APPARATUS, SYSTEM AND METHOD FOR PROVIDING AN INTERNALLY SUPPORTED WALL SYSTEM

Abstract

The present invention provides a light weight wall system including a wall supporting apparatus to install multiple panels simultaneously while resisting lateral and vertical forces applied to the wall system during installation. According to one aspect of the present invention, the wall system of the present invention includes an upper wall segment and a lower wall segment. According to further aspects of the present invention, the upper wall segment preferably includes a bottom panel including a central convex projection which extends through the length of the upper wall segment. According to a further aspect of the present invention, the lower wall segment preferably includes a top panel which includes a central convex projection which extends through the length of the lower wall segment. According to a further aspect of the present invention, the present invention preferably further includes an internal supporting insert which includes an upper supporting insert configured to insert within the upper wall segment and a lower supporting insert configured to insert within the lower wall segment.

Claims

1. A wall system including an internal wall supporting apparatus, the wall system comprising: an upper wall segment, wherein the upper wall segment comprises a left panel, a right panel and a bottom panel; further wherein the bottom panel further comprises a left wall portion, an upward extending central concave projection, and a right wall portion; further wherein the central concave projection extends through the length of the upper wall segment; a lower wall segment, wherein the lower wall segment comprises a left panel, a right panel and a top panel; further wherein the top panel further comprises a left wall portion, an upward extending central convex projection, and a right wall portion; further wherein the central convex projection extends through the length of the lower wall segment; and an internal supporting insert, wherein the internal support insert further comprises a left connecting flange, a right connecting flange, and a plurality of supporting internal vertical ribs which vertically extend through the body of the internal supporting insert; wherein the internal supporting insert further comprises an upper supporting insert configured to insert within the upper wall segment and a lower supporting insert configured to insert within the lower wall segment; wherein the lower supporting insert comprises left surface, a right surface, a first lower surface, and a second upper surface; wherein the second upper surface comprises a left lower surface, a convex center surface, and a right lower surface; wherein the upper supporting insert comprises a left surface, a right surface, a third top surface, and a fourth lower surface; wherein the fourth lower surface comprises a left lower surface, a concave center surface, and a right lower surface; wherein the internal supporting insert further comprises a plurality of back support extensions; wherein the plurality of back support extensions are configured to stiffen the internal supporting insert and prevent the internal supporting insert from rotating on its central axis.

2. The wall system of claim 1, wherein the distance between the second upper surface and the fourth lower surface are uniform.

3. The wall system of claim 2, wherein the distance between the second upper surface and the fourth lower surface is greater than the combined thickness of the upward extending central concave projection of the upper wall segment and the upward extending central convex projection of the lower wall segment.

4. The wall system of claim 3, wherein the distance between the second upper surface and the fourth lower surface is within the range of 0.3 to 0.8 inches.

5. The wall system of claim 3, wherein the distance between the second upper surface and the fourth lower surface is within the range of 0.4 to 0.6 inches.

6. The wall system of claim 4, wherein the internal supporting insert has a thickness in the range of 2 to 5 inches.

7. The wall system of claim 6, wherein the internal supporting insert has a total length in the range of 4 to 7 inches.

8. The wall system of claim 7, wherein the internal supporting insert has a total width in the range of 2 to 3 inches.

9. The wall system of claim 6, wherein the internal supporting insert has a total length in the range of 5 to 6 inches.

10. The wall system of claim 9, wherein the internal supporting insert has a total width in the range of 2.4 to 2.8 inches.

11. The wall system of claim 6, wherein the internal supporting insert has a total length in the range of 5.4 to 5.8 inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Elements in the figures have not necessarily been drawn to scale in order to enhance their clarity and to improve the understanding of the various elements and embodiments of the invention. Furthermore, elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the invention. Thus, it should be understood that the drawings are generalized in form in the interest of clarity and conciseness.

[0010] FIG. 1 shows a cutaway view of a wall system in accordance with a first preferred embodiment of the present invention.

[0011] FIG. 2 shows a cutaway view of a wall system in accordance with a first preferred embodiment of the present invention including an internal supporting insert.

