US20020023391A1

US20020023391A1 - Wall and display systems and components

Info

Publication number: US20020023391A1
Application number: US09/823,965
Authority: US
Inventors: R. Nymark
Original assignee: BUILD SYSTEMS Inc
Current assignee: BUILD SYSTEMS Inc
Priority date: 1997-09-03
Filing date: 2001-03-28
Publication date: 2002-02-28

Abstract

A wall system capable of rapid and easy transport and storage, wherein the wall panels are locked in place but are capable of easy removal without disturbing the supporting framework, and further, the horizontal members interact with and are capable of being locked to vertical supports of a variety of configurations and yet are replaceable without the necessity of disassembly. The wall panels for the current system may selectively be uniform and decorative or alternatively serve as a support for brackets, shelves or the like.

Description

BACKGROUND OF THE INVENTION

The present application is a continuation-in-part of U.S. application Ser. No. 08/923,857, filed Sep. 3, 1997.[0001]

TECHNICAL FIELD

The present invention relates to versatile lightweight wall and display systems constructed from interlocking extruded aluminum extrusion frames and panels.

A number of display wall and enclosure systems are known. Many of these systems have significant disadvantages, including expensive and/or difficult assembly and disassembly, short-term durability, structural weakness, limited configuration possibilities, and heavy weight.

Various wall and display systems are in relatively widespread use at present. For example, one display booth system typically used at conventions and similar events is constructed from frames of hollow plastic piping which provide support for a variety of fabric materials used to create an opaque enclosure. Such “pipe and drape” systems lack means for displaying heavy objects, are cumbersome, and lack versatility commonly demanded in the field.

Other display wall and enclosure wall systems use more rigid structural materials and display wall elements. One widely employed system is the “slotwall” product manufactured by Slotwall, Inc. (Atlanta, Ga.). This display wall system is fabricated from I inch thick composite wood particle board having parallel “C” shaped slots cut horizontally into the display side of the board. Slotwalls accommodate a wide variety of standard hardware fixtures, such as hangers, hooks, shelf brackets, and the like. However, slotwall type systems must be affixed to an existing wall with screws or other fasteners, and therefore cannot be used to construct complete free-standing enclosures. Without the capacity for free-standing configurations, such systems are inherently limited in their useful applications. Additionally, a number of other limitations are associated with such systems, including but not limited to availability in a single wall sheet size, tendency of the particle board to warp over time, tendency for the particle board to chip in and around the slots used to hang display hardware, limited load-bearing capacity, difficulty in changing surface materials (to add different colors of textures), and the heavy weight of the particle board materials (requiring two individuals to carry one wall sheet).

Several display wall systems are constructed from metallic vertical and horizontal framing members that hold various types of display panels (e.g., solid plastic boards, various laminated foam boards, wood, Plexiglas and other acrylic materials, glass, Formica, etc.). Some of these systems are constructed from extruded aluminum. Such systems are generally limited to particular configurations (do not provide capacity to arrange adjacent wall panels at any angle in relation to each other) and require trained personnel to assemble and disassemble (actions requiring substantial time and labor cost). Configuration changes to wall systems of this type are difficult and time consuming, requiring trained personnel to unlock the horizontal members and remove panels. This, in turn, places undue wear and tear on the sensitive locking components and panels.

Still other display wall systems are generally constructed from plastic or metallic structural and/or display elements. Such systems are as numerous as the applications to which they relate. In regards to interior enclosures, a commonly used system is the familiar office cubicle constructed with metallic vertical and horizontal structural members within which a number of composite materials are placed to create walls which in turn form the enclosures. A number of manufacturers provide such enclosure systems. These systems generally provide for configurations of waits at right angles, are heavy and cumbersome to assemble and disassemble, are not easily portable, and provide limited configuration versatility. These enclosure systems generally are not designed to efficiently accommodate the range of objects displayed in the retail sales, trade show, convention, and similar environments.

Technology for manufacturing metallic extrusions having a wide variety of industrial applications is well known. Hard, durable grade aluminum alloys, such as 6061 and 6063 grades, are the preferred materials for fabricating metallic extrusions. Similar technology has been used to manufacture extrusions of plastic materials.

SUMMARY OF THE INVENTION

The present invention relates to durable, lightweight, adjustable and foldable display and wall systems. The display and wall systems of the invention comprise slim and lightweight extrusions of metallic alloys, preferably aluminum, which have been engineered for maximum strength, and which are used to build structural frames for displays, walls, and enclosures. Another extrusion provided by the invention is itself a panel which is designed to be used alone (e.g., attached to an existing surface) or together with the structural frames of the invention (and as an integral part of the wall and display systems of the invention. In a preferred embodiment, a wall system of the invention comprises a self-supporting, integrated construction of foldable, hinged, extruded aluminum structural frames, into which interlocking display panels may be inserted. The structural frames are specifically designed to accommodate various types of panels having a range of thicknesses (in the preferred embodiment, panels should be 1.14 inches or less in thickness in order to provide folding wall systems, although thicker panels may be attached to the frames by using adapters). Although any number of display panels may be placed into the structural frames herein provided, the invention provides a particular display panel, also fabricated as a metallic extrusion, which is designed to interlock with the frame and support a number of configurations and display needs.

The extrusions used as frames in the wall systems of the invention are engineered to provide maximum strength and load-bearing characteristics while minimizing the weight of the extrusions and the systems built from them, thus achieving a maximal strength to weight ratio. The extruded display panel of the invention is also engineered to maximize the weight to strength ratio and incorporates design features which enable the panels to support heavier hanging weights at a substantially reduced manufacturing cost in comparison to other display panels. The light weight aluminum extrusions of the invention are more cost efficient and translate into stronger, less expensive, and lighter weight wall systems in relation to presently available systems.

