NZ223053A - Acoustically insulating room divider panel - Google Patents

Description

22 3053 Priority Oate(s): Complete Specification Filed: Class: fe. ^ 2T"0rC"t390r"- Publication Date: P.O. Journal. No: . ....132.9, NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION CHi;/ ROQH DIVIDER AND METHOD OF MANUFACTURE We, ASHELWOOD PRODUCTS PTY.LTD., a company incorporated under the laws of the State of South Australia, whose registered office is -situate at 7A Boskenna Avenue, Norwood 5067, State of South Australia, Commonwealth of Australia, do hereby declare the invention, for which we pray that a Patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- - 1 - (Followod by—1-A-) m 22 3053 O f This invention relates to a room divider and method of manufacture.

Room dividers are already known in the art, and earlier types are generally of the form comprising a 5- frame-work of cellular construction with sound absorbing material held in the cells and with perforated cover sheets over which is positioned a wall fabric or other material which aids in sound deadening and aesthetic appearance.

. According to the earlier inventions special joining means were provided whereby panels could be interconnected to allow free-standing panels to be used and these also included ducting at the base for electrical leads where this was required.

. As examples of the prior art, the specifications of British Letters Patent No. 1 600 990 in the name of Ashelwood Products Pty. Ltd., shows how sectional panels of planar or curved form can be joined together by a special four-pin joining member, 20. Australian Specification AU 26028/84 in the name of Geoffrey Ballantyne Ashton shows how shelving can be a. lied to such panels, showing also a cellular form with insulation in the cells and showing ducting in a cavity at the base of the stucture, PCT/AU85/00145 25. shows a panel with perforated metal walls supporting an insulating material in cells formed in the panel, Offenlegungsschrift 24 58 835 in the name of Champion International Corporation teaches the art of a panel having a surround and perforated sheet on one side 30. with a filler of glass fibre or sheet, and U.S.

Patent No. 3,289,368 in the name of E.H. Mark shows a special form of ducting. o c 3.

The object of the present invention is to provide an improved form of room divider in which the panels are of improved construction and in which a novel method of construction is involved which results in a durable, strong and aesthetic unit which has high sound proofing characteristics and allows ready accommodation of electric leads where this is required in a non-conductive capacity.

The objects of the invention are achieved by forming a perimeter frame to outline the panel and fixing to the perimeter frame plywood or similar walls and then injecting into the cavity defined between the walls and the surrounding frame a foam material preferably of the fire-proof type such as polyurethane foam while maintaining the walls in a press or former, whereby by holding the walls in position, the injected foam material fills the cavity between the walls and forms a spacer for the walls so that when the foam has set a rigid and durable, relatively sound proof, structure results, the bonding of the walls to the foam ensuring required rigidity and sound-proofing which is required.

The invention thus consists of a room divider comprising a panel having a rigid surround to which is secured wall members to form a cavity therebetween and in which cavity is disposed a core of sound-deadening material, the panel being characterised by having the said core injected into the said cavity to fill the cavity to form support means between at least the said wall members whereby the core bonds to the surround as well as to the wall members to rigidly bond the surround and the wall members of the panel together, and further by a ducting member extending at least along the panel secured to the panel to be in the plane of the panel, and by a fabric cover extending over the said panel. 22 3 05 3 V«Jr-» /-f .

I • 4.

The invention also relates to the structural components of the surround and a covering for the panel.

The method of manufacture comprises the steps of 5- forming a surround, attaching wall members thereto to form and define a cavity between the surround, holding the wall members in press members, injecting a sound-deadening material to fill the cavity, and subsequently removing the press members.

The panel so formed is provided means to join such a panel to other panels such as apertures in a top rail at appropriate locations to allow panels to be interconnected by pin plates, whereby to form room dividers. - xhe base of such a panel preferably comprises a ducting member which is moulded from a high density material such as polyurethane which again is fireproof and this is preferably constructed to have a central web with a plurality of channels on each . side with the outer edges terminating at a width approximately that of the width of the panel itself so that this ducting member fits neatly to the bottom of the panel and forms the bottom surround member.

The plywood or similar walls and the surround are - then covered by drawing over the panel so formed a bag of a wool material which can extend over the top, around the two sides and terminates at the J 22 3 0 53 . base of the panel preferably at its junction with a ducting member.

