Modular wall system having thin walls

Patent metadata

Field	Value
Publication number	US-11952773-B2
Application number	US-202017312896-A
Country	US
Kind code	B2
Filing date	Feb 21, 2020
Priority date	Feb 22, 2019
Publication date	Apr 9, 2024
Grant date	Apr 9, 2024

Abstract

A pre-fabricated wall system can include a first thin wall module and a second thin wall module. The two thin wall modules have a depth defined by a distance from a front surface of each thin wall module to aback surface of each thin wall module. The pre-fabricated wall system can further include a vertical connection post that has a first connection interface on a first side configured to secure to the first thin wall module. The first connection interface can include a first channel. The vertical connection post can also include a second connection interface on a second side opposite the first side configured to secure to the second thin wall module. The second connection interface can include a second channel. The two thin wall modules can be parallel or co-planar to one another when the two thin wall modules are secured to the vertical connection post.

First claim

What is claimed is:

1. A pre-fabricated wall system configured for a thin wall module configuration, comprising:
two thin wall modules, including a first thin wall module and a second thin wall module, the two thin wall modules having a depth defined by a distance from a front surface of each thin wall module to a back surface of each thin wall module, wherein the first wall module includes a first vertical end frame that includes a first channel, the first channel comprising, a first channel protrusion, and wherein the second wall module includes a second vertical end frame that includes a second channel, the second channel comprising a second channel protrusion;
a vertical connection post comprising:
a first connection interface on a first side configured to secure to the first thin wall module, the first connection interface including a corresponding first channel that includes a corresponding first channel protrusion; and
a second connection interface on a second side opposite the first side configured to secure to the second thin wall module, the second connection interface including a corresponding second channel that includes a corresponding second channel protrusion, wherein the first channel protrusion of the first channel of the first vertical end frame of the first wall module is configured to align with the corresponding first channel protrusion of the corresponding first channel of the first connection interface, and wherein the second channel protrusion of the second channel of the second vertical end frame of the second module is configured to align with the corresponding second channel protrusion of the corresponding second channel of the second connection interface; and

first and second connectors, wherein:
the first connector is configured to fit over at least a portion of the first channel protrusion and the corresponding first channel protrusion to secure the first thin wall module to the vertical connection post; and
the second connector is configured to fit over at least a portion of the second channel protrusion and the corresponding second channel protrusion to secure the second thin wall module to the vertical connection post;

wherein the two thin wall modules are parallel or co-planar to one another when the two thin wall modules are secured to the vertical connection post.

2. The pre-fabricated wall system of claim 1 , wherein the first connection interface is positioned on the first side such that the two thin wall modules are co-planar when the two thin wall modules are secured to the vertical connection post.

3. The pre-fabricated wall system of claim 1 , further comprising:
first and second channel inserts, wherein:
the first channel insert is configured to reside within the first channel of the first connection interface and the channel of the first vertical end frame of the first thin wall module to secure the first thin wall module to the vertical connection post; and
the second channel insert is configured to reside within the second channel of the second connection interface and the channel of the second vertical end frame of the second thin wall module to secure the second thin wall module to the vertical connection post.

4. The pre-fabricated wall system of claim 1 , wherein the first and second connectors comprise seals configured to fill gaps formed between the first and second thin wall modules and the vertical connection post when the first and second thin wall modules are secured to the vertical connection post.

5. The pre-fabricated wall system of claim 1 , wherein the first and second thin wall modules each comprise a wall tile that comprises a solid sheet of material such that no interior cavity is formed within the wall tiles of the first and second thin wall modules.

6. The pre-fabricated wall system of claim 1 , wherein the first and second thin wall modules are less than four inches thick.

7. The pre-fabricated wall system of claim 1 , wherein the first and second thin wall modules are between 1.5 inches and 2.75 inches thick.

8. The pre-fabricated wall system of claim 1 , wherein the two thin wall modules comprise solid glass.

9. The pre-fabricated wall system of claim 1 , wherein the first and second vertical end frames comprise an acoustic filler material extending through additional channels of the first and second vertical end frames.

10. A pre-fabricated wall system configured for a thin wall module configuration, comprising:
two wall modules, including a first wall module and a second wall module, the first and second wall modules having a depth defined by a distance from a front surface of each wall module to a back surface of each wall module;
a first vertical end frame attached to a vertical edge of the first wall module;
a second vertical end frame attached to a vertical edge of the second wall module; wherein:
each of the first and second vertical end frames includes a channel;

a vertical connection post comprising:
a first connection interface on a first side configured to secure to the first wall module, the first connection interface including a first channel; and
a second connection interface on a second side opposite the first side configured to secure to the second wall module, the second connection interface including a second channel; and

first and second channel inserts, wherein:
the first channel insert is configured to reside within the first channel of the first connection interface and the channel of the first vertical end frame of the first wall module to secure the first wall module to the vertical connection post; and
the second channel insert is configured to reside within the second channel of the second connection interface and the channel of the second vertical end frame of the second wall module to secure the second wall module to the vertical connection post;

wherein the first and second wall modules are arranged non-parallel to one another when the first and second wall modules are secured to the vertical connection post.

11. The pre-fabricated wall system of claim 10 , wherein the first and second wall modules form a right angle when both are secured to the vertical connection post.

12. The pre-fabricated wall system of claim 10 , wherein the vertical connection post comprises a corner protrusion configured to receive a seal for sealing a gap formed between the first and second wall modules when the first and second wall modules are secured to the vertical connection post.

13. The pre-fabricated wall system of claim 10 , wherein:
the first and second wall modules each comprise a wall tile that comprises a solid sheet of material that is less than one inch thick, such that no interior cavity is formed within the wall tiles of the first and second wall modules; and
the first and second vertical end frames of the first and second wall modules are less than three inches thick.

14. A pre-fabricated wall module for use in the pre-fabricated wall system as recited in claim 10 , the pre-fabricated wall module configured for a thin pre-fabricated wall configuration, comprising:
a pre-fabricated wall tile; and
a third vertical end frame connected to a vertical edge of the pre-fabricated wall tile, the third vertical end frame comprising:
a first channel configured for receiving the vertical edge of the pre-fabricated wall tile; and
a second channel disposed opposite the first channel, comprising:
a shared channel wall that is shared between the first channel and the second channel;
a second channel opening that faces a direction that is opposite to a first channel opening of the first channel;
channel protrusions extending in

Assignees

• Dirtt Environmental Solutions

Inventors

• Gosling Geoff W
• Brown Thomas A
• Blehm Colin V
• Merchant Taylor W

Classifications

• E04B2/7453 Primary

  with panels and support posts, extending from floor to ceiling · CPC title

• E04B2002/7461

  Details of connection of sheet panels to frame or posts · CPC title

• E04B2002/7492

  used in partitions extending from floor to ceiling · CPC title

• E04B2/7836

  with only two sides of the profiles having substantially similar undercut grooves or connecting projections · CPC title

• E04B1/6162

  the connection made by an additional locking key · CPC title