System and method of interlocking wall panels

Abstract

An interconnectable wall panel system and method of forming and assembling the same are provided. A plurality of wall panels are provided that are interconnectable in a predetermined manner and arrangement, and wherein the wall panels comprise features for enhancing ease and accuracy of assembly. Wall panel members of the present disclosure are suitable for use in constructing modular building units, such as bathroom pods.

Claims

1. A method of forming a modular building unit, comprising: providing a plurality of pre-formed wall panels operable to be interconnected; wherein a first pre-formed wall panel of the plurality of pre-formed wall panels comprises a first end and a second end and a planar surface extending between the first end and the second end; the planar surface of the first pre-formed wall panel comprising a plurality of female receiving members comprising a predetermined distribution along the planar surface; the first pre-formed wall panel comprising a plurality of metal studs on an opposing side of the first pre-formed wall panel from the planar surface and wherein at least one of the plurality of female receiving members is provided adjacent to a metal stud of the first pre-formed wall panel; a second pre-formed wall panel of the plurality of pre-formed wall panels comprising a first end and a second end and a planar surface extending between the first end and the second end, the first end of the second pre-formed wall panel comprising a plurality of male extensions, the male extensions being sized and operable to be received within the plurality of female receiving members, and wherein the male extensions comprise substantially the same predetermined distribution as the female receiving members; providing a plurality of support elements on the first second preformed wall panel, wherein each of the plurality of support elements comprises a metal stud provided on an opposing side of the second preformed wall panel from the planar surface of the second preformed wall panel; wherein at least one of the plurality of male extensions comprises a rectilinear member having at least one vertical member and a pair of horizontal members, and wherein the at least one of the plurality of male extensions members is joined to or co-formed with at least one metal stud of the second pre-formed wall panel and wherein the pair of horizontal members are connected to the at least one metal stud; inserting the plurality of male extensions of the second pre-formed wall panel into the plurality of female receiving members in the first pre-formed wall panel to secure the first pre-formed wall panel and the second pre-formed wall panel to form at least one of an interior corner and an exterior corner; and wherein the method is devoid of taping and mudding the first pre-formed wall panel and the second pre-formed wall panel.

2. The method of claim 1, wherein the plurality of pre-formed wall panels are at least partially comprised of a gypsum material.

3. The method of claim 1, wherein at least one of the plurality of female receiving members and at least one of the plurality of male extensions are formed with an accuracy of plus-or-minus 0.001 inches relative to a desired dimension.

4. The method of claim 1, wherein at least one of the plurality of pre-formed wall panels comprises a thickness of between 0.5 inches and 0.625 inches.

5. A method of forming a modular building unit, the method comprising: providing a first wall panel member comprising a first portion and a second portion; wherein the first portion of the first wall panel member comprises a wall surface member, and wherein the second portion of the first wall panel member comprises a first metal stud; providing a second wall panel member comprising a plurality of metal studs on a first side and a planar surface on a second, opposing side; forming a plurality of apertures in the second wall panel member, wherein the plurality of apertures are formed using a computer-numeric controlled process and wherein at least one of the apertures is provided adjacent to one of the plurality of metal studs; forming an extension on the first portion of the first wall panel member, wherein the extension is formed using a computer-numeric controlled process and wherein at least a portion of the extension is provided co-planar with a surface of the first portion; wherein the second portion of the first wall panel member comprises a rectilinear member having at least one vertical member and a pair of horizontal members, and wherein the extension is joined to or co-formed with the first metal stud; securing the first portion of the first wall panel member to the second portion of the first wall panel member; and inserting the rectilinear member into an aperture of the plurality of apertures in the second wall panel member to secure the first wall panel member and the second wall panel member and at least partially define an interior volume of a room.

6. The method of claim 5, wherein the first and second wall panel members are provided and secured at a perpendicular angle to one another.

7. The method of claim 5, wherein the method is devoid of taping and mudding the first and second wall panel members.

8. The method of claim 5, wherein the first portion of the first wall panel member comprises gypsum.

9. The method of claim 5, wherein the rectilinear member is joined to or conformed with the rigid structural member.

10. The method of claim 5, wherein the first portion of the first wall panel member comprises a thickness of between 0.5 inches and 0.625 inches.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) The accompanying drawings which are incorporated herein and constitute a part of the specification, illustrate various embodiments of numerous inventions and together with the general description of the invention given provide the detailed description, and the drawings serve to explain the principles of these embodiments.

