US20190390452A1

US20190390452A1 - Modular walls and related technology

Info

Publication number: US20190390452A1
Application number: US16/440,914
Authority: US
Inventors: Theodore W. Baker
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-06-26
Filing date: 2019-06-13
Publication date: 2019-12-26

Abstract

A wall unit in accordance with a particular embodiment of the present technology includes a first face panel, a second face panel, a first side panel, and a second side panel that together define a main interior volume. The wall unit can further include a first flange and a second flange carried by the first face panel and the second face panel, respectively. The first flange can protrude vertically from the first face panel and can at least partially define a first slot outside the main interior volume of the wall unit. Similarly, the second flange can protrude vertically from the second face panel and can at least partially define a second slot outside the main interior volume of the wall unit. The first and second slots can occupy a vertical plane within 10% of being equally spaced between the first side panel and the second side panel.

Description

CROSS-REFERENCE TO RELATED APPLICATION AND LIST OF OTHER APPLICATIONS INCORPORATED BY REFERENCE

This claims the benefit of prior U.S. Patent Application No. 62/689,984, filed Jun. 26, 2018, which is incorporated herein by reference in its entirety.
The following applications are also incorporated herein by reference in their entireties:
U.S. patent application Ser. No. 15/140,785, filed Apr. 28, 2016, entitled “Dynamic Interstitial Hotels and Related Technology,”
U.S. patent application Ser. No. 15/263,527, filed Sep. 13, 2016, entitled “School Spaces Retrofitted for Alternative Uses and Related Technology,”
U.S. patent application Ser. No. 15/390,731, filed Dec. 27, 2016, entitled “Garages Retrofitted for Alternative Uses and Related Technology,”
U.S. patent application Ser. No. 15/456,523, filed Mar. 11, 2017, entitled “Commercial Loading, Storage, Parking, and Vehicle-Servicing Spaces Retrofitted for Alternative Uses and Related Technology,” and
U.S. patent application Ser. No. 15/675,745, filed Aug. 13, 2017, entitled “Commercial Storefront Spaces Retrofitted for Alternative Uses and Related Technology.”
To the extent the foregoing applications or any other material incorporated herein by reference conflicts with the present disclosure, the present disclosure controls.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present technology can be better understood with reference to the following drawings. The relative dimensions in the drawings may be to scale with respect to some embodiments of the present technology. With respect to other embodiments, the drawings may not be to scale. The drawings may also be enlarged arbitrarily. For clarity of illustration, reference-number labels for analogous components or features may be omitted when the appropriate reference-number labels for such analogous components or features are clear in the context of the specification and all of the drawings considered together. Furthermore, the same reference numbers may be used to identify analogous components or features in multiple described embodiments.
FIG. 1 is an isometric view of a modular wall in accordance with at least some embodiments of the present technology in a first state.
FIG. 2 is an exploded isometric view of the modular wall shown in FIG. 1 in the first state.
FIG. 3 is an isometric view of a main unit of the modular wall shown in FIG. 1.
FIG. 4 is an exploded isometric view of the main unit of the modular wall shown in FIG. 1.
FIG. 5 is an isometric view of a kit for making a shell of the main unit of the modular wall shown in FIG. 1.
FIGS. 6a and 6b are isometric views of a first face panel and associated portions of the main unit of the modular wall shown in FIG. 1 taken from different respective angles.
FIGS. 7a and 7b are isometric views of a first side panel and associated portions of the main unit of the modular wall shown in FIG. 1 taken from different respective angles.
FIG. 8 is an exploded isometric view of a reinforcing insert of the main unit of the modular wall shown in FIG. 1.
FIG. 9 is an isometric view of a kit for making the reinforcing insert of the main unit of the modular wall shown in FIG. 1 and for connecting the reinforcing insert to the shell of the main unit of the modular wall shown in FIG. 1.
FIGS. 10a and 10b are isometric views of a first interior panel and associated portions of the main unit of the modular wall shown in FIG. 1 taken from different respective angles.
FIGS. 11a and 11b are isometric views of a coupler of the main unit of the modular wall shown in FIG. 1 taken from different respective angles.
FIG. 12 is an isometric view of an end unit of the modular wall shown in FIG. 1.
FIG. 13 is an exploded isometric view of the end unit of the modular wall shown in FIG. 1.
FIG. 14 is an isometric view of a base unit of the modular wall shown in FIG. 1.
FIG. 15 is an isometric view of a cap unit of the modular wall shown in FIG. 1.
FIG. 16 is a cross-sectional isometric view taken along the line A-A in FIG. 1 of the modular wall shown in FIG. 1 in the first state in which the reinforcing inserts of the main units of the modular wall are present.
FIG. 17 is a cross-sectional isometric view taken along the line A-A in FIG. 1 of the modular wall shown in FIG. 1 in a second state in which the reinforcing inserts of the main units of the modular wall are not present.
FIGS. 18a and 18b are top plan views of small and large L-shaped junction units, respectively, of a modular wall in accordance with at least some embodiments of the present technology.
FIGS. 19a and 19b are top plan views of small and large T-shaped junction units, respectively, of a modular wall in accordance with at least some embodiments of the present technology.
FIGS. 20a and 20b are top plan views of small and large cross-shaped junction units, respectively, of a modular wall in accordance with at least some embodiments of the present technology.