[0012] FIG. 3 shows a front view of an internal supporting insert in accordance with a preferred embodiment of the present invention.

[0013] FIG. 4 shows a side view of an internal supporting insert in accordance with a preferred embodiment of the present invention.

[0014] FIG. 5 shows a back view of an internal supporting insert in accordance with a preferred embodiment of the present invention.

[0015] FIG. 6A shows a top view of an internal supporting insert in accordance with a preferred embodiment of the present invention.

[0016] FIG. 6B shows a bottom view of an internal supporting insert in accordance with a preferred embodiment of the present invention.

[0017] FIG. 7 shows a perspective view an interconnected wall system in accordance with a further preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0018] Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address any of the problems discussed above or only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below. In the following discussion that addresses a number of embodiments and applications of the present invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention.

[0019] Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead, these examples or illustrations are to be regarded as illustrative only. Those of ordinary skill in the art will appreciate that any term or terms with which these examples or illustrations are utilized will encompass other embodiments which may or may not be given therewith or elsewhere in the specification and all such embodiments are intended to be included within the scope of that term or terms.

[0020] Reference is now made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. As used throughout this application, the word may is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e. meaning must).

[0021] FIG. 1 shows a cutaway view of a wall system 100 in accordance with a first preferred embodiment of the present invention. As shown, the wall system 100 of the present invention may preferably include an upper wall segment 102 and a lower wall segment 104. As shown, the wall segments 102, 104 may preferably be hollow. Alternatively, the wall segments 102, 104 may be filled with any of a variety of materials. As shown, the upper wall segment 102 may preferably include a left panel 106, a right panel 108 and a bottom panel 110. As shown, a bottom panel 110 of the upper wall segment 102 preferably includes level left wall portion 112, an upward extending central concave projection 114, and a level right wall portion 116. Preferably, the central concave projection 114 of the bottom panel 110 extends through the length of the upper wall segment 102.

[0022] As further shown in FIG. 1, the lower wall segment 104 preferably further includes a left wall panel 126, a right wall panel 128 and an upper wall panel 118. As shown, the upper wall panel 118 of the lower wall segment 104 preferably includes level left wall portion 120, an upward projecting central convex projection 124, and a level right wall portion 122. Preferably, the central convex projection 124 of the upper wall panel 118 extends through the length of the lower wall segment 104.

[0023] FIG. 2 shows a further cutaway view of a wall system in accordance with a first preferred embodiment of the present invention including an internal supporting insert 130. As shown, the internal supporting insert 130 preferably is inserted within the upper wall segment 102 and the lower wall segment 104. As shown, the internal supporting insert 130 preferably includes a left connecting flange 132, a right connecting flange 134 and a group of supporting internal vertical ribs 136 which vertically extend through the body of the internal supporting insert 130. As further shown, the internal supporting insert 130 preferably further includes an upper supporting insert 140 which is inserted within the upper wall segment 102. Further, the internal supporting insert 130 preferably further includes a lower supporting insert 142 (shown in FIG. 3) which preferably inserts into the lower wall segment 104. As still further shown, the internal supporting insert 130 preferably further includes one or more central supporting extensions 138 as discussed in more detail below.

[0024] According to further aspects of the present invention, the left connecting flange 132 and the right connecting flange 134 may preferably be configured to further interlock with connecting flanges from other internal supporting inserts (not shown) so to connect the two supporting inserts together. In this way, the present invention may laterally connect multiple wall segments/system in series.

[0025] FIG. 3 shows a front view of an internal supporting insert 130 in accordance with a preferred embodiment of the present invention. As shown, the internal supporting insert 130 preferably includes an upper supporting insert 140 for inserting within the upper wall segment 102 and a lower supporting insert 142 for inserting within the lower wall segment 104. As shown, the upper supporting insert 140 preferably includes a lower surface 144 which preferably includes a left lower surface 146, a raised center surface 150 and a right lower surface 148. As further shown, lower supporting insert 142 preferably includes a top surface 152 which preferably includes a left lower surface 154, a raised center surface 156 and a right lower surface 158.