A primary advantage that the wall systems of the invention provide over existing systems is full configuration adjustablity. The wall systems of the invention may be designed and assembled to adopt virtually any floor plan configuration. Thus, for example, walls may be assembled at any angle relative to one another. In addition, once the wall systems of the invention are assembled, their configurations may be adjusted by the user without the need for disassembly and reassembly. In other words, configurations may be changed and adjusted at any time, including when the system is assembled and standing. Another advantage is that the wall systems of the invention may be folded together for shipping or storage, again without the need for time consuming disassembly.

The wall systems of the invention may be constructed to form many different configurations, and thus can accommodate the display and storage requirements homes, retail stores and other businesses, trade shows, exhibitions, conventions, offices, etc. The systems are simple to assemble and dismantle, simple to reconfigure, and may be efficiently folded and stored without disassembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. Preferred embodiment of vertical framing member in cross-section views. (A) extrusion cross-section profile; (B-E) cross-section views of interlocked paired members and hinge assembly, depicting gear-type rotation. [0013]
FIG. 2. Extrusion engineering specifications of preferred embodiment of vertical framing member depicted in FIG. 1 (cross-section view). [0014]
FIG. 3. Cross-section view of alternative embodiment of vertical framing member. [0015]
FIG. 4. Extrusion engineering specifications of alternative embodiment of vertical framing member depicted in FIG. 3 (cross-section view). [0016]
FIG. 5. Extrusion engineering specifications of additional specific embodiment of vertical framing member (cross-section view). [0017]
FIG. 6. Connector for attachment of horizontal framing members to vertical framing members. [0018]
FIG. 7. Preferred embodiment of horizontal framing members in cross-section views. (A) extrusion cross-section profile of upper horizontal framing member; (B) extrusion cross-section profile of lower horizontal framing member; (C) cross-section profile of back-to-back smartwall panels stacked in between upper and lower horizontal framing members. [0019]
FIG. 8. Extrusion engineering specifications of preferred embodiment of upper horizontal framing member depicted in FIG. 7A (cross-section view). [0020]
FIG. 9. Extrusion engineering specifications of preferred embodiment of lower horizontal framing member depicted in FIG. 7B (cross-section view). [0021]
FIG. 10. Cross-section views of stacked upper and lower horizontal framing members. [0022]
FIG. 11. Cross-section view of an alternative embodiment of horizontal framing member for use with alternative embodiment of vertical framing member shown in FIGS. 3 and 4. [0023]
FIG. 12. Cross-section view of back-to-back smartwall panels stacked in between horizontal framing members (alternative embodiment of FIG. 11). [0024]
FIG. 13. Preferred embodiment of smartwall panel in cross-section views. [0025]
FIG. 14. Cross-section views of vertically stacked smartwall panels (preferred embodiment), and detail of vertical stacking point feature. [0026]
FIG. 15. Cross-section and perspective cross-section views of smartwall panels (preferred embodiment) connected back-to-back. (A) cross-section of two smartwall panels assembled back-to-back with connector plugs; (B) perspective view of (A); (C) spacer plug integrated into single smartwall panel; (D) typical connector plugs for single and back-to-back smartwall panels. [0027]
FIG. 16. Extrusion engineering specifications of preferred embodiment of smartwall panel (cross-section view). [0028]
FIG. 17. Cross-section view of alternative embodiment of smartwall panel. [0029]
FIG. 18. Extrusion engineering specifications of alternative embodiment of smartwall panel depicted in FIG. 17 (cross-section view). [0030]
FIG. 19A. Shelf bracket integrated into and hanging from smartwall panel. [0031]
FIG. 19B. Wall system of three wall units joined together by vertical framing members and incorporating vertically stacked, back-to-back smartwall panels. [0032]
FIG. 20. Top view of vertical framing members interlocked by gear teeth and joined by hinge connector, showing horizontal framing member connection assembly using the connector shown in FIG. 6. [0033]
FIG. 21. Top views of wall systems comprising wall units oriented at straight and right angles. Individual wall unit frames, comprising two vertical framing members connected by one upper and one lower horizontal framing members to form a rectangular frame, are joined together along the gear tooth faces of adjacent vertical framing members. [0034]
FIG. 22. Perspective view of an alternate vertical member having locked thereto an easily removable horizontal member secured by a slidable lock. [0035]
FIG. 23. Perspective view of an alternative embodiment of the lock of FIG. 7. [0036]
FIG. 24. Side elevational view of the lock of FIG. 23 in the closed or unlocked position. [0037]
FIG. 25. Side elevational view of the lock of FIG. 23 in the open or locked position. [0038]
FIG. 26. Perspective view of the inventive securement means allowing easy replacement of panels in the wall display system. [0039]
FIG. 27. Top plan view of the inventive securement device used with a wall and post. [0040]
FIG. 28. Top plan view of the inventive securement device in corner installation.[0041]

DETAILED DESCRIPTION OF THE INVENTION

5.1. Components For Constructing Wall Unit Frames

Described below are aluminum extrusions which are used cooperatively as interlocking vertical and horizontal framing members in the construction of the structural frames of the wall systems of the invention. These framing members interconnect to form square or rectangular frames into which a wide variety of standard display or wait panels may be attached. The frames, in turn, interconnect with one another by means of the vertical framing member described below to form multi-unit walls, partitions, display booths, interior enclosures, etc. As used herein, the term “wall unit” includes any square or rectangular frame or surface used for display, wall, or partition purposes. [0042]
A metallic display panel, specifically designed to cooperatively interlock with the framing members of this invention, is separately described in Section 5.2., infra. Wall systems comprising the framing members are described in Section 5.3., infra. [0043]

