US3423894A - Panel wall system - Google Patents

Description

Jan. 28, 1969 c. R\CHARDSON IANEL WALL SY STEM RN NN C- RICHARDSON Jag. 28, 1969 PANEL WALL SYSTEM Sheet Filed Dec. 4, 1967 3wW W 2% W 5, m, M

Jan. 28, 1969 c. RICHARDSON 3,423,894PANEL WALL SYSTEM 2 83 [Aft [#7223 3r auras flaw/P250 ,2? F I G. 6

Imp/K675.

United States Patent 7 Claims ABSTRACT OF THE DISCLOSURE A panel system in which supporting members at the floor and ceiling location provide the anchorage for slide or lift in panels and panel stiffening members, and also wherein a few simple form pieces adapt the system to a wide variety of installations.

This invention relates to improvements in panel wall systems and in particular to non-load bearing panelled walls for original installation or as a cover or refacing on an existing wall.

The problems in the field of panel wall systems for buildings are generally summed up as being too complicated except for highly skilled persons and too expensive for the average person interested in having a panelled wall. It is also a known problem that many panel wall systems must have appreciable depth or thickness to develop lateral strength. Other prior panel wall systems are objectional for universal application because they usually have only one finished face surface and when both face finishes are needed a second wall assembly is required. Still other systems rely on extensive use of fastening 'means which usually renders such wall panel systems entirely unsuited for reuse in any other place.

It is, therefore, an important object of this invention to provide a panel wall system that avoids most of the problems usually associated with them.

It is a general object of this invention to provide an improved panel wall system in which standardization of parts and simplicity of form and assembly of such parts is of paramount interest and importance.

A preferred embodiment of this invention includes installation of lower and upper channel runners secured to a fixed part of a building, and thereafter the fitting together of the panels and stiffeners in the channels without fastening means. It is a feature of the present system that the panels are seated in grooves and slots about the periphery thereof such that a substantially fully interlocked wall will result. Other embodiments and variations will be described in the course of the following specification which refers to the drawings, in which:

FIG. 1 is a perspective view of the panel wall system installed on three sides of a room in a building, residence, basement, or similar structure;

FIG. 2 is a sectional view taken at line 2-2 in FIG. 1;

FIG. 3 is a greatly enlarged sectional view at line 3-3 in FIG. 1;

FIG. 4 is a greatly enlarged sectional view of a modified type of a wall stiffener which may be employed in the wall system of FIG. 1, the view being taken atline 44 in FIG. 1;

FIG. 5 is a fragmentary exploded perspective view of the stiffener means shown in FIG. 4;

FIG. 6 is a greatly enlarged vertical sectional view taken at line .66 in FIG. 1;

FIG. 7 is a fragmentary view of a one-piece panel stiffener differing from that seen in FIGS. 4 or 5;

FIG. 8 is a greatly enlarged perspective view of a filler molding piece;

FIG. 9 is a fragmentary view of a supporting corner channel for a corner assembly;

FIG. 10 is a greatly enlarged fragmentary sectional view of a typical wall meeting junction.

FIG. 11 is a greatly enlarged view of a modified corner assembly for the panel wall system;

FIG. 12 is a greatly enlarged sectional view of a wall meeting junction including a door mounting treatment;

FIG. 13 is a vertical sectional view of a panel installation to show details of the supporting upper and lower channels;

FIG. 14 is a perspective view of the corner assembly details for the upper channel shown in FIG. 13

FIG. 15 is a perspective view of the corner assembly details for the lower channel shown in FIG. 13; and

FIG. 16 is a view similar to FIG. 13, but showing a modified arrangement.

Reference will now be directed to FIGS. 1 to 9 inclusive for details of a preferred panel wall system. In FIG. 1 the panel wall system is shown in elevational perspective between afloor surface 20 and ceiling 2.1 of acoustical tile or the like. The wall is composed of Vertically extendingpanels 22 all of which are essentially cut to a modular width and interlocked with panel stiffeners orstuds 23 and 24. The corners include anassembly 25 of pieces to be described in FIG. 3. Thestud 24 is of a type to allow finishing the meeting of two panel stretches in a simple manner as is shown in FIGS. 4 and 5, while thestuds 23 of FIG. 7 are applied in other places for supporting thepanels 22, such as in the assembly of FIG. 1. Modular panels are usually four feet wide and any length from eight feet to twelve feet. When extra stiffness is desired the panels can be reduced in width.

