Modular non-combustible wall system

Abstract

A modular wall system and methods of manufacture are disclosed, the system comprising a composite panel, hanging elements, coupling elements, vertical frames, and horizontal frames. The vertical frames can support the horizontal frames. The horizontal frames can support the composite panel using the hanging elements and the coupling elements. In some embodiments, the composite panel comprises a MgO core that may confer non-combustibility to the wall system. The MgO core may be constructed from at least one layer of MgO slurry and at least one fibreglass sheet. In addition to the MgO core, the composite panel may further comprise an aesthetically pleasing top layer, a hardener layer configured to secure the top layer to the MgO core, a balancing layer, and a fire-resistant or non-combustible sheet. The modular wall system may also comprise a backer configured to hinder airflow between or around the composite panel.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 764,409 filed on Feb. 27, 2025, entitled “MODULAR NON-COMBUSTIBLE WALL SYSTEM,” the entire contents of which are incorporated by reference.FIELD OF INVENTION

[0002] The present disclosure relates to modular wall systems, specifically non-combustible modular wall systems.BACKGROUND

[0003] Conventional modular wall systems may provide versatile and efficient solutions for various construction needs, including interior partitions, temporary barriers, and architectural features. These systems may utilize prefabricated panels or components that are easy to assemble and disassemble, making them suitable for both permanent installations and spaces requiring frequent reconfiguration. Additionally, modular wall systems may incorporate features such as aesthetic customization.

[0004] However, conventional modular wall systems may present issues related to fire resistance and non-combustibility. Many systems may use materials such as wood-based composites, polymers, or foam cores, which may not meet stringent fire safety standards. Even when fire-resistant treatments are applied, these solutions may degrade over time or under prolonged heat exposure, reducing their effectiveness and potentially posing a safety hazard. Furthermore, such systems may allow fire to spread rapidly due to the combustible nature of their core materials, compromising the safety of occupants and the structural integrity of the building.

[0005] Accordingly, there are a number of disadvantages in the art that can be addressed.SUMMARY OF INVENTION

[0006] A modular wall system can comprise at least one composite panel, one or more hanging elements secured to the at least one composite panel, one or more coupling elements secured to the at least one composite panel, one or more vertical frames, and one or more horizontal frames. The one or more vertical frames can support the one or more horizontal frames. The one or more horizontal frames can support the composite panel using securing elements that correspond to the one or more hanging elements and the one or more coupling elements. The modular wall system can also be non-combustible.

[0007] In some embodiments, the at least one composite panel comprises a MgO core that may confer non-combustibility to the wall system. The MgO core may be constructed from at least one layer of MgO slurry having a first grain size and at least one layer of at least one fibreglass sheet. In preferred embodiments, the MgO core may be constructed from a first layer of MgO slurry having the first grain size, a first layer of at least one fibreglass sheet, a second layer of MgO slurry having a second grain size, a second layer of at least one fibreglass sheet, and a third layer of MgO slurry having the second grain size. In addition to the MgO core, the at least one composite panel may further comprise an aesthetically pleasing top layer disposed on at least one face of the MgO core, a hardener layer configured to secure the top layer to the MgO core, a balancing layer disposed on a back face of the MgO core, and a fire-resistant layer or non-combustible sheet disposed on at least one face of the MgO core.

[0008] The modular wall system may also comprise a backer configured to hinder airflow between or around the at least one composite panel. In some embodiments, the modular wall system has an overall thickness of between about 0.5 inches to about 12 inches.

[0009] Additional features and advantages of exemplary implementations of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of such exemplary implementations. The features and advantages of such implementations may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of such exemplary implementations as set forth hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0011] FIG. 1 illustrates a non-combustible modular wall system of the present disclosure;

[0012] FIG. 2 illustrates a partially exploded segment of a non-combustible modular wall system of the present disclosure;

[0013] FIG. 3 illustrates a panel of the present disclosure;

[0014] FIGS. 4A and 4B illustrate cross-sections of panels of the present disclosure;

[0015] FIG. 4C illustrates a cross-section of a panel core of the present invention;

[0016] FIG. 5A-D illustrates a hanger of the present disclosure;

[0017] FIG. 6A-D illustrates a coupler of the present disclosure;

[0018] FIG. 7 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure;

[0019] FIG. 8 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure;

[0020] FIG. 9 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure;

[0021] FIG. 10A illustrates embodiments of panels of the present disclosure;

[0022] FIG. 10B illustrates a magnified view of one of the panels of FIG. 10A; and

[0023] FIG. 11 illustrates a fire test chamber used to obtain testing data of panels of the present disclosure.DETAILED DESCRIPTION

[0024] The present invention extends to a modular wall system comprising at least one composite panel, one or more hanging elements secured to the composite panel, one or more coupling elements secured to the composite panel, one or more vertical frames, and one or more horizontal frames. In preferred embodiments, the modular wall system is non-combustible. Methods of manufacturing the modular wall system described herein are also provided.