The ducting has a series of removable covers to give access to the ducts and these covers can be secured in any way but are preferably shaped to be complimentary to the divisions between the channels to fit neatly thereto and clip into position so that when required they can be removed by a suitable tool to allow wiring to be inserted or removed or changed.

The end cover members may be so dimensioned that when a panel is joined at right angles to another panel, the ducts are in communication when the appropriate end cover member is removed, and these cover members are arranged to embody switches or power outlets or other access means to the wiring.

A panel formed according to this invention thus is of simple construction, the panel itself comprising only a surround supporting wall members with the cavity filled with sound-deadening and optionally fire-proof material to give the necessary rigidity and acoustic properties and fire-proofing, and as the ducting member may also be formed of material such as polyurethane, but of high density type, it will also be realised that the whole structure forms an effective fire barrier when in use.

The fabric covering the panel can also be rendered fire-proof, or can be of a fire-proof type, as can the surround and plywood or similar walls which 22 3053 l can be appropriately treated to increase their non-inflammability.

To enable the form of the invention to be fully appreciated, reference may be had to the accompanying 5- drawing in which a form of the invention is illustrated, but the invention is not necessarily to be limited to details illustrated.

In the drawings; FIG. 1 is a fragmented perspective view of a typical 10- panel according to this invention, showing the panel sectioned transversely and the cover members broken away to better show the structure, FIG. 2 shows in perspective a locking member which can be used to lock the panel to a floor or other 15- support, FIG. 3 is a transverse section of the lower part of a panel, showing another panel joined thereto, showing two cover members removed, the section being taken on line 3-3 of FIG. 4, . FIG. 4 is a sectional plan of the panels shown in FIG. 3 taken on line 3-3 of FIG. 2, line 3-3 of FIG. 2, FIG. 5 shows in perspective a modified form of the locking member, and 1 ■ 22 3 0 5 3 FIG. 6 is a side elevation illustrating the method used whend forming the panel during the manufacturing process.

The panel illustrated in FIG. 1 and shown in 5- perspective, has part omitted as the panel can be of considerable height, the panel being fragmented ; to show constructional features. The panel is I sectioned near one end immediately adjacent to a > | side rail (not shown). r f t 10* A surround 1 is formed by a top rail 2 which is ] joined to a pair of side rails 3 which extend down | from each end of the top rail 1 and are joined to j a base member 4. Two wall members 5, are joined to J the surround 1 to form a cavity 6 between the j 15. surround 1 and wall members 4. % i The cavity 6 is filled with a core 7 of foam material, the foam material being injected while the sides are held in a press so that when the foam sets it forms a rigid structure having low acoustic transfer. The press members 8 or plattens of a press are shown in FIG. 6 which illustrates the method of manufacture.

. The base member 4 has a series of ducts 9 formed between spacers 10 extending outwards on each side from a central web 11, and these ducts 9 are covered 25. by sectional cover members 12 which clip into position, having lugs 13 along a top edge to engage into recesses 14 when the cover members 12 are appropriately outwardly extended, the cover members 12 being then swung downwardly to engage hooked o © , \ ; 22 3 05 3 8. lower ends 15 into longitudinal recesses 16 in the lowermost spacer. The end rear cover member 12 of FIG. 3 is shown displaced to show a lug 9, and this cover member 12 is preferably of a dimension such that when it is removed, the ducts of a similar abutting transversely positioned panel mate with the ducts of the panel. The cover member 12 of the transverse panel is removed at 17.

The ducts 9 preferably have keepers 18 spaced apart 10. along their length to hold wiring, these being of lesser height than the openings of the ducts 9 to facilitate placement of wiring.

The cover members 12 have longitudinal reinforcing ribs 19 adjacent each spacer 6. < 15. xhe cover members 12 are adapted to carry switches, power outlets, computer connectors or the like which can take any usual or approved form, one being indicated by 20 in FIG. 3.

A wool or other flexible covering 21 in the form of a bag is drawn over the panel to give a pleasing appearance and aid acoustic absorption.

Apertures 22 in the top rail 2 and on the underside of base members 4 allow adjacent panels to be interconnected.

