Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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AN OFFICE SPACE DIVIDING PANEL AND METHOD
FOR CONSTRUCTING SAME
.. . . .
TECHNICA~ PIELD
The invention relates in yeneral to open office
~pace dividing systems, and more ~pecifically ko an of~ice
space dividing panel and method for construc~ing same.
BACKGROUND ART
Office ~pace dividing systems are constructed of
a plurality of oPfice space dividing panel~, which may be
directly connected together in desired configurations, or
interconnec~ed via posts or o~her ~uitable conneckors.
lo U.S. Patent 3,762~116, which is a~signed to the same
assignee as the present application, is an example of an
office space dividing system which utilizes posts to
support vertical edges o~ space dividing panels.
It is common to cover first and second major
opposed flat sides of a rec~angular space dividing panel
with rectangular fabric pieces for sound absorption and
esthetics. Each space dividing panel has an outer
- perimetrical edge whi~h defines first and second substan-
tially continuous p~ripheral spline grooYes. During
assemb~y of a space dividing panel, each fabric piece i6
manually placed on a major ~ace o~ a space dividing panel
and the edges of the fabric piece are held in the spline
grooves by spline beads, ~imilar to the attachment of a
sareen to a screen door. Appli¢ation Serial No.
07/523,772, filed May 15, 1990, entitled "Office Space
Dividing System~, which application i6 assigned to the
same assignee as the present application, is an example of
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a space dividing panel which includes spline groovQ~ and
splins beads ~or holding ~abric pieces on the outer
sur~aces of a substrate.
It take~ a considerable amount o~ ~ime and
5 assembly skill on the part of an assembler to manually
stretch a fabric piece and place a spline head in a
substantially continuous spline groove which extends about
all four edges of a support ~rame, while maintaining
desired tensions in X Y frame and fabria directions, ie.,
in the directions o~ the width and length (height) of the
panel. Thus, the quality and appearance of the resulting
panel depends upon the skill of the assembler, and the
manufacturing cost of the panel includes manual fabric
attachment time. It would be desirable, and it is an
object of th~ present invention, to provide a new and
improved space dividing panel, and new ~nd improved
methods for assembling space dividing panels, which
enables fabric pieces to be automatically attached to a
substrate or frameO
SUMM~RY OF THE INVEI~TION
Briefly, the pr~sent ir.vention includes a new
and improved method of attaching fabric pieces to a
substrate during the assembly of a ~pace dividing panel.
The ne~ and improved method includes the step of providing
a rectangular frame having first and second major flat
sides which define predetermined length and width dimen-
sions, an outer perimetrical edge extending between the
first and second sides, and a substantially ¢ontinuous
peripheral groove in the outer edge for each fabric piece
to be applied to the frame. In a preferred embodiment of
the invention, the frame is on a conveyor and the length
and width dimension~ are automatically measured. This
length and width information is then used by other
automatic processes of the method.
A next step of the method includes providing a
rectangular fabric piece which has length and width
dimensions which exceed the length and width dimensions,
respectively, o~ the rectangular frame. Since the size of
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the next frame coming along a conveyor is known from the
frame measuring step of a preferred embodlment, the fabric
piece may be automatically cut to size from a roll of
fabric. Once the dimensiona of the next ~rame to be
processed are k~own, the dimensions o~ a rectangular
~abric piece required to provide a desired uniform overlap
of the ~abric past the perimekrical edye of the frame can
be determined.
While a frame is approaching a ~tation where a
fabric piece is to be applied, the step of placing a
pressure sensitive a~hesive in a peripheral groove of the
frame is per~ormed, ie., in a peripheral groove which is
associated with the side of the ~rame to be covered with
the fabric piece. In a preferred embodiment, the pressure
sensitive glue is sprayed into the groove by a robot
holding an adhesive gun which moves about the perimeter of
the frame.
In order to obtain a "soft" layer or bead of
adhesive in the groove, economical usage of the adhesive,
and the dçsired spraying consistency, the adhesive is
heated and foamed with an inert ga~ prior to the spraying
step. The l'soft" bead of adhesive enables the ~abric to
be more easily pressed into the peripheral groove.
