HK1260260B - Prefabricated demising wall with external conduit engagement features - Google Patents

Description

Prefabricated household wall with external conduit jointing function

Cross Reference to Related Applications

This application claims priority to U.S. provisional application No. 62/304,868, filed 3, 7, 2016, the entire contents of which are incorporated by reference for all purposes.

Background

Building design and construction is the large industry of the last manual construction product in the world (office buildings, shopping malls, apartments, etc.). The persons designing the building (architects and engineers) are usually separated from the persons building the building (contractors) for liability reasons. The architect does not want to assume responsibility for how the building is built, instead the contractor does not want to assume responsibility for how the building is drawn and designed. Moreover, buildings are built by persons with special trade skills in a linear sequence deployment, and buildings are usually built by hand outside the element range. Thus, conventional construction is more of a process than a product, resulting in substantial waste and inefficiency.

Disclosure of Invention

The present disclosure relates generally to modular building construction components and more particularly to methods and apparatus for a dividing wall assembly, and to methods of installing a dividing wall assembly. In one embodiment, a prefabricated wall sub-assembly comprises: two substrates, each substrate having an inner surface and an outer surface. The base plate may be configured to span between a floor and a ceiling of the building unit. The wall may include a plurality of metal studs connecting the inner surfaces of the two substrates, wherein the plurality of metal studs define a space between the substrates. The wall may include a fire sprinkler conduit between the two base plates, wherein at least some of the plurality of metal studs have apertures that receive the fire sprinkler conduit through an interior of the household wall assembly. A plurality of suspension elements may be operably attached to the outer surfaces of the two base plates, and the plurality of suspension elements may be configured to connect to a plurality of removable finishing plates.

Some exemplary embodiments include a method of assembling a prefabricated household wall in a building. In some embodiments, the method may comprise: a wall sub-assembly is placed on a first beam of a structural frame of a building, the wall sub-assembly comprising two wall substrates and further comprising metal studs connecting inner surfaces of the wall substrates. The lower portion of the wall assembly may then be attached to the structural frame using corner brackets attached to opposite sides of the wall assembly. The upper portion of the dividing wall may then be connected to the upper floor and ceiling panels using compensating rails that are removably connected to the metal studs.

An exemplary method of assembling a prefabricated wall sub-assembly at a site remote from a construction site may also be disclosed. The method may include attaching a plurality of non-combustible panels to a frame including a plurality of metal studs to form two wall substrates of a household wall panel separated by a space therebetween. Each of the two wall substrates may have an inner surface and an outer surface, and the wall substrates may be configured to span between a floor and a ceiling of the building unit. An inner surface of each of a plurality of suspension elements may be attached to the outer surface of at least one of the two wall substrates. A conduit configured for routing electrical wires may then be installed at or near at least one of the plurality of suspension elements, and electrical wires may then be installed into the conduit configured for routing the electrical wires. A plurality of finishing plates may then be removably mounted to the plurality of suspension elements.

Drawings

The foregoing and other features of the present disclosure will be apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings in which:

FIG. 1 is a schematic partially cut-away elevational view of an embodied wall-dividing assembly at a floor and ceiling interface;

FIG. 2A is a partial schematic view of the wall assembly of FIG. 1 taken along line 2-2;

FIG. 2B is a schematic partial cross-sectional elevational view of an alternative embodied wall-dividing assembly;

fig. 3 is a partially cut-away, elevational, schematic view of an embodied wall-dividing assembly.

Fig. 4 is a right side schematic view of an embodied dividing wall assembly.

Fig. 5 is a schematic top view of the wall assembly of fig. 4.

Fig. 6 is a cross-sectional schematic view of the bulkhead assembly of fig. 4 taken along line 6-6.

Fig. 7 is a partial schematic view of the divider wall of fig. 6 taken along line 7-7.

Fig. 8 is a partial schematic view of the divider wall of fig. 6 taken along line 8-8.

Fig. 9 is a cross-sectional schematic view of the household wall assembly of fig. 4 taken along line 6-6.

All of the figures are arranged in accordance with at least some embodiments of the present disclosure.

Detailed Description

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like reference numerals generally refer to like parts unless the context indicates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are implicitly contemplated herein.

More particularly, the present disclosure relates to methods, systems, products, apparatuses, and/or apparatus generally related to a prefabricated sub-wall assembly including two base panels, each having an interior surface and an exterior surface. The base plate is configured to span between a floor and a ceiling of the building unit. The wall may include a plurality of metal studs connecting the inner surfaces of the two substrates, wherein the plurality of metal studs define a space between the substrates. The wall may include a fire shower conduit between the two substrates, wherein at least some of the plurality of metal posts have holes to accommodate the fire shower conduit through the interior of the household wall assembly. A plurality of suspension elements may be operably attached to the outer surfaces of the two base plates, wherein the plurality of suspension elements may be configured to connect to a plurality of removable termination plates.

The sub-wall assembly may be a sub-assembly that may address and/or mitigate the following problems in mid-and high-rise residential projects: (a) expensive and time-consuming on-site construction of household (or isolation) walls between units; (b) providing acoustic isolation between cells; (c) water, energy and thermal isolation between units; (d) providing an interior finish for a portion of the living space. The sub-wall assembly may satisfy and/or contribute to satisfying: fire protection standardization; acoustic level of ambient noise transfer; an energy level; tolerances for joining other panels; heat preservation and moisture protection. It should be understood that not all embodiments may solve and/or mitigate all or even any of the above-described problems, which are provided to facilitate an understanding of aspects of some embodiments described herein.

