Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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FIELD OF THE INVENTION
2 This invention relates to a sandwich panel unit for
3 use in a partition wall and to a wall assembly incorporating
4 a plurality of such sandwich panel units.
BACRGROUND OF THE INVENTION
6 In modern office bui~dings, the space is commonly
7 sub-divided by removable partition walls.
As stated, these walls are not permanent in nature.
g From time to time, the wall assembly may be removed totally
or disassembled and re-located in a new position.
11 So the ease or simplicity with which a removable
12 partition wall may be erected or disassembled is ar. important
feature of the wall. If the wall is easy to install and re-
4 locate, then the degree of skill required of the installation
workers becomes less and the man-hours required to install
16 the wall diminishes.
17 In disassembling the wall, some of the components
18 making up the wall may be damaged, with the result that they
19 must be replaced if the wall is to be re-assembled. These
walls commonly have gypsum board panels as a major component.
21 Gypsum board is a relatively delicate material that can be
22 easily damaged when being separated from other components.
Z3 As stated, the wall typically incorporates side~by-
24 side, vertically extending gypsum board panels. These panels
have "joints" where the side edge of a panel comes close to
26 or abuts the next element in the wall. These joints in some
27 known wall systems are unsightly because of gaps left between
28 the elements and/or jointing hardware and it i5 common to
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1 mask them with protruding battens. In recent years, wall
2 systems have be~n developed which are adapted to permit of
3 the wall elements being drawn close together to create a
4 "pencil-line joint", thereby eliminating the need for a
protruding batten. The resulting appearance of the segmented
6 wall is described in the trade as being llmonolithic".
7 In summary then, it would be desirable to provide a
8 removable partition wall system which has the following
9 characteristic~:
- That it can quickly be assembled and
11 disassembled;
12 _ That it lends itself to assembly and
13 disassembly by relatively unskilled workers;
14 - That the gypsum board panels can be
disassembled with little damage; and
16 - That it has pencil-line joints and a
7 monolithic appearance.
18 These desirable characteristics of a partition wall
19 system will be better appreciated by shortly describing some
of the prior art commercial systems currently being used and
21 identifying their shortcomings in these respects.
22 One prior art system involves providing a frame of
23 laterally spaced, vertical channel studs extending between
24 ceiling and floor channels or "tracks~. Gypsum ~oard panels
are secured to the two sides of ~he studs by screws or
26 adhesive. This involves fitting and levelling difficulties
27 which, in turn, requires the use of skilled workers. In
28 additionl there are usually vertical gaps left between the
29 side edges of adjacent gypsum board ~anels. As a result,
1 protruding battens must be used with the system. If the gypsum
2 board panels are removad, they commonly must be discarded, due
3 to damage incurred when detaching them from the studs.
4 Another prior art wall system incorporates what are
referred to ln the trade as sandwich panels. Each such sandwich
6 panel comprises a pair of steel or gypsum board facing panels
7 secured by adhesive to a central lightweight core of material
8 such as paper honeycomb or foam plastic. When the components are
9 so secured, the assembly provides a discrete integral and rigid
unit. The sandwich panels are normally assembled in a faotory
11 and shipped to the work site. Here they are inserted between
12 floor and ceiling channels. They are secured together and
13 maintained in alignment by suitable clamping brackets. Some
14 undesirable features of this system are:
- That the sandwich panels have to be assembled in
16 a factory and shipped in the assembled state.
17 They are heavy and unwieldy and consequently easy
18 to damage. The entire unit must be discarded if
19 it is damaged;
- The unit, being heavy, typically requires the
21 services of at least two workers when being
22 handled;
23 - Due to the use of adhesive to unite the core and
24 panels, the components cannot be disassembled in
order to accommodate future changes to wiring or
26 other services normally buried in the wall cavity;
27 and
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1 - Because of the rigid glued sandwich panel
2 construction, there is extended contact
3 between the bacXs of the facing panels and the
4 core material. This close and rigid contact
promotes the transmission of sound through the
6 sandwich panel and an inefficient sound
7 barrier is the result.
8 However, the sandwich panels do ha~e the advantage that they
g easily may be de-mounted, re-located, and re-erected.
A third prior art system, to which the present
11 applicants were contributors, is shown in U.S. Patent
12 3,948,011. This system involves providing a framework
comprising floor and ceiling channels, vertical stud
14 channels, and horizontal suspension channels extending
through and being supported by the stud channels intermediate
16 the latters' ends. Suspension assemblies are attached to
each gypsum board panel at its rear surface. The suspension
18 assemblies are arrayed in vertically spaced, horizontal lines
19 that will correspond with the vertically spaced suspension
channels. Each suspension assembly comprises a gang nail
2l plate having tangs which embed in the gypsum board panel.