The method further includes the step of tension-
ing the fabric piece in the directions of the length andwidth of the fabric piece. It was found that an effer-tive
way of holding and tensioning the ~abric wa~ to insert a
plurality of closely ~paced, slanted needles into the four
edges of the fabric piece, with needle bars employed to
hold the needles being movable, such as via air or
hydraulically operated cylinders, to simultaneously
stretch and tension the ~abric in both the lengkh and
width directions of the fabric piece.
The method then includes the step of automatic-
ally wrapping the tensioned ~abric piece over the ~rameedges, while covering th~a ~ir~t major side o~ the frame
with tha fabric piece. ~hil2 the ten~ioned fabric piece
is so held, a step o~ pressing the tensioned fabric piece
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into the ~ubstantially continuous peripheral groove i5
automatlcaIly performed by movable tucking bar~ which, for
example, ~ay be attached to air or hydraulic cylinders.
The tucking bars advance towards the edges o~ the frame to
press the fabric into the peripheral groove and agalnst
the layer or bPad of adhesive. The resulting pressure af
the fabric and tucking bar against the adhesive during
this pressing step causes the preesure ~ensitive adhesive
to immediately set, which results in the ~abric being
~irmly bonded to and held in the peripheral groova
notwiths~anding the ~uick retraction of the tucking bars
from the peripheral groove.
The frame is then manually or automatically
turned over, and the hereinbefore recited method steps are
repeated to apply a fabric piece to the remaining major
side or face of the frame.
The method results in a new and improved space
dividing panel, as the fabric pieces are consistently
highly tensio~ed in both the length ~nd width directions
of the fabric piece, improving the appearance o~ the space
dividing panel. The panel i8 further devoid of spline
beads, which can di~lodge from a spline groove and release
the tension in the fabric. Tha adhesive consistently and
continuously holds the fabric pieces in tension with no
chance of mechanical dislodgement o~ the fabric pieces
from the associated spline groove.
BRIEF DESCRIPTION OF_THE DRAMINGS
The invention will become more apparent by
reading the following detailed description in conjunction
with the drawings which are shown by way of example only,
wherein:
Figure 1 is a perspective view o~ a spac~
dividing panel which may be con~tructed according to the
teachings o~ the invention;
Figure 2 is a view ~imilar to Figure 1, except
illustrating a perspective viaw of only a panel ~rame with
fabric pieces attached thereto, eliminating a raceway
illustrated in Figure 1, which is attached to the lower
- ~ ~ 3 2 ;~ ~ r~
56,231
edge of the ~ramP, as well as eliminating ~lotted stan-
dards and post connec~or hook~ shown in Figur4 1 which are
attached to v~rtical edges of the panel;
Figure 3 is a fragmentary cross sectional view
of the panel frame and fabric asse~bly shown in Figure 2,
taken between and in the direction of arrows III - III,
illustrating the attachment of fabric pieces to tha frame,
along a frame stile;
Figure 4 is a fragmentary sectional view similar
to that of Figure 3, except it illustrates the frame
before fabric pieces are attached thereto;
Figure 5 is a block diagram which illustrates
method steps of applying fabric pieces to a rectangular
frame, according to the teachings of the invention;
Figure 6 is a fragmentary view similar to Figure
4, illustrating a method step of applying an adhesive to a
groove defined by the perimetrical edge of the ~rame; and
Figure 7 ls a ~ragmentary vlew similar ~o Figure
6, illustraking a method ~tep of wrapping a fabric piece
over the perimetrical edge of the frame, as well a~
illustrating a tucking bar which performs a method step of
pressing tensioned fabric into the peripheral groove to
set the adhesive and hold the fabric firmly in the
peripheral groove after the fabria piece is released by
needle bars shown in Figure 7.