The dividing wall assembly may be a fully integrated subassembly comprising a 9 'x 22' non-combustible base plate internally connected by metal studs, wherein the base plate is externally connected to a horizontal suspension element, and wherein the suspension element is configured for external connection to a finish plate.

Fig. 1 is a partially cut-away, elevational, schematic view of an embodied wall-dividing assembly at a floor and ceiling interface, according to at least some embodiments described herein. Fig. 1 shows a wall assembly 100; two substrates 105, 110 having inner surfaces 135, 155 and outer surfaces 145, 165; a floor 115; a ceiling 120; the space 130 between the substrates 105, 110; a plurality of suspension elements 200 having an inner surface 215; a finishing board retention feature 230; the sound insulating member 190; a plurality of individual finishing plates 185; a plurality of corner brackets 305; repairing the track 410; and a fastener 183. The various components depicted in fig. 1 are merely exemplary embodiments and other variations, including elimination, combination, and substitution of components are contemplated.

An exemplary embodiment may include a wall assembly 100 having two base panels 105, 110, each base panel 105, 110 configured to span between a floor 115 and a ceiling 120 of a building unit. The two substrates 105, 110 have a space 130 between them. The first substrate 105 includes an inner surface 135 and an outer surface 145. The first substrate 105 may be a non-combustible material such as a magnesium oxide (MgO) shield or other lightweight, waterproof non-combustible material. The second substrate 110 includes an inner surface 155 and an outer surface 165. The second substrate 110 may be a non-combustible material such as a magnesium oxide (MgO) shield or other lightweight, waterproof non-combustible material. The substrates 105, 110 may be attached to a plurality of studs with the inner surfaces of the substrates facing each other. The corner bracket 305 may be attached (e.g., mechanically fastened using fasteners 183) to the wall assembly 100 (e.g., to the base plates 105, 110) and may be used to attach the wall assembly 100 to the floor 115. When the partition wall assembly 100 is coupled to the ceiling 120, a compensating channel 410 may be provided at the top of the partition wall assembly 100. The compensating channel 410 may be movably connected to the lower portion of the household wall assembly 100, which may reduce the transfer of loads from structures above the household wall assembly 100 to the lower portion of the household wall assembly 100.

The household wall 100 may also include a plurality of suspension elements 200, which may be arranged generally horizontally along one or more base plates. The length of the suspension member 200 may be equal to the majority of the length of the wall assembly 100 or the entire length of the wall assembly 100. In some embodiments, the suspension element 200 may be implemented in the form of a continuous bracket extending substantially the entire length of the dividing wall assembly 100. In some embodiments, the suspension element 200 may span only a portion of the length of the wall assembly 100. In further embodiments, the suspension elements 200 may be implemented as a plurality of separate, shorter brackets disposed at intermittent locations along the length of the wall assembly. Other variations or combinations may be used.

The inner surface 215 of the suspension element 200 may be attached to an outer surface (e.g., surface 145 or 165) of a substrate (e.g., substrate 105 or 110), for example, using fasteners (not shown). One or more finish plates 185 may be adjacent to the first outer surface 220 of the suspension element 200 and the finish plate retention feature 230. The suspension element 200 may be configured to position the finish plates in spaced relation relative to the outer surfaces 145, 165 of the base plates 105, 110 to accommodate additional components (e.g., wires, insulation) therebetween. In this regard, the suspension elements 200 may be interchangeably referred to as spacer elements.

In certain embodiments, the corner bracket 305 may be attached to the floor 115 with fasteners 183. The corner brackets 305 may be used to provide alignment of the bottom edges of the wall assembly 100 during installation of the wall assembly and also to then attach the wall assembly 100 to the floor 115 or a component of the floor 115.

In some embodiments, the acoustic barrier 190 can be disposed within the space defined between the finish plate 185 and the outer surfaces 145, 165 of the base plates 105, 110. In some embodiments, the acoustic barrier 190 may be mounted above and below the suspension element 200 and between the finish plate 185 and the outer surface 150 of the first substrate 105, and also above and below the suspension element 200 and between the finish plate 185 and the outer surface 165 of the second substrate 110. In some embodiments, the acoustic barrier 190 may occupy only a portion of the space between the finish plate 185 and the outer surfaces 145, 165 of the base plates 105, 110. In some embodiments, additional components, such as electrical conduits and/or air ducts, may be provided in the space between the finish plate 185 and the outer surfaces 145, 165 of the substrates 105, 110.

Fig. 2A is a partial schematic view of the household wall assembly of fig. 1 taken along line 2-2, in accordance with at least some embodiments described herein. Fig. 2A shows a suspension element 200 having: an upper portion 205; a lower portion 210; an inner surface 215; a first outer surface 220; a U-shaped channel 225 having a width 226 and an inner surface 227; a U-shaped channel 228; a finishing board retention feature 230; an inner bore 240; an outer bore 250; a plurality of catheter engagement features 260; and at least one finish plate 185. The various components depicted in fig. 2 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

Embodiments of suspension element 200 may be symmetrical about horizontal plane 2A such that upper portion 205 is a mirror image of lower portion 210. This may allow greater versatility for suspension element 200, as it may be installed in a variety of configurations. In an exemplary embodiment, the suspension element 200 may be made of plastic, fiber reinforced plastic, or other composite materials such as fiber reinforced resin. The suspension element 200 may be manufactured according to pultrusion or extrusion techniques, various composite manufacturing techniques, molding, casting, machining, or other techniques. In some embodiments, the suspension element 200 may be manufactured as an extruded metal (e.g., aluminum, steel, iron, or alloy) member.

