23. The reconfigurable wall system defined in claim 14 wherein the solid-core panels include gypsum material.

24. A reconfigurable wall system comprising:

a load-bearing solid-core wall including a plurality of solid-core panels, the panels being arranged in two adjacently abutting vertical layers, each layer comprising a plurality of said solid-core panels arranged in edge-to-edge abutment, the abutting edges forming vertical seams, the vertical seams in each layer being laterally offset from the vertical seams in the adjacent layer;

a plurality of vertically adjustable, reinforcing vertical studs disposed on opposite faces of the solid-core wall, each of the vertical studs being aligned with a vertical stud on the opposite side of the solid-core wall;

a plurality of horizontally spaced apart fasteners which extend through the solid-core wall and connect the aligned vertical studs on opposite sides of the solid-core wall, the vertical studs and the fasteners being constructed to permit vertical adjustment of the vertical studs;

a plurality of wall covering panels removably mounted with frictional connectors on the vertical studs;

a core cap extrusion secured to an end of the solid-core wall; and

a glass wall portion connected in-line with the solid-core wall, the glass wall portion comprising a glass wall base and a glass wall panel supported on the glass wall base, and a glass jam connected to a side edge of the glass wall panel, the glass wall being connected in-line to the solid-core wall by an in-line connector extrusion attached to the core cap extrusion and to the glass jam, the core cap extrusion and the in-line connector extrusion having abutting tabs which are secured together by a resilient clip.

25. A reconfigurable wall system comprising:

a load-bearing solid-core wall comprising a double layer of gypsum panels, each having a bottom edge;

pairs of reinforcing studs located on opposite sides of the solid-core wall and fasteners connecting each of the pair of reinforcing studs together against the gypsum panels so that the reinforcing studs stiffen and support the gypsum panels, thus giving the gypsum panels sufficient stability to bear a weight of the wall system, the reinforcing studs being vertically adjustable on the fasteners and including a bottom end spaced above the bottom edge of the gypsum panels, the reinforcing studs having apertures; and

cover panels covering the solid-core wall, the cover panels having connectors releasably frictionally engaging the apertures in the reinforcing studs.

26. A reconfigurable wall system comprising:

a load-bearing solid-core wall;

pairs of reinforcing studs located on opposite sides of the solid-core wall;

fasteners securing the pairs of reinforcing studs together;

the reinforcing studs each having a first flange engaging a face of the solid-core wall, a second flange extending from the first flange away from the face, a third flange extending from the second flange that is parallel but not coplanar with the first flange, and notches that extend through the third flange and at least partially into the second flange; and

a horizontally extending channel closely engaging the notches of the reinforcing studs and defining a horizontal raceway across the wall system.