5.1.1. Vertical Framing Member

The vertical framing member comprises a linear extrusion of a metal alloy, preferably an aluminum alloy, having an extrusion profile substantially as shown in FIGS. 1, 2, [0044] 3, 4, or 5. The preferred material for forming the vertical framing member extrusion is aluminum, more preferably 6061 or 6063 grade aluminum. The vertical framing member may be extruded and/or cut to any length to serve particular needs. Similarly, the extrusion may be fabricated in larger or smaller dimensions relative to those shown in FIGS. 1-5, provided that the extrusion profile is substantially maintained in the design. Those skilled in the art will understand that as the radius of the gear face arc is made smaller, fewer gear teeth will be necessary.
The preferred embodiment of the vertical framing member is depicted in FIGS. 1 and 2, which show cross-section views of the extrusion. FIG. 2 provides extrusion engineering specifications for this extrusion. [0045]
Referring now to FIG. 1A, the preferred embodiment of the vertical framing member comprises an elongated, hollow-chambered, aluminum extrusion having a cross-section profile comprising: [0046]
(a) A primary panel/accessory interface side A comprising a recessed trapezoidal-shaped slot [0047] 1 with an opening 2 centered within the largest side of the trapezoidal shape, flanked by lips 3, which slot provides means for holding horizontal framing members and display or wall panels perpendicular to the long vertical axis of the extrusion by means of connectors which fit into said slot. A preferred connector is depicted in FIG.6, and its means of locking into the slot (thereby attaching a horizontal framing member to a vertical framing member) is depicted in FIG. 20. Other connectors capable of being firmly seated within said slot may be used, as will be obvious to those skilled in the art.
(b) Two secondary panel/accessory interface sides B which are oriented at 90 degrees relative to the primary panel/accessory interface side A and opposite but parallel to each other, each of the two secondary panel/accessory interface sides comprising a recessed trapezoidal-shaped slot [0048] 4 with an opening 5 centered within the largest side of the trapezoidal shape, which slot provides means for holding horizontal framing members, display or wall panels, floor supports, connecting supports, signage, and the like perpendicular to the long vertical axis of the extrusion by means of connectors which fit into said slot.
(c) An interconnection side C which is oriented opposite and symmetrical to the primary panel/accessory side and perpendicular and symmetrical to the secondary panel/accessory sides, comprising a 180 degree arc of outward-facing evenly-spaced gear teeth [0049] 6, which teeth provides means for joining adjacent vertical framing members in an interlocking arrangement and provides lateral force stability to wall units joined thereby.
(d) A circular or semi-circular chamber, or pivot point, [0050] 7 centered at the axis (radius origin) of the arc of the interconnection side C, which provides means for seating a pin or screw to provide means for affixing a rotatable hinge or connector between two adjacent vertical framing members interlocked along the teeth of their respective interconnection sides, thus providing stabilized interconnection of adjacent vertical framing members.
(e) A center, approximately pentagonal shaped, hollow chamber [0051] 8 which is oriented symmetrically between the trapezoidal shaped slots of the two secondary interface sides.
(f) A second, approximately fan-shaped hollow chamber [0052] 9.
(g) An arrow-shaped [0053] guide marker 10 which is used to orient two vertical framing members that are to be interconnected so that the resulting hinge can be fully folded for flat storage of multi-wall systems. Proper interconnection of adjacent vertical framing members is achieved by positioning the extrusions so that the arrow markers of both members are pointing in the same direction when the two vertical framing members are side-by-side, i.e., when the secondary panel/accessory interface sides are adjacent. See FIG. IB.
The trapezoidal shaped slots [0054] 1 and 5, the hollow chambers 8 and 9, and the pivot point 7 may be used for inserting connectors that can link vertical framing members end-to-end, or as conduits for running wiring, cables, water lines, etc.
The primary interface side A of the vertical framing member is used to hold display and wall panels integrated into the wall unit as well as the horizontal frame members (described in Section 5.1.2) used to construct a wall unit frame. The recessed trapezoidal slot [0055] 1 therein provides means for inserting connecting hardware, such as the connector shown in FIG. 6, that can fixedly attach inserted panels and horizontal frame members to the primary interface side of the extrusion.
The trapezoidal-shaped slots [0056] 5 recessed into the secondary interface sides B provide means for attaching horizontal framing members, panels, including the metallic display panel described in Section 5.2., infra, as well as a number of accessory items, including lateral floor supports, connecting plates and panels, informational signs, and the like.
The interface provides means for making a stable 90 degree angle connection between the vertical framing member and the inserted horizontal framing member, panel, floor support, or other accessory. [0057]
The vertical framing member thus provides three interface points from which wall frames, panels, floor supports and other accessories may radiate. This feature, together with the hinged interconnections between adjacent vertical framing members, makes numerous applications and floor plan configurations possible. [0058]
The ability to make a stable 90 degree connection between the vertical framing member and a floor support provides means for supporting a wall frame upright and perpendicular to the floor on which the frame rests. This feature of the vertical framing member provides a single wall unit or multi-unit walls or systems with stand-alone functionality. Floor supports also add stability to interconnected multi-unit walls. Floor supports may be placed into the trapezoidal slots and affixed thereto by means of an interlocking connector, such as the connector shown in FIG. 6, a similar connector, or any other connecting device capable of being seated firmly within the trapezoidal slot. One embodiment of this aspect of the invention is depicted in FIG. 21, illustrating how such floor supports may be attached to the trapezoidal slots of the secondary interface sides of the member. Any number of floor support designs may readily be incorporated into the system, so long as they are capable of interlocking with the slot (alone or by means of a connector) and provide sufficient structural support for the wait unit. Any object designed to make stable contact between the vertical frame element and a floor or similar surface which is capable of providing support sufficient to maintain the wall unit upright and relatively perpendicular to the floor surface may be used. Floor supports providing a means for adjusting the level of the wall unit relative to the floor surface may be preferred. Floor supports may optionally incorporate means for fixing the support firmly into the floor surface by, for example, the use of a bore hole designed to accommodate a bolt or similar fastener. Still other supports may be designed to fit into a hole or other shape recessed into the floor surface on which the wall unit is to be placed. Such supports may be desirable where the wall unit will be subjected to lateral forces such as wind, water, or rocking motions (i.e., on a train, truck, aircraft, or ship). Those skilled in the art will be able to design and use a variety of floor support designs to accommodate particular application needs. [0059]
Informational signs, menu boards, lighting, sound equipment, smartwall and other display panels, windows, doors, and the like may be similarly fixed to the vertical framing member extrusion via attachment to the secondary interface side trapezoidal slots. [0060]
The length of the vertical framing members of a wall unit, and thus the height of a wall unit constructed therewith, may be cut to length as desired or extended by stacking vertical framing member extrusions linearly end-to-end. Stacked extrusions may be fixed to each other by means of connectors inserted within one or more of the hollow chambers in the extrusion, or by means of a connector attached to the outer side of the extrusion, preferably via or within the secondary interface side trapezoidal slots. An example of such a connector is a metallic plate attached to the collinear trapezoidal slots of stacked vertical framing members resulting in a stable connection. Another example of a connector for this purpose is a solid trapezoidal shaped bar that can slide into one of the three trapezoidal slots in a stacked arrangement. Such bar-type connectors may be firmly seated into the trapezoidal chambers by means of a set screw or similar hardware. [0061]
The vertical framing member serves as both a side support element of a wall unit frame and as a connector for interlocking adjacent wall units together. In particular, the vertical framing member is designed to interlock with an adjacent vertical framing member in vertical, length-wise orientation along the gear tooth faces of their interconnecting sides. Cross-sectional views of two interlocked vertical framing members joined by a connecting hinge are depicted in FIGS. [0062] 1B-E. In a preferred embodiment, referring to FIG. ID, a connecting hinge 20 attaches two interlocked vertical framing members by means of hingepins 21 tapped into the pivot points. The hinge 20 may be oriented on the ends of the extrusions or within the extrusions. For the latter, it is necessary to cut an appropriately wide opening into the interconnection side of the extrusions to provide space for the hinge to move back and forth as the connected vertical framing members are rotated about each other or put into folded conformation. Various types of connector hinges will be obvious to those skilled in the art. The objective is that the hinge permit interlocking pivotal rotation of one vertical framing member around another, thus providing a means for rotating adjacent wall units so joined to any desired angle (0 to 360 degrees). This feature of the invention thus enables multiple wall sections to be joined in virtually any floor-plan configuration by placing the wall units in any angle relative to each other, from 0 to 360 degrees.
In addition, interlocked frames and wall systems may be rotated 360 degrees around each other without removing the connecting hinge, which is designed to provide pivotal rotation between interlocking vertical framing members. In order to achieve full 360 degree rotation capacity, it is important to orient the gear teeth of interlocked gearman extrusions so that the first gear tooth (“II in FIG. IA) of one extrusion will be in contact with the groove ([0063] 12 in FIG. 1A) of the other extrusion when the two extrusions are oriented in the folded or 360 degree rotation (as depicted in FIG. IB). A primary advantage of the systems of the invention is that rotation or folding of wall units may be accomplished with fully assembled and interlocked walls. This results in simplified floor-plan configuration adjustments and modifications while the wall system is fully erect and without the need for any disassembly. This also provides means for optimal storage, as multiple wall units interconnected along adjacent vertical framing members may be folded together without removing the connector hinge, the display panels incorporated within the wall unit frame, or any of the horizontal support members used in framing the wall units.
Structurally, the interlocked gear tooth faces of two vertical framing members provides exceptional resistance to lateral forces exerted at any angle on one or both of the wall units connected thereby. Additionally, interlocked vertical framing members provide a nearly sealed edge through which light, drafts, etc. will not pass, resulting in an aesthetic attractive and functional corner or joint in a wall system. [0064]
Other embodiments of the vertical framing member extrusion are shown in FIGS. 3 and 4, and [0065] 5. The extrusion shown in FIG. 5 is the preferred embodiment for light weight table-top display needs. In a specific embodiment, this design is used to fabricate aluminum extrusions having the profile and specifications shown in FIG. 5, which are used as the vertical frame members of lightweight desktop display units.

