Partition wall assembly

Abstract

A partition wall assembly 100 comprising: a first face 130 and second face 140, each including a plurality of wall panels 500 / 550 / 600 / 650; a base track 200 for supporting lower edges of the first and

Description

Field of the Invention The present application relates to partition wall assemblies and to partition walls assembled from such assemblies. Background to the invention Partition walls are non-load-bearing walls that are used to divide the interiors of buildings into separate rooms or spaces. The most common form of a partition wall is a series of plasterboard panels - sometimes called drywall or gypsum boards - supported on a frame of metal or wooden studs. Such plasterboard and stud walls may be single stud walls, in which plasterboard panels are mounted on both sides of a frame of studs, or twin stud walls which use two parallel frames of studs separated by a gap, each with plasterboards mounted thereon to define one face of the wall. Single stud walls have poor sound and thermal insulation and twinstud walls, such as twin metal stud walls are widely in construction to provide a desired level of acoustic and thermal insulation. Such twin-stud metal walls typically consist of two parallel frames of metal studs, each with upper and lower metal 'U' tracks mounted to the floor and ceiling and a plurality vertical metal 'C' studs therebetween. Plasterboards are mounted to the outer faces of the frames and insulation may be provided between the studs of the frames. A gap, typically of a width prescribed by building regulations, is provided between the two frames to provide the desired sound and thermal insulation. Such twin stud metal walls are expensive and time-consuming to construct and have a large thickness, typically at least 220mm and often more than 300mm, which significantly reduces the available floorspace in interiors where they are installed. An aim of the present invention is to provide improved partition walls without the aforementioned drawbacks. Summary of the Invention According to a first aspect of the invention, there is provided a partition wall assembly comprising: a first face and a second face, each including a plurality of wall panels; a base track for supporting lower edges of the first and second faces; a head track for retaining upper edges of the first and second faces; and a plurality of brackets for extending between and interconnecting the first and second faces; wherein the wall panels of the first and second face each comprise: an outer layer defined by a sheet of paper-faced material folded at grooves along edges of a front section thereof to define a base, a top and at least one sidewall perpendicular to the front section, the at least one sidewall extending between the top and the base; and at least one peripheral connector on the at least one sidewall for connecting to with a corresponding peripheral connector of an adjacent wall panel. Unlike traditional stud-based partition walls, panels in the partition wall assembly are not mounted on and supported by a framework of studs. Instead, the wall panels interconnect with each other using peripheral connectors to define the two faces of the wall, which are in turn supported by the head and base tracks. Strength is provided to the individual faces of the wall by the folding of the panels and to the wall as a whole by the brackets extending between the two faces. The brackets extending between the wall conduct significantly less sound and heat than studs that span the full width of single stud walls while allowing the partition wall to be significantly thinner than twin stud walls which require the thickness of two frames of studs and a gap therebetween to separate their faces. Replacing metal studs with a gap spanned only by brackets can improve the acoustic and thermal insulation provided by the wall, as well as remove the risk of thermal expansion of metal studs during a fire, which could potentially create air paths through the wall. Additionally, constructing a partition wall from interconnecting panels, tracks and brackets can drastically simplify its construction by reducing the number of necessary components through the use of modular prefabricated elements, simplifying the process of finishing the wall by reducing an amount of joint filling necessary, enable construction by less skilled workers and reduce the amount of waste produced by the construction process. In some embodiments, the partition wall assembly may be an assembled partition wall, in which the base supports the lower edges of the first and second faces, the head track retains the upper edges of the first and second faces, the brackets extend between and interconnect the first and second faces, and the peripheral connectors of the wall panels connect with each other. In such embodiments, the base track may be mounted on and / or secured to a floor surface and the head track may be mounted on and / or secured to a ceiling. Alternatively, the partition wall assembly may be a kit of parts for assembling such a partition wall. In such embodiments, the prefabricated nature of the wall panels and the connectors comprised thereby may significantly facilitate the construction of a partition wall. The partition wall assembly includes first and second faces, each with a plurality of panels. The first and second faces, and the panels thereof may comprise substantially planar surfaces and may be configured to be arranged parallel to each other, such that they define opposite faces of a straight wall. The plurality of panels may be substantially rectangular to facilitate the construction of the wall therefrom. The wall assembly comprises a base track for supporting lower edges of the first and second faces. The base track may support bases of wall panels of the first and second faces that extend to the bottom of said faces, for example, a lowermost row of wall panels of each face. The base track may comprise a first rail for supporting the lower edge of the first face and a second rail for supporting the lower edge of the second face. Such rails may be separate components which may be configured to be mounted on and affixed to a floor surface separately in use. This may minimise the conduction of sound or heat across the gap between the first and second faces of the wall by ensuring that the gap between them extends to the floor. The base track (and / or each rail thereof) may comprise a plurality of connectors for connecting to corresponding connectors on the bases of wall panels of the first and second faces. Such connectors may secure the wall panels and by extension the faces to the base track and hold them in position. Connectors for connecting to wall panels the first face may be laterally offset from connectors for connecting to with wall panels of the second face. The connectors of the base track may be or may comprise male and / or female connectors for connecting with corresponding female and / or male connectors on the bases of the wall panels of the first and second faces. For example, the connectors may be a plurality of mortises for receiving tenons for interlocking with corresponding mortises in the bases of the wall panels of the first and second faces. In embodiments in which the connectors are mortises for receiving tenons for interlocking