In starting the erection of a panel assembly a lower channel 26 (FIGS. 1 and 6) is first secured by nails or other appropriate securing means 27 to thefloor 20. The lower channels are formed with an outerlow flange 28 and a rearhigh flange 29 spaced by theweb 30. Where thechannels 26 meet at a corner, a miter seam 31 (FIG. 9) is formed. Vertically above thelower channels 26 the upper orceiling channels 32 are secured by 'means 33 to theceiling 21. Eachupper channel 32 is formed with afront flange 34 and arear flange 35 spaced by theweb 36. The lower andupper channels 26 and 32, respectively, are carefully vertically aligned and brought into longitudinal parallelism such that the vertical distance is substantially uniform along the lengths thereof.

Thewall panels 22 are then assembled by starting at the corners, as in FIG. 1. Referring now to FIG. 3 thecorner assembly 25 is made 'by placing an outsidevertical angle stud 37 in thelower channel 26 in abutment with therear flanges 29. The upper end of thisoutside angle stud 37 is best inserted into theupper channel 32 first. This is made possible by reason of thelow flange 28 on thebottom channel 26. A cooperating insidevertical angle stud 38 is next inserted into thechannels 26 and 32. Thesecorner studs 37 and 38 are substantially the same in size and shape, and are dimensioned to form slots therebetween to receive themargins 22a of thewall panels 22 in a snug fit. To the left of thecorner assembly 25 in FIG. 3 thepanel 22 has its oppositemarginal edge 22a fitted into oneedge slot 23a of avertical stud 23 of the character seen in FIG. 7. Thestud 23 is mounted in thechannels 26 and 32 and slid toward thepanel edge 22a to make the connection. This assembly procedure is repeated outwardly from two opposite corners (FIG. 2) until a final meeting joint is reached.

The meeting joint of FIG. 2 is established with the installation ofstud 24 of FIGS. 4 and 5.Such stud 24 is composed of arear stud element 24a having a pair of rabbetedsteps 39 which leave a central raised flat 40 therebetween. The facing stud element 24b is a fiat member which abuts the face of the raised fiat 40' and forms lips over eachstep 39 such that opposite full length slots are created to receive theedges 22a of twoadjacent panels 22. The stud elements are secured together byblind fasteners 41 havingtoothed edges 42 for biting into the surfaces of receivingrecesses 43 and 44 in therear stud element 24a and the face element 24b respectively. A plurality offasteners 41 are spaced along the length of thestud 24 to obtain a secure assembly.

On reaching the joint atstud 24 therear stud element 24a is first placed in position. The twoadjacent panels 22 are then inserted by pushing the upper ends upwardly inchannel 32 so the lower end will clear thelow flange 28 of thelower channel 26. Thepanels 22 are then lowered into thechannel 26, but the upper end (FIG. 6) will remain within theflange 34 of theupper channel 32. The facing stud element 24b is then placed in position and is pushed inwardly so thefasteners 41 enter the recesses 44 (FIG. 4) and retain the element 24b tight against theadjacent panels 22.

The panel wall is finished by inserting filler molding strips 45 (FIG. 8) into thelower channel 26 betweenstuds 23 and 24. Eachfiller strip 45 may have adecorative molding edge 46 of any suitable configuration. A similar molding filler strip 47 (FIG. 6) is placed in theupper channel 32 between thestuds 23 and 24. The upper strips 47 are dimensioned somewhat differently from thelower strips 45 and are secured by applying a suitable mastic r adhesive 48 on the hidden edge opposite the exposed shapededge 49.

In the foregoing description it is evident that no nails, screws or the like are used or required to assemble thepanels 22 and thestuds 23 or 24. The exceptions are the securing means 27 and 33 to initially locate and retain the lower and upper channels respectively, and the blind fastening means 41 for the joint formingstuds 24. Where, as in FIG. 1, only one surface of thepanels 22 and thestuds 22 and 24 are exposed to the room side, suitable surface finishing is applied. The surfaces thus exposed may be given a desired wood or painted finish, or it may be covered with a patterned or plane paper of any desired color, or color combination.