DESCRIPTION OF PREFERR}~D EMBODIMENTS
Referring now to the drawing~, and to Figures 1
and 2 in particular, there is shown in Figure 1 a space
dividing panel 10 which may be constructed according to
the teachings of the invention. Space dividing panel 10
includes a frame-fabric assembly 12, which is more clearly
shown in Figure 2. Remaining with Figure 2, frame-fabric
assembly 12 includes a rectangular frame 14 con~tructed of
interconnected metallia rails and stile~, such as first
and second vertical stiles 16 and 18 and upper and lower
rails 20 and 22. One or more rein~orcing aro~ rail~ (not
shown) may be provided, as required by the dimensions of
frame 14. The upper rail 20 may be at the top of the
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assembly 12, or, as illustrated, a wiring trouyh 24 may be
mounted on the upper rail 2~. In a pre~Qrred embodiment
of the invention, the metallic ~rame 14 has a solid core
26, such as a solid ~ypsum core which has been ~oamed in
place within the rails and stiles oP the ~rame~ U.S.
Patent Application Serial No. 06/872,053, f~led June 6,
1986, entitled ~Space Dividing Wall Panel~, which is
assigned to the ~ame assignee a~ the pre~ent application
describes space divider panels wlth ~oamed-in-place gypsum
cores. However, o~her ~uitable ~rame-core arrangements
may be used. .
Raturning to Figure 1, the space dividing panel
10 is completed by fastening a raceway 28 to the lower
rail 22, fastening slotted standards 30 and 32 to the
first and second stiles 16 and 18~ and attaching first and
second ~abric pieces 34 and 36, shown in Figures 1 and 3,
to the fra~e 14.
Frame 14, as shown in Figure 2, has horizontal
width W and vertical length L (height) dimensions, with
tha width dimension W, which is measured from the outer
edge o~ stile 16 the outer edge of stile 18, normally
being selected from a range of about 10 to 60 inchesy and
with tha length dimension L,, which is measured from the
lower edge of bottom rail 22 to the top edge of the wiring
trough 24, normally being selected from a range of about
36 to 76 inches. Frame 14 has a constant depth or
thickness dimension D regardless of the width and length
dimensions W and h, such as a thickness dimension in a
range of about 1.5 to 3 inches.
Frame 14 has first and second flat major opposed
sides, faces or sur~aces 38 and 40, best shown in Figure
4j which are respectively covered by fabric pieces 34 and
36, as best shown in Figure 3. Frame 14 has an outer
perimetrical edge 42 which includes the horizontally
oriented edge~ de~ined by wiring trough 24 and lower rail
22 and the vertically oriented edges defined by tha ~irst
and second stiles 16 and 18.
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Figure 3 i~ a cros~ sectional view o~ ~rame 14,
taken between and in the direction o~ arrows III III in
Figure 2, illustrating the ~lrst stile 16. Plgure 4 is a
view similar to Figure 3, except illustrating ~rame 14
prior ko application o~ ~abric piecea 3~ and 3~. The
outer facing side o~ skile 16, which i8 the side which
~orms part o~ the perimetri.cal edge 42 o~ ~rame 14, is
formed into a c~nfiyuratlon which includes ~irst and
second grooves 44 and 46 immediately adjacent to the flat
major side~ 3~ and 40, respectively, o~-~rame 14. An
intermediate or bridging portion 48 i~ integrally joined
to the sides of grooves 44 and 46. All of the rails and
stiles have a like configuration. If a wiring trough 24
is used, the top o~ the wiring trough would al~o have two
spaced grooves similar to grooves 44 and 46. In order to
provide wlre lay~in capability, the wiring ~rough 2~ would
not have an interconnecting or bridging portlon 48 between
th~ groove~ 44 and 46, as shown for stile 16. Thus, the
outer perimetrical edge 42 o~ frame 14 has ~irst and
second substantially continuous peripheral grooves 44 and
46, which extend about frame 14 closely adjacent to sides
38 and 40, respectively.
Figure 5 is a block diagram which illustrates a
method of applying and attaching fabric pieces 34 and 36
to frame 14 according to the teachings of the invention.
