Modular wall systems having thick and thin walls

Patent metadata

Field	Value
Publication number	US-12000144-B2
Application number	US-202017312895-A
Country	US
Kind code	B2
Filing date	Feb 12, 2020
Priority date	Feb 12, 2019
Publication date	Jun 4, 2024
Grant date	Jun 4, 2024

Abstract

A pre-fabricated wall system that joins wall modules of different thicknesses can include a thin wall module having a depth defined by a distance from a front face thereof to a back face thereof, a thick wall module having a depth that is greater than the depth of the thin wall module, and a vertical connection post. The vertical connection post can include a first connection interface on a first side configured to secure to the thin wall module and a second connection interface on a second side opposite the first side configured to secure to the thick wall module. The thin wall module and the thick wall module can be arranged parallel or co-planar to None another when both the thin wall module and the thick wall module are secured to the vertical connection post.

First claim

What is claimed is:

1. A pre-fabricated wall system that joins wall modules of different thicknesses, comprising:
a thin wall module having a depth defined by a distance from a front face thereof to a back face thereof;
a thick wall module having a depth that is greater than the depth of the thin wall module; and
a vertical connection post comprising:
a first connection interface on a first side configured to secure to the thin wall module;
a second connection interface on a second side opposite the first side configured to secure to the thick wall module;
a first channel insert configured to reside within the first connection interface and to secure to the thin wall module; and
a second channel insert configured to reside within the second connection interface and to secure to the thick wall module;

wherein:
the first channel insert secures the thin wall module to the vertical connection post;
the second channel insert secures the thick wall module to the vertical connection post;
the thin wall module and the thick wall module are arranged parallel or co-planar to one another when both the thin wall module and the thick wall module are secured to the vertical connection post; and
the thin wall module comprises: a wall tile; and a vertical end frame connected to a vertical edge of the wall tile, the vertical end frame comprising a channel.

2. The pre-fabricated wall system of claim 1 , wherein:
the first connection interface is positioned on the first side; and
a face of the thin wall module and a face of the thick wall module are co-planar when both the thin wall module and the thick wall module are secured to the vertical connection post.

3. The pre-fabricated wall system of claim 1 , wherein:
the first connection interface is positioned on the first side; and
center planes of both the thin wall module and the thick wall module are aligned when both the thin wall module and the thick wall module are secured to the vertical connection post.

4. The pre-fabricated wall system of claim 1 , wherein the first connection interface comprises a channel.

5. The pre-fabricated wall system of claim 4 wherein:
the first channel insert is configured to reside within both the channel of the vertical end frame and the channel of the first connection interface;
the second channel insert is configured to reside within both the channel of the vertical end frame and the channel of the second connection interface; and
the channel insert secures the thin wall module to the vertical connection post.

6. The pre-fabricated wall system of claim 4 , wherein:
the channel of the vertical end frame of the thin wall module has a channel protrusion that is configured to align with a channel protrusion of the channel of the first connection interface.

7. The pre-fabricated wall system of claim 6 , further comprising:
a connector configured to fit over at least a portion of the channel protrusion of the vertical end frame and the channel protrusion of the first connection interface to secure the thin wall module to the vertical connection post.

8. The pre-fabricated wall system of claim 7 , wherein:
the connector is configured to fit over at least a portion of a connection protrusion of the thick wall module and a corresponding protrusion on the second connection interface; and
the connector secures the thick wall module to the vertical connection post.

9. The pre-fabricated wall system of claim 8 , wherein the connector comprises a seal configured to fill:
a gap formed between the thin wall module and the vertical connection post when the thin wall module is secured to the vertical connection post, or
a gap formed between the thick wall module and the vertical connection post when the thick wall module is secured to the vertical connection post.

10. The pre-fabricated wall system of claim 7 , further comprising a plurality of connectors.

11. The pre-fabricated wall system of claim 1 , wherein the thick wall module comprises an interior cavity sized to house electrical wiring.

12. A pre-fabricated wall system that joins walls of different thicknesses, comprising:
a thin wall module having a depth defined by a distance from a front face thereof to a back face thereof;
a thick wall module having a depth that is greater than the depth of the thin wall module; and
a vertical connection post comprising:
a first connection interface on a first side configured to secure to the thin wall module; and
a second connection interface on a second side configured to secure to the thick wall module;
wherein:
the thin wall module and the thick wall module are arranged non-parallel to one another when both the thin wall module and the thick wall module are secured to the vertical connection post; and
the vertical connection post comprises a corner protrusion that receives a seal for sealing a gap formed between the thin wall module and the thick wall module when both the thin wall module and the thick wall module are secured to the vertical connection post.

13. The pre-fabricated wall system of claim 12 , wherein the thin wall module and the thick wall module form a right angle when both are secured to the vertical connection post.

14. A pre-fabricated wall system, comprising:
a plurality of wall modules, wherein:
a thickness of each of the wall modules is defined by a distance between a front face of each wall module and a back face of each wall module; and
at least two of the plurality of wall modules have different thicknesses;
a vertical connection post comprising a plurality of connection interfaces configured for securing to each of the plurality of wall modules, including the at least two of the plurality of wall modules that have different thicknesses; and
channel inserts securing the vertical connection post to the wall modules;
wherein:
the vertical connection post and the wall modules each include a vertical channel, and
the channel inserts reside within the vertical channels to secure the vertical connection post to the wall modules.

15. The pre-fabricated wall system of claim 14 , wherein:
the plurality of wall modules comprises two thick wall modules and one thin wall module, the thick wall modules having a thickness that is greater than a thickness of the thin wall module; and
the connection interfaces of the plurality of connection interfaces are arranged on the vertical connection post such that the two thick wall modules form a right angle when secured to the vertical connection post.

16. The pre-fabricated wall system of claim 14 , wherein:
the plurality of wall modules comprises two thick wall modules and one thin wall module, the thick wall modules having a thickness that is greater than a thickness of the thin wall module; and
the connection interfaces of the plurality of connection interfaces are arranged on the vertical connection post such that the two thick wall modules are co-planar when secured to the vertical connection post.

17. The pre-fabricated wall system of claim 14 , wherein:
the plurality of wall modules comprises one thick wall module and two thin wall modules, the thick wall module having a thickness that is greater than a thickness of the thin wall modules; and
the connection interfaces of the plurality of connection interfaces are arranged on the vertical connection post such that the two thin wall modules form a right angle when secured to the vertical connection post.

18. The pre-fabricated wall system of claim 14 , wherein:
the plurality of wall modules comprises one thick wall mod

Assignees

• Dirtt Environmental Solutions

Inventors

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

Classifications

• E04B2/7453 Primary

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

• E04B2/78

  characterised by special cross-section of the frame members {as far as important for securing wall panels to a framework with or without the help of cover-strips} · CPC title

• E04B2002/7464

  clasping a flange of a profile · CPC title

• E04B2002/7488

  Details of wiring · CPC title

• E04B2/7433 Primary

  with panels and support posts · CPC title