[0025] Accordingly, the modular walls of the present disclosure provide users with the benefits of a modular wall system while also having the benefits of a non-combustible wall system. Non-combustible walls reduce the risk of fire spread, offering greater protection for occupants and property and complying with stringent building codes and testing requirements. Non-combustibility is particularly valuable in high-risk environments like schools, hospitals, and industrial facilities where safety is paramount. Combining non-combustibility with a modular design adds significant advantages, as modular walls are easy to install, reconfigure, and scale to meet evolving needs. Their versatility allows users to customize layouts, create dynamic spaces, and minimize installation time, all while maintaining the durability and safety of non-combustible materials. Together, these features provide a solution that is not only safer but also practical and adaptable to various applications.

[0026] Non-combustible materials can provide superior fire safety because they can refrain from burning or contributing fuel when exposed to flames under many conditions, effectively preventing the spread of fire altogether. In contrast, fire-resistant materials only slow fire progression for a limited time, eventually degrading under intense heat. As used herein, “non-combustible” refers to a material that does not ignite or burn when subjected to predefined fire or heat conditions. Accordingly, a non-combustible material resists combustion and contributes minimally to fire growth or spread, and a non-combustible modular wall system comprises a design validated or tested to limit both the flame spread and the smoke developed during a fire. One set of example predefined fire or heat conditions is characterized by the “Class A” standard. To achieve a Class A standard, a material must have a flame spread of less than 25 feet in a 10-minute test. This is measured by measuring the distance a flame travels over a material during the 10-minute test. The material must also exhibit less than or equal to a smoke development index of less than about 450 during the 10-minute test. The smoke development index is determined by the smoke particles that exist within the exhaust of a burning material and can be measured by a light beam photometer. Other example predefined fire or heat condition standards are set described hereinafter.

[0027] FIG. 1 illustrates a non-combustible modular wall system, wall system 100 of the present disclosure. Wall system 100 is designed to be non-combustible. For instance, wall system 100 can refrain from igniting or burning when subjected to predefined fire or heat conditions set forth under ASTM E84, CAN ULC S102 (a Canadian equivalent of ASTM E84), NFPA 286, ASTM D3273, and / or ASTM E72 standards. Other fire or heat conditions (e.g., as set forth in standards recognized or defined by one or more regulatory bodies of one or more jurisdictions) may be utilized to indicate whether a wall system 100 is non-combustible, in accordance with the disclosed subject matter.

[0028] FIG. 1 shows wall system 100 comprising two segments 110a and 110b, each segment having at least one panel 120, shown as their respective panels 120a and 120b, as well as vertical frame 130. Wall system 100 can also comprise additional segments, vertical frames, horizontal frames, levers, panels, backing, connectors, hangers, couplers, and additional connection hardware. The number, selection, and arrangement of such elements herein described will be obvious to achieve the desired arrangement and specifications of wall system 100. In particular, although present embodiments are described with reference to segments 110a and 110b, including their respective panels 120a and 120b, it will be understood that a particular application of wall system 100 may call for a different number of segments 110 and panels 120, or such further arrangements and combinations of segments 110 and panels 120 as may be achieved using wall system 100 in its various embodiments described herein.

[0029] Having further regard for FIG. 1, panels 120a and 120b may be located proximate each other such that their respective edges, including edge 121 of panel 120a, are directly adjacent to each other and may be in contact along the length of the edges. In other embodiments, panels 120a and 120b may be spaced apart such that gap 122 is formed between their respective edges, including edge 121 of panel 120a. In some embodiments, the edges of panels 120a and 120b may be substantially straight, curved, or have any other desired profile. The edges may be complementary such that they remain proximate about their length or such that the width of gap 122 remains substantially constant about their length. In other embodiments, the edges may not be complementary, resulting in gap 122 having an inconsistent width along their length and / or no gap 122 along portions of their length. Panels 120a and 120b may be disposed side-by-side as shown in FIG. 1, one positioned above the other (not shown), or positioned on opposite sides of wall system 100 as shown in FIG. 2, as will be described in more detail. It will be appreciated that any arrangement and combination of two or more panels may be achieved.

[0030] In some embodiments, vertical frames of wall system 100, including vertical frame 130, can be selectively coupled to horizontal frames, ceilings, and floors. An assembler of a wall system 100 can selectively couple horizontal frames perpendicular to and / or between one or more vertical frames 130. As shown in subsequent figures, including FIG. 2, horizontal frames can include embodiments of horizontal frame 140. Horizontal and vertical frames can be an extruded metal or alloy (e.g., aluminum).

[0031] In some embodiments, wall system 100 can be single-sided, meaning that panels 120 are located on only one side of the horizontal and vertical frame members to form a barrier structure. In other embodiments, wall system 100 can be doubled-sided, meaning that there can be panels 120 on both sides of the horizontal and vertical frame members that together form a barrier structure.