A source 50 o~ ~rames 14 provides one frame after another
to the process, such as via a powered roller conveyor
which serially ~rings frames 14 to the various stations
which perform the steps of the method. When the frames 14
are constructed according to the teachings of th~ herein-
be~ore mentioned Application Serial No. 06/872,053,
for example, the frames leaving ~he process which provides
the foamed-in-place gypsum core may be the ~rame source
50.
Since the width and length dimensions W and L o~
the ~rame 14 may vary widely, such as in the hereinbafore
stated dimen~ional ranges, in a pre~erred embodimPnt o~
the invention each ~rame 14 1B automatically measured to
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obtain its width and length dimensions W and L ~o that khe
size o~ the ~rame 1~ will be known hy proce6sing station~
to which the ~rame will advancP. In one embodiment o~ khe
measuring step, one of the ~rame dimensions, such as the
width dimension W o~ ~rame 14, i5 detected as th~ ~ram~
moves along the conveyor. Conveyor speed and the time
required for the ~rame to pass a ~ensor provid~s inputs
required for a computer to calculate the width dimension
W. Then, frame 14 is stopped at a ~rame measurement
station, indicated at 52 in Figure S. At this station, a
sensor whesl is moved along the length dimension of frame
14 by a drive motor. Revolutions of the sensor drive
motor are counted and provided as an input to a process
computer. The process computer then cal~ulates the length
dimension L from the known diameter of the sensor wheel.
After the measuring step 52, frame 14 advances
to a station 54 where an adhesive is applied to the
surface of one o~ the peripheral grooves 44 or 46. As
illustrated in Figure 6, in a preferred embodiment of the
invention a robot 56 supports an adhesive gun 58 and the
robot 56 traverses the perimeter of frame 14, praying an
adhesive 60 into a selected one of the peripheral grooves,
such as peripheral groove 4~. The travel path o~ robot 5 6
is automatically programmed using th~ frame size informa-
25 tion obtained from the frame measuring step 52~
The adhesive 60 is a pressure sensitive adhesiveselected such that it will bead and stand at room tempera-
ture for hours without setting, requiring pressure to
activate the setting process. An adhesive or glue having
the required characteristics is commercially available
from the H.B. Fuller Company with their designation ~L-
1108.
Adhesive XL-1108 is a hot melt glue which is
; heated to a temperature of ~bout 375 to 400 degrees F
prior to spraying. Al~o, in a pre~erred embodiment of the
invention/ the adhesive 60 i~ ~oamed with an inert gas,
such as nitrogen, ju~t prior to spraying. The ~oaming o~
the adhesive 60 provides the advantages o~ providing a
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"softer" strip or bead of adhesive, enabling ~abric piec~
34 to be more easily pressed into ~he peripheral groove
46. The ~oaming of ~he adhe~ive also enables the amoun~
o~ adhesive applied ~o each ~ram~ 14 to be ~educed, ie.,
it provides increased adhesive mileag~. Suitable hot melt
processors which mix an inert gas with a hot adhesi~e, as
well as suitable adhesive guns, are commercially available
from Nordson corporation, Norcroes, GA. A suitable hot
melt-foam processor is Nordson corporationls 150 Series
Processor, and a suitable adhesive gun is Nordson corpora-
tion's H-201 Zero Cavity.&un.
Fabric piece 34 is provided to the process by a
fabric source 62. Fabric source 62, for example, may be a
roll of fabric which i~ manually or automatically cut,
using the ~ize information ob~ained ~rom the panel
measuring step 52. Fabric piece 34 is cut into a rectan-
gular con~iguration and sized such that it will completely
cover ma~or side 38 of frame 14 while uni~ormly overlapp-
ing all four sides o~ frame 14 by a pred2termined dimen~
sion. ~he predetermined dimension is selected to provide
sufficiant fabric such that the ~abric will enter the
requisite peripheral groove and extend outwardly there~rom
by a dimension su~ficient for fabric pick-up apparatus to
~irmly hold the fabric piece 34 throughout fabric applica-
tion steps indicated generally at 64. In a preferredembodiment o~ the invention, a laminated fabric having a
resilient ~oam backing is used, such as a closed cell
polyurethane foam, but other fabrics may be used.