[0026] As shown in FIG. 3, the spacing and dimensions between the lower surface 144 and the top surface 152 are preferably uniform and of a consistent width to receive the combined widths of the bottom panel 110 of the upper wall segment 102 and the upper wall panel 118 of the lower wall segment 104. In particular, the spacings and dimensions between the lower surface 144 and the top surface 152 are preferably formed with a width and a shape for receiving the combined thickness and shape of the concave projection 114 of the upper wall segment 102 and the convex projection 124 of the lower wall segment 104. As further shown, in accordance with a further preferred embodiment of the present invention, the distance between the lower surface 144 and the top surface 152 may preferably be in the range of 0.3 to 0.8 inches. According to a further preferred embodiment, the distance between the lower surface 144 and the top surface 152 may preferably be in range of 0.4 to 0.6 inches.

[0027] FIG. 4 further provides a side view of the internal supporting insert 130. As shown, the internal supporting insert 130 preferably includes an upper supporting insert 140 for inserting within the upper wall segment 102 and a lower supporting insert 142 for inserting within the lower wall segment 104. As shown, the internal supporting insert 130 may preferably have a total width in the range of 2 to 5 inches and a total length in the range of 4 to 7 inches. According to a further preferred embodiment, the internal supporting insert 130 may preferably have a total width in the range of 2 to 3 inches and a total length in the range of 5 to 6 inches. According to a further preferred embodiment, the internal supporting insert 130 may preferably have a total width in the range of 2.4 to 2.8 inches and a total length of 5.4 to 5.8 inches.

[0028] With reference now to FIG. 5, a back view of an internal supporting insert 130 in accordance with a preferred embodiment of the present invention shall now be discussed. As shown in FIG. 5, the internal supporting insert 130 may preferably include a left connecting flange 132, a right connecting flange 134, and vertical ribs 136 extending through the body of the internal supporting insert 130. A further shown, the internal supporting insert 130 preferably further includes a central supporting rib 160 which extends horizontally across the body of the internal supporting insert 130. As further shown, the central supporting rib 160 preferably further includes one or more back support extensions 138.

[0029] FIG. 6A further shows a top view and FIG. 6B further shows a bottom view of an internal supporting insert 130 in accordance with a preferred embodiment of the present invention. As shown, the internal supporting insert 130 preferably includes an upper supporting insert 140, a lower supporting insert 142, a right connecting flange 134 and a left connecting flange 132. As further shown, the internal supporting insert 130 preferably further includes back support extensions 138. According to preferred embodiments of the present invention, the back-support extensions 138 may preferably act to stiffen the internal supporting insert 130 and prevent the internal supporting insert 130 from rotating on its central axis or otherwise acting like a hinge.

[0030] FIG. 7 shows a perspective view of an inter-connected wall system 170 in accordance with a further preferred embodiment of the present invention. As shown in FIG. 7, internal support inserts 180, 182, 184 are provided between respective lateral segments 172, 174, 176 178. As discussed with respect to FIGS. 2-6, the internal support inserts 180, 182, 184 connect each pair of lateral wall segments 172, 174, 176, 178 to resist lateral and vertical forces applied to the wall system.

[0031] While this invention has been described and illustrated with reference to particular embodiments, it will be readily apparent to those skilled in the art that the scope of the invention is not limited to the disclosed embodiments but, on the contrary, is intended to cover numerous other modifications and equivalent arrangements which are included within the spirit and scope of the following claims.

[0032] The above descriptions of illustrated embodiments of the present invention are not intended to be exhaustive or to limit the present invention to the precise forms disclosed. It should be understood that various equivalent modifications are possible within the scope of the described embodiments as those skilled in the relevant art will recognize. Further, the elements of the various embodiments described above can be combined to provide further embodiments without limitation. These and other changes can be made to the disclosed system and apparatus in light of the above detailed description.

[0033] In the following claims, the terms used should not be construed to limit the specific embodiments disclosed in the specification and the claims, but instead the scope of the present invention is intended to be determined entirely by the claims.