with corresponding mortises in the bases of wall panels, the tenon may be secured in one of the pair corresponding mortises (such as the mortises in the base track) using an adhesive or fastener and may be removably inserted into the mortises in the other of the pair (such as the mortises in the bases of the wall panels). Such tenons may be considered to be comprised by the connectors in which they are secured. In some embodiments, the connections between the base track and the bases of the wall panels may be magnetic (preferably, in addition to interlocking), for example the connectors comprised by the base track (such as tenons secured in mortises in the base track) may be magnetic and the corresponding connectors comprised by the bases of the wall panels (such as mortises) may comprise ferromagnetic elements for connecting thereto (such as a steel base to the mortises in the bases of the wall panels). The connectors comprised by the base track and / or by the bases of the wall panels may be substantially identical to peripheral connectors on the at least one sidewall of the wall panels. In some embodiments, the base track (and / or each rail thereof) may comprise one or more apertures, such as predrilled holes, for securing it to a ground surface such as a floor. Alternatively, or additionally, an adhesive such as mastic or intumescent may be used to affix the base track to a ground surface. The base track may comprise a layer of plywood for facilitating mounting the base track on a ground surface using fasteners such as screws. In some embodiments, an upper surface of the base track (and / or each rail thereof) comprises a layer of fire-resistant material such as glass reinforced gypsum (GRG) or magnesium oxide (MgO). Such a material may provide a seal between the top of the base track and the bases of the wall-panels supported thereon, preventing any air gaps in the wall, improving fire resistance of the wall, and / or facilitating jointing of the wall. The layer of fire-resistant material may be 5mm or 6mm thick. At thicknesses below 5mm, it is difficult to fill the gaps between the faces of adjacent panel with a filler in a finishing process after constructing the wall, so this may be a minimum thickness. In some embodiments, the base track (and / or each rail thereof) may comprise a layer of sound / dampening material, such as closed cell neoprene. This material may reduce sound conduction through the base of the partition wall assembly. The sound dampening material may be encased in an outer layer of paper-faced material such as plasterboard, which may be folded along grooves parallel to the length of the base track to adopt an inverted U-shaped cross section over the sound dampening material. In some embodiments the base track (and / or rails thereof) may comprise a plurality of interconnectable lengths, for example with mating or interlocking ends. The wall assembly comprises a head track for retaining upper edges of the first and second faces. The head track may support upper edges of wall panels of the first and second faces that extend to the top of said faces, for example, an uppermost row of wall panels of each face. The head track may comprise a first upper rail for retaining the upper edge of the first face and a second upper rail for retaining the upper edge of the second face. Such rails may be separate components which may be configured to be mounted on and affixed to a ceiling surface separately in use. This may minimise the conduction of sound or heat across the gap between the first and second faces of the wall by ensuring that the gap between them extends to the floor. In some such embodiments, the first and second upper rails may each comprise one or more sockets for receiving an end of a corresponding specifically dimensioned alignment tool for ensuring the rails are at a correct separation. When the alignment tool is received in sockets in both rails, those sockets, and by extension the first and second rails may be held at a pre-set separation which may correspond to a desired separation between the walls. After the rails have been secured to a ceiling with such a separation, a plumb line down from the rails may be used to ensure the base rails are also correctly positioned. Alternatively, the first and second base rails may also comprise such sockets. The head track may comprise a first lip configured to extend past the upper edge of the first face and / or a second lip configured to extend past the upper edge of the second face. Such lips may prevent outward movement of either face and hold the upper edge of the wall in position. For example, first and second upper rails may have L-shaped cross sections each with a first surface for contacting and securing the rail to a ceiling and a second surface at right angles thereto defining a lip extending downwards past the upper edge of the retained face. During assembly of the partition wall, wall panels at the upper edge of the first and second faces may be temporarily affixed to such lips, for example using temporary fixings, which may be removed after the partition wall has been assembled. The lips may comprise apertures therethrough for such fixings. The head track (and / or rails thereof) may comprise or be formed of a paper-faced material such as plasterboard. The paper-faced material may be folded along lengthwise grooves, for example, to form rails with L-shaped cross-sections as described above. In some embodiments, the head track (and / or each rail thereof) may comprise one or more apertures, such as predrilled holes, for securing it to a ceiling. Alternatively, or additionally, an adhesive such as mastic or intumescent may be used to affix the head track to a ceiling. In some embodiments the head track (and / or rails thereof) may comprise a plurality of interconnectable lengths, for example with mating or interlocking ends. The wall assembly comprises a plurality of brackets for extending between and interconnecting the first and second faces. The plurality of brackets may each comprise a metal bar with a fastener at each end for connecting to a wall panel, for example to a sidewall and / or a vertical spline thereof. In use a first end of the bar may be fastened to a wall panel of the first face and a second end to a wall panel of the second face, for example, one end may be a sidewall of a wall panel of one faces, and the other end may connect to a central vertical spline of a wall panel of the other face, in which the wall panels are offset from those of the other by half a panel's width. The fastener may comprise a bolt and barrel nut arrangement for extending through an end of the bar, a sidewall or vertical spline of a wall panel, and optionally a washer or plate on the far side of the sidewall or vertical spline from the bar. The bar may comprise a crank or other bend to account for an offset between the points where it connects to the panels of the two faces. The brackets and / or the fasteners thereof may comprise noise dampening means for reducing the transmission of vibrations or noise between the faces via the brackets. For example, the bracket may comprise a sleeve, washer or cap formed from a sound / dampening material, such as neoprene, on each fastener that connects it to a wall panel. The first and second faces each comprise a plurality of