Suitable fabrics, including foam backed fabrics, are
commercially available from Miliken Company, Guil~ord
Company, and Burlington Company. A~ter the fabric piece
34 is cut it is placed at a loading station associated
with fabric source 62.
The next skeps of the method, shown generally at
64, include a step o~ applylng ~abric piece 34 to ~rame
14. Fabric piece 34 ig picked up at the loading station,
on all ~our sides thereo~, by a ~ixture or assembly 65
which al~o has four sides, automatically adju~table to the
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siæe of the frame 14 being processed. Assembly 65
includes a plurality o~ slanted needles 66 mounted on bars
68. The needles 66 engage fabric piece 34 close ko the
edges thereof. The needle bars 68 are mounted ~or
rectilinear movement, such as by air or hydraulic cylin-
ders ~0. A~ter khe ass~mbly 65 and needle bars 68 move
- down and engage fabric piecs 34 on all four sides~ needle
bars 68 retract to stretch and tension ~abric piece 34 in
the directions of its width and length.
The tensioned ~abric piece 34 is then moved over
frame 14 and downwardly to khe position shown in Figure 7,
wrapping fabric piece 34 downwardly over the ~our perimat-
rical edges of frame 14. Assembly 65 fur~her includes
tucking bars 72 disposed on all ~our sides o~ assembly 65,
with the tucking bars 72 being mounted Por rectllinear
movement, such as via air or hydraulic cylinders 74.
After fabric piace 34 has been wrapped sver the edge of
frame 14, cylinders 74 advance the tucking bars 72 to
press the fabric piece 34 firmly i~to peripheral groove 46
and against the pressure sensitive adhesive 60. The
pressure sensitiv~ adhesive 60 instantly sets in responss
to the pressure applied thereto, bonding a~d holdlng the
fabric piece 34 tightly and uniformly in the desired
position covering the flat major side 38 of frame 14,
The pressing step performed by tucking bars 72 adds to the
tension in the ~ahric piece 34, providing a tightly
tensioned fabric covering over the frame face 38 which
provides a pleasing appearance. The adhesive 60 maintains
its holding strength indefinitely, and unliXe the prior
art use of spline beads, there is no danger of accidental
local detachment of a spline bead and fabric~ from the
frame, which detachment relaxes the tension in the ~abric
and creates wrinkles, or otherwise detracts from the
appearance o~ a ~inished panel 10.
At this point o~ the process, excess fabric may
be manually or automatically trimmed from the ~abric piece
34, or the trimming step may be per~ormed after both
fabric pieces 34 and 36 have been applied, as desired.
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After fabric piece 3~ has been applied and
securely bonded to ~rame 14, step 76 invert~ or turns
~rame 14 over, and the hereinbefore described process is
repeated to apply fabric piece 3~ to cover ~la~ major side
5 40 of frame 14. Step 78 applies hot, fo~med pressure
sensitive adhesive 60 to peripheral groove 44, ~tep 30
cuts ~abric piece 36 to the proper rectangular con~igura-
tion and dimensions, step 82 applies and bonds fabric
piece 36 to side 40 o~ ~rame 14, and etep B4 trims excess
fabric from both pieces 3~ and 36, if piece 34 had not
been prqviously ~rimmed, or only ~rom piece 36 if piece 34
had been previously trimmed. Figure 3 illustrates panel
10 after both fabric pieces 34 and 36 have bsen applied to
frame 14 and trimmed~
In summary, there has been disclosed a new and
improved method of applying fabric pieces 34 and 36 to a
frame 14 during the assembly of a space dividing panel 10
for use in office space dividing furniture systems. The
method eliminates manual attachment of fabric pieces to a
frame via ~pline beads, and it provides a superior of~ice
space dividing panel 10 without reliance upon ~he skill o~
an assembler. The fabric pieces 34 and 36 are more highly
tensioned than fabric pieces applied ma~ually, and ~he
fabric pieees 34 and 36 are pe~manently bonded to the
metallic frame, eliminating accidental local di~lodgement
of a spline bead and fabric edges from spline grooves
formed in the perimetrical edge of the frame.
