Modular wall mounting system

Abstract

A modular wall mounting system comprising one or more modular wall panels 18 with a stud 16 17 located at the base, a base plate 1 comprising an extruded profile with a pair of ridges each with a top

Description

[002] Modular building construction has rapidly evolved due to its distinct advantages over traditional building methods. By breaking down a building into multiple prefabricated modules that are manufactured off-site and assembled on-site like building blocks, this technique promotes industrialization, minimizes construction time, and reduces labour costs. However, despite its numerous benefits, there exist inherent challenges, particularly in the assembly of the building's wall structures.

[003] Two conventional methods are commonly used to secure modular walls to a building's floor foundation. The first involves using a U-shaped channel fixed to the floor foundation. The modular wall is dropped into the channel and secured via numerous fixings, thereby anchoring the wall to the floor foundation. The second method employs a rectangular timber profile fixed to the floor foundation. The wall panel, typically a Structural Insulated Panel (SIP), has a channel machined at the bottom that locates over the timber profile. The faces of the wall straddle over the timber base plate, and fixings are secured through these wall faces into the timber floor plate.

[004] While both methods are widely accepted, they each have notable drawbacks. Firstly, they require a significant number of fixings and a high degree of skill to ensure accurate positioning of the wall panels. Incorrect positioning often necessitates time-consuming disassembly and reassembly, leading to delays in the construction process. Secondly, the relocation of the building can become a cumbersome and prolonged task due to the labour-intensive disassembly of the fixed wall panels. Lastly, the traditional materials used in these methods, such as synthetic plastics, lightweight masonry products, and composite materials, can lead to increased transportation costs.

[005] Given these challenges, there is a need for a modular wall mounting system that is not only easy to assemble and disassemble but also ensures accurate positioning of wall panels. The system should be capable of reducing labour costs, minimizing material usage, and accommodating quick 1 building relocation. Furthermore, the system should eliminate the need for complex tools such as nail guns or screw guns, which adds complexity to the installation process and requires specific skillsets.

[006] In light of these needs, the current invention proposes a novel approach that combines modular wall panels with pre-installed studs, a uniquely profiled foundation base plate, and a locking clip mechanism. This innovative system provides a simple, fast, and cost-effective method for attaching modular walls to a base floor foundation, thereby addressing the limitations of the existing systems.

[007] It is within this context that the present invention is provided. Summary

[008] The present invention addresses the field of modular building, particularly focusing on the structure of wall assembly for modular rooms and their attachment to a building's floor foundation. This invention presents a significant advancement by simplifying the process of attaching modular walls to a building's foundation, while reducing labour, material costs, and providing an accurate mechanism for positioning the wall panels.

[009] In one embodiment, the invention includes modular wall panels with pre-installed studs on their bases. The studs are configured to align with and be inserted through keyhole openings arranged in pairs at regular intervals along the top surface of a foundation base plate. The positioning is set by the base plate profile, factory machined to ensure total accuracy.

[010] In another embodiment, the invention comprises a Locking Clip, which is inserted through guide slots in the side of the foundation base plate to secure the stud-keyhole coupling. The planes of the guide slots are perpendicular to the plane of the keyhole openings. The configuration ensures that as the Locking Clip is pushed into the guide slot of the base plate, it pulls the studs tightly down onto the base plate, securing the wall panel to the base plate swiftly. [Oil] Additionally, the Locking Clip is designed with a crumple zone that allows the clip to deform around the base of the wall studs while maintaining the required tension on the wall studs. This aids in accommodating material tolerances and dealing with the stresses caused by the downward force on the Locking Clip. A grip tab, which remains accessible even when the Locking Clip is fully inserted, facilitates the removal of the Locking Clip if the wall assembly needs to be dismantled.

[012] The invention is suitable for constructing or disassembling modular buildings quickly and accurately, eliminating the need for nail guns or screw guns, thereby greatly simplifying the installation process. Brief Description of the Drawings

[013] Various embodiments of the invention are disclosed in the following detailed description and accompanying drawings.

[014] FIG. 1 illustrates an isometric view of an exemplary modular building floor foundation profile (1) with the inner (22, 23) and outer (21, 24) side walls forming ridges along its length and pairs of keyhole openings (2) arranged at regular intervals on the top surfaces of these ridges.

[015] FIG. 2, FIG. 3, and FIG. 4 respectively display an isometric, plan, and side view of the Locking Clip (5). It comprises a rectangular shape with a shaped slot, forming two arms having contours (6, 7, 8, 9) for securing around the wall studs (16), and a grip tab (20) at one end for easy removal.

[016] FIG. 5 depicts an isometric view of a Modular wall panel (18) featuring pre-installed fixing studs (16) at its base.

[017] FIG. 6 shows an isometric view of a modular wall with fixing studs on the base, aligned over the keyhole slots in a modular building floor foundation profile.

