Modular wall systems and related methods

Abstract

Aspects of the present disclosure relate to modular wall systems and methods of installing modular wall systems in hygienic environments. In one aspect, gap cover apparatus are disclosed. In one aspect, backplate arrangements are disclosed. In one aspect, non-progressive installation methods are disclosed. The modular wall systems can eliminate protruding ledges while maintaining structural integrity and hygienic properties.

1 . A modular wall system for medical treatment environments, comprising:
 a support structure;   a corner apparatus attached to the support structure, wherein the corner apparatus comprises:
 a first leg intersecting a second leg, 
 a third leg intersecting a fourth leg, wherein the first leg and the third leg are spaced from one another to define a first opening and the second leg and the fourth leg are spaced from one another to define a second opening; and 
   a plurality of modular wall units attached to the support structure and arranged as a wall, wherein a first modular wall unit of the plurality of modular wall units is positioned at least partially within the first opening of the corner apparatus.   
     
     
         2 . The modular wall system of  claim 1 , wherein a second modular wall unit of the plurality of modular wall units is positioned at least partially within the second opening and the corner apparatus forms a corner between the first modular wall unit and the second modular wall unit. 
     
     
         3 . The modular wall system of  claim 1 , wherein the first leg is perpendicular to the second leg. 
     
     
         4 . The modular wall system of  claim 1 , wherein the third leg is perpendicular to the fourth leg. 
     
     
         5 . The modular wall system of  claim 1 , wherein the corner apparatus comprises a middle wall that intersects each of the first leg, the second leg, the third leg, and the fourth leg. 
     
     
         6 . The modular wall system of  claim 5 , wherein the middle wall intersects each of the first leg, the second leg, the third leg, and the fourth leg at an oblique angle. 
     
     
         7 . The modular wall system of  claim 1 , wherein the third leg is longer than the first leg. 
     
     
         8 . The modular wall system of  claim 1 , wherein the fourth leg is longer than the second leg. 
     
     
         9 . The modular wall system of  claim 1 , wherein the corner apparatus comprises a first middle wall that intersects the first leg and the third leg perpendicularly and a second middle wall that intersects the second leg and the fourth leg perpendicularly. 
     
     
         10 . The modular wall system of  claim 1 , wherein the corner apparatus is configured to create a seal with the first modular wall unit via an interference fit. 
     
     
         11 . The modular wall system of  claim 1 , comprising one or more fasteners extending through a portion of the third leg and beyond the first leg into the support structure to mount the corner apparatus to the support structure. 
     
     
         12 . The modular wall system of  claim 1 , wherein the corner apparatus is a single monolithic body that is integrally formed. 
     
     
         13 . The modular wall system of  claim 1 , wherein the support structure comprises a plurality of backplates fastened to a plurality of studs. 
     
     
         14 . The modular wall system of  claim 13 , wherein the plurality of backplates are fastened to the plurality of studs through one or more pieces of drywall. 
     
     
         15 . The modular wall system of  claim 1 , wherein each of the plurality of modular wall units comprises:
 a panel, comprising:
 a front side, 
 a first side turned back at a first oblique angle relative to the front side, 
 one or more first flanges turned at a second oblique angle relative to the first side, 
 a second side turned back relative to the front side, the second side opposing the first side, and 
 one or more second flanges turned relative to the second side. 
   
     
     
         16 . The modular wall system of  claim 1 , comprising a seal positioned between a portion of the first modular wall unit not positioned within the first opening of the corner apparatus and a portion of a third modular wall unit. 
     
     
         17 . The modular wall system of  claim 16 , wherein the seal comprises:
 a head;   a first sealing leg extending relative to the head along a first direction; and   a second sealing leg extending relative to the head along a second direction that is away from the first direction, the first sealing leg and the second sealing leg having a thickness that is less than a width of the head.   
     
     
         18 . The modular wall system of  claim 17 , wherein in an unset configuration, an end of the first sealing leg and an end of the second sealing leg are separated by a width that is greater than a gap between the first modular wall unit and the third modular wall unit. 
     
     
         19 . The modular wall system of  claim 18 , wherein, in a set configuration, the first sealing leg is configured to conform to a sidewall of the first modular wall unit. 
     
     
         20 . The modular wall system of  claim 19 , wherein, in the set configuration, the second sealing leg is configured to conform to a sidewall of the third modular wall unit.