[0032] Wall system 100 can include a backer. A backer can be an adhesive membrane, adherable material, mastic material, sealant material, or the like. An assembler can install a backer before, after, or simultaneously with their installation of panel 120 (for example, panels 120a and 120b). A backer can be installed along the entire length of wall system 100, between the panels 120 (such as between panels 120a and 120b) in gap 122, or in specified locations along the length of wall system 100. In one example implementation, an assembler can install a backer to substantially fill the gap 122 between panels 120a and 120b and / or space behind the gap 122 such that the backer extends no more than from the edge 121 of panel 120a (or 120b) to the horizontal center 123 of panel 120a (or 120b). The inclusion of a backer can aid in preventing the flow of air / oxygen should a fire start. This can slow or even stop the fire from growing and expanding as it can make it harder for the fire to receive fuel.

[0033] Wall system 100 can have a range in overall thickness from about 0.5 inches to about 12 inches. For example, wall system 100 can have an overall thickness of about 1 inch, about 2 inches, about 3 inches, about 4 inches, about 5 inches, about 6 inches, about 7 inches, about 8 inches, about 9 inches, about 10 inches, about 11 inches, or about 12 inches. In at least one embodiment, wall system 100 can have an overall thickness of more than 12 inches. Wall system 100 can have a thickness that is incrementally different from any of the herein-listed thicknesses. It will be appreciated that the thickness of wall system 100 contributes to its weight, strength, ease of transport and installation, and ability to prevent the spread of fire and smoke. It is desirable for wall system 100 to have a minimum thickness and minimum weight while still being able to provide desired strength and prevent the spread of fire and smoke. The composition and arrangement of elements of wall system 100 described herein allows for these desirable characteristics while having the thicknesses described above.

[0034] FIG. 2 illustrates a partially exploded segment of a non-combustible modular wall system, segment 110. Segment 110 may comprise at least one panel 120, including panels 120a and 120b, at least one vertical frame 130, and any number of horizontal frames 140. FIG. 2, in particular, shows one embodiment of segment 110 and details the interrelation between horizontal frames 140a, 140b, 140c, and 140d with vertical frames 130a and 130b. In one embodiment, horizontal frames 140a, 140b, 140c, and 140d are identical extruded members. As illustrated, however, horizontal frames 140a, 140b, 140c, and 140d vary in their extrusion pattern. A cross-section view of horizontal frame 140a can be seen in FIG. 7, a cross-section view of horizontal frames 140b and 140c can be seen in FIG. 8, and a cross-section view of horizontal frame 140d can be seen in FIG. 9. FIG. 2 also shows an embodiment of panel 120b secured on the opposite side of segment 110 from panel 120a. As illustrated, segment 110 is a double-sided modular wall system having panels on both of the major sides. As mentioned above, in another embodiment, a non-combustible modular wall system only includes panels on one of its sides.

[0035] FIG. 2 illustrates how panels 120a and 120b are designed to selectively couple with the horizontal frame members 140a, 140b, 140c, and 140d. An assembler first hangs panels 120a and 120b from any one or more horizontal frame members 140 using a hanging element 150, shown in more detail in FIGS. 3 and 5A-5D. In some instances, the hanging element can allow assemblers to install the panels without needing a ladder. An assembler can then cause one or more coupling elements 170, shown in more detail in FIGS. 3 and 6A-6D, to interface and couple with any one or more horizontal frame members 140, such as by engaging prongs 181, shown in more detail in FIGS. 8 and 9, that are disposed on or a part of one or more horizontal frame members 140. FIG. 2 shows a horizontal frame member 140 that is capable of hanging a panel. In at least one embodiment, an assembler can install two or more horizontal frame members 140 between vertical frame members 130 to allow for two or more panels to be hung and installed. In such an example, rather than one panel 120a running from the floor to the ceiling, two or more panels can be installed in a vertical orientation relative to one another in order to cover the space on the segment between the floor and the ceiling. In another example implementation, two or more panels can hang on a single horizontal frame 140 side-by-side. Other arrangements will be appreciated.

[0036] FIG. 3 illustrates panel 120 of the present disclosure. Panel 120 can comprise an MgO-formed panel. Panel 120 includes one or more embedded hanging elements 160 and one or more coupling elements 170. FIG. 3 shows four hanging elements 160 and 12 coupling elements 170. In at least one embodiment, a single extended hanging element or coupling element can be used in place of one or more of the rows of hanging or coupling elements. Hanging elements 160 and coupling elements 170 are positioned on the back surface of panel 120 to align with connectors, hangers, and prongs located on the horizontal frames of a wall system during installation of the panel 120 on the horizontal frame members 140. Panel 120 can have a chamfered upper edge and a chamfered bottom edge configured to interface with features of a wall system of the present disclosure.