As shown in fig. 2A, both the upper portion 205 and the lower portion 210 of the suspension element 200 have an inner surface 215 and a first outer surface 220. Both the upper portion 205 and the lower portion 210 of the suspension element 200 may further include a U-shaped channel 225 having a width 226 and an inner surface 227. The first outer surface 220 of each portion 205, 210 may be adjacent to the finish board retention feature 230. As described below with reference to fig. 4, the finish board retention feature 230 may have a continuous length along the entire length of the suspension element 200, or in an alternative embodiment, the finish board retention feature 230 may be intermittently interrupted by a vertical rod retention feature (not shown).

The suspension element 200 may have an inner bore 240 and an outer bore 250. Apertures 240, 250 may serve as or further include conduit engagement features 260 such that conduit 265 (not shown) may be placed over the entire horizontal length of suspension element 200. (this embodiment is described below with reference to fig. 9). Also, the horizontal surface 207 of the upper portion 205 or the lower portion 210 may serve as a conduit engagement feature 260 such that a conduit 265 (not shown) may be placed near the horizontal length of the suspension element 200. This embodiment is described below with reference to fig. 9. In some embodiments, the catheter engagement feature 260 may be integrally formed with the suspension element 200. In some embodiments, the catheter engagement feature 260 may be connected to the suspension element 200.

Fig. 2B is a partially cut-away, front schematic view of an alternative embodied dividing wall assembly in accordance with at least some embodiments described herein. Fig. 2B shows a suspension element 200 having: an upper portion 205; a lower portion 210; a U-shaped channel 225 having an inner surface 227; a U-shaped channel 228 having an inner surface 207; an inner bore 240; a middle aperture 245; an outer bore 250; catheter engagement features 260, 260a, 260b, 260c, 260d, 260 e; a conduit 265; and at least one finish plate 185. The various components depicted in fig. 2B are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

The suspension element 200 of fig. 2B may be similar to the suspension element 200 of fig. 2A with some structural differences. For example, the suspension element 200 of fig. 2B may have a central bore 245 in addition to the inner bore 240 and the outer bore 250. Apertures 240, 245, and 250 may serve as or further include conduit engagement features 260 such that conduit 265 may be placed over the entire horizontal length of suspension element 200.

As shown in fig. 2B, both the upper portion 205 and the lower portion 210 of the suspension element 200 have an inner surface 215 and a first outer surface 220. Both the upper portion 205 and the lower portion 210 of the suspension element 200 may feature conduit engagement features 260 such that the conduit 265 may be installed at various locations along the length of the wall assembly. In one embodiment, the conduit engagement feature 260c is located on the inner surface 227 of the U-shaped channel 225 so that the conduit can be installed to be located within the U-shaped channel 225. In further embodiments, conduit engagement feature 260b is located within an inner bore 240 formed by suspension element 200 and outer surface 145 of base plate 105 such that conduit 265 may be mounted to extend within suspension element 200. In further embodiments, the conduit engagement feature 260a is connected to the U-shaped channel 228 such that the conduit 265 may be mounted to sit on the surface 207 of the U-shaped channel 228. In further embodiments, the conduit engagement feature 260d can be coupled to the outer bore 250 such that the conduit can be mounted 265 to be located within the outer bore 250. In further embodiments, conduit engagement feature 260e is located within intermediate bore 245 such that conduit 265 may be mounted to extend within suspension element 200.

Fig. 3 is a schematic partially cut-away elevational view of a wall assembly according to at least some embodiments described herein. Fig. 3 shows the dividing wall assembly 100; two substrates 105, 110; inner surfaces 135, 155; outer surfaces 145, 165; a plurality of suspension elements 200, each suspension element having an inner surface 215 and a first outer surface 220; a fastener 183; at least one separate finishing panel 185 having an inner surface 185a, a first vertical edge 185b, a second vertical edge 185c, a top horizontal edge 185d, a bottom horizontal edge 185e, and an outer surface 185 f; and a finishing board retention feature 230. The various components depicted in fig. 3 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

The inner surface 215 of the suspension element 200 may be attached to the outer surface 145, 165 of the base plate 105, 110 using fasteners 183. The finish plate 185 may be adjacent to both the first outer surface 220 of the suspension element 200 and the finish plate retention feature 230. The separate finishing sheet 185 has an inner surface 185a, a first vertical edge 185b, a second vertical edge 185c, a top horizontal edge 185d, a bottom horizontal edge 185e, and an outer surface 185 f. The inner surface 185a of the finish plate 185 can be adjacent the first outer surface 220 and the bottom horizontal edge 185e can be adjacent the finish plate retention feature 230. In an alternative embodiment, the interior surface 185a of the finish panel can be adjacent the first exterior surface 220 and the top horizontal edge 185d can be adjacent the finish panel retention feature 230. A separate end plate 185 may be attached to the first outer surface 220 of the suspension element 200 using fasteners 183 (not shown). It should be understood that one or more individual trim panels 185 may be attached to the suspension elements 200 of the wall assembly, which may depend on the desired internal layout and/or particular arrangement of the suspension elements 200.

