Modular wall nesting system

• US 9,003,731 B2
• Filed: 06/11/2012
• Issued: 04/14/2015
• Est. Priority Date: 06/11/2011
• Status: Active Grant

• Current Assignee: Dirtt Environmental Solutions
• Original Assignee: Dirtt Environmental Solutions
• Inventors: Gosling, Geoff, Smed, Mogens
• Primary Examiner(s): Triggs, Andrew J
• Application Number:
  US13/579,257
• Publication Number:
  US 20140102021A1
• Time in Patent Office: 1,037 Days
• Field of Search: 522/39, 522/207, 52/361, 524/812, 160/135
• US Class Current: 52/239
• CPC Class Codes: E04B 2/7422 with separate framed panels without intermediary support posts
• CPC Class Codes: E04B 2/7424 Glazing details
• CPC Class Codes: E04B 2/7435 Glazing details
• CPC Class Codes: E04B 2/745 Glazing details
• CPC Class Codes: E04B 2/7453 with panels and support posts, extending from floor to ceiling
• CPC Class Codes: E04B 2002/7483 Details of furniture, e.g. tables or shelves, associated with the partitions

Abstract

Implementations of the present invention relate to systems, methods, and apparatus for incorporating face- and center-mounted panels into a single wall module to form nested wall modules. For instance, face-mounted panels can nest within the center-mounted panels. Additionally or alternatively, center-mounted panels can nest within the face-mounted panels to form windows.

Claims

1. A nested wall module for use in a modular wall system, the nested wall module having at least one center-mounted panel mounted to opposing face-mounted panels, so that the center-mounted panel and at least one of the face-mounted panels are exposed as viewable surfaces of the modular wall system at the same time, the nested wall module comprising:

a support frame having at least two upright supports that are each attached to one or more horizontal cross members;

a center-mounted panel secured within a channel of the one or more horizontal support members;

a pair of opposed face-mounted panels secured about the support frame and about the center-mounted panel, such that an exposed surface of at least one of the face-mounted panels is parallel to one of the exposed surfaces of the center-mounted panel, and such that the exposed surface of the at least one face-mounted panel extends further away from the support frame relative to the center-mounted panel; and

a nesting frame assembly coupling the center-mounted panel and the pair of face-mounted panels together

wherein one of;

the center-mounted panel is nested within the pair of face-mounted panels;

or

the pair of face-mounted panels are nested within the center-mounted panel.

2. The nested wall module as recited in claim 1, wherein the nesting frame assembly comprises:

one or more panel channels within which the center-mounted panel is secured; and

a plurality of engagement protrusions to which the pair of face-mounted panels are secured.

3. The nested wall module as recited in claim 2, wherein:

the nesting frame assembly comprises a plurality of nesting brackets; and

each bracket including a panel channel and a plurality of engagement protrusions.

4. The nested wall module as recited in claim 3, further comprising a plurality of adjustable cinch assemblies coupling the plurality of nesting brackets together.

5. The nested wall module as recited in claim 2, wherein:

the pair of face-mounted panels each comprise a hole within which the center-mounted panel is secured; and

the center-mounted panel is nested within the pair of face-mounted panels.

6. The nested wall module as recited in claim 5, wherein:

the nested wall system comprises one or more additional center-mounted panels nested within the pair of face-mounted panels; and

the pair of face-mounted panels conceals the support frame.

7. The nested wall module as recited in claim 6, further comprising a second pair of face-mounted panels nested within the center-mounted panel, wherein the second pair of face-mounted panels protrude outwardly from an exposed surface of the center-mounted panel.

8. The nested wall module as recited in claim 2, wherein the center-mounted panel comprises a hole within which the pair of face-mounted panels are secured.

9. The nested wall module as recited in claim 1, wherein the nested wall module comprises a functional component nested therein.