[0037] FIGS. 4A and 4B illustrate cross-sections of example panels of the present disclosure. Specifically, FIG. 4A shows panel 120. Panel 120 can include top layer 124, hardener 125, sheet 126, first adhesive layer 127, second adhesive layer 128, balancing layer 129, and core 150. Top layer 124 can comprise a thermofoil, paint, plastic, metal, glass, or similar aesthetic layer. Top layer 124 can cover and / or be disposed over the front face of a panel as well as one or more side faces of a panel. Hardener 125 can comprise a mixed compound layer. Hardener 125 can provide rigidity and structural strength to panel 120 and act as an adhesive to bond or secure top layer 124 to the rest of panel 120. Hardener 125 can also provide a smooth / flat surface over which the aesthetic top layer is disposed / formed, which can mitigate surface irregularities of the core 150. In some embodiments, hardener 125 may act as a promoter, as described below. Sheet 126 can comprise a fire-resistant and / or non-combustible sheet, paper, or other type of layer. Adhesive 127 is designed to adhere and / or secure core 150 to the front side layers of panel 120 (e.g., sheet 126, hardener 125, top layer 124).

[0038] FIG. 4A shows the back face of an embodiment of panel 120, which can have an adhesive layer 128 and a balancing layer 129. Adhesive 128 can adhere or secure balancing layer 129 to the back face of panel 120. Balancing layer 129 is designed to provide a structural counterforce or balancing force to panel 120. Balancing layer 129 can prevent the layers applied to the front of core 150 from warping or curving panel 120. Balancing layer 129 can include phenolic sheets, composite sheets, metal or alloy sheets, cement sheets, or another type of sheet that can provide dimensional stability and warp resistance. Balancing layer 129 can comprise one or more layers or materials used in combination.

[0039] FIG. 4B shows another embodiment of panel 120. Panel 120 can include top layer 124, hardener 125, sheet 126, adhesive layer 127, and core 150. Top layer 124 can comprise an aesthetic layer, as previously described. Top layer 124 can additionally or alternatively serve as a functional layer. For example, top layer 124 can comprise a whiteboard surface that allows a user to draw or write on its outer surface. Hardener 125 may be a promoter and can provide a smooth backing to top layer 124 and promote a user's drawing / writing and removal of writing from top layer 124. Sheet 126 can comprise a magtile metal sheet or similar style sheet (e.g., metal, alloy, thermofoil, etc.). Sheet 126 can provide a smooth surface for supporting top layer 124, as core 150 often is not inherently smooth and of a consistent elevation. As discussed, adhesive 127 can comprise a tape, liquid, spread, mud, putty, or similar material. The example shown in FIG. 4B does not include a balancing layer or any layer disposed on the back face of panel 120. However, a manufacturer can install an adhesive and a balancing layer in a given embodiment.

[0040] In another embodiment, a manufacturer can construct a panel having a thermofoil or similar top coat, a hardener layer, a curable layer, and an adhesive layer. These layers would be secured or adhered to the front face of panel 120. A balancing layer can be similarly adhered or secured to the back face of panel 120.

[0041] Core 150 can comprise asymmetrically constructed MgO board 151. For example, having regard for FIG. 4C, a manufacturer can construct MgO board 151 by first spreading first layer of MgO slurry 152 preferably having a fine grain, followed by first two layers of fiberglass sheet 153, followed by second layer of MgO slurry 154 having either a fine grain or a more course grain, followed by second two layers of fiberglass sheet 155, followed by third layer of MgO slurry 156 that may have similar grain size to the second layer of MgO slurry 154. Core 150 and / or MgO board 151 can have an overall thickness of about 4 millimeters (mm) to about 20 mm. For example, core 150 and / or MgO board 151 can have a thickness of 12 m. It will be appreciated that the layering and composition of MgO board 151, including the grain size of MgO slurry layers 152, 154, and 156, may be varied from the example described above, provided that the resulting construct of one or more MgO slurry layers and any number of support structures such as any number of fibreglass sheets is structurally stable and provides the desired non-combustible and aesthetic qualities.

[0042] In some embodiments, the asymmetrical design of the MgO boards of the present disclosure can provide a product with a more presentable or aesthetic front face that has less pitting or uneven elevations when compared to the side and back faces.

[0043] FIG. 5A-5D illustrates various views of hanging element 160, which may interface with elements of horizontal frames 140. Specifically, FIG. 5A shows a back side view of hanging element 160, 5B shows a front side view of hanging element 160, 5C shows a side view of hanging element 160, and 5D shows a back perspective view of hanging element 160. In some embodiments, it will be appreciated that hanging elements 160 may be used to secure the at least one composite panel 120 to at least one horizontal frame 140. As can be seen from the various views, hanging element 160 comprises front face 161 and back face 162. Hanging element 160 can be constructed from a metal, alloy, plastic, or similar material (e.g. zinc, aluminum, steel, etc.). In some implementations, the hanging elements 160 are constructed from zinc or aluminum, which can contribute to the fire-resistant and / or non-combustible characteristics of an assembled modular wall system.

