Reusable and Recyclable Modular Wall System for a Construction Barrier

Abstract

A modular wall system includes a plurality of wall panels, each with a core, a front skin, a rear skin, and at least one edging piece along at least one edge. The edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length. A floor track has a base flange and a substantially vertical panel-receiving channel. At least one vertically oriented H-spline is provided for resting on the floor track and being positioned between two adjacent wall panels. The H-spline has a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels. The lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web. The rear flange extends over a portion of the rear skins of the adjacent wall panels. A top channel is disposed along a top of the modular wall system and receives a plurality of the wall panels. A first side channel is disposed along a side of the modular wall system and receives at least one of the wall panels.

1 . A modular wall system for temporary erection at a construction site, comprising:
 a plurality of wall panels each having a core, a front skin, a rear skin, and at least one edging piece along at least one edge, wherein the edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;   a floor track having a base flange and a substantially vertical panel-receiving channel;   at least one vertically oriented H-spline resting on the floor track and positioned between two adjacent wall panels, the H-spline having a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels, wherein the lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skins of the adjacent wall panels;   a top channel disposed along a top of the modular wall system and receiving a plurality of the wall panels; and   a first side channel disposed along a side of the modular wall system and receiving at least one of the wall panels.   
   
   
       2 . The modular wall system of  claim 1  further comprising:
 a hinge disposed along a substantial length of the top channel;   a canopy channel attached to the top end channel via the hinge; and   a top wall panel mounted within the canopy channel and adapted to be mounted to relatively permanent structure at the site.   
   
   
       3 . The modular wall system of  claim 1  further comprising:
 a hinge disposed along a substantial length of the first side channel;   a second side channel attached to the first side channel via the hinge;   a extension floor track having a base flange and a substantially vertical panel-receiving channel, the extension floor track extending non-parallel from the floor track; and   a side wall panel mounted within the second side channel and the vertical panel-receiving channel of the extension floor track.   
   
   
       4 . The modular wall system of  claim 1  further comprising:
 a plurality of angle braces, each attached to a respective rear flange of a respective H-spline and to a relatively permanent structure at the site.   
   
   
       5 . The modular wall system of  claim 4  wherein the relatively permanent structure is comprised of a floor or ground underlying the modular wall. 
   
   
       6 . The modular wall system of  claim 4  wherein the relatively permanent structure is comprised of an upper structure of a building on the site. 
   
   
       7 . The modular wall system of  claim 1  further comprising:
 a locking pin mounted through aligned holes in the vertical panel-receiving channel and one of the plurality of wall panels.   
   
   
       8 . The modular wall system of  claim 1  further comprising:
 a locking pin mounted through aligned holes in the top channel and one of the plurality of wall panels.   
   
   
       9 . The modular wall system of  claim 1  further comprising:
 a plurality of locking pins including at least a first locking pin mounted through aligned holes in the vertical panel-receiving channel and one of the plurality of wall panels and a second locking pin mounted through aligned holes in the top channel and a different one of the plurality of wall panels.   
   
   
       10 . The modular wall system of  claim 1  including a pre-hung door section for installation between a pair of wall panels in the modular wall system, the door section comprising:
 a frame having outwardly extending C-channels at its sides and top and a sill at its bottom;   a door panel hung within the frame; and   a plurality of locking pins mounted through respective aligned holes in the C-channels and respective wall panels on each lateral side of the door section.   
   
   
       11 . The modular wall system of  claim 10  further comprising:
 a lintel wall panel inserted into the C-channel at the top of the frame; and   a pair of H-splines mounted to the lateral sides of the lintel wall panel.   
   
   
       12 . The modular wall system of  claim 1  wherein the core, front skin, rear skin, and edging piece of each wall panel are comprised of recyclable plastic. 
   
   
       13 . The modular wall system of  claim 12  wherein the core is corrugated. 
   
   
       14 . The modular wall system of  claim 1  wherein the floor track, H-spline, top channel, and side channel are comprised of extruded aluminum. 
   
   
       15 . The modular wall system of  claim 1  wherein the floor track further comprises a resilient layer applied to the base flange. 
   
   
       16 . A method of installing a modular wall system for temporary erection at a construction site, the method comprising the steps of:
 laying a floor track, wherein the floor track has a base flange and a substantially vertical panel-receiving channel;   inserting a first wall panel into the panel-receiving channel, wherein the first wall panel has a core, a front skin, a rear skin, and at least a first edging piece along at least one edge, wherein the first edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining a first intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;   inserting an H-spline onto the first edging piece and resting on the floor track, wherein the H-spline has a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the first intermediate groove of the first edging piece of the first wall panel, wherein the lesser length of the second edgewise extensions of the first edging piece provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skin of the first wall panel;   inserting a second wall panel into the panel-receiving channel, wherein the second wall panel has a core, a front skin, a rear skin, and at least a second edging piece along at least one edge, wherein the second edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining a second intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length, wherein the front flange of the H-spline further receives the second intermediate groove of the second edging piece of the second wall panel, wherein the lesser length of the second edgewise extensions of the second edging piece provides a gap for receiving the web, wherein the rear flange extends over a portion of the rear skin of the second wall panel, and wherein there is substantially flush abutment of the front skins of the first and second wall panels;   inserting a top channel over the first and second wall panels; and   inserting a first side channel disposed along a side of one of the wall panels.   
   
   
       17 . The method of  claim 16  further comprising the step of:
 bracing the H-spline to a relatively permanent structure on the site.   
   
   
       18 . The method of  claim 16  further comprising the step of:
 bracing at least one of the top channel or first side channel to a relatively permanent structure on the site.   
   
   
       19 . The method of  claim 18  wherein the braced top channel or side channel is hinged to a C-channel, and wherein the bracing step is comprised of:
 inserting a third wall panel into the C-channel; and   attaching the third wall panel to a relatively permanent structure on the site.   
   
   
       20 . A modular wall system for temporary erection at a construction site, comprising:
 a plurality of wall panels each having a core, a front skin, a rear skin, and at least one edging piece along at least one edge, wherein the edging piece has first and second edgewise extensions extending first and second lengths, respectively, and defining an intermediate groove, wherein the first extension is adjacent the front skin, and wherein the first length is greater than the second length;   a floor track having a base flange and a substantially vertical panel-receiving channel;   at least one vertically oriented H-spline resting on the floor track and positioned between two adjacent wall panels, the H-spline having a front flange and a rear flange joined by a web, wherein the front flange has a transverse width adapted to be received in the intermediate grooves of edging pieces of the adjacent wall panels while permitting substantially flush abutment of the front skins of the adjacent wall panels, wherein the lesser length of the second edgewise extensions of the edging pieces provides a gap for receiving the web, and wherein the rear flange extends over a portion of the rear skins of the adjacent wall panels; and   a brace for bracing the H-spline to a relatively permanent structure on the site.