(2) FIG. 1 is a perspective view of a plurality of wall panels according to one embodiment of the present disclosure.

(3) FIG. 2A is a perspective view of a plurality of wall panels according to one embodiment of the present disclosure, and wherein the wall panels are positioned for assembly.

(4) FIG. 2B is a perspective view of the plurality of wall panels according to the embodiment if FIG. 2A, and wherein the wall panels are assembled.

(5) FIG. 3 is a detailed perspective view of a first and second wall panel according to one embodiment of the present disclosure.

(6) FIG. 4 is a dimensioned drawing of a wall panel according to one embodiment of the present disclosure.

(7) FIG. 5 is a dimensioned drawing of a wall panel according to one embodiment of the present disclosure.

(8) FIG. 6 is a perspective view of a plurality of wall panels according to one embodiment of the present disclosure

(9) FIG. 7 is an exploded perspective view of the plurality of wall panels according to the embodiment of FIG. 6.

(10) FIG. 8 is an exploded perspective view of the plurality of wall panels according to the embodiment of FIG. 6.

(11) FIG. 9 is a top plan view of the plurality of wall panels according to the embodiment of FIG. 6.

(12) It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

(13) The following is a listing of components according to various embodiments of the present disclosure, and as shown in the drawings:

(14) The following is a listing of features and components of the various embodiments:

(15) TABLE-US-00001 Component # Component 2 Wall panel system 4 Wall panel member 6 Female receiving port 8 Male extension 10 Doorway 12 Ducting aperture 14 Electrical aperture 16 Edge 18 Wall panel surface 20 Wall panel member 22 Wall panel member 24 Support member 26 Support member 28 Male extension 30 Female aperture

(16) FIG. 1 is a perspective view of a wall panel system 2 according to one embodiment of the present disclosure. As shown, a plurality of wall panel members 4a, 4b, 4c, 4d, 4e, 4f, 4g, 4h, 4i are provided. The wall panel members 4 are provided in-line and spaced apart for illustration purposes. The wall panels are not provided in an assembly arrangement in FIG. 1. The wall panel members 4 of FIG. 1 comprise a plurality of different-sized wall panel members that are intended to be assembled in at least one specific arrangement to provide an enclosed building unit or pod. The wall panel members 4 of FIG. 1 comprise various features including, for example, female receiving ports 6 and male extensions 8, wherein the female ports and male extensions 6, 8 are operable to be connected and enhance ease, efficiency, and accuracy of assembling the wall panel members 4 into a modular enclosure, room or pod. The wall panel members 4 further comprise various features including, for example, doorways 10, ducting apertures 12, and electrical apertures 14 for receiving and accommodating various additional building features as will be recognized by one of ordinary skill in the art.

(17) FIG. 2A is a perspective view of the wall panel system 2 according to the embodiment of FIG. 1, wherein the wall panel members 4 are arranged and prepared for assembly. As shown in FIG. 2A, the wall panel system 2 comprises a plurality of wall panel members, and at least some of the wall panel members comprise female receiving ports 6 and at least some of the wall panel members 4 comprise male extensions 8 adapted to be received within the female receiving ports 6. In certain embodiments, each of the wall panel members 4 comprise at least one female receiving port 6 on a first end of the wall panel and at least one male extension 8 provided on a second end of the wall panel 4. In such embodiments, each wall panel member 4 comprises a first end operable to receive an adjacent wall panel member and a second end operable to be at least partially inserted into a second adjacent wall panel. In certain embodiments, wall panel members 4 are provided comprising a specific arrangement of female receiving ports 6 and male extensions 8 wherein the arrangement and spacing of the female receiving ports 6 and male extensions 8 only permit a specific assembled arrangement of the wall panels. For example, and referring now to FIG. 2A, it is contemplated that a first wall panel member 4c is to be connected to a second wall panel member 4d on one end, and to a third wall panel member 4b on a second end. To facilitate such an assembly, the first wall panel member 4c comprises an arrangement of female receiving ports 6 that correspond to and permit acceptance of the male extensions 8 provided on the second wall panel member 4d. Similarly, a second end of the first wall panel member 4c comprises an arrangement of male extensions 8 that are operable to be inserted into female receiving portions 6 provided on a third wall panel member 4b. Preferably, the first end of the first wall panel member 4c is capable of receiving the male extensions of the second wall panel member 4d, but not the male extensions 8 provided on the third wall panel member. In such embodiments, a wall panel system 2 may only be assembled in a predetermined orientation (for example, a first wall panel 4c can only receive a second wall panel 4d on a first end and can only receive a third wall panel 4b on a second end). It is further contemplated that wall panels 4 of the present disclosure may comprise labelling or indicia to indicate which wall panels should be connected at specific locations.