22 The gang nail plate is shown in U.S. Patent 4,128,979. It
23 forms a slot assembly, intermediate its ends, for receiving a
24 spring steel clip having a downwardly angled cam portion. A
"line of weakness" or crease line extends laterally across
26 the plate just above the clip-receiving slot assembly. Nhen
27 the clips are inserted into the slots and the gypsum board
28 panel is lowered so that the cam portions of the downwardly
29 extending clips engage the upwardly projecting leg of the
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1 suspension channel, the panel will be suspended from the
2 channel. The angled clips function to draw the panel in
3 firmly against the framework. The line of weakness enables
4 the upper and lower portions of the gang nail plate to crease
slightly along the line, to angle the tangs into clinching
6 engagement with the core of the heavy gypsum board panel~ so
7 that it will not tear away.
8 This third system is characterized by the following
g advantages:
- There is lateral adjustability of the panels
11 along the suspension channels, to enable close
12 abutment to adjacent elements of the wall,
13 thereby achie~ing a pencil-line joint and a
monolithic appearance;
- The gang nail plates may be attached in the
16 field
17 - The panel may be lifted away and separated
18 from the frame, without damage to the panel;
19 - The wall may be assembled and disassembled
quickly by relatively unskilled workers; and
21 ~ The facing panels are resiliently attached to
22 the panel framing members and consequently
23 provide an efficient barrier to the passage of
24 sound through the completed panel and frame
assembly.
26 It is an objective of the present invention to
27 incorporate some of the features and advantages of the third
28 system into a sandwich panel unit system.
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1 $UMMARY_OF THE INVEN~IQ~
2 In accordance with the invention, a rectangular frame
3 is provided, formed of top, bottom, and side memberæ and at least
4 one suspension channel extending horizontally between the side
members. The suspension channel preferably has a V-shaped
6 confi~uration. The ~rame members are substantially rigidly but
7 disengageably secured together by connectors. Preferably, screw
8 splines are used as the connectors, as they are particularly
9 use~ul in ensuring the rigidity and plumbness of the frame. Two
gypsum board panels are mounted to the frame. Each panel has at
11 least one linear array of suspension assemblies secured to it at
12 its rear surface. Each suspension assembly preferably is of the
13 gang nail plate/cam clip type. The panels are mounted to the
14 frame by suspending them from the suspension channels using the
suspénsion assemblies. The panels preferably have the same
16 perimeter dimension as the frame and the suspension channels and
17 suspension a~semblie~ correspond in their positioning, so that
18 the panel edges end up flush with the edges of the frame when
lg assembled. The suspension assemblies cooperate with the
suspension channels to draw the panels in tightly against the
2I frame so that the former bear evenly against the latter.
22 Disengageable bracket means are provided for locking with the
23 frame and simultaneously clamping each panel tightly against the
24 frame. Thus the clamping action of the bracket means contributes
~5 to the drawing in tightly of the panPls against the frame. The
26 bracket means are preferably further adapted to extend across and
27 bear against the panel's upper and lower edge surfaces. As a
28 result of drawing the panels in tightly against the frame, and
29 the edge supporting action of the bracket means, the panels in
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1 essence become unitary with the frame. As a result, the panels
2 reinforce the frame and a cohesive, rectangular, substantially
3 non-racking unitary assembly is provided.
4 It will be noted that:
- The frame is preferably "knock-down" in nature
6 and the suspension ~ssemblies can be attached at
7 the erection site. Thus the components of the
8 sandwich panel can be shipped in a disassembled
9 form and assembled and erected on site;
- Once assembled, the sandwich panal unit can be
11 moved without disassembly, if sufficient workmen
12 are available. But, if necessary, the sandwich
13 panel unit can be disassembled, usually without
14 damage, and moved in pieces by one worker~
- If one of the gypsum board panels is damaged, it
16 can be removed from the unit and a new panel
17 substituted;
18 - If a gypsum board panel is riding a little high
19 on the frame, there is some give in the spring
alip and suspension channels, which will usually
21 permit one to drive the panel downwardly far
22 enough so that its top and bottom edges are flush
23 with the corresponding edges of the ~rame- and
24 - A monolithic appearance can be well achieved if
the following requirements are met:
26 - the gypsum board panels and frame members
27 are of consistent thickness,
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1 - a plurality of lines of suspension assemblies
2 and V-channels is used and they cooperate to
3 pull the panels of a unit into even contact
4 with the frame, and
- levelling means are provided and adjusted t~
6 bring the panel unit into a plumb condition.