[018] FIG. 7 and FIG. 8 present cross-section and isometric views, respectively, of the modular wall panel (18) with pre-installed fixing studs on the base, installed in the floor foundation profile, and a Locking Clip (5) ready for insertion to secure the coupling.

[019] FIG. 9 portrays a cross-section view of the configuration from FIG. 7, after the Locking Clip (5) has been inserted, securing the connection between the wall studs (16) and the foundation profile (1).

[020] FIG. 10 offers a close-up isometric view of the Locking Clip (5), highlighting the crumple zone, which allows for deformation around the base of the wall studs (16), while maintaining the required tension.

[021] The drawings are intended to depict the nature of the embodiment. They are not to scale and are simplified for clarity. It will be appreciated that variations and modifications, incorporating the principles of the invention, will be readily apparent to those skilled in the art. Therefore, the drawings should not be taken as limiting the scope of the invention, which is defined by the claims and their equivalents. Detailed Description and Preferred Embodiment

[022] The following is a detailed description of exemplary embodiments to illustrate the principles of the invention. The embodiments are provided to illustrate aspects of the invention, but the invention is not limited to any embodiment. The scope of the invention encompasses numerous alternatives, modifications and equivalent; it is limited only by the claims.

[023] Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. However, the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured. DEFINITIONS:

[024] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[025] As used herein, the term "and / or" includes any combinations of one or more of the associated listed items.

[026] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise.

[027] It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[028] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[029] The terms "first," "second," and the like are used herein to describe various features or elements, but these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present disclosure.

[030] Figure 1 depicts an isometric view of the foundation wall profile base plate 1, which is an elongated extruded profile featuring a square groove along its length. The base plate 1 includes inner side walls 22 and 23, as well as outer side walls 21 and 24. These walls form ridges on each side of the groove. The top surfaces of these ridges contain pairs of keyholes 2 arranged at regular intervals. To facilitate the location of stud base plates 16 into the base plate 1, guide slots are formed in both the inner and outer walls of each ridge. Specifically, there are first guide slots 3 in the outer side wall 21, second guide slots 3a in the inner side wall 22, third guide slots 4 in the inner side wall 23, and fourth guide slots in the outer side wall 24.

[031] The slot widths of the guide slots correspond to the width of the Locking Clip element 5. When the Locking Clip element 5 is fully inserted into the base plate 1, the slots precisely accommodate the clip. The base plate 1 may have machined slot elements, typically in a keyhole shape, in walls 23 and 24 to facilitate the location of the stud base plate 16 into the base plate 1. The studs 16 are designed with a large head and a narrower neck portion 17. This allows the head to be inserted into the wider end of the keyhole 2, while preventing the stud from being pulled out when the neck is laterally moved into the smaller end of the keyhole 2.

[032] Figure 2 presents an isometric view of the Locking Clip element 5, which is generally rectangular and flat. The clip features a shaped slot through the centre of one end, forming two arms on either side of the slot. The edges of the slot are shaped with contours 6 and 7, which securely hold the stud 16 within the base plate 1 when the Locking Clip is in place.

[033] To facilitate easier insertion through the guide slots of the base plate 1, the outer edges of the locking clip arms are provided with contours 8 and 9. Additionally, the narrowing tips 10 of the arms assist in the insertion process. When the Locking Clip is inserted, the arms move sequentially through the guide slots, such as guide slots 3, 3a, 4, and 4a, at a given point along the length of the base plate 1. The rear end of the locking clip 5, opposite the tips 10, features a grip tab 20. This tab protrudes from the base plate 1 even when the locking clip 5 is fully inserted, allowing for easy removal of the clip.

[034] The Locking Clip element 5 can be made from a thermoplastic material such as Glass Filled Nylon. This material provides the required flexibility and strength to hold the stud base plate 16 securely in position within the base plate 1.

[035] Figures 3 and 4 provide detailed elevation views of the Locking Clip 5, showcasing its thickness. Notably, the locking clip 5 increases in thickness at points 12 and 14, which correspond to the inner contours where the arms come into contact with the studs 16. The increased thickness pulls the stud 16 tightly to the floor foundation base plate 1, ensuring a secure connection.

[036] Figure 5 illustrates an example of a modular wall panel 18 with pre-installed fixing studs 16 located at its base. Each stud 16 has a wide head and a thinner neck portion 17. The studs are arranged in pairs, aligning with the pairs of keyholes 2 on the base plate 1. Typically, a wall panel has at least two pairs of studs 16, which are affixed to the base plate at two different points on its base. This arrangement provides stability to the wall assembly. The wall panel extends past the studs 16 on either side to a length of approximately half the interval between keyholes 2 on the base plate 1. This ensures that adjacent wall panels fit snugly against one another when installed on top of the base plate 1.