DETAILED DESCRIPTION

Specific details of several embodiments of the present technology are disclosed herein with reference to FIGS. 1-20 b. It should be noted, in general, that other embodiments in addition to those disclosed herein are within the scope of the present technology. For example, embodiments of the present technology can have different configurations, components, and/or operations than those disclosed herein. Moreover, a person of ordinary skill in the art will understand that embodiments of the present technology can have configurations, components, and/or operations in addition to those disclosed herein and that these and other embodiments can be without configurations, components, and/or operations disclosed herein without deviating from the present technology.
FIGS. 1 and 2 are an isometric view and an exploded isometric view, respectively, of a modular wall 100 in a first state in accordance with at least some embodiments of the present technology. With reference to FIGS. 1 and 2 together, the modular wall 100 can include units configured to be assembled with one another in a stacked and interlocking arrangement. In at least some cases, the units are configured to stack and to interlock without the use of tools. Among the units, the modular wall 100 can include main units 102 (individually identified as main units 102 a-102 r) arranged in horizontal rows 104 (individually identified as rows 104 a-104 d). Seams 106 (one labeled in FIG. 1) between the main units 102 in a given one of the rows 104 can be horizontally staggered (e.g., evenly offset) relative to the seams 106 in the row or rows 104 vertically neighboring the given row. The modular wall 100 can also include cap units 108 (individually identified as cap units 108 a-108 j) arranged in a row overlying the rows 104, and base units 110 (individually identified as base units 110 a-110 j) arranged in a row underlying the rows 104. For clarity of illustration, the horizontal spacing in FIG. 2 between the cap units 108, between the base units 110, and within the rows 104 is not uniform. When the modular wall 100 is fully assembled on a flat surface (not shown), it can be self-supporting and free-standing.
As shown in FIG. 1, the modular wall 100 can be L-shaped, and can have a first end portion 112, a second end portion 114, and a corner portion 116 therebetween. Due to the horizontal staggering of the seams 160, the main units 102 in the rows 104 b, 104 d can form insets at the first end portion 112 and at the second end portion 114. At these insets, the modular wall 100 can include end units 118 (individually identified as end units 118 a-118 d). The end units 118 can be configured to fill the insets such that the modular wall 100 is straight rather than staggered at the first end portion 112 and at the second end portion 114. When straight end portions are not needed, the end units 118 can be omitted. Similarly, when finished bottom and/or top portions are not needed, the cap units 108 and/or the base units 110, respectively, can be omitted. Furthermore, the main units 102, the cap units 108, the base units 110, and the end units 118 can be arranged to form shapes other than L-shapes. For example, the main units 102 a, 102 b, 102 f, 102 j, 102 k, 102 o, the cap units 108 a-108 c, the base units 110 a-110 c, and the end units 118 a, 118 c can be collectively rotated 90 degrees about a vertical axis and assembled with the other units of the modular wall 100 in a straight line. As another example, the main units 102 b, 102 g, 102 k can be arranged to project from the corner portion 116 in three different respective directions and interconnected with other units to form a T-shaped junction. As another example, the main units 102 b, 102 g, 102 k, 102 p can be arranged to project from the corner portion 116 in four different respective directions and interconnected with other units to form a cross-shaped junction. Furthermore, a greater or lesser number of rows 104 can be used to change the height of the modular wall 100 in any of its potential shapes. Also, a greater or lesser number of main units 102, cap units 106, and base units 108 can be used to change a length of any portion of the modular wall 100 in any of its potential shapes. This versatility and/or the ease of assembling and disassembling the modular wall 100 in its illustrated shape and other shapes can be particularly useful for temporary and/or dynamic installations.
FIGS. 3 and 4 are an isometric view and an exploded isometric view, respectively, of the main unit 102 i. In at least some cases, the individual main units 102 have the same construction and are interchangeable with one another. Accordingly, the same reference numbers used herein to identify portions of the main unit 102 i may also be used herein to identify corresponding portions of main units 102 other than the main unit 102 i. With reference to FIGS. 3 and 4 together, the main unit 102 i can include a shell 120, a reinforcing insert 122, and couplers 124 (individually identified as couplers 124 a-124 l) detachably coupled to one another. As parts of the shell 120, the main unit 102 i can include a first face panel 126, a second face panel 128 parallel to and spaced apart from the first face panel 126, a first side panel 130, and a second side panel 132 parallel to and spaced apart from the first side panel 130. The first face panel 126, the second face panel 128, the first side panel 130, and the second side panel 132 can be detachably connected to one another via the couplers 124 a-124 h. The shell 120 and the reinforcing insert 122 can be detachably connected to one another via the couplers 124 i-124 l.
