Portable Wall System and Related Methods

This application claims the benefit of U.S. provisional application Ser. No. 63/573,072 filed Apr. 2, 2024, and U.S. Provisional Patent Application No. 63/773,138 filed on Mar. 17, 2025 which are hereby incorporated herein in their entireties by reference.

The present disclosure relates generally to modular wall systems, and more particularly, to portable wall systems and related methods.

Portable wall panel systems, also known as modular wall systems or mobile partitions, are versatile and reconfigurable wall structures designed for various applications. These systems are typically made of materials such as aluminum or steel frames combined with panels or inserts made of materials like wood, plastic, or fabric. Portable wall panel systems provide temporary or semi-permanent partitions within a space, allowing for the creation of separate rooms, training areas, or enclosed environments. These systems are highly adaptable and can be assembled, disassembled, and rearranged to meet changing spatial requirements.

One of the primary uses of portable wall panel systems is in the event and exhibition industry, where they are used to create customizable booth spaces, meeting rooms, or product display areas. Their modular nature allows for quick setup and teardown, making them ideal for trade shows, conferences, and other temporary events.

In another application, portable wall panel systems are used in first responder training for police and firefighters. Here, portable wall panel systems play an important role in simulating realistic scenarios. These systems can be configured to create mock environments, such as residential or commercial buildings, allowing trainees to practice tactics, procedures, and emergency response techniques in a controlled and safe setting.

For example, portable wall panel systems can be used to construct simulated apartments, offices, or hallways, providing trainees with a realistic environment to practice room-clearing techniques, hostage rescue scenarios, or fire suppression strategies. The modular nature of these systems allows for easy reconfiguration, enabling trainers to create new and challenging scenarios for each training session.

With respect to traditional portable wall panel systems for training purposes, they tend to be made from heavier materials to withstand the rigors and abuse from training exercises. As a result, they can be cumbersome to transport. Moreover, the added weight and manner in which such system are connected together may also make their assembly and/or disassembly challenging as well.

A modular wall system may include a plurality of wall panels each having at least one slot along an outer edge thereof, and at least one connector. The connector(s) may include a handle having a proximal end and a distal end, and a head connected to the distal end of the handle and comprising opposing pairs of first prongs facing away from one another. The head may be configured to be positioned within the slots of a first pair of the wall panels with their outer edges adjacent one another, and each pair of first prongs may be configured to engage a respective slot of one of the adjacent wall panels when the proximal end of the handle is rotated.

In an example implementation, the head may further include a respective second prong between the first prongs of each pair of first prongs, and the second prongs may be shorter than the first prongs. Each wall panel may comprise a core and a frame coupled along outer edges of the core, and the slot may be defined in the frame. By way of example, the core may comprise foam, and the frame may comprise fiber-reinforced plastic (FRP).

In some implementations, the at least one slot may comprise a plurality of spaced apart slots along the outer edge of each panel. In example implementations, the outer edge of each panel may have sides orthogonal to one another, and the at least one slot may comprise at least one respective slot on each side of the outer edge for connecting the first pair of the wall panels in-line or orthogonal to one another.

In one implementation, the at least one connector may comprise a plurality thereof, and the system may further include a door frame having at least one respective slot on a side thereof for receiving the head of a respective connector. More particularly, in accordance with one example the door frame may have a plurality of keyhole slots on at least one side thereof, and the system may further include a door panel and at least one hinged bracket connected to the door panel and including a respective support member configured to slidably engage each keyhole slot on the door frame. In accordance with another example, the doorframe may include a pair of opposing vertical sides each with a respective track adjacent a bottom thereof, and a threshold having opposing ends slidably connected to respective tracks.

A related connector, such as the one described briefly above, and a method for connecting a plurality of modular wall panels each having at least one slot along an outer edge thereof are also provided. The method may include positioning at least one connector within the slots of a first pair of the wall panels with their outer edges adjacent one another, and rotating the proximal end of the handle to cause each pair of first prongs to engage a respective slot of one of the adjacent wall panels.

The present disclosure is provided with reference to the accompanying drawings, in which various implementations are shown. However, other implementations in many different forms may be used, and the disclosure should not be construed as limited to the particular implementations set forth herein. Rather, these implementations are provided so that this disclosure will be thorough and complete, and will fully convey the claim scope to those skilled in the art. Like numbers refer to like elements throughout.