In FIG. there is shown a portion of an assembly where a room divider panel is connected. Thewall panel assembly 50 is erected as described in connection with FIGS. 1, 2 or 3. Theroom divider wall 51 is then located in alignment with astud 23, for example, and thelower channel 26 is secured in position on thefloor 20. The ceiling channel 32 (not shown) is likewise properly located as before described. Anabutment stud 52 having a singlevertical slot 53 is placed in thechannel 26 and a plurality ofscrews 54 are inserted in theslot 53 to penetrate thestud 23 and form blind fastening of thestud 52 to thestud 23. Next thepanel 22 is brought into position, and filler strips 45 are dropped into position on each side of thepanel 22 to secure the lower end of the panel. In this installation both sides ofpanel 22 are exposed and may be finished as desired. Theedge 22a of thepanel 22 fully conceals the fastening screws 54 so that a neat and secure abutment is obtained.

Referring to FIG. 11 there is shown a modifiedcorner assembly 55. Thelower channels 26 in this assembly are secured in desired position as before described. The mitered corner is occu ied with a one-piecevertical stud 56 having two adjacent edges formed withslots 57 to receive theedges 22a of twomeeting panels 22. Filler strips 45 are then dropped into position in thechannels 26 to secure the lower ends of the panels and provide a finishing molding.

FIG. 12 illustrates a panel assembly to accommodate adoor 60. In this assembly astud 23 in a wall panel of the character before described is selected for supporting adoor jamb member 61. Thejamb 61 is similar to thestud 52 shown in FIG. 10. The lower end of thejamb 61 is secured in a channel 26a which is an abbreviated length of the channel of FIG. 6. Thejamb 61 is secured by spacedscrews 62 to the face ofstud 23, and adoor stop strip 63 is secured to the margin of thejamb 61 so that the edge of the door is concealed in the usual manner. The opposite margin of the door opening is defined by asecond jamb 61 which is positioned in the terminal end of thechannel 26. The jamb is placed with its singlevertical slot 63 directed to receive theedge 22a ofpanel 22. Filler strips 45 are assembled to finish the bottom margin ofpanel 22 on both exposed sides. Finally adoor stop 64 is attached to thejamb 61 to receive the outer edge of thedoor 60. A plurality of door hinges 65 are applied to swing the door from thejamb 61 abutting thestud 23. Thejambs 61 are identical so that a minimum number of different parts are required to make up the assembly of this view.

Turning now to FIGS. 13, 14 and 15 a further modification is seen for supporting thewall panels 22 and joining studs 23 (orstud 24 as the case may be). In this view, no filler strips 45 or 47 are required. Instead thelower channel 66 is formed with a lower facingflange 67 having aninturned mold flange 68 with a hidden lip 69 to add stiffness and provide an abutment on the lower end of thepanel 22. Thechannel 66 has a highrear flange 70 spaced from theflange 67 by thebottom web 71. Securing means 72 is applied through theWeb 71 to hold the channel on thefloor 20. The upper orceiling channel 73 is formed with a finishingmolding flange 74 of cove configuration (other shapes may be selected as desired). Thecove flange 74 has an integral molded or shapedflange extension 75 and an inturnedhidden lip 76 abutting the upper end of thewall panel 22. The integral forming of the flange extension ormolding 75 requires that at each location of astud 23 or 24 a portion must be cut away to allow the assembly of the studs. In a modular system the cut away portions are easily pre-formed so that no extra work is usually necessary at the site of installation. The rear flat flange 77 is spaced from thecove flange 74 by theweb 78, and securing means 79 is driven through theweb 78 into theceiling 21.

As can be seen in FIG. 14, theupper channels 73 require a separately constructed corner member 73a having matchingcove flanges 74a and flange extensions 75a with hidden lips 76a and flat rear flanges 77a. The web 78a is also modified to provide adepressed finger element 80 in each branch of the corner. The fingers are formed by lancing the material in known manner. In a similar manner the joining ends of thechannels 73 are formed with lanceddepressed finger elements 81 similar tofinger elements 80.Alignment plates 82 are provided to fit over thefinger elements 80 and 81 at the junction ofchannels 73 with the corner member 73a and substantially align the channels with the corner members. Theplates 82 are suflieiently wide to snugly fit inside the channels and corner member so that proper matching of thecove flanges 74 and 74a is obtained.