(18) FIG. 2B is a perspective view of the system 2 according to the embodiment of FIG. 2A, and wherein the wall panel system 2 has been assembled. In FIG. 2B, each of the wall panels 4 have been interconnected to form a completed modular unit or pod. The assembly may comprise, for example, a modular bathroom pod that is operable to be inserted into a larger building or construction project. The male extension members 8 and female receiving portions 6 shown and described herein are contemplated as comprising guide members, wherein the male extension members 8 and female receiving portions 6 help guide and align an assembly process. The male extension members 8 and female receiving portions 6 are also contemplated as providing some structural stability or support for connecting adjacent wall panel members 4. In certain embodiments, adjacent wall panels 4 are further secured or interconnected using additional connecting means. Such connecting means include, but are not limited to, known fasteners and connectors for securing wall panels. Such fasteners and connectors include bolts, rivets, adhesives, screws, welds, etc.

(19) FIG. 3 is a detailed perspective view of adjacent wall panel members 4a, 4b readied for interconnection. As shown, a first end of a first wall panel member 4a comprises a plurality of female receiving portions 6. A second end of a second wall panel member 4b comprises a plurality of male extension members 8. The male extension members 8 of the second wall panel member 4b are spaced and distributed in an arrangement that corresponds to a spacing and arrangement of the plurality of female receiving portions 6 of the first wall panel member 4a. The male extension members 8 also preferably comprise coplanar and/or flush extensions of the wall panel 4b, wherein an interior wall surface is flush or coplanar with a surface of the male extensions.

(20) FIG. 4 is a dimensioned drawing of a wall panel 4 and a male extension 8 according to one embodiment of the present disclosure. Various dimensions are provided in FIG. 4, but it will be recognized that the present disclosure and embodiments of the present disclosure are not limited to the dimensions or proportions provided in FIG. 4. The illustrated dimensions are provided to illustrate one embodiment of the present disclosure. Various modifications are contemplated. As shown in FIG. 4, the wall panel 4 comprises a male extension 8 extending from the wall panel. The male extension 8 comprises radii to the corners of the extension 8 to facilitate assembly of wall panels and insertion of the male extension 8 into female receiving portions (see FIG. 5, for example).

(21) FIG. 5 is a dimensioned drawing of a wall panel 4 and a female receiving portion 6 extension according to one embodiment of the present disclosure. Various dimensions are provided in FIG. 5, but it will be recognized that the present disclosure and embodiments of the present disclosure are not limited to the dimensions or proportions provided in FIG. 5. The illustrated dimensions are provided to illustrate one embodiment of the present disclosure. Various modifications are contemplated. As shown in FIG. 5, the wall panel 4 comprises a female receiving portion 6 with the illustrated shape, dimensions and proportions.

(22) The wall panel members 4a, 4b of FIG. 3 are provided as adjacent and perpendicular wall panel members, wherein the male extensions 8 of the second wall panel member 4b extend from an end 16 of the wall panel member 4b. The female receiving portions 6 of the first wall panel member 4a are provided flush with a surface 18 of the wall panel member 4a. The features of wall panel members 4 as shown and described herein provide for quick and simple assembly of a modular building unit by enabling and facilitating vertical and horizontal alignment of wall panels. The arrangement of male and female members also allows for clean interior corners and, in at least some embodiments, clean outer corners wherein an interior corner and an exterior corner comprise flush perpendicular surfaces substantially devoid of extensions, overhangs, etc.

(23) FIG. 6 is a perspective view of a system according to one embodiment of the present disclosure. As shown, a first wall panel member 20 and a second wall panel member 22 are provided. The wall panel members 20, 22 comprise interlocking members. The members 20, 22 may comprise wall panels of various dimensions, including various lengths, widths and heights. The members 20, 22 provided in FIG. 6 are truncated for illustrative purposes, and no limitation with respect to the dimensions of the members is provided.

(24) The first wall panel member 20 comprises a male extension 28 that is operable to extend through a female aperture 30 provided in the second wall panel member 22. The first wall panel member 20 comprises a first portion 21 and a second portion 24. The first portion 21 preferably comprises a wall surface member such as gypsum. The second portion 24 comprises a preferably rigid structural member such as a metal or wood stud or frame member. The first wall panel member 20 is formed or shaped such that at least a portion of the first portion 21 and the second portion 24 are provided as the male extension 28.