Within the shell 120, the main unit 102 i can have a main interior volume 134 defined by the first face panel 126, the second face panel 128, the first side panel 130, and the second side panel 132 together. The main unit 102 i can also have a first corner portion 135 a at which the first face panel 126 is detachably connected to the first side panel 130, a second corner portion 135 b at which the first face panel 126 is detachably connected to the second side panel 132, a third corner portion 135 c at which the second face panel 128 is detachably connected to the first side panel 130, and a fourth corner portion 135 d at which the second face panel 128 is detachably connected to the second side panel 132. In at least some cases, the main interior volume 134 is shaped as a rectangular solid. The main unit 102 i can further include a first flange 136 carried by and inwardly positioned relative to the first face panel 126, and a second flange 138 carried by and inwardly positioned relative to the second face panel 128. The main unit 102 i can also include a first slot 140 and a second slot 142 defined by the first flange 136 and the second flange 138, respectively. The first flange 136 and the second flange 138 can protrude vertically from the main interior volume 134 of the main unit 102 i such that the first slot 140 and the second slot 142 are outside the main interior volume 134 of the main unit 102 i. With reference to FIGS. 1-4 together, the first slot 140 and the second slot 142 of a given one of the main units 102 (e.g., main unit 102 i) can be positioned to receive respective portions of the first side panel 130 of a first vertically neighboring one of the main units 102 (e.g., main unit 102 n) and the second side panel 132 of a second vertically neighboring one of the main units 102 (e.g., main unit 102 m).
One, some, or all of the main unit 102 i, the shell 120, the reinforcing insert 122, the couplers 124, the first face panel 126, the second face panel 128, the first side panel 130, the second side panel 132, the first flange 136, and the second flange 138, individually, can be made at least primarily (i.e., at least 50% by weight) of one or more pieces cut from one or more sheet materials. Examples of sheet materials include wood-based sheet materials (e.g., plywood, medium-density fiberboard, high-density fiberboard, oriented strand board, particle board, hardboard, etc.), plastic sheet materials (e.g., polyethylene, polypropylene, polycarbonate, polystyrene, polyvinyl chloride, acrylonitrile butadiene styrene, etc.), gypsum board, and cement board. Among sheet materials, cement board is particularly well suited for use in at least some embodiments of the present technology. Cement board includes cementitious binder (e.g., calcium silicate based cement) and, optionally, other materials, such as sand, cellulose, and glass fibers. One example of a cement board well suited for use in at least some embodiments of the present technology is HARDIEBACKER® 500 cement board available from James Hardie Building Products (Chicago, Ill.).
FIG. 5 is an isometric view of a kit 144 for making the shell 120. As shown in FIG. 5, when detached from one another, the first face panel 126, the second face panel 128, the first side panel 130, the second side panel 132, and the couplers 124 a-124 h can be packed together in a compact arrangement well suited for shipping. FIGS. 6a and 6b are isometric views of the first face panel 126 and associated portions of the main unit 102 i taken from different respective angles. FIGS. 7a and 7b are isometric views of the first side panel 130 and associated portions of the main unit 102 i taken from different respective angles. In at least some cases, the first face panel 126 and the second face panel 128 have the same construction and are interchangeable with one another. Similarly, the first side panel 130 and the second side panel 132 can have the same construction and be interchangeable with one another. Accordingly, the same reference numbers used herein to identify portions of the first face panel 126 may also be used herein to identify corresponding portions of the second face panel 128 and vice versa. Also, the same reference numbers used herein to identify portions of the first side panel 130 may also be used herein to identify corresponding portions of the second side panel 132 and vice versa.
With reference to FIGS. 1-7 b together, the first face panel 126, the second face panel 128, the first side panel 130, and the second side panel 132, individually, can have a first horizontal edge portion 146, a second horizontal edge portion 148 vertically spaced apart from the first horizontal edge portion 146, a flat inner surface 150, and a flat outer surface 152. The first flange 136 can overlap the second horizontal edge portion 148 of the first face panel 126. Similarly, the second flange 138 can overlap the second horizontal edge portion 148 of the second face panel 128. The first flange 136 and the second flange 138, individually, can have a flat inner surface 154 and a flat outer surface 156. The outer surface 156 of the first flange 136 can be in the same vertical plane as a portion of the inner surface 150 of the first face panel 126 at the first horizontal edge portion 146 of the first face panel 126. Similarly, the outer surface 156 of the second flange 138 can be in the same vertical plane as a portion of the inner surface 150 of the second face panel 128 at the first horizontal edge portion 146 of the second face panel 128. The first slot 140 can have sides defined by the first flange 136, and an end defined by the second horizontal edge portion 148 of the first face panel 126. Similarly, the second slot 142 can have sides defined by the second flange 138, and an end defined by the second horizontal edge portion 148 of the second face panel 128. A width of the first slot 140 in a plane parallel to the first face panel 126 can be from 100% to 125% of a sum of a thickness of the first side panel 130 and a thickness of the second side panel 132. Similarly, a width of the second slot 142 in a plane parallel to the second face panel 128 can be from 100% to 125% of the sum of a thickness of the first side panel 130 and a thickness of the second side panel 132. Furthermore, the first slot 140 and the second slot 142 can be in a vertical plane within 10% of being equally spaced between the first side panel 130 and the second side panel 132. These and other features of portions of the main unit 102 i can facilitate forming interlocking connections between the main unit 102 i and the cap units 108, between the main unit 102 i and the base units 110, between the main unit 102 i and the end units 118, and between the main unit 102 i and the other main units 102 within the modular wall 100.