wall panels, each of which comprises an outer layer defined by a sheet of paper-faced material folded at grooves along edges of a front section thereof to define a base, a top and at least one sidewall perpendicular to the front section, the at least one sidewall extending between the top and the base. The outer layer defines a plurality of faces of the panel, including a front, a top, a base and at least one sidewall. The sheet of paper-faced material may be a sheet of plasterboard. Using a paper-faced material, such as plasterboard, allows the sheet to be folded at grooves cut into the material up to, but not through, the paper facing, in order to define the structure of the panel. The grooves may be scored or cut into the paper-faced material. The grooves may be V-shaped grooves, for example, grooves with edges at 45° to the surface of the material, such that when opposite sides of the grooves are folded together, they define a 90° fold, such that the folded sections are perpendicular to the front section. The grooves may have edges at greater than 45°, for example, between 45° and 50° to the surface, to account for thickness of the adhesive therein. Alternatively, or additionally, the edges of the grooves may have indents for receiving adhesive and / or a gasket therein. The sheet of paper-faced-material comprises a front section which may define a front of the panel that forms part of the outer surface of the partition wall in use, and a plurality of sections extending from edges thereof. Grooves are formed along these edges between front section and the seconds defining the top, base and at least one sidewall and the extending sections are folded at these grooves such that they are perpendicular to the front section. The top, base and at least one sidewall may contact and / or engage with tops, bases or sidewalls of other wall panels or with the base track or head track. Each folded section may be held in its folded position by an adhesive within its associated groove, one or more connections between it and adjacent folded sections and / or one or brackets within the wall panel. The front section may be a rectangular, such that the top and base of the panel are parallel to each other and perpendicular to the at least one sidewall. In some embodiments, one or some of the panels may comprise a sheet of paper-faced material folded to define two sidewalls that extend between the top and the base thereof. Where the panel and front section thereof are rectangular, these sidewalls may be parallel to each other and perpendicular to the top and base and the panels may define substantially cuboid recesses enclosed on five sides within the folded sheet. Such wall panels may be substantially tray-shaped and / or box-shaped. Additionally, one or some of the panels may only comprise a single folded sidewall. Where the panel and front section thereof are rectangular, the panels may define substantially cuboid recessed enclosed on only four sides. In some such panels, the folded top and base may only extend part way along the width of the front section of the sheet, such that a portion of the front section of the sheet does not have any portions extending backwards therefrom, such a portion of the panel may be fitted over a wall anchor at an end of its face in an assembled partition wall. In some embodiments, the portion that fits over a wall anchor in use may be cut to size, so as to adjust the width of the wall panel defining the end of the face of the wall, and by extension of face itself, to fit a gap across which the partition wall will extend. Such a wall anchor may be mounted on another wall from or to which the partition wall extends, connecting the partition wall thereto. Such a portion may be affixed to such a wall anchor, for example via screws extending therethrough. In some embodiments, each face of the partition wall assembly may comprise one or more panels with only a single folded sidewall on their left hand side (for fitting over and / or connecting to a wall anchor at a right hand side of the that face), one or more panels with only a single folded sidewall on their right hand side (for fitting over and / or connecting to a wall anchor at a left hand side of the that face), and one or panels with two folded sidewalls for arranging intermediate the two ends of the face. In some embodiments, one, some, or all of the wall panels may comprise an inner layer of paper-faced material, which may be provided inside a recess defined by the panel on inner faces of the front section, top, base, and / or sidewall and may be secured thereto. Such an inner layer may provide a surface for additional elements such as sound dampening inserts to be secured to without connectors extending through the exterior of the wall panel. In some embodiments, one, some, or all of the wall panels may comprise horizontal and or vertical splines extending across a recess defined by the panel. Such splines may provide additional strength and / or rigidity to the wall panel. In some cases, one, some or all of the wall panels may comprise one or more acoustic dampening inserts arranged within the recess defined by those wall panels. Such acoustic inserts may comprise layers acoustic dampening material (such as acoustic plasterboard or a closed cell foam such as neoprene) spanning the recess or a section thereof bounded by splines. The acoustic inserts may be secured within the recess, for example by fasteners extending through the acoustic dampening inserts and an inner layer of the wall panel as described above. Such fastener arrangements may comprise a sleeve, washer or cap formed from a sound / dampening material, such as neoprene. Each wall panel comprises at least one peripheral connector on its at least one sidewall for connecting to a peripheral connector of an adjacent wall panel of the face that it is comprised by. Wall panels comprising multiple sidewalls may comprise such peripheral connectors on each sidewall, for connecting to peripheral connectors of adjacent wall panels of the face. One, some, or each of the wall panels may comprise at least one peripheral connector on its base for connecting to an adjacent connector, such as a peripheral connector on a top of an adjacent wall panel beneath it, or a connector of the base track as discussed above. One, some, or each of the wall panels may comprise at least one peripheral connector on its top for connecting to an adjacent peripheral connector, such as a peripheral connector on a base of an adjacent wall panel above it. The peripheral connectors on the sidewalls (and optionally on tops and / or bases) may be or may comprise male and / or female connectors for connecting with corresponding female and / or male connectors on other wall panels or the base track. For example, the connectors may comprise a plurality of mortises for receiving tenons for interlocking with corresponding mortises in adjacent wall panels (and / or base rails). In embodiments in which the connectors are mortises for receiving tenons for interlocking with corresponding mortises in adjacent wall panels (or the base track), the tenon secured in one of the pair corresponding mortises using an adhesive or fastener and may be removably inserted into the mortises in the other of the pair. Such tenons may be considered to be comprised by the connectors