7 Broadly state~, the invention is a discrete sandwich
8 panel unit for use in a partition wall, comprising: a pair of
9 gypsum board panels having front and rear faces; a plurality of
suspension asssmblies of the gang nail plate/cam clip type
11 ~ecured to each panel at its rear face to form at least one
12 transverse linear array located between the upper and lower ends
13 of the panel; a rectangular frame formed of top, bottom and side
14 members detachably secured together by connectors at the corners,
said frame further aomprising at least one horizontal suspension
16 channel detachably secured by connectors at its ends to the side
17 members, each such channel being positioned to correspond with
18 an array, each such suspension channel having upwardly projecting
19 means for supporting and engaging the suspension assemblies, said
connectors and frame members cooperating to form a substantially
21 rigid and plum frame; the rear face of each panel abutting a main
22 face of the frame, said panel belng suspended from the suspension
23 ~ ohannel by the suspension assemblies, whereby said panels bracket
24 the frame; said suspension assemblies being adapted to draw the
,
panels in tightly against the frame as the panels are suspended
26 ~rom the suspénsion channel; and disengageable bracket means,
,
27 adapted to lock with the frame, for clamping each panel against
~:~:28 the frame; so that the drawing of the panals in tightly against
29 ~he frame, the clamping actlon of the braoket meane, and the
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1 rigidity of the frame itself combine to provide a cohesive,
2 rectangular, substantially non-racking, unitary assembly.
3 DESCRIPTION OF THE DRAWINGS
4 Figure 1 is a perspective front vi~w showing a
plurality of abutting sandwich panel units positioned between
6 ceiling and floor channels, with one sandwich panel unit partly
7 broken away to show the internals and frame;
8 Figure 2 is a sectional side view of the sandwich panel
9 unit engaging a ceiling channel and a floor channel;
Figure 3 is a top plan view showing a pair of adjacent
11 sandwich panel units held together in aligned formation by
12 brackets;
13 Figure 4 is a perspective view showing a single
14 suspension assembly engaging a V-shaped suspension;
Figure 5 is a plan view of a suspensionlassembly;
16 Figure 6 is an end view of a V-shaped suspension
17 ahannel;
18 Figure 7 is an end view of a horizontal frame bottom
l9 member;
Figure 8 is an end view of a vertical frame side
21 ~member;
22 Figure 9 is an end view of a post cap jointer or
23 alignment bracket;
24 Figure 10 is an end view of a clamping bracket; and
Figure 11 is a perspective view of a spacer used to
26 support the panels.
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1 DESCRIPTION OF THE PREFERRED EMBODIMENT
2 The sandwich panel unit 1 comprises a rectangular frame
3 2 formed of channel-like aluminum extrusions. More paxticularly,
4 the frame 2 comprises top and bottom members 3 & 4 r~spectively,
a pair of side members 5, and a plurality of horizontal, v-
6 shaped suspension channels 6. The members 3,5 and 4,5 are joined
7 together at the corners by screw splines 7, which are screwed
8 into receptacles 7a formed on the members themselves. ~he
9 suspension channels 6 are similarly connectsd by screw splines
7 to the side members 5 at vertically spaced locations. The
11 resulting frame is quite rigid and plumb, however it still has
12 some tendency to rack.
13 A pair of gypsum board panels 8 are provided. Each
14 panel 8 has a plurality of horizontally extending, linear arrays
9 of suspension assemblies 10 secured to it at its rear face 11.
16 Each suspension assembly 10 is of the known gang nail plate/cam
17 clip type. More particularly, it comprises a gang nail plate 12
18 having tangs (which are formed by punching out sections 13 of the
19 plate 12), which may be embedded in the panel 8. The gang nail
plate 12 further forms a clip-engaging slot assembly 14 and has
21 a pair of scored lateral lines 15 of weakness located just above
22 and below the slot assembly 14. The upper portions 16 of the cam
23 clips 17 may be inserted into the slot assemblies 14, as shown.
2A The lower, downwardly angled cam portions 18 of the clips 17,
when dropped into engagement with the suspension channels 6,
26 function to co-act with the lips 19 of the channels to draw the
27 panel 8 in tightly against th~ frame 2. When the panel 8 is hung
28 from the suspension channels 6 in this way, the upper and lower
29 portions 16, 18 of the gang nail plates 12 bend slightly about
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1 the weakness lines 15, so that the tangs clinch into the panel
2 material at a slight angle.
3 One panel 8 is mounted on each side of the frame 2 so
4 that the rear face 11 of each panel abuts a main face 2la of the
frame 2. The panels 8 thus bracket the frame 2.
6 Spacers 37 are suspended from the suspension channels
7 6, to bear against the rear faces 11 of the panels 8 at 24~
8 spacings. Stated otherwise, the spacers 37 function like
9 vertical studs at 24" spacing to lend support and rigidity to the
easily flexed panels.
11 Con~entional sound-proofing material 20 may be stuffed
12 into the space between the panels 8.