5.1.2. Horizontal Framing Member

The horizontal framing members utilized in constructing the wall systems of the invention comprise linear extrusion of a metal alloy, preferably an aluminum alloy. The preferred material for forming these extrusions is aluminum, more preferably 6061 or 6063 grade aluminum. The horizontal framing members may be extruded and/or cut to any length to serve particular needs. [0066]
In preferred embodiments of the wall systems of the invention, two types of horizontal framing members are used, and are designated as “upper” and “lower” horizontal framing members for convenience. It is to be understood, however, that using only one type of horizontal framing member is possible and may be preferred for certain applications. Two different horizontal framing members are provided here primarily for use in constructing wall systems which will incorporate the metallic display panels of the invention, described in Section 5.2., infra. The preferred embodiment of the upper horizontal framing members is depicted in FIGS. 7A and 8, both of which show cross-section views of the extrusions. FIG. 8 provides extrusion engineering specifications for this extrusion. The preferred embodiment of the lower horizontal framing members is depicted in FIGS. 7B and 9, both of which show cross-section views of the extrusions. FIG. 8 provides extrusion engineering specifications for this extrusion. [0067]
Referring now to FIG. 7A, a preferred embodiment of an upper horizontal framing member comprises a single-chambered, aluminum extrusion having a four-sided, generally rectangular, profile which comprises an upper side containing a recessed rectangular-shaped slot [0068] 30 with an opening 31 centered within the upper edge of the rectangle (as oriented in FIG. 7A), which slot provides means for mounting display or wall panels; two sides 32, perpendicular to the upper edge of the extrusion, and flanked at their upper and lower edges by guiderails 33 that provide means for inserting thin panels along the sides of the extrusion; a vertical stacking guide 34 protruding from the lower aspect of the extrusion, and shaped like an inverted “Y”, which provides means for stacking an upper horizontal framing member on top of a lower horizontal framing member (or a single or double sided smartwall panel as depicted in FIG. 7C); and a hollow, rectangular shaped channel 35 which provides space for locating a lock or connector (such as the connector shown in FIGS. 6 and 20) for joining the horizontal framing member to the primary interface side of a vertical framing member or to serve as a conduit for wires, tubes, etc.
Referring now to FIG. 7B, a preferred embodiment of a lower horizontal framing member comprises an elongated, hollow-chambered, aluminum extrusion having a four-sided, generally rectangular, profile which comprises a vertical stacking point [0069] 36 located at the top of the profile (as depicted in FIG. 7B) which contains a slot 37, which slot provides means for mounting panels, flanked by two identical grooves 38 which provide a stacking point complementary to the vertical stacking guide of an upper horizontal framing member (or the vertical stacking guides of the lower edges of smartwall panels as shown in FIG. 7C); two identical sides 39 perpendicular to the upper and lower sides of the extrusion, and flanked at their upper and lower edges by guiderails 40 that provide means for inserting thin panels along the sides of the extrusion; a lower side which contains a recessed rectangular-shaped slot 41 with an opening 42 centered within the lower edge of the rectangle, which slot provides means for mounting display or wall panels; and a hollow, rectangular shaped channel 43 which provides space for locating a lock or for joining the horizontal framing member to the primary interface side of a vertical framing member or to serve as a conduit for wires, tubes, etc. The horizontal framing member is typically linear but may also be fashioned in a curved configuration, depending upon the desired configuration the wall or enclosure. Where planar wall unit frames are desired, linear horizontal framing members are used. Where curved frames and/or walls are desired, horizontal framing members may be extruded or bent into arcs to achieve curved wall panel frames. An alternative embodiment of the horizontal framing member for use with the vertical framing members depicted in FIGS. 3 and 4 is shown in FIG. 11.