[0044] FIG. 5A shows hanging element 160 having a substantially flat back face 162. In the example shown in FIG. 5A, supports 163 protrude from the substantially flat back face 162 of hanging element 160 and comprise a substantially circular shape (e.g., when viewed from the back side view represented in FIG. 5A). In at least one embodiment, supports 163 can comprise square, triangular, or other geometric shape (e.g., when viewed from the back side view represented in FIG. 5A). Supports 163 can form perimeter walls that define an opening and recess that is at least partially surrounded by the perimeter walls. Supports 163 (e.g., the perimeter walls formed by the supports) can be designed to be embedded into a panel of the present disclosure (e.g., such that at least some the material of the panel at least partially extends into the recess defined by the perimeter walls of the supports 163) to provide structural support and transfer the weight of the panel to a horizontal frame member. A manufacturer can hammer or press hanging elements 160 into a panel to embed supports 163 into the panel.

[0045] Hanging element 160 can define one or more apertures 164. Apertures 164 can comprise elongated holes that extend through the hanging element (e.g., from a front face 161 of the hanging element 160 to a back face 162 of the hanging element 160). Apertures 163 can be configured to receive one or more elongated features of one or more fasteners, such as one or more arms of one or more staples, nails, or similar fasteners. Advantageously, the apertures 163 can permit fasteners such as nails or staples to be used to secure the hanging element 160 to a panel (without drilling or piercing through the hanging element 160 at the point of installation) when the hanging element 160 is formed from a non-combustible or fire-resistant material (e.g., zinc or metal).

[0046] FIG. 5B shows the front side or hanger side of hanging element 160. Hanging element 160 can include a hanger 165 and indents 166. Indents 166 can comprise indentations, recesses, or locations with a lower surface height than at least a portion of font face 161 on the front side of hanging element 160. A manufacturer can install apertures 164 within the bounds of indents 166. Such a configuration can enable a staple or other fastener to advance through the apertures 164 to secure the hanging element 160 to a panel while preventing the head or other outward-facing features of the fastener from extending further outward than the outer surface of the hanging element that surrounds the indents 166 (e.g., the face of the hanging element 160 shown in FIG. 5B that surrounds the indents 166), which can mitigate the incidence of the fasteners catching on objects.

[0047] Hanger 165 can comprise an arm or extrusion designed to interface with a horizontal frame member of the present disclosure. As shown in FIG. 5C, hanger 165 can comprise a socket 167 designed to receive a portion of a horizontal frame member.

[0048] FIG. 5D shows a perspective rear view of hanging element 160.

[0049] FIG. 6A-6D illustrates coupling element 170, which may interface with elements of horizontal frames 140. Specifically, FIG. 6A illustrates a backside view of the coupling element 170, FIG. 6B illustrates a front-side view of the coupling element 170, FIG. 6C illustrates a side view of the coupling element 170, and FIG. 6D illustrates a perspective view of the coupling element 170. In some embodiments, it will be appreciated that coupling elements 170 may be used to secure the at least one composite panel 120 to at least one horizontal frame 140. Coupling elements 170 may be used in combination with hanging elements 160 to provide an additional or alternative means for securing panel 120 to horizontal frames 140.

[0050] FIG. 6A shows coupling element 170 having one or more supports 171. Support 171 can comprise a rounded or sloped protrusion, which can be embedded into the material of a panel to support the connection between the coupling element 170 and the panel. Apertures 172 can straddle or flank the side of each support 171. The apertures 172 can permit passage of a fastener to secure the coupling element 170 to a panel and can serve a function similar to the apertures 164 described hereinabove with reference to FIGS. 5A through 5D (e.g., the coupling element 170 may define one or more indents similar to the indents 166 of the hanging element 160 described above). A portion of a prong of the present disclosure can recess within a cavity 173 defined by support 171.

[0051] FIG. 6B shows coupling element 170 as including one or more arms 174. Arms 174 can be flexible and elastically deformable to allow them to interface with a prong that is part of a horizontal frame of the present disclosure. As shown (and detailed in FIGS. 6C and 6D), arms 174 can be substantially curved members, each having an arched portion 175. Arched portion 175 can be designed to retain and interface with the back side of a prong (e.g., prong 181 shown in FIG. 8). The distal sloping of the arched portion 175 can allow for arm 174 to be spread apart by a tapered region on a prong so that an assembler only has to press together the prong and coupling element in order to secure them together. The proximal sloping can also allow an assembler to apply a force and uncouple the coupling element from a prong without having to physically interact with the coupling element or prong.