Fig. 4 is a right side schematic view of an embodied dividing wall assembly in accordance with at least some embodiments described herein. Fig. 4 shows: a dividing wall assembly 100; a first substrate 105 having an outer surface 145; a plurality of suspension elements 200; and a plurality of corner brackets 305. The various components depicted in fig. 4 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

In one embodiment, the wall assembly 100 may include a plurality of base plates 105 and 110 (shown in fig. 1) connected to a plurality of suspension elements 200. The embodiment of the wall assembly 100 as shown in fig. 4 has a plurality of first substrates 105 that surround most of the length of the wall assembly 100. A plurality of suspension elements 200 are mounted on the outer surface 145 of the first substrate 105. A plurality of corner brackets 305 are attached to a lower portion of the outer surface 145 of the first substrate 105. The suspension elements 200 may be regularly or irregularly spaced. In some embodiments, the vertical spacing between adjacent suspension elements 200 may be up to about 6 inches. In some embodiments, the vertical spacing between adjacent suspension elements 200 may be greater than 6 inches, such as about 10 inches, about 12 inches, or more. As previously mentioned, in some embodiments, the suspension elements 200 may be implemented as discrete individual brackets, for example arranged in a pattern determined by the shape and size of the finish plate, such that the suspension elements 200 are provided at least at the corners of the finish plate for attachment thereto.

Fig. 5 is a schematic top view of the bulkhead assembly of fig. 4 according to at least some embodiments described herein. Fig. 5 shows: a dividing wall assembly 100; two substrates 105, 110 having inner surfaces 135, 155 and outer surfaces 145, 165; the space 130 between the substrates 105, 110; a plurality of metal studs 175; a plurality of suspension elements 200; and a plurality of corner brackets 305. The various components depicted in fig. 5 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

A plurality of metal studs 175 having a length equal to the vertical height or a majority of the vertical height of the wall assembly 100 may be vertically aligned and connect the inner surface 135 of the first substrate 105 with the inner surface 155 of the second substrate 110. A plurality of metal studs 175 are spatially separated along the inner surfaces 135, 155. In one embodiment, the metal studs 175 may be shaped like C-shaped channels with the openings of the inner studs facing in the same direction. In different embodiments, the vertical metal posts 175 may be shaped differently from each other. The length of the suspension element 200 may be substantially the same as the length of the entire wall assembly 100. The plurality of corner brackets 305 may be spatially separated along the outer surfaces 145, 165.

Fig. 6 is a cross-sectional schematic view of the dividing wall assembly of fig. 4 taken along line 6-6 in accordance with at least some embodiments described herein. Fig. 6 shows: a dividing wall assembly 100; two substrates 105, 110 having inner surfaces 135, 155 and outer surfaces 145, 165; a space 130; a plurality of suspension elements 200; a plurality of corner brackets 305; a compensation track 410; and a metal strip 420. The various components depicted in fig. 6 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

In the embodiment shown in fig. 6, the wall assembly 100 may be connected to the ceiling 120 (see, e.g., fig. 1) by way of compensating channels 410 attached to metal strips 420 and to the floor 115 (not shown) by way of corner brackets 305. A plurality of suspension elements 200 may be coupled to the outer surfaces 145, 165 of the two base plates 105, 110. Details regarding attachment to a ceiling are discussed in more detail below with reference to fig. 7. Details regarding attachment to the floor are discussed in more detail below with reference to FIG. 8.

Fig. 7 is a partial schematic view of the dividing wall of fig. 6 taken along line 7-7 in accordance with at least some embodiments described herein. Fig. 7 shows: a dividing wall assembly 100; two substrates 105, 110 having inner surfaces 135, 155 and outer surfaces 145, 165; a space 130; a metal stud 175; a plurality of suspension elements 200; a compensation track 410; a metal strip 420; a fastener 183; and at least one downwardly extending flange 411. The various components depicted in fig. 7 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

Fig. 7 shows the top of the dividing wall assembly 100. The household wall assembly 100 may include a compensating track 410 movably connected to one or more studs 175. The compensating track 410 may include a generally U-shaped channel (shown as an inverted U-shape) having opposing flanges 411. As shown in one embodiment, the compensation track 410 may be connected to a metal strip 420. During installation of the sub-wall assembly in a building, the metal strips may be attached to a ceiling 120 (see, e.g., fig. 1) and/or a structural frame of the building. In an alternative embodiment, the compensating track 410 may be directly connected to the ceiling 120 or the structural frame. The compensation track 410 may be arranged such that a downward facing flange 411 of the compensation track 410 may be received between the substrates 105, 110 and the metal stud 175. In some embodiments, additional layers (e.g., sound damping layers, fire barrier layers) may be disposed between the inner surfaces 135, 155 of the substrates 105, 110 and the metal studs 175. The additional layer may terminate below the flange 411 of the compensation track, thereby defining a cavity in which the flange 411 may be received.