5.2. Smartwall Display Panels

The invention provides a metallic display panel which is specifically designed to cooperatively interlock with the framing members described above. The panel, termed “smartwall panel” herein, may also be applied to existing walls or other structures. [0070]
The smartwall panel comprises a generally planar extrusions of a metal alloy, preferably an aluminum alloy, having an extrusion profile substantially as shown in FIGS. [0071] 13-18. The preferred material for forming the extrusion is aluminum, more preferably 6061 or 6063 grade aluminum. The panel may be extruded and/or cut to any length to serve particular needs.
The preferred embodiment of the smartwall panel is depicted in FIGS. [0072] 13-16, which show various cross-section view of the panels alone, stacked with each other, and oriented in back-to-back configurations. FIG. 16 provides extrusion engineering specifications for this extrusion.
Referring now to FIG. 13A, the preferred embodiment of the smartwall panel comprises a generally planar, slotted, and chambered aluminum extrusion, more particularly having on one side of the plane a plurality of evenly spaced, parallel, lengthwise, trapezoidal shaped chambers [0073] 50 with openings 51 centered within the largest side of the trapezoidal shape, and guiderails 52 flanking the upper and lower edges of the chambers and protruding perpendicularly from the plane of the largest side of the trapezoidal shape, which chambers provide means for hanging display hardware such as hangers, hooks, tables, shelves, etc., and which guiderails provide means for inserting informational, decorative, or other functional panels, which panels are held in place by said guiderails; a plurality of evenly spaced, parallel, lengthwise slots 53, having essentially flat surfaces parallel to the plane of the extrusion, and flanked by upper and lower guiderails 52, which slots and guiderails provide means for inserting informational, decorative, or other functional panels; said slots 53 and said chambers 50 arranged in alternation one next to the other; having on the opposite side of the extrusion plane a plurality of evenly spaced, parallel, lengthwise trapezoidal shaped connector slots 54 with openings 55 centered within the largest side of the trapezoidal shape, which connector slots provide means for hanging said smartwall panel onto a surface by, for example, hanging the upper lip 56 created by the opening in the trapezoidal shaped slots onto a wall bracket, hanger, peg, 15 screw, or other connector, etc., said connector slots also providing means for attaching two smartwall panels back-to-back (as shown in FIG. 15), by using connectors (such as the connector 61 shown in FIG. 15); a vertical stacking point 57, comprising a slot 58, and a vertical stacking guide 59, comprising a flange 60, which flange and which slot fit together and provide means for interlocking stacking of one smartwall panel on top of another, in the same plane, such that the front and back sides of the stacked panels appear as a single panel (as depicted in FIG. 14).
The guiderails [0074] 52 may be used to insert solid panels of plastic or similar materials simply to close off any chambers 50 which are not being used for hanging hardware. The chambers 50 and the connector slots 54 may be used as conduits for running wires, tubes and the like (e.g., electrical and telecommunications wiring and cables used in the assembled wall system). The smartwall panels are designed to stack on top of each other to any height, both when incorporated into a wall frame and when affixed to an existing wall or similar structure. In particular, referring to FIG. 14, complementary vertical stacking points provide interlocking stacking of multiple smartwall panels. This feature of the design allows multiple smartwall panels to be stacked on top of one another while maintaining the appearance of a single, contiguous panel (see, also, FIG. 19B).
The smartwall panel may be used to insert widely available standard display and utility hardware (i.e., shelf brackets, garment hangers, hooks, brochure holders, desks, etc.) (see, for example, FIG. 19A). [0075]
The smartwall panel incorporates high-grade extruded aluminum together with structural elements in its design which result in exceptional strength. The smartwall panel of the invention is lighter, more durable, and stronger than wooden slotwall products, and greatly increase the load bearing capacity in relation to wooden slotwall products. In addition, smartwall panels will not warp or chip, and may be stacked to achieve any desired height. [0076]
Other embodiments of the smartwall panels of the invention comprise metallic or plastic extrusions having essentially the same functionality as the above-described preferred embodiment 6061 or 6063 grade aluminum. [0077]
An alternative embodiment of the smartwall panel is depicted in FIGS. [0078] 17 (cross-section) and 18 (extrusion cross-section and engineering specifications) and is fabricated from 6061 or 6063 grade aluminum. Smartwall panels may be extruded and/or cut to any length to serve particular needs. In addition, smartwall panels may be fabricated in larger or smaller dimensions relative to those shown in FIG. 13-18, provided that the extrusion profile is substantially maintained in the design.