13 The panels 8 are sized so as to substantially conform
14 to the perimeter of the frame 2. The arrays 9 of suspsnsion
assemblies 10 ars positioned on the panels 8 so as to
16 sub~tantially correspond with the locations of the V-shaped
17 suspension channels 6. The arrays 9 may be deliberately located
18 a trace high. When this is done and the panel 8 rides a little
19 high, it may be forced downwardly a short distance - the "give"
of the channel lip 19 and the cam clips 17 will permit this to
21 occur. When this is done, the panels 8 are drawn in particularly
22 tightly against the frame 2, thereby contributing to forming the
23 sandwich panel unit 1 into an integral cohesive article.
24 A pair of L-shaped bayonet members 21 project
downwardly and outwardly from the bottom surface 22 of the
26 bottom frame member 3. A similar pair of L-shaped bayonet
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1 members 23 project upwardly and outwardly from the top
2 surface 24 of the top frame member 3. The lower bayonet
3 members 21 cooperate with the surface 22 to form a slot 25.
4 Similarly, the upper bayonet members 23 cooperate with the
surface 24 to form a slot 26. Upper and lower clamping
6 brackets 27 are provided to cooperate with each of the
7 bayonet members 21, 23 to clamp and lock each gypsum board
8 panel 8 tightly to the frame 2. More particularly, each
9 clamping bracket 27 is generally L-shaped in configuration
and comprises a vertical portion 28 and a pair of spaced
11 apart, horizontal portions 29, 30. The horizontal portions
12 29, 30 form a socket 31, for receiving the appropriate
bayonet member 21 or 23. The horizontal portions 29, 30 each
14 have inwardly projecting ratchet-type t0eth 32 for locking
onto the enlarged head 33 of the pertinent bayonet member 21
16 or 23. Nhen each clamping bracket 27 is secured to the
17 pertinent bayonet member 21 or 23, it cooperates with the
18 vertical side wall 34 of the adjacent top or bottom frame
19 member 3 or 4 to form a vice, which receives, clamps and
supports the end portion of the panel 8.
21 From the foregoing description, it is seen that the
22 clamping brackets 27 lock with the frame 2 by means of th~
23 bayonet members 21, 23 and are operative to clamp the panels
24 8 tightly against the frame 2.
As a result of the combination of:
26 - the interac~ion of the cam clips 17 and the
27 channel lips 19, and
28 - the interaction of the clamping brackets 27
29 with the bayonet members 21, 23,
13
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1 the two gypsum board panels B in essence become integral and
2 cohesive with the frame 2, to produce a unitized assembly
3 which is adequately resistive to racking and which may be
4 moved about as a unit.
The frame 2 is provided with a pair of laterally
6 spaced, vertically extending, threaded bolts 38 projecting up
7 through openings formed in the horizontal web 39 of the frame
8 bottom member 4. Each bolt 38 has a large hexagonal head 40
9 at its lower end, which may be turned to level and plumb the
sandwich panel unit 1.
1l A plurality of the sandwich panel units 1 are used
12 in conjunction with floor and ceiling tracks 41, 42,
13 alignment brackets 43 and jointer members 60, to form a
partition wall 45.
15 More particularly, a channel-like ceiling track 42
16 is suspended from the building ceiling by a T-bar 46. The T-
17 bar 46 has secured to it a downwardly extending threaded bolt
18 47. The ceiling track 42 is secured to the T-bar 46 by a nut
lg 48 threaded onto bolt 47. Sound-proofing material 49 may be
provided between the T-bar 46 and the track 42.
21 The ceiling track 42 has an outwardly projecting
22 bayonet member 50 on each side. A pair of elongated L-
23 shaped alignment members 43 are provided, each having a
24 vertical portion 51 and spaced apart, parallel, horizontal
25 portions 52, 53. The portions 52, 53 have inwardly
26 protruding, ratchet-type teeth 54. The alignment brackets
27 43, when snapped onto the bayonet members 50, function to
28 align adjacent sandwich panel units 1 in linear formation and
14
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~o support them laterally at their upper ends so that they
2 are prevented from toppling over.
3 The floor track 41 is provided on its underside
4 with a strip 55 of carpet hook fastener, which secures it to
the carpet. An inverted channel-like member 56 is positioned
6 within the track 41 to laterally suppor~ the le~elling bolt
7 38. A pair of elongated base trim members 57 clip onto the
8 track side legs 58 and extend up to the base portions of the
9 panels 8, to mask the assembly at the foot of the unit 1.
l Adjoining sandwich panel units l are joined
ll together by a jointer member 60. More particularly, the
l2 frame side members 5 are formed with bayonet members 61. The
13 jointer member 60 has inwardly projecting members 62, 63
l4 which form sockets that snap onto the bayonet members 61 to
hold the units 1 together.
16 The system shown in the drawings is a specific form
l7 of the invention. The scope of the invention is defined by
18 the claims now following.