As shown in FIG. 5, the first flange 136 can include a first leaf 158 at one side of the first slot 140, and a second leaf 160 spaced apart from the first leaf 158 at an opposite side of the first slot 140. Similarly, the second flange 138 can include a first leaf 162 at one side of the second slot 142, and a second leaf 164 spaced apart from the first leaf 162 at an opposite side of the second slot 142. Alternatively, a counterpart of the first flange 136 can extend through an area corresponding to the area between the first leaf 158 and the second leaf 160, inwardly adjacent to the first face panel 126, and vertically adjacent to the first slot 140. Similarly, a counterpart of the second flange 138 can extend through an area corresponding to the area between the first leaf 162 and the second leaf 164, inwardly adjacent to the second face panel 128, and vertically adjacent to the second slot 142.
As shown in FIGS. 5, 6 a and 7 a, the main unit 102 i can include panel-connecting hooks 166 (individually identified as panel-connecting hooks 166 a-166 p). The individual panel-connecting hooks 166 can be carried by one of the first face panel 126, the second face panel 128, the first side panel 130, and the second side panel 132. With reference to FIGS. 1-7 b together, when the main unit 102 i is assembled, the individual panel-connecting hooks 166 can be at one of the first corner portion 135 a, the second corner portion 135 b, the third corner portion 135 c, and the fourth corner portion 135 d. The individual couplers 124 a-124 h can also be at one of the first corner portion 135 a, the second corner portion 135 b, the third corner portion 135 c, and the fourth corner portion 135 d. The panel-connecting hooks 166 and the couplers 124 a-124 h can be inwardly positioned relative to the first face panel 126, relative to the second face panel 128, relative to the first side panel 130, and relative to the second side panel 132.
The couplers 124 a, 124 e at the first corner portion 135 a can be detachably connected to the first face panel 126 via the panel-connecting hooks 166 b, 166 j, respectively, and detachably connected to the first side panel 130 via the panel-connecting hooks 166 c, 166 k, respectively. The couplers 124 d, 124 h at the second corner portion 135 b can be detachably connected to the first face panel 126 via the panel-connecting hooks 166 a, 166 i, respectively, and detachably connected to the second side panel 132 via the panel-connecting hooks 166 h, 166 p, respectively. The couplers 124 b, 124 f at the third corner portion 135 c can be detachably connected to the second face panel 128 via the panel-connecting hooks 166 e, 166 m, respectively, and detachably connected to the first side panel 130 via the panel-connecting hooks 166 d, 166 l, respectively. The couplers 124 c, 124 g at the fourth corner portion 135 d can be detachably connected to the second face panel 128 via the panel-connecting hooks 166 f, 166 n, respectively, and detachably connected to the second side panel 132 via the panel-connecting hooks 166 g, 166 o, respectively. The main unit 102 i can also include first insert-connecting hooks 168 (individually identified as first insert-connecting hooks 168 a-168 d) individually carried by one of the first face panel 126 and the second face panel 128. The first insert-connecting hooks 168 are discussed below with regard to the reinforcing insert 122.
FIG. 8 is an exploded isometric view of the reinforcing insert 122 (FIG. 4). FIG. 9 is an isometric view of a kit 170 for making the reinforcing insert of 122. FIG. 9 is an isometric view of a kit 170 for making the reinforcing insert 122 and for connecting the reinforcing insert 122 to the shell 120 (FIG. 4). With reference to FIGS. 1-9 together, as parts of reinforcing insert 122, the main unit 102 i can include a first interior panel 172 within the main interior volume 134 of the main unit 102 i, and a second interior panel 174 also within the main interior volume 134 of the main unit 102 i. The first interior panel 172 can be parallel to the first side panel 130 and to the second side panel 132, and can be in a vertical plane within 10% of being equally spaced between the first side panel 130 and the second side panel 132. In at least some cases, the first interior panel 172, the first slot 140, and the second slot 142 are in the same vertical plane. In these and other cases, the first interior panel 172 can have a thickness from 75% to 125% of a sum of a thickness of the first side panel 130 and a thickness of the second side panel 132. The second interior panel 174 can be perpendicular to the first interior panel 172, to the first face panel 126, to the second face panel 128, to the first side panel 130, and to the second side panel 132. When the main unit 102 i is assembled, the second interior panel 174 can be vertically supported by the first flange 136 and by the second flange 138.