In FIG. 15, thelower channel 66 requires aseparate corner member 66a having front low flanges 67a andinturned mold flanges 68a with hidden stiffening lips 69a. The member is provided with high rear flanges 70a spaced from the flanges 67a by theflat webs 71a. Thecorner member 66a is properly aligned with thechannel 66 by an alignment strip orplate 83 which fits between the flanges 67a and 70a and slides into thechannel 66 between flanges 67 and 70. The form of thecorner member 66a of FIG. 15 is adapted to receive acorner assembly 25 shown in FIG. 3 and for this purpose eachmold flange 68a is notched at 84.

In FIG. 16 a modified panel assembly is shown. This form of assembly includes alower channel 85 having a pair oflow flanges 86 spaced by aflat web 87 through which a securing means 88 is driven into thefloor 20. Eachflange 86 is finished by aninturned mold flange 89 and each has a hiddenlip 90 to increase the stiffness thereof. Theupper channel 91 is formed withopposite cove flanges 92 and finishinglips 93. The lips abut the faces of thestuds 23 and betweenstuds 23 filler strips 47 are placed, as in FIG. 6. Thestrips 47 are held in assembly by suitableadhesive material 48 against theflat web 94. Securing means 95 holds thechannel 91 on theceiling 21.

There has been set forth in the above description certain preferred forms of the wall panel assembly which constitutes the present invention. It is now evident that a major portion of the assembly is composed of similar parts so that only a minimum number of specially formed parts is needed. The manner of assembly is unique and simple to the extent that the panels and studs can be easily maneuvered into position and all the room necessary for assembly is concealed by the ceiling channels after the studs and panels are lifted upwardly into the ceiling channels and lowered into the floor channels. It is especially unique that the parts are securely interlocked without fasteners, and it is the aim to include the several embodiments of this invention within the scope of the appended claims.

What is claimed is:

1. A panel wall system including lower and upper channel supports substantially vertically aligned and horizontally substantially parallel, said lower channel opening upwardly and having flanges defining the channel space therebetween, said upper channel opening downwardly and having flanges defining the channel space therebetween, a series of studs spaced along said channel supports and fitted snugly between said flanges, wall panels mounted in said channel supports between said flanges and engaged with said studs, said studs supporting and stiffening said panels, and means to finish off the space between said panels and at least one flange of said lower and upper channel supports, said finish means being on the same side of the panels.

2. The panel wall system of claim 1 wherein said finish means are strips having a mold edge exposed between adjacent studs, said finish means stiffening said wall panels between said studs.

3. The panel wall system of claim 1 wherein said lower channel flanges comprise a low front flange and a high rear flange, and said finishing means between said panel and low flange of the lower channel being at least as high as said high rear flange.

4. The panel wall system of claim 1 wherein at least one of said flanges on said floor and ceiling channels is integral with said finish means, and said integral flange and finish means are on the same side of said wall panels.

5. The panel wall system of claim 1 and including a corner assembly for wall panels meeting at an angle to each other, said corner assembly comprising lower and upper corner shaped channels, and stud means in said corner channels providing slots to receive and support edge margins of said adjacent wall panels meeting at the corner.

6. The panel wall system of claim 5 in which said stud means in said corner channels comprises two angle members of substantially the same shape and dimensions.

7. A wall panel system including an upwardly opening floor mounted channel having front and rear flanges, a downwardly opening ceiling mounted channel having front and rear flanges aligned with the corresponding flanges of said floor channel, a series of wall panels p0- sitioned between said floor and ceiling channels, stud means interposed between said series of panels, said stud means engaging edge margins of said panels and locking said panels between said front and rear flanges on said floor and ceiling channels, one of said stud means comprising two elements jointly engaging edge margins of two adjacent panels, means locking said two elements in assembled abutment to secure said series of wall panels in assembly, and mold means closing the space between each panel and said front flanges of said floor and ceiling channels.

References Cited UNITED STATES PATENTS

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