in which they are secured. In some embodiments, the pairs of corresponding connectors may be magnetic (preferably, in addition to interlocking), for example the connectors comprised by a sidewall of one wall panel (such as tenons secured in mortises therein) may be magnetic and corresponding connectors comprised by a sidewall of another wall panel (such as mortises) may comprise ferromagnetic elements for connecting thereto (such as a steel base to the mortises). In some embodiments, one or some of the panels comprise a layer of fire-resistant material, such as glass reinforced gypsum (GRG) or magnesium oxide (MgO), on the exterior of one of their at least one sidewalls. Such a material may provide a seal between that sidewall and an adjacent wall panel, preventing any air gaps in the wall, improving fire resistance of the wall, and / or facilitating jointing of the wall. In some embodiments, panels comprising multiple sidewalls may only comprise such a layer on one of their sidewalls, for example, all on their left sidewalls, or all on their right sidewalls, as only one of two adjacent sidewalls requires such a layer thereon to fill the gap between the panels. The layer of fire-resistant material may be 5mm or 6mm thick as described above. In some embodiments, one or some of the panels may comprise a layer of fire-resistant material, such as GRG or MgO, on their tops and / or their bases. Such panels may only comprise a layer of fire-resistant material on one of their top and their base. In some embodiments, the wall assembly may further comprise one or more wall anchors for connecting an end of the wall assembly to another wall. The wall anchor may be an elongate body, such as a substantially cuboid body, for extending upwards from the base track to the head track in use. The wall anchor may comprise a central plywood shaft surrounded by a layer of paper-faced material such as plasterboard. Such a structure may facilitate securing the wall anchor (and by extension a partition wall comprising the wall anchor) to an adjacent wall, for example using screws. The wall assembly may further comprise a layer of fire-resistant material, such as glass reinforced gypsum (GRG) or magnesium oxide (MgO) on one or more of its lateral faces, which may be used to provide a seal between the wall anchor and adjacent wall panels or an adjacent wall. The layer may be 5mm or 6mm thick as described above. The assembly may comprise separate wall anchors for the first and second faces and / or separate wall anchors for each of two ends of the partition wall. According to a second aspect of the invention, there is provided a method of constructing a partition wall. The method comprises: mounting a base track on a ground surface and a head track on a ceiling; arranging a plurality of wall panels to define a first face with a lower edge supported by the base track and an upper edge retained by the head track; wherein each wall panel comprises an outer layer defined by a sheet of paper-faced material folded at grooves along edges of a front section thereof to define a base, a top and at least one sidewall perpendicular to the front section, the at least one sidewall extending between the top and the base, and at least one peripheral connector on the at least one sidewall for connecting to a peripheral connector of an adjacent wall panel; connecting a plurality of brackets to the first face; and arranging a plurality of wall panels to define a second face with a lower edge supported by the base track, an upper edge retained by the head track, and connected to the plurality brackets such that the brackets extend between the first and second faces. The assembled partition wall and / or the components thereof may comprise any of the optional features of the wall assembly described above. Mounting the base track on the ground surface may comprise affixing it to the ground surface mechanically, for example using fasteners extending through the base track or predrilled holes therein. Mounting the head track on the ceiling may comprise affixing it to the ceiling using an adhesive such as mastic or intumescent. It may further comprise subsequently mechanically affixing the head track to the ceiling surface using fasteners. Arranging the plurality of wall panels of each face may comprise arranging an initial wall panel of the face with its base supported on the base track (and / or being connected thereto) and subsequently arranging the remaining wall panels of the face such that peripheral connectors thereof (such as connectors on a base or sidewall thereof) connecting to peripheral connectors of at least one previously arranged wall panel (such as peripheral connectors on tops or sidewalls thereof). Wall panels in a lowermost row of the face may be supported on the base and wall panels in an uppermost row of the face may be affixed to the head track. S. It will be appreciated that in some embodiments, the lowermost row may also be the uppermost row if the face comprises only a single row of wall panels. After both the first and second faces have been constructed by arranging their wall panels and have been interconnected by the plurality of brackets, the method may comprise removing fixings between the head track and wall panels in uppermost rows of the faces. After both faces have been assembled and interconnected such fixings may no longer be necessary to retain the upper edge of the faces, for example wherein the upper edges of the two faces are both held between a pair of lips of the head track. In some embodiments, the method may comprise mounting one or more wall anchors to adjacent walls. In such embodiments, the initial wall panel arranged when constructing a face of the wall may be connected to such a wall anchor. In some embodiments, the method may further comprise jointing the constructed wall, applying a filler to fill gaps between adjacent panels and / or other components of the wall assembly. The wall may be sanded after the filler has been cured. Brief Description of the Drawings Exemplary embodiments of the invention will now be described in detail with reference to the accompanying figures, in which: Fig. 1 shows an isometric view of an assembled first partition wall according to an embodiment of the invention; Fig. 2a shows an isometric view of the outside of first face of the partition wall of Fig. 1; Fig. 2b shows an isometric view of the inside of face shown in Fig. 2a Fig. 2c shows an exploded isometric view of the inside of face shown in Fig. 2a; Fig. 3a shows an exploded isometric view of a lower intermediate wall panel; Fig. 3b shows a partially exploded horizontal cross section through a lower intermediate wall panel; Fig. 4 shows isometric and cross-sectional views of a base track rail; Fig. 5 shows isometric and cross-sectional views of a head track rail; Fig. 6 shows isometric and cross-sectional views of a wall anchor; Fig. 7a shows a cross-sectional view of a bracket; Fig. 7b shows a first isometric view of the bracket of Fig. 7a; Fig. 7c shows a second isometric view of the bracket of Fig. 7a; Fig. 7d shows an isometric view of an alternative configuration of the bracket of Fig. 7a; Fig. 8a shows an isometric exploded view of a portion of a second partition wall according to an aspect of the invention; Fig. 8b shows an assembled view of the