FIGS. 10a and 10b are isometric views of the first interior panel 172 and associated portions of the main unit 102 i taken from different respective angles. With reference to FIGS. 1-10 b together, the first interior panel 172 and the second interior panel 174 can be detachably connected to the first face panel 126, to the second face panel 128, to the first side panel 130, and to the second side panel 132. The first interior panel 172 and the second interior panel 174 can also be detachably connected to one another. For example, the main unit 102 i can include a third slot 176 defined by the first interior panel 172 that slidably receives a portion of the second interior panel 174. Similarly, the main unit 102 i can include a fourth slot 178 defined by the second interior panel 174 that slidably receives a portion of the first interior panel 172. The main unit 102 i can also include second insert-connecting hooks 180 (individually identified as second insert-connecting hooks 180 a-180 d) carried by the first interior panel 172. The couplers 124 k, 124 l can be detachably connected to the first face panel 126 via the first insert-connecting hooks 168 a, 168 b, respectively, and detachably connected to the first interior panel 172 via the second insert-connecting hooks 180 a, 180 d, respectively. Similarly, the couplers 124 i, 124 j can be detachably connected to the second face panel 128 via the first insert-connecting hooks 168 c, 168 d, respectively, and detachably connected to the first interior panel 172 via the second insert-connecting hooks 180 c, 180 b, respectively.
At least some of the panel-connecting hooks 166 (FIGS. 6a and 7a ), the first insert-connecting hooks 168 (FIG. 6a ), and the second insert-connecting hooks 180 (FIG. 10a ) can have the same construction. Furthermore, at least some of the panel-connecting hooks 166, the first insert-connecting hooks 168, and the second insert-connecting hooks 180 can be made at least primarily of built-up pieces of sheet material (e.g., cement board). As one example, the second insert-connecting hook 180 a (FIG. 10a ) can include a projecting piece 182 and a connecting piece 184 sandwiched between the projecting piece 182 and the first interior panel 172. Likewise, the first interior panel 172 can be made at least primarily of one or more pieces of sheet material (e.g., cement board). As shown in FIGS. 10a and 10 b, the first interior panel 172 can include two subpanels 186 (individually identified as subpanels 186 a, 186 b) laminated together. The first interior panel 172 can further include stabilizing pieces 188 (individually identified as stabilizing pieces 188 a, 188 b) adjacent to the third slot 176 at opposite respective sides of the first interior panel 172. The stabilizing pieces 188 can be useful, for example, to stabilize a detachable connection between the first interior panel 172 and the second interior panel 174.
FIGS. 11a and 11b are isometric views of the coupler 124 a taken from different respective angles. In at least some cases, the individual couplers 124 have the same construction and are interchangeable with one another. This interchangeability and the other interchangeability discussed above with reference to other components of the modular wall 100 can be useful to simplify manufacturing and installation of the modular wall 100 and components thereof. The same reference numbers used herein to identify portions of the coupler 124 a may also be used herein to identify corresponding portions of couplers 124 other than the coupler 124 a. In at least some cases, the couplers 124 are configured to slidably connect to the corresponding ones of the panel-connecting hooks 166, the first insert-connecting hooks 168, and the second insert-connecting hooks 180. For example, the couplers 124 can be drop-in couplers and/or be otherwise configured to move vertically to detachably engage or disengage with the corresponding ones of the first face panel 126, the second face panel 128, the first side panel 130, the second side panel 132, and the first interior panel 172 via the corresponding ones of the panel-connecting hooks 166, the first insert-connecting hooks 168, and the second insert-connecting hooks 180.
As shown in FIGS. 11a and 11b , the coupler 124 a can include a plate 190, a first bracket 192 extending along one side portion of the plate 190, and a second bracket 194 extending along another side portion of the plate 190. The first bracket 192 and the second bracket 194 can be at a right angle relative to one another. In at least some cases, the plate 190 is shaped as a right triangle (e.g., an isosceles right triangle), and the first bracket 192 and the second bracket 194 extend along the legs of the right triangle, respectively. In these and other cases, the first bracket 192 and the second bracket 194, individually, can be L-shaped. Furthermore, the first bracket 192 and the second bracket 194 can individually be shaped to snugly receive the connecting pieces 184 (FIG. 10a ) of the panel-connecting hook 166 b and the panel-connecting hook 166 c, respectively, when the first face panel 126 and the first side panel 130 are abutting one another at a right angle. Similarly, the other couplers 124 can be configured to interact with the connecting pieces 184 of corresponding ones of the panel-connecting hooks 166, the first insert-connecting hooks 168, and the second insert-connecting hooks 180 to form right-angle connections between corresponding pairs of the first face panel 126, the second face panel 128, the first side panel 130, the second side panel 132, and the first interior panel 172.