In some embodiments, the compensation track 410 may include at least one downwardly extending flange 411 connected to the plurality of metal studs 175 by fasteners 183 passing through slots in the at least one downwardly extending flange 411. The slot may have a length that allows the at least one downwardly extending flange 411 to move substantially vertically relative to the plurality of metal studs 175 to reduce the transfer of loads (e.g., deflection from the floor 115 and ceiling 120) to the wall assembly 100.

Fig. 8 is a partial schematic view of the dividing wall of fig. 6 taken along line 8-8 in accordance with at least some embodiments described herein. Fig. 8 shows a household wall 100; two substrates 105, 110 having outer surfaces 145, 165; a space 130; a metal stud 175; a plurality of suspension elements 200; and a plurality of corner brackets 305. The various components depicted in fig. 8 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

In the embodiment of fig. 8, a plurality of corner brackets 305 contact the outer surfaces 145, 165 of the substrates 105, 110. The corner bracket 305 may be fastened to the floor 115 (not shown) by fasteners 183 (not shown). The corner bracket 305 may then be fastened to the outer surface 145, 165 of the base plate 105, 110 using fasteners 183 (not shown).

Fig. 9 is a cross-sectional schematic view of the dividing wall assembly of fig. 4 taken along line 6-6 in accordance with at least some embodiments described herein. Fig. 9 shows: a dividing wall assembly 100; two substrates 105, 110 having inner surfaces 135, 155 and outer surfaces 145, 165; a space 130; a plurality of suspension elements 200; a plurality of corner brackets 305; an inner bore 240; an outer bore 250; a compensation track 410; a metal stud 175; a metal strip 420; catheter engagement features 260, 260a, 260b, 260c, 260 d; a conduit 265; a U-shaped channel 228 having a surface 207; a U-shaped channel 225 having a surface 227; an air duct 450; a fire conduit bore 140; and a fire conduit 141. The various components depicted in fig. 5 are merely examples, and other variations, including elimination, combination, and replacement of components are contemplated.

In the embodiment shown in fig. 9, the wall assembly 100 has two base plates 105, 110, the inner surfaces 135, 155 of which are attached by a plurality of metal studs 175. In one embodiment, each metal stud 175 has a fire conduit bore 140. A fire conduit 141 may be installed through the hole 140 of each metal stud 175. The wall assembly 100 also has a plurality of suspension elements 200 attached to the outer surfaces 145, 165 of the two base plates 105, 110. The suspension element 200 features a conduit engagement feature 260 such that the conduit 265 can be installed at various locations along the length of the wall assembly. In one embodiment, the conduit engagement feature 260c is located on the inner surface 227 of the U-shaped channel 225 so that the conduit can be installed to be located within the U-shaped channel 225. In further embodiments, the conduit engagement feature 260b is located within the inner bore 240 formed by the suspension element 200 and the outer surfaces 145, 165 of the base plates 105, 110 such that the conduit 265 may be mounted to extend within the suspension element 200. In further embodiments, the conduit engagement feature 260a is connected to the U-shaped channel 228 such that the conduit 265 may be mounted to sit on the surface 207 of the U-shaped channel 228. In further embodiments, the conduit engagement feature 260d can be coupled to the outer bore 250 such that the conduit 265 can be mounted to be located within the outer bore 250.

The functions and features of the wall assembly 100 as shown in fig. 1-9 will be described in more detail below.

The sub-wall assembly may be assembled at a location remote from the job site where it is ultimately installed. The assembly process may begin with the joining of the metal studs 175, the base plates 105, 110, and the suspension element 200. As shown in fig. 5, a plurality of metal studs 175 may be spaced at varying intervals along the length of the wall assembly 100 and also positioned at the end 102 of the wall assembly 100.

Various additional components may be temporarily installed. This temporary installation may improve the overall efficiency of the installation process. The components are sized to fit the current household wall assembly 100, thereby saving the installer the time to measure and cut the item to length at the job site. It also ensures that the required components are transported to the job site, thereby saving the installer the time associated with finding the correct part to mate with the assembly. It also prevents the potential for confusing material so that the wrong part is cut or purchased for assembly, and the possibility that the correct part is misplaced at the job site or may be removed by use in a different incorrect assembly, which saves the installer time associated with solving these problems.

In some embodiments, the metal stud 175 has a fire conduit bore 140, and the fire conduit 141 may be installed within the fire conduit bore 140. In some embodiments, the conduit 265 may be temporarily installed into the conduit engagement feature 260 of the at least one suspension element 200. In some embodiments, the acoustic barrier 190 may be temporarily installed above and below the at least one suspension element 200. In some embodiments, the air chute 450 may be temporarily mounted above or below the at least one suspension element 200. In some embodiments, the end trim panels 185 may be temporarily installed, with each end trim panel contacting the first outer surface 220 of the suspension element 200 and the end trim panel retention feature 230. In some embodiments, the compensating track 410 may be temporarily mounted on top of the dividing wall assembly.

The pre-assembled wall sub-assembly 100 may then be transported to the job site where it is to be installed. The finish plate 185, the conduit 265, the insulator 190, the air duct 450, and the compensation track 410 may be removed prior to permanently installing the dividing wall assembly 100. The removal of these components increases the ease of installation of the household wall assembly 100, as these elements may not be permanently attached to the household wall assembly 100 and may become dislodged and damage or damage other items during the acquisition and installation of the household wall assembly 100.