[0052] FIG. 7 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure. Specifically, FIG. 7 shows a cross-section of two horizontal frames 140 secured to a vertical frame 130. Horizontal frame 140 can comprise an angled support surface 180 that can interface with the chamfered edges of a panel. Horizontal frame 140 can have prongs 181 and 182. Prong 181 can comprise a tapered member that includes both a front and rear taper designed to interface with the arms 174 of a coupling element 170 (shown in detail in FIGS. 6A-6D). Prong 182 can comprise an angled shelf or support member that is designed to hang a hanging element and be received by a hanging element's 160 hanger 165 (shown in detail in FIG. 5B-5D). Prongs can be part of the extruded nature of horizontal frame 140, meaning they extend the entire length of the horizontal frame, or they can be distinct protrusions at set intervals along the length of the horizontal frame.

[0053] FIG. 8 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure. Specifically, FIG. 8 shows a cross-section of two horizontal frames 140 secured to a vertical frame 130. Horizontal frames 140 can include one or more prongs 181 and a support face 183. Support face 183 is designed to abut and support the rear face of a panel of the present disclosure. Support face 183 can comprise a vertical surface and a part of the horizontal frame's 140 extrusions. Support face 183 can be flanked by one or more prongs 181 (e.g., above and below, as shown in FIG. 8).

[0054] FIG. 9 illustrates a cross-sectional view of a non-combustible modular wall system of the present disclosure. Specifically, FIG. 9 shows a cross-section of two horizontal frames 140 secured to a vertical frame 130. FIG. 9 shows one or more panels 120, one or more horizontal frames 140, one or more stoppers 184, a leveler 185, and a floor grip 186. Horizontal frame 140 can include one or more prongs 181 and a support face 183. Support face 183 can be a separate portion or extrusion of horizontal frame 140 than prong 181. In some implementations, stopper 184 functions similar to support face 183 by providing a supporting structure for a panel to abut when secured to horizontal frame 140. Leveler 185 and floor grip 186 can be designed to support the weight of the wall system as well as facilitate leveling of the wall system.

[0055] FIGS. 10A and 10B show another embodiment of a modular wall panel of the present disclosure. Specifically, FIG. 10A shows embodiments of panels 120a and 120b. Panels 120a and 120b can be constructed from at least a ceramic or a glass material. Panels 120a and 120b can be monolithic in construction or can comprise one or more layers. For example, panels 120a and 120b can comprise a backer material such as a metal to allow for magnetic properties. In at least one embodiment, an aesthetic coating or layer may be applied to the front face of panels 120a and 120b, such as the front face of panel 120a. For example, a paint coating can be applied to the front face.

[0056] FIG. 10A shows an embodiment of a panel 120 having railings 190a, 190b, 190c, and 190d. A manufacturer can adhere railing 190(a-d) to a back face of panel 120. Railings 190(a-d) can comprise an aluminum extrusion. Railing 190(a-d) can support and couple to one or more hanging elements 160 and / or coupling elements 170. For example, railing 190a may couple to one or more hanging elements 160 (see FIG. 10B) to allow panel 120 to hang from a horizontal frame (such as horizontal frame 140). In such an embodiment, railing 190b can couple to one or more coupling elements 170 (see FIG. 10B) to secure panel 120 to a horizontal frame (such as horizontal frame 140).

[0057] FIG. 10B illustrates the top right corner of the back side of panel 120. As described previously, railing 190a can be coupled with one or more hanging elements 160, and railing 190b can be coupled with one or more coupling elements 170. In at least one embodiment, hanging element 160 can have substantially similar or the same features, dimensions, and characteristics as hanging element 160 described above with reference to previously described figures. In at least one embodiment, coupling element 170 can have substantially similar or the same features, dimensions, and characteristics as a coupling element 170 described above with reference to previously described figures.

[0058] Having further regard for FIG. 10B, in one example, an assembler can first secure one or more hanging or coupling elements (160 or 170) to a railing 190. The assembler can then secure the railing 190 to a horizontal frame member (such as horizontal frame member 140). The assembler can then apply an adhesive to the railing 190 and finally secure the panel (such as panel 120) to the railing 190. The assembler can apply pressure to the panel and allow the adhesive to adhere the panel to the railing.