FIGS. 12 and 13 are an isometric view and an exploded isometric view, respectively, of the end unit 118 a. In at least some cases, the individual end units 118 have the same construction and are interchangeable with one another. With reference to FIGS. 12 and 13 together, the end unit 118 a can include panels 196 (individually identified as panels 196 a-196 d) and couplers 198 (individually identified as couplers 198 a-198 h) through which the panels 196 are detachably coupled to one another. In at least some cases, the individual couplers 198 have the same construction and are interchangeable with one another and with the individual couplers 124 (FIG. 4). The end unit 118 a can further include flanges 200 (individually identified as flanges 200 a-200 d) carried by and inwardly positioned relative to the individual panels 196, respectively. The individual flanges 200 can be similar to the first leaf 158 of first flange 136 (FIG. 6a ), the second leaf 160 of first flange 136 (FIG. 6a ), the first leaf 162 of second flange 138 (FIG. 6b ), and the second leaf 164 of second flange 138 (FIG. 6b ), individually. The end unit 118 a can also include an interior panel 201 similar to the second interior panel 174 (FIG. 8). The interior panel 201 can be horizontal and supported by the flanges 200 when the end unit 118 a is assembled.
As mentioned above with reference to FIGS. 1 and 2, the end units 118 can be configured to fill insets associated with staggering of the main units 102. Accordingly, the lengths of the individual end units 118 parallel to the modular wall 100 can be half the lengths of the individual main units 102 parallel to the modular wall 100 when the main units 102 are configured to be evenly staggered. With reference to FIGS. 2, 12 and 13 together, the individual main units 102 can be configured to receive the flanges 200 of a vertically neighboring one of the end units 118. Similarly, the individual end units 118 can be configured to receive the second leaf 160 of the first flange 136 (FIG. 6a ) and the first leaf 162 of the second flange 138 (FIG. 6b ) of a vertically neighboring one of the main units 102 or the first leaf 158 of first flange 136 (FIG. 6a ) and the second leaf 164 of second flange 138 (FIG. 6b ) of a vertically neighboring one of the main units 102.
FIGS. 14 and 15 are isometric views of the base unit 110 a and the cap unit 108 a, respectively. In at least some cases, the individual base units 110 have the same construction and are interchangeable with one another. Similarly, the individual cap units 108 can have the same construction and be interchangeable with one another. As shown in FIG. 14, the base unit 110 a can include a five-sided shell 202 and parallel slats 204 (one labeled) within the shell 202. As shown in FIG. 15, the cap unit 108 a can similarly include a five-sided shell 206 and parallel slats 208 (one labeled) within the shell 206. The cap unit 108 a can further include flanges 210 (individually identified as flanges 210 a-210 d) projecting from the shell 206. The individual flanges 210 can be similar to the individual flanges 200 (FIG. 13). As shown in FIG. 2, the individual base units 110 can be configured to receive the flanges 200 of a vertically neighboring one of the end units 118, the second leaf 160 of the first flange 136 (FIG. 6a ) and the first leaf 162 of the second flange 138 (FIG. 6b ) of a vertically neighboring one of the main units 102 or the first leaf 158 of first flange 136 (FIG. 6a ) and the second leaf 164 of second flange 138 (FIG. 6b ) of a vertically neighboring one of the main units 102. The individual main units 102 and the individual end units 118 can be configured to receive the flanges 210 of a vertically neighboring one of the cap units 108.
FIG. 16 is a cross-sectional isometric view taken along the line A-A in FIG. 1 of the modular wall 100 in a first state in which the reinforcing inserts 122 of the main units 102 are present. In the first state, the main units 102 can carry a vertical load on the modular wall 100 evenly via the first face panels 126 (FIG. 4), the second face panels 128 (FIG. 4), the first side panels 130 (FIG. 4), the second side panels 132 (FIG. 4), and the first interior panels 172 (FIG. 9). FIG. 17 is a cross-sectional isometric view taken along the line A-A in FIG. 1 of the modular wall 100 in a second state in which the reinforcing inserts 122 of the main units 102 are not present. In the second state, the main units 102 can carry a vertical load on the modular wall 100 at least primarily via the first face panels 126 (FIG. 4) and the second face panels 128 (FIG. 4). In both the first state and the second state, the modular wall 100 can have significant load-bearing capacity. When the modular wall 100 is in the first state, however, this load-bearing capacity can be greater than when the modular wall 100 is in the second state. In at least some cases, it can be useful to assemble the modular wall 100 in the first state when there is a need for the modular wall 100 to support a significant load, such as from an associated ceiling (not shown) and to assemble the modular wall 100 in the second state when there is not a need for the modular wall 100 to support a significant load. When there is not a need for the modular wall 100 to support a significant load, the second state can be advantageous, for example, to reduce the weight, material cost, and assembly effort associated with the reinforcing inserts 122 and the couplers 124 i-124 l. Furthermore, not all main units 102 within the modular wall need to be in the same state. For example, the main units 102 at some portions (e.g., load-bearing portions) of the modular wall 100 can be assembled in the first state and the main units 102 at other portions (e.g., non-load-bearing portions) of the modular wall 100 can be assembled in the second state.