The corner brackets 305 may be permanently attached to the floor 115 prior to installation of the wall assembly 100. Additionally, the compensating track 410 may be attached to the ceiling 120, or it may be attached to a metal strip 420 that is then permanently attached to the ceiling 120. The mounting of the corner brackets and compensating rails allows for a footprint to be formed such that the wall assembly 100 can slide therebetween. This eliminates errors during installation because the wall footprint is properly established prior to installation of the wall. In an alternative embodiment, the corner brackets 305 may be connected to the wall of a household before the wall is installed in a building.

The dividing wall assembly 100, consisting of the two base plates 105, 110 connected and attached by the plurality of metal studs 175 to the suspension element 200, can then be slid into place with the bottom edge of the dividing wall assembly 100 slid against the floor 115. When installed, the proper alignment and position of the embodiment of the wall assembly 100 is determined by the pre-installed corner brackets 305 and the compensating track 410. The outer surfaces 145, 165 may contact the inner surface of the angle support 305. The wall assembly 100 may then be permanently attached to the corner bracket 305 using the fastener 183. In an alternative embodiment of the mounting corner bracket 305 before the wall assembly 100 is slid into place, the compensation track 410 provides alignment of the wall assembly 100 during installation.

In the upper portion of the wall assembly 100, the inner surfaces 135, 155 may contact at least one downwardly extending flange 411. The wall assembly 100 is not permanently connected to the ceiling 120 because the permanent connection takes into account that the wall assembly may be damaged when the floor or ceiling is vertically displaced. Embodiments of the partition wall assembly 100 allow for the partition wall to shift as the floor 115 and ceiling 120 expand and contract such that the top edge of the partition wall assembly 100 never contacts the ceiling 120.

Once the division wall assembly 100 is installed, the fire conduit 141 may be connected to the building's fire protection system. Appropriate wires may then be added to the conduit 265, and the conduit 265 may then be connected to the conduit engagement feature 260. In an alternative embodiment, appropriate wires may be added to the conduit before the dividing wall is transported to the job site. In either embodiment, the wires may then be connected to the electrical system of the building. The air duct 450 may be connected to a dividing wall assembly and then to a ventilation system of a building. The acoustic barrier 190 may then be installed against the outer surfaces 145, 165. Once the dividing wall interior components are connected to the dividing wall assembly 100, the finishing plate 185 may be connected to the hanging element 200.

In addition to the efficiencies gained by pre-assembling components off-site, the features of the current embodiment that enable the conduit 265 to be mounted on the exterior of the substrates 105, 110 comprise an improvement over the prior art. As previously known in the art, when a conduit is installed between substrates, the person installing the conduit and associated equipment has a very small working area, and sometimes the installation of the equipment may damage the substrates such that the acoustic envelope created between the substrates is broken and cannot be repaired. As disclosed in embodiments herein, when the conduit 265 is located only behind the finish plate 185, any type of maintenance involving the conduit and its contents may be accomplished in less time and may be more easily accomplished because the interstitial space 130 between the substrates does not require damage to the substrates 105, 110 to complete the maintenance.

In an alternative embodiment, the wall assembly 100 may have a plurality of vertical rods that may be connected to the vertical rod retaining features of a plurality of suspension elements 200. A plurality of vertical bars may be placed such that the outer vertical surfaces of the bars contact the vertical edges 185b and 185c of the finish plate 185. The plurality of vertical poles may have a consumer attachment feature that enables a consumer to removably attach items (e.g., bookshelves, pictures, etc.) to the vertical poles without damaging the entire household wall assembly. This may enable a user (e.g., a tenant or occupant of a cell) to customize his or her cell without permanently damaging and/or deforming the wall finish or structure. This functionality may allow tenants the ability to temporarily hang items, the ability to change locations as desired.

In an alternative embodiment, the wall assembly 100 may also feature an Aluminum Composite (ACM) panel mounted between the exterior surfaces 145, 165 of the base panels 105, 110. In an exemplary embodiment, an embodied individual wall assembly 100 with an ACM board may be located in a lower position. The ACM plate has an inner surface, a top horizontal edge, a bottom horizontal edge, and an outer surface. In the lower position, the bottom horizontal edge of the ACM plate is located in the U-shaped channel 225 of the uppermost positioned plurality of suspension elements 200. The outer surface of the ACM plate may also contact the inner surface 227 of the U-shaped channel 225. Alternatively, the inner surface of the ACM plate may also contact the inner surface 227 of the U-shaped channel 225. The internal width 226 of the U-shaped channel 225 is at least slightly greater than the width of the ACM board. There is a gap between the top horizontal edge of the ACM panel and the ceiling 120. In the lower position, the top horizontal edge of the ACM board is vertically lower than the top edge of the dividing wall assembly 100. The ACM board may be in this first position prior to permanent installation of the dividing wall assembly 100.

After the dividing wall assembly 100 is permanently connected to the floor 115, the ACM board may be moved into the up position. In this upper position, the top horizontal edge of the ACM board is flush or nearly flush with the ceiling 120 such that the bottom horizontal edge of the ACM board is no longer located in the U-shaped channel 225 of the uppermost positioned plurality of suspension elements 200. The ACM plate in this upper position may be attached to the compensation track 410 by means of fasteners 183. It is possible that in this upper position, the outer surface of the ACM plate may still contact the inner surface 227 of the U-shaped channel 225 or the inner surface of the ACM plate may alternatively contact the inner surface 227 of the U-shaped channel 225. Any vertical displacement of the floor or ceiling will not damage the ACM board because the ACM board moves with the ceiling and there should be sufficient clearance between the bottom edge of the ACM board and the U-shaped channel 225.