[0059] As will be appreciated from the prior description, a non-combustible modular wall system having at least one composite panel having an MgO core may be manufactured by a method comprising the steps of providing a first layer of MgO slurry having the first grain size, providing a first layer of at least one fibreglass sheet, providing a second layer of MgO slurry having a second grain size, providing a second layer of at least one fibreglass sheet; and providing a third layer of MgO slurry having the second grain size. In some embodiments, the first layer of MgO slurry may be provided first, the first layer of fibreglass may then be layered thereon, the second layer of MgO slurry may then be layered thereon, the second layer of fibreglass may then be layered thereon, and the third layer of MgO slurry may then be layered thereon. Variations to the methods described herein will be appreciated, provided that the methods are useful to manufacture a composite panel having an MgO core that is non-combustible as defined herein.Testing Data

[0060] A burn test can involve a specimen measuring between 20 and 24 inches in width and 24 feet±12 inches in length, loaded onto the water-cooled ledge of the fire test chamber when conducted in accordance with ASTM E84 or CAN / ULC-S102 standards. In one embodiment, the specimen is positioned on the chamber floor. The fire test chamber can have internal dimensions of 17¾ inches±¼ inch wide, 12 inches±½ inch deep, and 25 feet in length. The test chamber can be a rectangular horizontal duct with a removable lid, and its sides and base can be lined with an insulated firebrick. One side can include pressure-tight observation windows and / or access door, allowing a technician to monitor flame progression during the 10-minute burn test.

[0061] Before testing, the chamber lid can be lowered into place, with a non-combustible concrete board positioned between the specimen and the lid. During the test, a constant draft of 240 feet per minute can be maintained inside the chamber using an electronic fan, afterburner, and electronically controlled damper system located downstream in the exhaust duct.

[0062] The test can begin when a flame is ignited at the front of the chamber. Smoke development is recorded using an electronic photocell system located downstream in the exhaust duct, while a technician manually tracks the flame spread. These measurements are used to calculate the Smoke Developed Index and the Flame Spread Index. The entire process is conducted over a 10-minute duration, adhering to the specified testing standards.

[0063] Prior to testing a specimen can be stored in a conditioning room maintained at a temperature of 70±5° F. and a relative humidity of 50±5% for at least 72 hours.Example A

[0064] A MgO tile with a Mag board front, Fresh White Glos 101-DRG2, was tested in accordance with ASTM E84-21, and the tile received a Class “A” ranking.Sample Ignition00:29(Minutes / Seconds)Max Flame Front5.1(Feet)Time to Maximum Spread02:08(Minutes / Seconds)Test Duration10:00(Minutes / Seconds)Flame Spread Score20(21 unrounded)Smoke Developed Score115(113 unrounded)

[0065] Observations during Example A testing: Charring was observed at 00:28; Bubbling was observed at 00:30; Blistering was observed at 00:35; Falling pieces was observed at 01:01.Example B

[0066] A MgO with FR Paper and Gatorply backer; Grade 2; OMNOVA Designer White TM50, was tested in accordance with ASTM E84-21, and the tile received a Class“A” ranking.Sample Ignition00:40(Minutes / Seconds)Max Flame Front1.1(Feet)Time to Maximum Spread1:20(Minutes / Seconds)Test Duration10:00(Minutes / Seconds)Flame Spread Score5(5 unrounded)Smoke Developed Score135(134 unrounded)

[0067] Observations during Example B testing: Charring was observed at 00:35; Dripping was observed at 00:50; Blistering was observed at 01:00. Cracking was observed at 01:00; Falling pieces was observed at 01:01; Peeling was observed at 01:05.Example C

[0068] A MgO tile having a UV-cured Topcoat grade 2 OMNOVA designer white TM50, was tested in accordance with ASTM E84-21, and the tile received a Class “A” ranking.Sample Ignition1:04(Minutes / Seconds)Max Flame Front0.0(Feet)Time to Maximum Spread8:13(Minutes / Seconds)Test Duration10:00(Minutes / Seconds)Flame Spread Score0(0 unrounded)Smoke Developed Score70(70 unrounded)

[0069] Observations during Example C testing: Blistering was observed at 00:19; Charring was observed at 00:35; Cracking was observed at 01:12; Bubbling was observed at 05:00.Example D

[0070] Three MgO tiles, having OMNOVA designer white TM50, were tested in accordance with CAN ULC S102, and the findings of the testing are shown below.Sample Ignition (Minutes / Seconds)00:2500:3500:40Max Flame Front (Feet)0.91.40.0Time to Maximum Spread (Minutes / Seconds)01:25 2:16 4:23Test Duration (Minutes / Seconds)10:0010:0010:00Flame Spread Score460Smoke Developed Score878885

[0071] Observations during Example D testing: Ignition Time on the sample was observed at 00:40. Blistering was observed at 00:14. Charring was observed at 00:17. Flaking Embers were observed at 00:58.Example E