10. A modular wall system incorporating nested wall modules, which include one or more face-mounted panels or one or more center-mounted panels, the system comprising:

a plurality of wall modules coupled together to form a divider or wall providing a viewable surface;

wherein;

one or more wall modules of the plurality of wall modules comprise a nested wall module; and

the nested wall module comprises;

a pair of face-mounted panels coupled to and concealing an outside surface of a support frame, and a center-mounted panel mounted within a channel formed in one of;

(i) an inside surface of the support frame; and

(ii) a bracket coupled to the pair of face-mounted panels; and

a nesting frame assembly securing the center-mounted panel and the pair of face-mounted panels together;

wherein the center-mounted panel, and at least one of the pair of face-mounted panels are both viewable as part of the viewable surface of the divider or wall.

11. The modular wall system as recited in claim 10, wherein the support frame comprises:

a first upright support;

a second upright support;

an upper cross member extending between the first and second upright supports; and

a lower cross member extending between the first and second upright supports.

12. The modular wall system as recited in claim 11, wherein:

the center-mounted panel extends;

between the first and second upright supports; and

between the upper cross-member and the lower cross member; and

the pair of face-mounted panels are nested entirely within an opening in the center-mounted panel.

13. The modular wall system as recited in claim 11, wherein:

the pair of face-mounted panels extends between the first and second upright supports;

a back surface of each panel of the pair of face-mounted panels is secured to the upper cross-member and the lower cross member; and

the center-mounted panel is nested entirely within an opening in the pair of face-mounted panels.

14. The system as recited in claim 11, further comprising:

wherein the nesting frame assembly comprises one or more nesting brackets, each bracket including;

the channel within which the center-mounted panel is secured;

a plurality of engagement protrusions to which a back surface of each of the pair of face-mounted panels is secured.

15. The modular wall system as recited in claim 10, wherein the nested wall module comprises a functional component nested therein.

16. A nesting frame assembly, comprising:

a plurality of nesting brackets, wherein at least two nesting brackets of the plurality of nesting brackets comprise mitered ends that define an angle of the nesting frame assembly; and

one or more corner cinch assemblies sized and configured to each couple two nesting brackets of the plurality of nesting brackets together;

wherein each bracket of the plurality of nesting brackets comprises;

a panel channel sized and configured to hold an edge of a center-mounted panel therein;

one or more cinch channels sized and configured to a corner cinch assemblies; and

one or more engagement protrusions configured to couple one or more connectors;

wherein at least one bracket of the plurality is configured to support a center-mounted panel on one side of the at least one bracket, and to support at least one face-mounted panel on another side thereof, so that both the center-mounted panel and face-mounted panel are supported by the same at least one bracket and are viewable as outside surfaces of a modular wall at the same time.

17. The nesting frame assembly as recited in claim 16, wherein at least one corner cinch assembly of the one or more corner cinch assemblies further comprises:

one or more cinch plates;

a corner cinch plate; and

a plurality of couplings configured to couple the one or more cinch plates to the corner cinch plate.

18. The nesting frame assembly as recited in claim 17, wherein:

the plurality of couplings are further configured to move the one or more cinch plates closer to the corner cinch plate; and

the at least one corner cinch assembly is configured to move at least two nesting brackets of the plurality of nesting brackets closer together when the one or more cinch plates move closer to the corner cinch plate.

19. The nesting frame assembly as recited in claim 16, wherein:

each mitered end of the mitered ends has an angle less than 90 degrees.

20. The nesting frame assembly as recited in claim 19, wherein:

the mitered ends have angles of approximately 45 degrees; and

the at least two nesting brackets of the plurality of nesting brackets are configured to form an approximately 90 degree angle therebetween when coupled by the one or more corner cinch assemblies.

21. The nesting frame assembly as recited in claim 16, wherein at least one cinch channel of the one or more cinch channels further comprises one or more lips sized and configured to retain at least one corner cinch assembly of the one or more corner cinch assemblies within the one or more cinch channels.

22. The nesting frame assembly as recited in claim 16, wherein the at least one bracket comprises a channel for holding and supporting the center-mounted panel.

23. The nesting frame assembly as recited in claim 22, wherein the at least one bracket comprises one or more engagement protrusions for receiving and holding one or more connectors of a face-mounted panel.

24. The nesting frame assembly as recited in claim 16, further comprising a functional component or functional feature mounted therein.