As shown in FIG. 2, in some embodiments, the first flanges 136 (FIG. 4), the second flanges 138 (FIG. 4), the flanges 200 (FIG. 13), and the flanges 210 (FIG. 14) project downward. In other embodiments, counterparts of the first flanges 136 (FIG. 4), the second flanges 138 (FIG. 4), and the flanges 200 (FIG. 13) can project upward. In these embodiments, the respective positions of counterparts of the base units 110 and the cap units 108 can be swapped. In other words, counterparts of the base units 110 can have the same construction as the cap units 108, and counterparts of the cap units 108 can have the same construction as the base units 110. Furthermore, rather than receiving the first side panel 130 and the second side panel 132 from below, counterparts of the first slots 140 and the second slots 142 can receive counterparts of the first side panel 130 and the second side panel 132 from above.
As discussed above, the main units 102 b, 102 g, 102 k can be arranged to project from the corner portion 116 in two respective directions opposite one another, in two respective directions at a right angle to one another, in three respective directions at right angles to one another, or in four respective directions at right angles to one another and interconnected with other units to form a straight line, an L-shape, a T-shape, or a cross-shape, respectively. Alternatively or in addition, modular walls in accordance with at least some embodiments of the present technology include junction units different than the main units 102. For example, small and large L-shaped junction units can be alternatingly stacked to form two staggered ends suitable for extension by interconnection with the main units 102. Similarly, small and large T-shaped junction units can be alternatingly stacked to form three staggered ends suitable for extension by interconnection with the main units 102. Also similarly, small and large cross-shaped junction units can be alternatingly stacked to form four staggered ends suitable for extension by interconnection with the main units 102.
FIGS. 18a and 18b are top plan views of a small L-shaped junction unit 300 and a large L-shaped junction unit 302, respectively. FIGS. 19a and 19b are top plan views of a small T-shaped junction unit 304 and a large T-shaped junction unit 306, respectively. FIGS. 20a and 20b are top plan views of a small cross-shaped junction unit 308 and a large cross-shaped junction unit 310, respectively. With reference to FIGS. 18a-20b together, the small and large L-shaped junction units 300, 302, the small and large T-shaped junction units 304, 306, and the small and large cross-shaped junction units 308, 310 can be made of square subunits 312 and/or rectangular subunits 314 connected to one another permanently (e.g., by gluing) or semi-permanently (e.g., by bolting) in the illustrated or other suitable arrangements. For example, the square subunits 312 and/or rectangular subunits 314 can interconnected permanently or semi-permanently before the junction units are stacked. The individual square subunits 312 can be the same as or similar to the individual end units 118 of the modular wall 100. Similarly, the individual rectangular subunits 314 can be the same as or similar to the individual main units 102 of the modular wall 100. Alternatively, some or all of the small and large L-shaped junction units 300, 302, the small and large T-shaped junction units 304, 306, and the small and large cross-shaped junction units 308, 310 can have other suitable forms, such as other suitable forms that do not include interconnected subunits.
This disclosure is not intended to be exhaustive or to limit the present technology to the precise forms disclosed herein. Although specific embodiments are disclosed herein for illustrative purposes, various equivalent modifications are possible without deviating from the present technology, as those of ordinary skill in the relevant art will recognize. In some cases, well-known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the present technology. Although steps of methods may be presented herein in a particular order, in alternative embodiments the steps may have another suitable order. Similarly, certain aspects of the present technology disclosed in the context of particular embodiments can be combined or eliminated in other embodiments. Furthermore, while advantages associated with certain embodiments may be disclosed herein in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages or other advantages disclosed herein to fall within the scope of the present technology. This disclosure and the associated technology can encompass other embodiments not expressly shown or described herein.
Throughout this disclosure, the singular terms “a,” “an,” and “the” include plural referents unless the context clearly indicates otherwise. Similarly, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in reference to a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all of the items in the list, or (c) any combination of the items in the list. Additionally, the terms “comprising,” “including,” and the like are used throughout this disclosure to mean including at least the recited feature(s) such that any greater number of the same feature(s) and/or one or more additional types of features are not precluded. Directional terms, such as “upper,” “lower,” “front,” “back,” “vertical,” and “horizontal,” may be used herein to express and clarify the relationship between various structures. It should be understood that such terms do not denote absolute orientation. Furthermore, reference herein to “one embodiment,” “an embodiment,” or similar phrases means that a particular feature, structure, operation, or characteristic described in connection with such phrases can be included in at least one embodiment of the present technology. Thus, such phrases as used herein are not necessarily all referring to the same embodiment. Finally, it should be noted that various particular features, structures, operations, and characteristics of the embodiments described herein may be combined in any suitable manner in additional embodiments in accordance with the present technology.

