Method of Forming a Temporary Wall System

Abstract

A method of forming a temporary wall system is disclosed. The method includes attaching a track to a floor and attaching cover panels including tongue and groove systems to the front and the rear surfaces of separate insulation layers to form several wall panels. In one embodiment, the method includes attaching the wall panels to each other via the tongue and groove systems disposed on the cover panels to form a wall and then mounting the wall onto the track to form an upstanding temporary wall. In another embodiment, the method includes first mounting the wall panels onto the track and then attaching the wall panels to each other via the tongue and groove systems while on the track to form the wall.

1 . A method of forming a temporary wall system, comprising:
 attaching a track to a floor and/or ceiling of an area;   attaching a first cover panel to a front surface of a plurality of insulation layers;   attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels;   attaching each of the plurality of wall panels to each other via a tongue and groove system to form a wall that spans the length of the track; and   mounting the wall on the track;   wherein the track includes a width substantially equal to the width of the wall, such that the track supports the wall therein in an upstanding position.   
     
     
         2 . The method of  claim 1 , wherein the track is a J-track and is attached to the floor and/or ceiling of an area by mounting the J-track onto the floor and/or ceiling and fastening the J-track with fasteners. 
     
     
         3 . The method of  claim 2 , wherein the first cover panel is attached to the front surface of each of the plurality of insulation layers with a bulk spray adhesive. 
     
     
         4 . The method of  claim 3 , wherein the bulk spray adhesive is sprayed on the entire front surface of each of the plurality of insulation layers prior to attachment of the first cover panel. 
     
     
         5 . The method of  claim 3 , wherein the second cover panel is attached to the rear surface of each of the plurality of insulation layers with a bulk spray adhesive. 
     
     
         6 . The method of  claim 5 , wherein the bulk spray adhesive is sprayed on the entire rear surface of each of the plurality of insulation layers prior to attachment of the second cover panel. 
     
     
         7 . The method of  claim 5 , wherein each of the plurality of insulation layers comprises a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer. 
     
     
         8 . The method of  claim 5 , wherein the first cover panel and the second cover panel each comprise a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side, wherein the tongue and groove are complimentary so as to mate and fasten with each other. 
     
     
         9 . The method of  claim 8 , wherein the plurality of wall panels are attached to each other by:
 joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel in sequential fashion; and   joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel in sequential fashion,   wherein attachment of the plurality of wall panels forms a wall.   
     
     
         10 . The method of  claim 9 , wherein the wall is mounted on the track by sliding the wall into the track such that the wall is coextensive with the track. 
     
     
         11 . A method of forming the temporary wall system, comprising:
 attaching a track to a floor of an area;   attaching a first cover panel to a front surface of a plurality of insulation layers;   attaching a second cover panel to a rear surface of the plurality of insulation layers to form a plurality of wall panels;   mounting the plurality of wall panels on the track sequentially until the plurality of wall panels span the length of the track; and   attaching the plurality of wall panels to each other via a tongue and groove system to form a wall;   wherein the track includes a width substantially equal to the width of each of the plurality of wall panels, such that the track supports each of the plurality of wall panels therein in an upstanding position.   
     
     
         12 . The method of  claim 11 , wherein the track is attached to the floor of an area by mounting the track onto the floor and fastening the track with fasteners. 
     
     
         13 . The method of  claim 12 , wherein the first cover panel is attached to the front surface of each of the plurality of insulation layers with a bulk spray adhesive. 
     
     
         14 . The method of  claim 13 , wherein the bulk spray adhesive is sprayed on the entire front surface of each of the plurality of insulation layers prior to attachment of the first cover panel. 
     
     
         15 . The method of  claim 13 , wherein the second cover panel is attached to the rear surface of each of the plurality of insulation layers with a bulk spray adhesive. 
     
     
         16 . The method of  claim 15 , wherein the bulk spray adhesive is sprayed on the entire rear surface of each of the plurality of insulation layers prior to attachment of the second cover panel. 
     
     
         17 . The method of  claim 15 , wherein each of the plurality of insulation layers comprises a thermal insulation board including a rigid cellular polyisocyanurate foam core disposed between a first foil facer defining the front surface of insulation layer and a second foil facer defining the rear surface of the insulation layer. 
     
     
         18 . The method of  claim 15 , wherein the plurality of wall panels are mounted on the track by sliding each of the plurality of wall panels into the track until the plurality of wall panels are coextensive with the track. 
     
     
         19 . The method of  claim 18 , wherein the first cover panel and the second cover panel each comprise a first side including a tongue extending along an edge of the first side and an opposing second side including a groove extending along an edge of the second side, wherein the tongue and groove are complimentary so as to mate and fasten with each other. 
     
     
         20 . The method of  claim 19 , wherein the plurality of wall panels are attached to each other by:
 joining the tongue of a first side of a first cover panel and the groove of a second side of a first cover panel; and   joining the tongue of a first side of a second cover panel and the groove of a second side of a second cover panel;   wherein attachment of the plurality of wall panels forms a wall.