second partition wall of Fig. 8a; Fig. 8c shows an isometric exploded view of a portion of a third partition wall according to an aspect of the invention; Fig. 8d shows an assembled view of the second partition wall of Fig. 8c; Fig. 9a shows an outside isometric view of a portion of a wall assembly including utility access panels; and Fig. 9b shows an inside isometric view of the portion of the wall assembly shown in Fig. 9a. Detailed Description of the Figures Referring to the figures generally, there are shown examples of partition wall assemblies according to embodiments of the present invention and partition walls constructed using such assemblies. The illustrated partition wall assemblies comprise a selection of prefabricated modular components including: base track rail lengths 200, head track rail lengths 300, wall anchors 400, lower end panels 500, upper end panels 550, lower intermediate panels 600, upper intermediate panels 650, and brackets 700. These components can be assembled on site to define straight partition walls 100 of various different lengths between adjacent walls. The partition wall can be used in place of traditional stud wall such as twin metal stud walls widely used in the construction industry. Fig. 1 shows an isometric view of a partition wall 100 defined by an assembled partition wall assembly. The assembled partition wall includes a base track 110, defined by a plurality of base track rail lengths 200; a head track 120 defined by a plurality of head track rail lengths 300, and two faces 130, 140, each defined by a pair of wall anchors 300, two lower end panels 400, two upper end panels 450, two lower intermediate panels 500 and two upper intermediate panels 550. Lower and upper edges of the two faces 130, 140 are held in position by the base track and head track respectively and the two faces are interconnected by brackets 600 (not visible in Fig. 1) which span a gap 150 between them. The constructed partition wall comprises two sides, each with one of the two faces 130, 140 and corresponding sections of the base track 110 and the head track 120 engaging that face. The two sides are arranged on opposite sides of the air gap 110 to minimise the conduction of sound and head across the wall. The base track 110 and the head track 120 are each divided into first and second rails for engaging with the first and second faces respectively, this ensures that the gap between the sides of the wall also extends between the sides of the base track 110 and head track 130 and limits the conduction of sound and heat between the sides of the wall to air gap 150 itself and the brackets 700 that extend across it to interconnect the two faces of the wall. Figs. 2a and 2b shows outside and inside view of one of the two sides of the assembled partition wall shown in Fig. 1, with a first face 130 supported by a corresponding base track rail 200 and retained by a corresponding head track rail 300. Fig. 2c shows an exploded inside view that face 130, base track rail 200 and head track rail 300, illustrating the separate components that constitute it. The first face 130 of the wall consists of a plurality of wall panels 500, 550, 600, 650 -which are connected to each other and the base track rail 200 by magnetic mortise and tenon joints - and a pair of wall anchors 400, which are fastened to adjacent walls (not shown) and to the end panels 500, 550 by fasteners such as screws. The illustrated wall comprises two horizontal rows of panels. In a lower row, lower end and intermediate panels 500, 600 are supported by (and connected to) the base track rail 200 on bases thereof. Above the lower row in an upper row, upper end and intermediate panels 550, 650 are supported on (and connected to) tops of the panels of the lower row. The uppermost portions of their front surfaces are in contact with an interior surface of the upper track rail 300 such that top of the face 130 is not free to move outward. The illustrated wall is four panels wide. It will be appreciated that in alternative embodiments or configurations of the wall assembly, different numbers and / or arrangements of wall panels may be used. For example, a face of the wall may only comprise a single row of wall panels (such as when taller wall panels are available), may comprise three or more rows of wall panels (such as when used to define a partition wall in an interior space with higher ceilings). Different numbers of wall panels and columns thereof of may also be used to define partition walls of different lengths, for example by introducing additional upper and lower intermediate wall panels 600, 650 between the end wall panels 500, 550. Such embodiments may comprise different lengths of base track rail 200, head track rail 300 or wall anchor 400, or may use a plurality of base track rails 200, head track rails 300 or wall anchors 400 arranged end-to-end. Fig. 3a shows a partially exploded detailed view of the rear side of one of the lower intermediate wall panels 600, which illustrates a number of features common to all of the wall panels of the wall assembly. Fig. 3b shows a partially exploded, horizontal cross section through such an intermediate wall panel 600. Each of the wall panels 500, 550, 600, 650 is formed from a sheet of plasterboard that is cut into a die configuration and folded to define a rectangular front section 710 (not visible in Fig. 3) and a backwards extending top 720, base 730 and at least one sidewall 740. The top 720, base, 730 and one or more sidewalls 740 are each perpendicular to the front section. The folds are made at V-shaped grooves along the edges of the front section that are cut into the plasterboard up to, but not through, the paper facing, such that the plasterboard can be folded using the paper facing as a guide. The folded base, top and sidewalls are held in their folded positions by adhesive within the folded grooves and by brackets in the interior of the corners of the panels. The sidewalls 740 extend between the top 720 and the base 730 of their wall panels. The intermediate wall panels 600, 650 comprise two sidewalls 740 on opposite sides of the front section 710, such that they define a box or tray shaped recess bounded on five sides by the plasterboard. In contrast, the end panels 500, 550 comprise only a single sidewall, and define a substantially cuboid recessed enclosed on only four sides. The folded top 720 and base 730 of the end panels 500, 550 only extend part way along the width of the front section of the sheet, so as to define a space for receiving a wall anchor 400, as shown in Figs. 2b and 2c. The intermediate and end wall panels 500, 550, 600, 650 further comprise an inner layer 750 of plasterboard, which is provided inside the recess defined by folded faces of the front section, top, base, and / or sidewall and may be secured thereto. The inner layer provides additional thickness to the wall panel and a surface to which barrel nuts 774 for additional fasteners 773, 772 are secured without the fasteners extending through the wall panel. Additionally, the intermediate and end wall panels 500, 550, 600, 650 further comprise horizontal and vertical splines 755 extending across their recesses, to provide additional strength and rigidity to the wall panel. The intermediate and end wall panels 500, 550, 600, 650 are configured to