5.3. Integrated Stand-Alone Wall Systems

Another aspect of the invention relates to stand-alone wall systems constructed with the framing members described supra (and, optionally, incorporating smartwall panels). The stand-alone wall systems of the invention typically will comprise single or multiple wall units joined together by interlocked vertical framing members. A single planar wall unit in turn comprises two vertical framing members which are connected, preferably, at the top and bottom ends, to two or more horizontal framing members, into which one or more slide-in wall panels may be placed, in planar arrangement to the frame, in order to provide display or similar functionality. The framing members preferably comprise aluminum, ideally 6061 or 6063 grade or the equivalent, but may also comprise plastic and composite resin materials having sufficient structural strength. In addition, the framing members may be optionally coated or overlaid with decorative laminates of various materials, such as papers, plastics, wood, and similar synthetic materials. The framing members described, supra, are designed to easily connect to and integrate with each other and a variety of display panels. Smartwall panels, described supra, may be inserted into the wall frame at intervals along the vertical framing members. Other panels may be placed in between the smartwall panels (i.e., above or below an inserted smartwall panel) to meet particular needs, including but not limited to solid plastic boards, various laminated foam boards, wood, Plexiglas and other acrylic materials, glass, Formica, etc. In constructing a rectangular wall frame, generally two horizontal framing members will be attached at 90 degree angles near or at the top and bottom ends of two vertical framing members, thus forming the top and bottom sides of the wall frame. Additional horizontal framing members may be incorporated into the frame at any point along the vertical members, at 90 degree angles thereto, for added stability, or to hold smartwall or other panels to be inserted into the wall frame, or for other functional and/or decorative purposes. Where smartwall panels are inserted within the wall frame, they are inserted in between horizontal framing members. In some configurations, smartwall panels will remain fixed within the frame by resting on top of another panel, such as a plastic panel, or in other configurations, by resting on top of a horizontal framing member inserted into the wall unit to provide support therefor. In other cases, load demands on the smartwall panel may require that a fixed horizontal framing member be placed into the frame such that it makes contact with the bottom edge of the panel, thereby providing support for the load. Inserted smartwall panels will have bottom and top edges that are parallel to the horizontal framing members of the frame, perpendicular to the vertical framing members of the frame, and coplanar with the frame. Where two or more smartwall panels are to be stacked within the overall frame, or where heavy loads on the panel are anticipated, it may be preferable to place horizontal framing members along the top and bottom edges of the stacked smartwall panels. Panels constructed from Plexiglas, wood, and other dense materials may be inserted in between supporting horizontal framing members. In some situations, panels of much lighter and less dense materials, such as Styrofoam and polystyrene, may be placed into the frame without need for support along the bottom edge. In other situations, it may be desirable to place such panels into the frame on top of a horizontal framing member for support. [0079]
Upper and lower horizontal framing members are connected, respectively, at right angles to the top and bottom of two vertical members form a basic frame for the stand-alone [0080] 35 single wall unit. The preferred means of connecting a horizontal framing member to a vertical framing member is shown in FIG. 20. The slots (4 in FIG. 1A) of the vertical framing members are used for attaching supports which stabilize the frame perpendicular to the floor surface. Smartwall panels, or other panels, may be inserted into the frame while it is being constructed or by removing only the upper horizontal framing member of an assembled unit and sliding the panel(s) down into the frame.
Single or double-sided back-to-back smartwall panels may be incorporated into the frame. Double-sided back-to-back smartwall panels are connected to one another as shown in FIG. 15. Back-to-back smartwall panels slide nicely into the frame and interlock with the horizontal framing members at the complementary stacking points on the horizontal framing members and those created on the upper and lower edges of the back-to-back configuration. Smartwall panels may also be stacked together in planar arrangement within the wall unit frame, and such stacked panels act both functionally and aesthetically as one panel. Thus, one may create a completely opaque wall with smartwall panels. Alternatively, the smartwall panels may be located in the frame to leave spaces for inserting other functional or decorative materials or panels. [0081]
Where multiple and connected wall units are desired for the construction of wall systems having angular floor plans, partial enclosures, zigzag walls, or polygonal shaped floor plans, and the like, then the invention utilizes the versatile vertical framing member to frame the wall unit and join adjacent wall units (Section 5.1.1). Thus, adjacent wall units may be used to form a wall system comprising a plurality of contiguous upright wall units, wherein adjacent wall units are joined together along adjacent vertical edges by means of interlocking vertical framing members which provide pivotal gear-type hinge rotation of one wall unit relative to its adjacent wall unit. [0082]
To connect adjacent wall units, one vertical frame member interlocks with another along their respective gear tooth faces, as described in Section 5.1.1., supra., and as depicted in, for example, FIGS. 1, 20, and [0083] 21. Connecting hinges linking adjacent vertical framing members provide means for pivotal gear-type rotation of one member about the other, thus providing a means for configuring any angle desired between the wall units. The invention thus enables multiple wall sections to be joined in virtually any configuration by placing the wall units in any angle in relation to each other. Because hinged and interlocked vertical framing members may rotate about each other within the context of a completely assembled wall system, the invention further provides for simplified configuration adjustments while the wall system is assembled. Floor supports may be added to the bottom of one or more vertical framing members in the completed wall system, if desired. In some cases, the angular arrangement of the adjacent wall units in the system will provide ample support to maintain the structure upright.
Wall systems constructed from wall units joined along their vertical edges by hinged, interlocked vertical framing members are also extremely portable. An entire enclosure constructed from multiple wall units may be folded, so that the wall units are flat against each other, to form a single folded configuration. The folded configuration may be packed and transported using a minimum of space and weight. This provides the user with substantial time and cost savings when compared to existing systems, many of which require tedious disassembly for storage. In the trade show industry, for example, substantial time is spent assembling and disassembling display booths to meet the needs of different shows. This time typically means that a day or more is needed to go from one show to the next. Display booths constructed from the components described herein may be folded and unfolded in a matter of minutes, and will therefore result in greater potential show capacities for trade and exhibition centers utilizing them. [0084]