The examples are provided for illustrative purposes only and should not be construed as limiting the scope of the present disclosure. Each exemplary embodiment may be practical for particular environments such as urban mixed-use development, low-rise dwelling units, and/or remote communities. The materials and dimensions of the various elements may be configured to comply with one or more of the following building codes: fire; energy; a disorder; life safety and sound (impact and ambient noise transfer) without departing from the scope of the principles of the present disclosure. The elements and/or systems can also be configured to comply with social and/or religious regulations, as desired. For example, the materials, systems, methods, and/or apparatus may be configured to conform to international building codes that have been adopted in one jurisdictional jurisdiction.

The present disclosure is not limited to the particular embodiments described in this application, which are intended to illustrate various aspects. As will be apparent to those skilled in the art, many modifications and many embodiments can be made without departing from the spirit and scope of the invention. Functionally equivalent methods and devices within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing description. Such modifications and embodiments are intended to fall within the scope of the appended claims. The disclosure includes the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compound compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. For clarity, various singular/plural permutations may be expressly set forth herein.

It will be understood by those within the art that, in general, terms used herein (and especially in the appended claims, e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.).

It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits the recitation of a claim containing such introduction to any particular claim containing only one such recitation of an embodiment, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" or "an" should be interpreted to mean "at least one" or "one or more"); the same is true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).

Further, in those instances where a convention analogous to "at least one of A, B and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand (e.g., "a system having at least one of A, B and C" would include but not be limited to systems having a alone, B alone, C, A and B together, a and C together, B and C together, and/or A, B and C together, etc.). In those instances where a convention analogous to "A, B or at least one of C, etc." is used, in general the meaning theory for such a structure is that the convention will be understood by those skilled in the art (e.g., "a system having at least one of a, B, or C" will include, but not be limited to, systems having a alone, B alone, C, A and B together, a and C together, B and C together, and/or A, B and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "a or B" will be understood to include the possibility of "a" or "B" or "a and B".

In addition, where features or aspects of the disclosure are described in terms of markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the markush group.

As will be understood by those skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily identified as being fully described and such that the same range is broken down into at least equivalent halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein may be readily broken down into smaller ranges. As will also be understood by those of skill in the art, all language such as "at most," "at least," "greater than," "less than," and the like includes the recited number and refers to ranges that may be subsequently broken down into subranges as described above. Finally, as will be understood by those skilled in the art, a range includes each individual member. Thus, for example, a group having 1 to 3 items refers to a group having 1, 2, or 3 items. Similarly, a group having 1 to 5 items refers to groups having 1, 2, 3, 4, or 5 items, and so forth.

The subject matter described herein sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely embodiments, and that in fact many other architectures can be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively "associated" such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as "associated with" each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being "operably connected," or "operably coupled," to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being "operably couplable," to each other to achieve the desired functionality. Particular embodiments that can be operably coupled include, but are not limited to, physically mateable and/or physically interacting components and/or wirelessly interactable and/or wirelessly interacting components and/or logically interacting and/or logically interactable components.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and not limitation, with the true scope and spirit being indicated by the following claims.

Claims (28)

1. A prefabricated household wall assembly, comprising:

two base plates, each base plate having an inner surface and an outer surface, wherein the two base plates are configured to span between a floor and a ceiling of a building unit;

a plurality of metal studs connecting the inner surfaces of the two substrates, wherein the plurality of metal studs define a space between the two substrates;

a fire sprinkler piping located between the two base plates, wherein at least some of the plurality of metal studs have holes that receive the fire sprinkler piping through the interior of the bulkhead assembly;

a plurality of suspension elements operably attached to the outer surfaces of the two base plates, wherein the plurality of suspension elements are configured to connect to a plurality of removable finishing plates; and

a conduit external to the two substrates, wherein the conduit is at least partially received in a conduit engagement feature of at least one of the plurality of suspension elements, wherein the conduit engagement feature is integrally formed in or connected to the at least one of the plurality of suspension elements.

2. The wall assembly of claim 1, wherein the at least one suspension element comprises an elongated member having a constant cross-section and extending horizontally along substantially an entire length of at least one of the two base panels.

3. The household wall assembly of claim 2, wherein the elongated member comprises fiber reinforced plastic.

4. The household wall assembly of claim 1, wherein the at least one suspension element comprises an extruded aluminum member.

5. The wall assembly of claim 1, further comprising a compensating track along a top of the wall assembly for connecting the wall assembly, wherein the compensating track is movably coupled to the plurality of metal studs.

6. The wall assembly of claim 5, further comprising a bar coupled to the compensating track and extending outwardly from opposite sides of the compensating track, wherein a length of the bar is greater than a distance between outermost ends of the plurality of suspension elements.

7. The dividing wall assembly of claim 5, wherein the compensating track includes at least one downwardly extending flange having a groove; and is

At least one of a plurality of metal studs is slidably connected to the at least one downwardly extending flange by way of the slot.