Referring initially to(), the present disclosure relates to a modular wall panel systemillustratively including panelsthat are relatively lightweight, durable, and versatile. Generally speaking, the panelsmay be fabricated in numerous sizes and form factors, then interconnected as desired for different applications (e.g., first responder training, trade show exhibits, temporary wall configurations, etc.). In the present example, a universal wall/window panelis fabricated which is 3′ wide×7′ tall, although other dimensions and shapes may also be used, as will be discussed further below. In one example implementation, the panelweighs approximately 45 lbs and is just under 3.5″ thick, which adds to the stability of the panels and accommodates the connector areasadjacent the periphery of the panel. In this example implementation, the panelsare made with a relatively lightweight closed-cell styrofoam corecovered by a durable fiberglass composite, although other suitable core and skin materials may also be used in different implementations, as will be discussed further below. The panelsmay be primed and/or painted prior to being wrapped or framed with edge trim pieces, which in one example are 20 gauge galvanized steel, although other materials may again be used for the edge pieces. A technical advantage of the above-described materials is that they allow for the panels to be used and/or stored outside for extended periods, if desired.

Slotsare formed in the connector areaswhere handles/connection pieces are to be located, as will be discussed further below. At the slotlocations (which may be created using a router, CNC machine, stamped, pre-molded to the desired dimensions, etc.), reinforcement pieces (not shown) may be inserted between the fiberglass skin and the foam core to provide a solid surface for attachment of the metal frame pieces (e.g., via rivets) where the handles and slots for connection pieces are to be located. By way of example, these pieces may be made out of metal, wood, etc., and in some implementations may be serrated (resembling a “crown”) or otherwise pointed to press into the foam core.

The assembled wall panelhas trim piecesinstalled on all four sides (top, bottom, left, right) as shown. In particular, the slotsin the trim piecesat the connector areasare not only for receiving connectorsthat secure each panel together. For the example 7′ tall panel, there are top, middle, and bottom slotsin a line on each of the side trim pieces, and a single slot on the top and bottom trim pieces. The middle sloton the side trim piecesis slightly wider in the example implementation and doubles as a handle area. The length of the elongated slotsadvantageously allows the panelsto be connected on uneven ground. That is, the connectorsmay travel up and down within the slot, allowing one wall panelto be stepped vertically up or down from an adjacent panel to match the grade or slope of the location in which the panels are being installed. By way of example, the elongated slots may have a length of at least 3 inches, and more particularly may be in a range of 6 to 12 inches, for example.

In the illustrated example there are slotson the front, edges, and back of each edge trim pieceas shown. This allows several options for the panelsto be interconnected (e.g., as wall panels, roof panels, etc.), either in a straight line or at an angle (e.g., orthogonal) to one another. A window panel may be formed by making a window cutout (not shown) in the coreand adding additional metal trim framing for the window cutout in some implementations, for example.

An example door hinge panelis shown in, which may be coupled with one of the above-described wall panelswith connectors, and to a door() via hingesto make a complete door assemblyas shown in. The doormay be created by adding a door stop plateto an edge of one of the panelsalong with a doorknob. Magnet insertsmay be used in some implementations to align and secure the door stop platein place prior to fastening (e.g., with screws). Note that in the example of, the wall panelused does not include slots, as connection to the hinge panelis made via the hingesinstead of the connectors, but a panel with slots may also be used for this purpose if desired.

It should be noted that other shapes and sizes of panelsmay be used in different implementations. For example, in one implementation a half-wall form factor (e.g. 48″ tall) may be used, which may be fabricated similarly to a full-size wall paneldescribed above except that it may have less connector slotsthan a full-size wall panel. Other form factors may include panels of narrower width (e.g., 12″), larger width, non-rectangular shapes, etc.illustrates a double hinge paneland door assembly including two hinge panels, which may be fabricated using similar steps to those described above.

Referring again to the example of, the double hinge panelassembly is combined with a wall panelto provide a swing away target panel integrated with a plurality of other wall panels to create a multi-room configuration suitable for police or fire training exercises, for example. The panelsand other components described above may be used to provide numerous types of portable training (or other) structures. Besides the ability to build training houses/structures, the panelsmay also be configured to simulate furniture within a training structure. The durability of the fiberglass composite may allow for use for law enforcement and military training exercises. In the illustrated example, the 2′ wide target panel is used to hold a standard 23″×35″ paper target. The targets (or other signs/indicators) can be secured with magnets on the panel frame, for example. This has numerous technical advantages, e.g., allowing the user to set the target at any height within that panel and avoiding the need for staples and/or tape.