[0072] MgO Non-combustible panels were tested pursuant to NFPA 286, Standard Methods of Fire Tests for Evaluating Contribution of Wall and Ceiling Interior Finish to Room Fire Growth (2015 Edition). As shown in FIG. 11, the testing occurred within fire test chamber 200 having ceiling or lid 201, floor 202, sides 203, and observation window or access door 204. Chamber 200 interior dimensions had a height h of 2.44 m±0.1 m (8 ft±3.9 in.), a width w of 2.44 m±0.1 m (8 ft±3.9 in.), and a depth d of 3.66 m±0.1 m (12 ft±3.9 in.), complying with NFPA 286. Further, chamber 200 comprised ceiling thermocouples 205 located 102 mm (4 in.) below ceiling, with one additional thermocouple located over burner 206 and 102 mm (4 in.) below ceiling. The following test results were recorded:CRITERIAResultPASS / FAIL40 kW Exposure Flames Reach CeilingDid not occurPASSDuring NFPA 286 testing, flames reachDid not occurPASSouter room extremitiesPeak Heat Release Rate ≤1 MW307 kWPASSHeat Flux Floor ≤20 kW / m24.5995PASSAverage Upper Temperature ≤600° C.874.69448° F.PASS(1,112° F.)(468° C.)Flames Exit DoorwayDid not occurPASSIgnition of paper targetsDid not occurPASSPeak Heat Release Rate ≤800 kW307 kWPASSTotal Smoke Production ≤1,000 m279.1PASSMaximum Peak Thermocouple Temperature Achieved:Ignition1466.6° F. (797° C.) Doorway530.6° F. (277° C.)Center  725° F. (385° C.)Quadrant 11466.6° F. (797° C.) Quadrant 2724.6724° F. (385° C.)  Quadrant 3  671° F. (355° C.)Quadrant 4786.2° F. (419° C.)Average Peak Upper Layer Temperature:874.69448° F. (468° C.)

[0073] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. A modular wall system comprising:at least one composite panel;one or more hanging elements secured to the at least one composite panel;one or more coupling elements secured to the at least one composite panel;one or more vertical frames; andone or more horizontal frames;wherein:the one or more vertical frames support the one or more horizonal frames;the one or more horizontal frames support the at least one composite panel using securing elements that correspond to the one or more hanging elements and the one or more coupling elements; andthe modular wall system is non-combustible.

2. The modular wall system of claim 1, wherein the at least one composite panel comprises a MgO core.

3. The modular wall system of claim 2, wherein the MgO core is constructed from at least one layer of MgO slurry having a first grain size.

4. The modular wall system of claim 3, wherein the MgO core is constructed from two or more layers of MgO slurry, the two or more layers comprising at least one layer having the first grain size and at least one second layer having a second grain size.

5. The modular wall system of claim 4, wherein the two or more layers of MgO slurry are layered asymmetrically.

6. The modular wall system of claim 3, wherein the MgO core is further constructed from at least one layer of at least one fibreglass sheet.

7. The modular wall system of claim 2, wherein the at least one composite panel further comprises a top layer disposed on at least one face of the MgO core.

8. The modular wall system of claim 7, wherein the at least one composite panel further comprises a hardener layer configured to secure the top layer to the MgO core.

9. The modular wall system of claim 2, wherein the at least one composite panel further comprises a balancing layer disposed on a back face of the MgO core.

10. The modular wall system of claim 2, wherein the at least one composite panel further comprises a sheet disposed on at least one face of the MgO core, the sheet constructed from a fire-resistant layer or a non-combustible layer.

11. The modular wall system of claim 1, further comprising a backer configured to hinder airflow between or around the at least one composite panel.

12. The modular wall system of claim 1, wherein the one or more horizontal frames comprises a support surface configured to interface with an edge of the at least one composite panel.

13. The modular wall system of claim 1, wherein the one or more hanging elements each comprise one or more apertures configured to allow the passage of a fastener.

14. The modular wall system of claim 1, wherein the one or more hanging elements are adapted to be secured to the one or more horizontal frames and each of the one or more hanging elements comprise one or more supports protruding therefrom, the one or more supports configured to be embedded in the at least one composite panel and transfer the weight of the at least one composite panel to the one or more horizontal frames.

15. The modular wall system of claim 1, wherein the one or more coupling elements each comprise one or more apertures configured to allow the passage of a fastener.

16. The modular wall system of claim 1, wherein the one or more coupling elements are adapted to secure the at least one composite panel to the one or more hanging elements and the one or more hanging elements are adapted to be secured to the one or more horizontal frames, thereby transferring the weight of the at least one composite panel to the one or more horizontal frames.

17. The modular wall system of claim 1, wherein the modular wall system comprises a design validated to conform to having a flame spread of fewer than about 25 feet during a 10-minute burn test.

18. The modular wall system of claim 17, wherein the modular wall system comprises a design validated to confirm to having a smoke development index of less than about 450 during the 10-minute burn test.

19. The modular wall system of claim 1, wherein the modular wall system has an overall thickness of between about 0.5 inches to about 12 inches.

20. A method of manufacturing a modular wall system having at least one composite panel having an MgO core, the method comprising the steps of:providing a first layer of MgO slurry having the first grain size;providing a first layer of at least one fibreglass sheet;providing a second layer of MgO slurry having a second grain size;providing a second layer of at least one fibreglass sheet; andproviding a third layer of MgO slurry having the second grain size;wherein the manufactured modular wall system is non-combustible.

Images