8. The dividing wall assembly of claim 7, further comprising:

an ACM board having a bottom surface; and is

Wherein at least one of the plurality of suspension elements further comprises an upwardly facing channel;

wherein, prior to installation of the dividing wall assembly, a bottom surface of the ACM panel is located in the upwardly facing channel of the at least one of the suspension elements;

wherein, after installation of the dividing wall assembly, the ACM plate is attached to the compensation track and the bottom surface is no longer located in the upward facing channel of the at least one of the plurality of suspension elements.

9. The household wall assembly of claim 1, wherein the conduit engagement feature comprises a U-shaped channel defined by an outer surface of the at least one suspension element.

10. The household wall assembly of claim 1, wherein the conduit engagement feature comprises a cavity defined by one or more interior surfaces of the at least one suspension element.

11. The household wall assembly of claim 1, further comprising at least one vertical rod connected to an outer surface of the plurality of hanging elements, wherein the at least one vertical rod is configured to vertically separate the plurality of removable finishing boards.

12. A method of assembling prefabricated individual walls in a building, the method comprising:

placing a wall assembly on a first beam of a structural frame of a building, wherein the wall assembly comprises two wall substrates and a metal stud connecting inner surfaces of the two wall substrates, wherein the wall assembly further comprises a plurality of suspension elements having an inner surface and an outer surface, wherein the inner surface of each of the plurality of suspension elements is connected to an outer surface of at least one of the two wall substrates;

attaching a lower portion of the wall assembly to the structural frame using corner brackets attached to opposite sides of the wall assembly;

connecting an upper portion of the dividing wall to an upper floor and ceiling panel using compensating rails movably connected to the metal studs; and

installing a catheter into a catheter engagement feature of at least one of the plurality of suspension elements, wherein the catheter engagement feature is integrally formed in or connected to the at least one of the plurality of suspension elements.

13. The method of claim 12, further comprising installing a sub-floor and ceiling panel prior to placing the dividing wall assembly on the first beam, wherein installing the sub-floor and ceiling panel comprises connecting the sub-floor and ceiling panel to the first beam using angle irons, and wherein attaching a lower portion of the dividing wall assembly to the structural frame comprises attaching the lower portion of the dividing wall to the angle irons of the dividing wall.

14. The method of claim 12, further comprising installing a lower floor and ceiling panel prior to placing the sub-wall assembly under the second beam, wherein connecting the upper portion of the sub-wall to the upper floor and ceiling panel comprises attaching metal strips to the upper floor and ceiling panel.

15. The method of claim 12, further comprising attaching a wall finish plate to one or more of the plurality of suspension elements such that a cavity is defined between the wall finish plate and the outer surface of at least one of the two wall base plates.

16. The method of claim 12, wherein the conduit passes through a cavity defined by at least one of the plurality of suspension elements prior to placing the dividing wall assembly on the first beam, and wherein the cavity serves as or includes the conduit engagement feature.

17. The method of claim 12, further comprising mounting a vertical rod having a consumer attachment feature to at least one of the plurality of suspension elements.

18. The method of claim 17, further comprising:

removing the previously installed vertical pole;

installing the household wall assembly; and is

Reinstalling the vertical pole.

19. The method of claim 12, wherein each of the metal studs has a hole that receives a fire conduit through an interior of the bulkhead assembly.

20. The method of claim 19, further comprising installing the fire conduit through the hole.

21. The method of claim 20, further comprising connecting the installed fire conduit to a fire protection system in the building.

22. A method of assembling a prefabricated wall sub-assembly at a site remote from a construction site, the method comprising:

attaching a plurality of non-combustible fenders to a frame comprising a plurality of metal studs to form two wall substrates of a household wall panel separated by a space therebetween, wherein each of the two wall substrates has an inner surface and an outer surface, and wherein the two wall substrates are configured to span between a floor and a ceiling of a building unit;

attaching an inner surface of each of a plurality of suspension elements to the outer surfaces of the two wall substrates;

installing a conduit configured for wire routing into a conduit engagement feature of at least one of the plurality of suspension elements, wherein the conduit engagement feature is integrally formed in or connected to the at least one of the plurality of suspension elements;

installing a wire into the conduit; and is

Removably mounting a plurality of finish plates to the plurality of suspension elements.

23. The method of claim 22, further comprising mounting the conduit configured for routing the electrical wires within the space between the wall substrate and the termination plate, and wherein the plurality of suspension elements have holes that serve as or include the conduit engagement features, the conduit being mounted within the holes.

24. The method of claim 22, wherein the plurality of suspension elements have an inner bore and an outer bore that serve as or include the conduit engagement feature, and wherein the conduit is mounted within the inner bore.

25. The method of claim 22, wherein the plurality of suspension elements have an inner bore and an outer bore that serve as or include the conduit engagement feature, and wherein the conduit is mounted within the outer bore.

26. The method of claim 22, wherein the plurality of suspension elements have an inner bore, a middle bore, and an outer bore that serve as or include the conduit engagement feature, and wherein the conduit is mounted within the middle bore.

27. The method of claim 22, wherein the conduit is temporarily installed.

28. The method of claim 22, wherein each of the plurality of suspension elements further comprises a first horizontal surface and a second horizontal surface; and wherein the method further comprises:

temporarily installing an acoustic barrier between the first horizontal surface of a first suspension element of the plurality of suspension elements and the second horizontal surface of a second suspension element of the plurality of suspension elements.