receive optional acoustic dampening inserts 770 within their recess between the splines 755, sidewalls 740, tops 720, and bases 730. Such inserts may be used in a wall when a greater degree of acoustic insulation is required. The wall panels 500, 550, 600, 650 comprise barrel nuts 774 embedded within the inner layer 750 of the plasterboard for attaching such optional acoustic inserts. The acoustic inserts may comprise a first layer of closed cell neoprene foam 778 and a second thicker layer of acoustic plasterboard 779. The acoustic inserts 770 are secured within the recess by bolts 772, which extend through dual threaded inserts 773 in the inserts that define flanges between the two layers 778, 779 thereof, into the barrel nuts 774 embedded in the inner layer 750 of plasterboard on the rear of the wall panels 500, 550, 600, 650. Neoprene sleeves 776 are provided between the acoustic dampening inserts 770 and the bolt's and barrel nut's extending therethrough to provide additional acoustic insulation. The arrangement of such fasteners, 772, 773, 774, 775 can be seen in detail in section 'F' of Fig. 3b. The lower wall panels 500, 600 each comprise a 5mm thick layer of glass reinforced gypsum (GRG) on the exterior of their tops, and the intermediate and right-hand end wall panels 600, 650, 500, 550 each comprise a GRG layer on their left hand sidewalls, such that each pair of adjacent wall panels has a layer of GRG therebetween, providing a seal between the wall panels preventing any air gaps in the wall, improving fire resistance of the wall, and / or facilitating jointing of the wall. The wall panels 500, 550, 600, 650 each comprise mortise and / or tenon connectors for connecting to adjacent wall panels (and in the case of the lower panels 500, 600, with the base track rail 200). Each panel with a right-hand sidewall 740 (the intermediate panels 600, 650 and the left-hand end panels 500, 550) comprises one or more tenons 800 thereon, and each panel with a left hand sidewall 740 (the intermediate panels 600, 650 and the right hand end panels 500, 550) comprises one or more corresponding mortises 850 thereon. The upper panels 550, 650 comprise one or more tenons 800 on their bases, for engaging with one or more mortises 850 comprised by the tops of the lower panels 500, 600. The lower panels further comprise one or more mortises 850 on their bases for engaging with tenons 800 on the base track rail 200. The mortises 850 are formed through the GRG layers on their edges of the wall panels and have a steel plate arranged in their base, fastened to the plasterboard defining that edge of the wall panel. The tenons 800 are also fastened to the plasterboard defining the edge of the wall panel (or upper surface of the base rail track 200) from which they protrude. The tenons 800 are magnetic and engage with the steel plates in the bases of the mortises 850 to more securely hold adjacent panels together and onto the base rail track 200. A plurality holes 705 are formed through the vertical splines 755 of the panel and through the sidewalls 740 and inner plasterboard layers 750 thereon. These apertures 705 are for fastening brackets 700 to those sidewalls 740 or splines and comprise associated recesses for receiving the brackets 700. Fig. 4 shows an isometric view of a base rail track 200 as well as a cross-sectional view therethrough. The base rail track comprises a upside-down U-shaped arrangement of cut and folded plasterboard 210 - which defines an outer surface of the base rail track 200, and by extension the wall assembly 100 - around a layer of plywood 220 - through which fasteners may be screwed to secure the base rail track 200 to a floor surface - and a layer of closed-cell neoprene foam 230 - for providing improved sound insulation to the base rail track 200. A layer of GRG 240 is formed on the upper surface of the base rail track 200 for forming a seal with the base of lower wall panels 500, 600 as described above. Magnetic tenons 800 on the upper surface of the base rail track extend upwards from the GRG layer for engaging with corresponding mortises 850 on the bases 730 of the lower wall panels 500, 600. Fig. 5 shows an isometric view of a head rail track 300 as well as a cross-sectional view therethrough. The head rail track 300 has an upside-down L-shaped cross-section with a horizontal surface for contacting and being secured to a ceiling surface, for example using an adhesive such as mastic, and a vertical surface for contacting an outside of one of the faces 130, 140 of the wall assembly, as shown in Figs. 1 &2a. The head rail track 300 is defined by inner and outer layers of folded plasterboard 305, 310. At the ends of the head rail track 300, the inner layer 305 is slightly offset from the outer layer 310 lengthwise so as to define a step for interlocking with adjacent head rail tracks when constructing longer partition walls. A layer of sound dampening material 305, such as closed cell neoprene foam 315 if provided between the inner and outer layers 305, 310. A series of apertures are formed through the vertical face of the head rail track 300 adjacent its lower edge. In use, as each wall assembly is constructed and each wall panel 550, 650 in the uppermost row is positioned, temporary fixings 320 through these apertures are used to temporarily secure the upper wall panels 550, 650 to the head rail track. After the entire partition wall has been assembled, these temporary fixings are no longer necessary as the two faces 130, 140 interconnected by the brackets contact the interior of the vertical faces of both head rail tracks 300, holding the wall in place, as shown in Fig. 1. A pair of sockets 330 are formed in the outer layer 310 of the horizontal surface of the rail 300 for receiving an end of a corresponding specifically dimensioned alignment tool for ensuring the rails are at a correct separation. When the alignment tool is received in sockets 330 in both rails 300 of a wall assembly, those sockets, and by extension the first and second rails 300 may be held at a pre-set separation which may correspond to a desired separation between the walls. The socket has an open side on the inside of the rail, so as to allow an alignment tool located therein to extend out of the rail 300 when it attached to a ceiling. Fig. 6 shows an isometric view of a head wall anchor 400 as well as a cross-sectional view therethrough. The wall anchor is an elongate cuboid body which is mounted to a wall to which an end of the partition wall will extend at the beginning of the wall construction process, in line with one of the base rail tracks 200 and head rail tracks 300, such that it defines an end of one of the faces 130, 140 of the wall assembly. The head wall anchor comprises a plywood core 410 through which fasteners such as screws may extend to secure the wall anchor 300 to the wall. A plurality of predrilled holes 420 are formed at least part way through the wall anchor to facilitate making such connections, these predrilled holes 420 may comprise neoprene bushings. After the wall anchor has been installed, a lowermost end wall panel 500 is arranged on the base track such that it overlaps the wall anchor (as shown in Fig. 2b), and fasteners secure that end panel 500 to the wall anchor through its front face 710. After the lower end panel 500 has been