Claims

I claim:

1. A wall unit, comprising:

a first face panel;

a second face panel parallel to and spaced apart from the first face panel;

a first side panel;

a second side panel parallel to and spaced apart from the first side panel, wherein the first face panel, the second face panel, the first side panel, and the second side panel together define a main interior volume of the wall unit;

a first flange carried by the first face panel, wherein the first flange protrudes vertically from the first face panel and at least partially defines a first slot outside the main interior volume of the wall unit; and

a second flange carried by the second face panel, wherein the second flange protrudes vertically from the second face panel and at least partially defines a second slot outside the main interior volume of the wall unit, and wherein the first slot and the second slot occupy a vertical plane within 10% of being equally spaced between the first side panel and the second side panel.

2. The wall unit of claim 1 wherein the first face panel and the second face panel are made at least primarily of cement board.

3. The wall unit of claim 2 wherein the first side panel and the second side panel are made at least primarily of cement board.

4. The wall unit of claim 3 wherein the first flange and the second flange are made at least primarily of cement board.

5. The wall unit of claim 1 wherein:

the first flange is inwardly positioned relative to the first face panel;

the first flange protrudes vertically from the main interior volume of the wall unit;

the second flange is inwardly positioned relative to the second face panel; and

the second flange protrudes vertically from the main interior volume of the wall unit.

6. The wall unit of claim 5 wherein:

the first face panel and the second face panel individually include—

a first horizontal edge portion, and

a second horizontal edge portion vertically spaced apart from the first horizontal edge portion;

the first flange overlaps the second horizontal edge portion of the first face panel;

the first flange has a flat outer surface in the same vertical plane as a flat inner surface of the first horizontal edge portion of the first face panel; and

the second flange overlaps the second horizontal edge portion of the second face panel;

the second flange has a flat outer surface in the same vertical plane as a flat inner surface of the first horizontal edge portion of the second face panel.

7. The wall unit of claim 1 wherein a width of the first slot in a plane parallel to the first face panel is from 100% to 125% of a sum of a thickness of the first side panel and a thickness of the second side panel.

8. The wall unit of claim 7 wherein a width of the second slot in a plane parallel to the second face panel is from 100% to 125% of the sum of the thickness of the first side panel and the thickness of the second side panel.

9. The wall unit of claim 1 wherein the first face panel, the second face panel, the first side panel, and the second side panel are detachably connected to one another.

10. The wall unit of claim 1, further comprising an interior panel within the main interior volume of the wall unit.

11. The wall unit of claim 10 wherein:

the interior panel is parallel to the first side panel and to the second side panel; and

the interior panel occupies the vertical plane.

12. The wall unit of claim 11 wherein a thickness of interior panel is from 75% to 125% of a sum of a thickness of the first side panel and a thickness of the second side panel.

13. The wall unit of claim 12 wherein the interior panel is detachably connected to the first face panel, to the second face panel, to the first side panel, and to the second side panel.

14. A modular wall, comprising:

a first wall unit;

a second wall unit horizontally neighboring the first wall unit; and

a third wall unit vertically neighboring the first and second wall units,

wherein—

the first wall unit, the second wall unit, and the third wall unit individually include—

a first face panel,

a second face panel spaced apart from the first face panel,

a first side panel,

a second side panel spaced apart from the first side panel,

a first flange carried by the first face panel,

a first slot at least partially defined by the first flange,

a second flange carried by the second face panel, and

a second slot at least partially defined by the second flange,

the first slot of the third wall unit receives a portion of the first side panel of the first wall unit and a portion of the second side panel of the second wall unit, and

the second slot of the third wall unit receives a portion of the first side panel of the first wall unit and a portion of the second side panel of the second wall unit.

15. The modular wall of claim 14 wherein the first wall unit, the second wall unit, and the third wall unit are made at least primarily of cement board.

16. The modular wall of claim 14 wherein the first face panel, the second face panel, the first side panel, and the second side panel of the first wall unit, the second wall unit, and the third wall unit individually are detachably connected to one another.

17. The modular wall of claim 14 wherein the third wall unit is above the first and second wall units.

18. The modular wall of claim 14 wherein the third wall unit is below the first and second wall units.

19. The modular wall of claim 14 wherein the first wall unit, the second wall unit, and the third wall unit individually include an interior panel parallel to the first side panel, parallel to the second side panel, and within 10% of being equally spaced between the first side panel and the second side panel.

20. The modular wall of claim 19 wherein:

in the first wall unit, the second wall unit, and the third wall unit individually, the interior panel is detachably connected to the first face panel and to the second face panel;

when the interior panels are absent, the first wall unit, the second wall unit, and the third wall unit carry a vertical load on the modular wall at least primarily via the first face panel and via the second face panel; and

when the interior panels are present, the first wall unit, the second wall unit, and the third wall unit carry a vertical load on the modular wall evenly via the first face panel, the second face panel, the first side panel, the second side panel, and the interior panel.