. The method of manufacture as shown in FIG. 6 preferably comprises joining one end of each side rails 3 to the ends of the top rail 2 and joining i • MJBStSt. . 22 3 0 5 3 the other ends of the side rails 3 to the ducting base 4 to form the surround 1, applying the wall member 5 to form the cavity 6, applying press members 8 to the so formed structure to define the cavity 5* width, and applying the core 7 by injecting the material which is to form the core into the cavity 6 through the supply duct 24.

When the material has set, the press members 23 are removed.

* The core material 7 bonds the wall members 5 together and to the surround 1 to form a rigid and effective panel.

The base member 4 is shown as formed in two similar but reversed sections joined together at a centre *5* line 25 by spacers 26 forming part of each section.

A gap 27 is formed between the two members adapted to receive holding brackets 28 secured to a support such as a floor, which holding brackets 28 can comprise a base 29 to engage the support and an upstand-flange 30 which passes through the gap and can be locked to the base member 4 by pin means 31 as shown in FIG. 2.

The holding bracket 28, instead of being formed as shown in FIG. 5 could be formed as shown in FIG. 25* 2 where the base 29 is extended to support two upstanding pins 32 which can engage apertures 33 as shown for instance in FIG. 1. 22 305 3 .

The structure described above the ducting member can be repeated below the ducting member to raise the ducting member to an intermediate height or an added ducting can be included.

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Claims (11)

WHAT WE CLAIM IS:

1. A room divider comprising a panel having a rigid surround to which is secured wall members to form a cavity therebetween and in which cavity is disposed a core of sound-deadening material, the panel being characterised by having the said core injected into the said cavity to fill the cavity to form support means between at least the said wall members whereby the core bonds to the surround as well as to the wall members to rigidly bond the surround and the wall members of the panel together, and further by a duct member extending at least along the panel secured to the panel to be in the plane of the panel, and by a fabric cover extending over the said panel.

2. A room divider according to claim 1 wherein the surround includes a top rail, a pair of side rails and a base member all joined together, at least the top rail having means to be engaged by joining members to connect said panel to other panels of the room divider.

3. A room divider according to claim 2 wherein the base member forms the duct member, and including removable sectional cover members engaging the said base member to close the ducts of the said duct member.

4. A room divider according to claim 3 wherein the base member is formed by two similar but reversed sections joined together so as to form a gap between the similar sections adapted to receive holding brackets secured to a floor or other support member, and means to lock the base member to the holding brackets.

5. A room divider according to any preceding claim characterised in that the surround is arranged in planar form and in that the wall members overlap the surround members, and wherein the edges of the wall members are secured over the members of the said surround.

6. A room divider according to claim 3 wherein the sectional cover members have lugs adapted to engage recesses in the base member and have hooked ends remote from the lugs to engage recesses in the base member on opposite sides of the space defined by the ducts.

7. A room divider according to claim 3 wherein some sectional cover members have a length equal to the width of a panel less the thickness of the panel to give access to the ducts when one panel is butted against another.

8. A room divider according to claim 3 wherein the ducts have keepers to retain wiring in the ducts, said keepers being of lesser height than the openings of the ducts to facilitate wiring positioning.

9. A room divider according to claim 2 wherein the surround extends beiow a duct member to position a duct member intermediate the top rail and the base.

10. The method of forming a room divider panel as defined in claim 1 characterised by the steps of forming the surround by joining a top rail to side rails one at each end to the top rail, and forming the side rails to a base member comprising longitudinal ducts formed of a non-conductive material and having openings covered by removable cover members of non-conductive material, engaging wall members on the surround to define a cavity within the surround, holding the wall members in press members, injecting a core of sound-deadening material into the cavity to engage the surround and the wall members, subsequently removing the press members, and, after the panel is formed, applying a fabric covering of wool cloth over the top rail and the side rails and the wall members to leave exposed the sectional cover memebers.

11. The method of claim 10 wherein the base member is formed with a longitudinal gap, the method including engaging the base member over holding brackets secured to support means, and securing the base member to the holding brackets. ^.ASHELWOOD PRODUCTS PTY. LTD their Attorneys : HENRY HUGHES IJfHlTED Per: o •