Preferred wall and display systems of the invention will have frames constructed from the preferred embodiments of the vertical and horizontal framing members described supra, as they are designed to coordinate and integrate perfectly with each other (i.e., the vertical framing members of FIG. 1 are combined with the horizontal framing members of FIG. 7, and, optionally, incorporating the smartwall panels of FIG. 13). Similarly, alternative embodiments may be constructed with the alternative framing member embodiments provided herein (i.e., the vertical framing members of FIGS. 3 and 4 are combined with the horizontal framing members of FIG. 11, and, optionally, incorporating the smartwall panels of FIGS. 17 and 18). [0085]
The wall systems of the present invention are designed to solve problems that have been associated with many other display wall systems. The wall systems of the invention utilize lightweight, strong, and functional aluminum extrusions for their key structural elements, numerous wall or enclosure configurations having use in a number of applications are possible. The wall systems of the invention provide integral functionality and adjustability in a user-friendly format, thus significantly reducing the time and cost of assembly and disassembly. These factors are critically important, for example, in industrial trade shows, conventions and the like, where the wall systems of the invention will find immediate application. In addition, the structural and display elements of the present wall systems are far more durable and stronger than other available wall systems. [0086]
Reference is now had to FIG. 22, wherein there can be seen an alternate [0087] vertical support member 100 with a plurality of radially outwardly facing receptive grooves 102, each including circumferentially directed lips 104 to receive a lock member as shown in FIG. 6 and 20, and further described in detail with respect to FIGS. 23-25. A horizontal member 106 as described with respect to FIGS. 7-11 is shown secured to the vertical member by the lock element as described hereinafter. It is to be noted that the lock member is accessed through a horizontal, elongated opening 108, in the horizontal member 106, allowing the lock member, which includes a set screw 112 and a pair of jaws 114 to be secured to the vertical upright 100. At times other than installation, the lock member and access is covered by a cap member 116. It is to be understood that although FIG. 22 discloses the assemblage with an 8 slot vertical member 100, it could equally as well be used in conjunction with any of the vertical elements shown in FIGS. 1-5 or indeed could be used in conjunction with a vertical member which is simply square configuration in section, as long the vertical member includes inwardly extending lips to interact with jaws 114 as explained hereinafter.
Reference is now had to FIGS. [0088] 23-25 wherein the lock member 110 is shown in greater detail and includes the set screw 112 which is threadably engaged with a pre-threaded steel insert 120 which is press fit into a provided recess 122 in the female member 124, which includes an arcuate receiving portion 126 opposite the jaw member 114 to receive a semi-cylindrical cross section portion 128 of male member 130. It is to be understood that the male member 130 and female member 124 are held in engaged position by a combination of the elongated rubber retainer element 132 tongue and groove portion 133 in conjunction with the shapes of the elements and set screw 112.
Reference is now had to FIGS. 24 and 25, wherein similar parts have similar numbers and the [0089] locking device 110 is shown in its closed position in FIG. 24 and its open position in FIG. 25. When the lock 110 is in the closed position as shown in FIG. 24, it is capable of being moved within the horizontal element 106 into and out of the slot formed by lips 104, thereby enabling the horizontal member 106 to be removed from the attachment to the vertical member without disassembly. When it is desired to lock the horizontal member 106 to the vertical 100, the set screw 112 is torqued against the male member 130, expanding the jaws 114 to physically, mechanically engage with the inwardly facing lips 104, securing the horizontal member in position.
Reference is now to FIGS. [0090] 26-28 wherein there is disclosed a quick release assembly for securing panels to vertical uprights. It is to be understood that for structural integrity the panels would be secured between or set upon horizontals as shown in FIG. 22, but that the panel could be quickly released and exchanged for another decorative panel or the like. As seen in this view, a vertical 140 is shown having a hollow interior which could be used as a conduit and 4 sides including inwardly turned lips 142 for interaction with horizontal members, but likewise as shown are easily removable panel members 144 secured on one side by a rigid locking member 146 elongated in shape and having in section a pair of parallel legs 148 of a U-shaped member including base element 150, wherein the legs terminate in outwardly projecting feet 152 which can be snapped into place behind the inner walls and locked behind the inner surfaces of the lips 142. Extending outwardly and integral with the new element are a pair of wings 154 which abut against the back wall of panel members 144 and hold them in position.
The front portion of the [0091] panel members 144 is releasably held in position by means of elongated element 160 which includes as its main portion the U-shape in cross section to secure the element 160 to the vertical 140, which likewise includes integral extensions 162 of the base 150 of the U-shaped element as well as wing members similar to those shown on the back of the element but including a flexible elongated joint element 164 which allows the exterior portion of the wing 166 to pivot about joint 164 moving locking leg 168 from behind extension 162. When the panel 144 is in position, the locking member 160 is pushed into place, locked to the vertical 140 and the wings 166 are snapped down and secured in place by interaction of elements 162 and 168.
As seen in FIGS. 27 and 28 are alternate versions of the elements described with respect to FIG. 26. In FIG. 27 it shows elements suitable for use when the vertical [0092] 140 is at the end of a panel section, and therefore, the elements include only one wing element and in FIG. 28, elements that are suitable for use in a corner situation and the interior of the corner panel can be secured by means of a cap member 180 shown in phantom which could include a leg 182 which would prevent inward movement of the panels 144.
Thus as can be seen, the present invention discloses unique interconnection and wall systems as well as a stand-alone wall unit and further includes mechanism, which allows secure fastening between the elements, and yet easy removal when used with the unique elements as disclosed. [0093]
The present invention is not to be limited in scope by the embodiments disclosed herein, which are intended as single illustrations of one aspect of the invention, and any which are functionally equivalent are within the scope of the invention. Indeed, various modifications of the invention, in addition to those shown and described herein, will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims.[0094]