[037] Figure 6 showcases an example of the modular wall assembly, with the studs 16 positioned to align with the floor foundation base plate 1 and the keyhole slots 2 within it. The studs 16 are ready to be inserted into the keyhole slots 2, securing the wall panel to the base plate.

[038] Figures 7 and 8 demonstrate the wall panel 18 with the studs 16 located in the keyhole slots 2, allowing the Locking Clip 5 to slide into the side guide slots 3 within the floor foundation base plate 1. The Locking Clip 5 is inserted perpendicularly to the studs and the length of the wall panel 18. Its arms move through the guide slots, ensuring a secure connection.

[039] Figure 9 depicts the complete assembly, with the wall panel 18 locked onto the wall foundation profile 1. The studs 16 are pulled down due to the thickness of the Locking Clip element 5 at points 12 and 14, creating a tight and secure connection between the wall panel and the base plate.

[040] Figure 10 provides an example of the Locking Clip 5, highlighting the presence of crumple zones at the thicker points of the clip. These crumple zones are created by groups of co-linear small slots 19 and 21, arranged parallel to the length of the locking clip and the direction of the arms. The presence of these slots allows for a degree of flexibility and compressibility in the arms of the clip 5. When there is excessive load or stress on the clip, these crumple zones enable the arms to deform while maintaining the overall structure and providing a downward force to firmly pull the wall down into position.

[041] The overall system provides a simple, fast, and cost-effective method of attaching modular walls to a building's floor foundation, eliminating the need for precise wall placement and traditional fixings.

[042] Unless otherwise defined, all terms (including technical terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[043] The disclosed embodiments are illustrative, not restrictive. While specific configurations of the system have been described in a specific manner referring to the illustrated embodiments, it is understood that the present invention can be applied to a wide variety of solutions which fit within the scope and spirit of the claims. There are many alternative ways of implementing the invention.

[044] It is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.

Claims

What is claimed is:

1. A modular wall mounting system for attaching modular walls to a building's floor foundation, comprising:one or more modular wall panels, each with a set of pre-installed studs at their bases,one or more foundation base plates, each comprising an elongated extruded profile forming a pair of ridges with a top wall and side walls, the top walls having key hole openings formed in pairs, one on each ridge, at equidistant intervals along the length of the base plate, and each side wall having sets of guide slots formed therein at corresponding positions along the length of the base plate to the key holes; anda plurality of locking clips having thin rectangular profiles with a central gap at one end to form two arms, the arms having contours for coupling about the studs of the wall panels;wherein the studs of the wall panels are arranged to align with and be inserted through the pairs of keyhole openings of the foundation base plate, the locking clips being then configured to be inserted through the guide slots to secure the coupling between the studs and the key holeswherein each set of guide slots is configured, by their arrangement and the width of their respective openings, to form a channel for the arms of a locking clip to slide through as it is inserted through the set of guide slots, the shape of the channel preventing the arms of said locking clip from splaying outwards as it is inserted, ensuring the arms form a snug fit about studs that have been inserted into the corresponding pair of key holes.

2. The modular wall mounting system of claim 1, wherein the guide slots in the foundation base plate are angled at a downwards incline tangent, causing the locking clips to push the studs further downwards into the base plate as the locking clips are inserted into the guide slots.

3. The modular wall mounting system of claim 1, wherein the locking clips have a thickness that increases at points corresponding to inner contours where the arms of the locking clips contact the studs, thereby pulling the studs tightly to the foundation base plate.

4. The modular wall mounting system of claim 1, wherein the locking clips comprise crumple zones formed by groups of colinear small slots arranged parallel to the length of the locking clips and the direction of the arms, providing flexibility and compressibility to the arms, allowing them to deform when subjected to excessive load while maintaining their overall structure and providing a downward force to secure the wall panels.

5. The modular wall mounting system of claim 1, wherein the base plate profile is extruded, and can be made of aluminum, pultrusion, rolled steel, or a combination thereof.

6. The modular wall mounting system of claim 1, wherein the locking clips are made of a thermoplastic material, such as Glass Filled Nylon, providing flexibility and strength to hold the studs in position.

7. The modular wall mounting system of claim 1, wherein the locking clips have a shape and dimensions that correspond to the guide slots, preventing the arms of the locking clips from bending outwards when inserted into the guide slots, ensuring a tight and secure connection with the studs inside the base plate.

8. The modular wall mounting system of claim 1, wherein the base plate profile comprises multiple profiles combined to form one large profile.

9. The modular wall mounting system of claim 1, wherein the extruded profile of the base plates forms a square or rectangular groove between the ridged sides, defined by inner side walls and outer side walls of the ridges.

10. The modular wall mounting system of claim 1, wherein the arms of the locking clips have tapering tips to facilitate easier insertion into the guide slots.

11. The modular wall mounting system of claim 1, wherein the locking clips have a grip tab at the opposite end to the tips of the arms for facilitating easy removal and disassembly of the modular system.

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