installed in this manner, adjacent lower intermediate panels may be installed one-by-one by placing them in position such that they are secured to the base track and at least one adjacent wall panel by magnetic mortise and tenon joints 800, 850. The upper end panel 550 may also be installed after the lower end panel 500 has been installed, and it may also be fastened to the wall anchor. The wall anchor 400 further comprises a layer 430 of GRG for forming an improved seal with adjacent panels and / or walls. Fig. 7a shows a cross-sectional view a bracket 700 for interconnecting the two faces of the wall as well as a cross-sectional view therethrough. Figs. 7b and 7c show front and back isometric view of the bracket 700. The bracket 700 comprises a metal strut 610 defining an acoustic bridge between two fasteners for connecting to wall panels of the opposite faces 130, 140 of the partition wall assembly 100. The strut 610 comprises a crank or offset bend 615 part way along its length to account for an offset between the alignment of wall panels and bracket receiving apertures 705 thereof. The bracket 700 comprises two fasteners at opposite ends for extending through apertures in sidewalls 730 or splines 755 of a wall panel to a plate 620 on an opposite side thereof. The faster comprises a threaded metal sleeve 630 located within the aperture, a button head machine screw 640 that extends into the sleeve 630 from the strut 610 and a countersunk machine screw 650 that extends into the sleeve from the metal plate. In order to reduce the transmission of vibrations from one face across the bracket 700 to the opposite face, the bracket further comprises an annular sound dampening neoprene cap or sleeve 660 separating the button head machine crew 640 and the strut at each fastener. The neoprene cap of sleeve 660 additionally provides a small degree of flexibility to the bracket 700, allowing the distance between the two fasteners 640, 650, and by extension between the two interconnected wall panels, to vary slightly, which may improve the durability of an assembled partition wall. The fasteners, sleeves 630 and plates 620 can be attached on either side of the metals strut 610. Fig. 7d shows an alternative configuration of the bracket in which the two metal plates are arranged on two opposite sides of the metal strut in order to define an offset bracket for connecting sidewalls 730 and / or splines 755 of opposite wall panels that are offset from each other by larger amounts. The use of both configurations of bracket 700 can be seen in Figs. 2b, 2c, and 8. Partition wall assemblies as described above may be assembled using a method comprising the following steps: mounting wall anchors 400 on an exterior wall from which the partition wall is to extend using mechanical fixings through predrilled holes 420 therein and checking the wall anchor 400 is vertical. - attaching the base track rails 200 to a ground surface using mechanical fixings through predrilled holes therein. - attaching the head track rails 300 to a ceiling using an adhesive such as mastic or intumescent before mechanically fixing it to the ceiling through predrilled holes. - arranging a lower end module 500 on an end of the first base track rail 200 such that it fits over a wall anchor 400 and fixing the lower end module 500 to the wall anchor using drywall screws. - arranging the upper end module 550 above the lower end module 500 such that fits over the wall anchor 400 and is connected to the lower end module by a magnetic mortise and tenon joint 800, 850, then fixing the upper end module 550 to the wall anchor using drywall screws and fixing the upper end module to the first head track rail 300 using one or more temporary fixings 320. - arranging a lower intermediate module 600 on the first base track rail 200 such that it is connected to a previously arranged panel by magnetic mortise and tenon joints 880, 850, then arranging an upper intermediate module 650 above the lower intermediate module 600 such that it is connected to the lower intermediate module 600 and an adjacent upper module by mortise and tenon joints 800, 850, then fixing the upper intermediate module to the first head track rail 300 using one or more temporary fixings 320. repeating the step above until all intermediate wall panels have been installed, then arranging a final lower end module 500 at the far end of the first base track rail 200 such that it fits over the opposite wall anchor 400 and is connected to an adjacent lower intermediate wall panel by a magnetic mortise and tenon joint 800, 850 and fixing the lower end module 500 to the wall anchor using drywall screws. - arranging a final upper end module 550 above the lower end module 500 such that fits over the wall anchor 400 and is connected to the lower end module and an adjacent upper intermediate panel 650 by magnetic mortise and tenon joints 800, 850, then fixing the upper end module 550 to the wall anchor using drywall screws, and fixing the upper end module to the first head track rail 300 using one or more temporary fixings 320. - Repeat the steps above along the length of the second base track rail 200, installing brackets 600 between panels of the two faces 130, 140. - Apply filler to the joints between the panels and any fixings to be covered, let the filler cure and sand it. Remove the temporary fixings 320 to the head track rails 300 and spot fill their holes. Figs. 8a to 8d show exploded and assembled isometric views of alternative embodiments of partition wall assembly as described above, comprising differently dimensioned wall panels with equivalent construction to those described above. The partition wall is shown partially assembled, with an entire first face and part of a second face. Figs. 9a and 9b show front and rear views of a portion of a partition wall assembly (with the head track 120 and portions of a second face 140 absent for visual clarity) including specialised wall panels 900, 910, 950 for providing access to utilities. In the first face 130 of the wall, one of the upper intermediate panels 650 has been replaced with a pair of alternative upper panels 900 with half the width of an upper intermediate panel and with halves of an access slot formed in sidewalls thereof. In the second face 140 of the wall, two of the upper intermediate panels have been replaced with second alternative upper panels 910 with the full width of an upper intermediate panel 650 and with halves of an access slot formed in sidewalls thereof. These panels 900, 910 together define an access slot through the wall, for example within which a vent can be located. In the wall assembly, one of the lower intermediate panels 600 has been replaced with an alternative panel 950 with the same overall structure but including an opening 955 for a knockout back box in which a pair of electrical sockets may be provided. It will be appreciated that a variety of different utility access panels may be provided with differently shaped and / or located apertures, recesses or other fittings for providing utilities access on the partition wall. It will be appreciated that the illustrated embodiments have been described by way of example only and that variation may be made to the embodiments described above without departing from the scope of the invention as defined by the claims.