Claims

What is claimed is:

1. A device allowing the rapid change of panels in a wall system utilizing at least two vertical supports including vertical slots with opposing lips, said device comprising:

an elongated u-shaped main body portion, including a base and flexible leg members adapted to snap fit into the vertical slot; and

a pair of opposing wing members extending outwardly from the base, said wing members including an elongated hinge member having memory urging the member to the closed position abutting a panel extending between the at least two supports and holding the panel in place.

2. An elongated locking device for securing removable panels adjacent to vertical posts, including longitudinal slots comprising, in profile:

a U-shaped locking section including a base and opposing legs, wherein the legs of the U are inserted into and temporarily locked into the longitudinal slot; and

at least one hinged wing element movable from an open to a closed position extending outwardly from the base opposite the legs at an angle thereto and returning inwardly at its extremity to contact the panel when in its closed position and allowing removal of the panel when in its open position.

3. A support system for portable wall panels, including a pair of opposing vertical frame elements and a joining panel wherein the frame elements comprise an elongated member which when seen in profile includes a substantially hollow member wherein one portion of the exterior shell is substantially semicircular and includes radially outwardly extending teeth and inwardly extending walls terminating in an open bore at the center of the semicircle, the remainder of the shell being substantially rectangular in outline, including at least one outwardly facing slot and wherein the joining panel is locked into said outwardly facing slot.

4. A support system as in claim 3, wherein adjoining panels may be interconnected by a bar rigidly secured to a pin inserted into each of the bores, wherein the bar is of a length that the teeth mesh enabling the relative angle between the panels to be infinitely varied.

5. A lock for securing a wall panel to a channeled upright, comprising:

a pair of elongated mating elements, each of which includes an outwardly projecting lip at one end thereof;

the male member including a bulbous protrusion extending in the opposite direction of the lip at the end opposite the lip;

the female member including a groove complementary to the bulbous portion of the male member at the opposite end and side from the lip such that when the members are mated the pair of elements may be pivoted about the interconnection spreading the lips and locking them within a channel; and

means for spreading the lips.

6. A lock as in claim 5, wherein the lock is secured within a rail which frames the wall panel.

7. A lock as in claim 6, wherein the lock is axially movable within the rail.

8. A portable wall unit comprising two or more sections, wherein the sections may be collapsed against each other for storage or transportation, and wherein easily removable panels are supported by horizontal structural units which are locked in place between a pair of vertical elements by locks which are retractable to a position within the horizontal unit, allowing removal of the unit without displacing the vertical elements.