(25) FIGS. 7-8 are exploded perspective views of the wall panel members 20, 22 according to the embodiment of FIG. 6. FIG. 8 comprises a view that is rotated by approximately 180 degrees about a substantially vertical axis from FIG. 7. FIG. 7 illustrates the first wall panel member 20, including a first portion 21 and a second portion 24 wherein the second portion 24 comprises a support member. In the embodiment of FIG. 7, the second portion 24 comprises a metal support member. The second portion 24 may comprise, for example, extruded aluminum or steel. A second wall panel member 22 is provided comprising a support member 26, a wall surface 27, and a female aperture 30. The male extension 28 of the first wall panel member 20 is sized and operable to extend into the female aperture 30. In some embodiments, the first portion 21 of the first wall panel member 20 comprises dimensions that are slightly larger than the second portion 24 at least in the area of the male extension 28. The first portion 21 may be cut or trimmed either before or during insertion of the first wall panel member 20 into the second wall panel member 22. For example, the first portion 21 may be provided as a gypsum or sheet-rock member that is easily shaped prior to assembly or during assembly.

(26) As shown in FIG. 7, the male extension 28 comprises at least one vertical member 32 and a pair of horizontal members 34 extending perpendicularly thereto. The vertical member 32 and at least a portion of each of the horizontal members are operable to be inserted to the female receiving portion 30 of the second wall panel member 22. The horizontal members 34 may be joined to, welded to, or co-formed with the support member 24 as shown in FIG. 7. However, as the horizontal members 34 and the male extension 28 are not intended to be load-bearing support features and are instead intended to guide and support assembly of multiple wall panels, a connection of the vertical member 32 and/or horizontal member 34 to the support member 24 and/or wall panel 20 may comprise various means and methods of construction.

(27) The male extension 28 and female receiving member 30 of the embodiment provided in FIG. 7 are provided as rectilinear members. It will be recognized, however, that various alternatives shapes and orientations may be provided without deviating from the scope and sprit of the inventions disclosed herein.

(28) FIG. 9 is a top plan view of the system according to the embodiment of FIG. 6. As shown in FIG. 9, a first wall panel member 20 and a second wall panel member 22 are provided. The first wall panel member 20 comprises a male extension 28 that extends through a portion of the second wall panel member 22. Each of the wall panel members comprise support elements 24, 26, such as studs or metal framing. In the arrangement shown in FIG. 9, the first wall panel member 20 and the second wall panel member 22 are joined together to form an interior corner 40. The interior corner 40 comprises a substantially perpendicular union of the two wall panel members and is operable to be provided as a corner to at least partially define a room or other structure. The structural support members 24, 26 are provided on exterior surfaces of the wall panel members with respect to the interior corner portion 40.

(29) In certain embodiments, wall panel members and associated features as shown and described herein eliminate a need to mud corners of a building module. Existing devices and methods for forming an interior corner of drywall construction typically comprise the steps of taping and mudding (i.e. applying a wet drywall joint compound and allowing it to dry). Such methods are known to significantly increase the amount of time required to a complete or finish an interior corner, largely due to the time required to allow a wet compound to dry. Wait times for such drying operations may increase assembly or construction schedules by days. Such delays may be acceptable when dealing with a non-modular structure, and wherein other functions and work may be performed while drying occurs. In the modular building arts, however, such delays generally serve to slow a manufacturing process and reduce the number of modular units that can be assembled and shipped in a given time period. Embodiments of the present disclosure provide systems and methods that enable quick, efficient, and clean assembly of interior corner portions without the need to mud the interior corners, thereby greatly enhancing overall manufacturing efficiency.

(30) It is contemplated that wall panel members 4 of the present disclosure are formed from and/or comprise various different materials suitable for use in building modules and wall panels. In certain embodiments, it is contemplated that the wall panel members 4 comprise gypsum. In various embodiments, wall panel members are contemplated as comprising various different thicknesses including but not limited to 0.5 inch and 0.625 inch thick wall panel members.

(31) While the present invention has been illustrated by description of preferred embodiments and while the illustrative versions have been described in considerable detail, it is not the intention of the inventors to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art upon reading this detailed description. Therefore, the invention, in its broader aspects, is not limited to these specific details, respective apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the inventor's general inventive concepts.

(32) The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

(33) Moreover, though the description of the invention has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.