Claims

1. A partition wall assembly comprising:a first face and a second face, each including a plurality of wall panels;a base track for supporting lower edges of the first and second faces;a head track for retaining upper edges of the first and second faces; anda plurality of brackets for extending between and interconnecting the first and second faces;wherein the wall panels of the first and second face each comprise:an outer layer defined by a sheet of paper-faced material folded at grooves along edges of a front section thereof to define a base, a top and at least one sidewall perpendicular to the front section, the at least one sidewall extending between the top and the base; andat least one peripheral connector on the at least one sidewall for connecting to a peripheral connector of an adjacent wall panel.

2. A partition wall assembly according to claim 1 wherein the at least one peripheral connector is magnetic.

3. A partition wall assembly according to claim 1 or claim 2 wherein each at least one peripheral connector comprises a tenon and / or mortise for interlocking with a corresponding mortise or tenon on an adjacent wall panel.

4. A partition wall assembly according to any preceding claim wherein each of the wall panels further comprises a peripheral connector on its top or base.

5. A partition wall assembly according to claim 4 wherein the base track comprises a plurality of connectors for connecting to peripheral connectors on the bases of the wall panels.

6. A partition wall assembly according to any preceding claim further comprising one or more anchors for connecting to an external wall and to one or more of the wall panels.

7. A partition wall assembly further comprising one or more acoustic dampening inserts for insertion into recesses defined by the front, base, top and sidewalls of the plurality of wall panels.

8. A partition wall assembly according to claim 7 wherein the acoustic dampening inserts each comprise a layer of closed cell acoustic foam and / or a layer of acoustic plasterboard.

9. A partition wall assembly according to any preceding claim wherein each of the plurality of brackets comprises a strut for extending between wall panels of the first and second faces, and fasteners for securing the bracket to wall panels of the first and second faces, wherein the fasteners each comprise an acoustic dampening cap, sleeve or washer.

10. A partition wall assembly according to any preceding claim wherein the base track and the head track each comprises spaced apart first and second rails for supporting a lower edge or retaining an upper edge of the first and second face respectively.

11. A partition wall assembly according to claim 10 wherein the first and second rails of the head track have substantially L-shaped cross sections each with a first surface for contacting and securing the rail to a ceiling and a second surface at right angles thereto defining a lip extending downwards past the upper edge of the retained face.

12. A method of constructing a partition wall, the method comprising:mounting a base track on a ground surface and a head track on a ceiling;arranging a plurality of wall panels to define a first face with a lower edge supported by the base track and an upper edge retained by the head track;wherein each wall panel comprises an outer layer defined by a sheet of paper-faced material folded at grooves along edges of a front section thereof to define a base, a top and at least one sidewall perpendicular to the front section, the at least one sidewall extending between the top and the base, and at least one peripheral connector on the at least one sidewall for connecting to a peripheral connector of an adjacent wall panel;connecting a plurality of brackets to the first face; andarranging a plurality of wall panels to define a second face with a lower edge supported by the base track, an upper edge retained by the head track, and connected to the plurality brackets such that the brackets extend between the first and second faces.

13. A method according to claim 12, wherein arranging the plurality of wall panels of each face comprises:arranging an initial wall panel of the face with its base supported on the base track, andsubsequently arranging the remaining wall panels of the face such that peripheral connectors thereof connect to peripheral connectors of at least one 5 previously arranged wall panel.Application No: GB2416741.3Claims searched: 1-13Examiner: Nicola DaviesDate of search: 8 May 2025Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance A - US 4000594 A (KIRK) See figures for a partition wall with two faces formed of multiple panels 28, base track 60 , head track 66; paper-faced material with side walls 24 with at least one connector (screws) A - US 4704837 A (MENCHETTI et al.) See figures for a partition wall with two faces formed of multiple panels 10, base track , head track, paper-faced material with side walls 24 A - WO 02 / 33187 A1 (LAFARGE PLATRES) See figures for a partition wall with two faces formed of multiple panels 10, base track , head track, paper-faced material with side walls 14 with connection 43Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if combined with one or more other documents of same category. P Document published on or after the declared priority date but before the filing date of this invention. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:Search of GB, EP, WO &US patent documents classified in the following areas of the UKC :Worldwide search of patent documents classified in the following areas of the IPC____________E04B_____________________________________________________The following online and other databases have been used in the preparation of this search report SEARCH - PATENTInternational Classification:Subclass Subgroup Valid From E04B 0002 / 74 01 / 01 / 2006

Images