An example connectorconfiguration for use with the frame slotsis now described with reference to. In the illustrated example, the connectorhas a generally “T” shaped profile when viewed from the side (), and an “H” shaped profile when viewed from the top (). More particularly, the connectorhas a handlewith a proximal endand a distal end, and a headconnected to the distal end of the handle. The headincludes opposing pairs of first prongsfacing away from one another to generally define the “H” shape when viewed from the top. The headis configured to be positioned within the slotsof a pair of abutting wall panels(or hinge panels, etc.) with their outer edges abutting one another. In the illustrated example, the headfurther includes a respective second prongbetween the first prongsof each pair of first prongs, and the second prongs are shorter than the first prongs as seen in.

Each side of the “H” shaped upper portion locks into the respective slot of two adjoining panels, as shown in. That is, each pair of first prongsis configured to engage a respective slotof one of the abutting wall panelswhen the proximal endof the handleis rotated. More particularly, two panelsare brought together and abut one another with the connectorspositioned between them in the unlocked position (). The handlesof the connectorsare then rotated () into the locking position () where the slotsof both panelsare engaged between a respective first prongand second prong, and therefore held together by respective sides of the “H” shaped upper portion of the connector. When it is time to disassemble the panels, the proximal endof the handleis rotated back to the unlocked position, and the panels may be separated.

In some implementations, the connectorsmay be made from steel or other suitable rigid material (e.g., plastic, etc.), and a magnetmay be connected to the handleto allow for easier assembly, including by a single person. That is, a user can set the connectorinto place and it will remain securely positioned with the headin the slotof a panelwhile a next panel is brought adjacent to the first panel during the assembly process. After moving the next panel in line with the connectors, the user may push up or pull down on the handleto secure the two panelstogether, as discussed further above. The user can then connect additional panels in line with, or perpendicular to, the previous wall panelor other panel.

Referring again to the double hinge configuration shown in, in an example implementation two hinged panelsthat are 4″ wide and 7′ tall allow a target panel (or any other panel) to pivot at multiple different angles. In another example configuration, one of the hinged pieces may be connected to a 2″ thick 31.5″ wide panel to simulate a door. The door panel may be 2″ shorter than the wall panels at 82″ to allow 1″ at top and bottom to open freely on uneven ground. The door may be easily changed from inward opening, outward opening, left side hinge, and right side hinge due to the above-described easy connecting system that the panelshave.

A top piecemay be incorporated for added support for doorways in some implementations. More particularly, the top piececan also be installed at the top of the above-described half wall, which again is a shorter 4′ tall panel. This would mimic a window when placed between taller 7′ panels, for example.

In another example implementation, 7′ tall and 4′ tall panels that are 1′ wide can be used with 3′×7′ and 3′×4′ panels to create stand-alone sets. These pieces can also be added to other panels to create various configurations as well. The above-described dimensions are provided by way of example, and other dimensions may be used in different implementations.

It should be noted that, in addition to the first responder/training applications described above, the foregoing modular wall panel systemmay be used for numerous other applications as well. For example, these may include convention center booths, outdoor events, temporary walls for construction, dividers for schools or offices, etc., as will be appreciated by those skilled in the art.

The above-described portable and modular wall panel systemprovides numerous technical advantages. The relatively lightweight, durable wall panelscoupled with the connectorsallow users to quickly and easily create many different wall structure configurations, in addition to simulated furniture, obstacles, and the like. The design of the wall panelsand the components of the walls also allows the user to build outside on uneven ground.

Referring now to, an associated targetmay advantageously be used with the above-described panel system is now described. In the illustrated example, the targetincludes a framethat is mounted to a hinge panelwith hingesso that it can swing out from the hinge panel like a door. However, the targetillustratively includes one or more clear panels or sheets(e.g., plexiglass) with a vinyl targetthereon. Here, the vinyl targetis a cutout of a person that is a “threat”. Because of the clear sheet, the target appears to be a person standing next to hinge panel, and therefore appears very realistic for training scenarios, for example. In other implementations, the frameof the targetcould be free standing as well, as need not be attached to the hinge panelor other wall panels.

In example implementations, the targetshapes may depict images of persons who may/may not be a “threat”, and may be implemented using vinyl decals, for example. The targetdecals may be close to or actual size for enhanced realism. In an example implementation, the target decals are approximately 24″ wide and approximately 72″ tall, although other dimensions may be used in different implementations. The decals may be affixed to sheets of clear polycarbonate, for example, which can then either be attached to a frame(e.g., pultrusion) using bolts or aluminum rivets, or they can be slid into slots defined in a pultrusion frame. The pultrusion framecan then either be attached to a hinge panelfor attachment to wall panels, or the framecan be attached to a base made out of pultrusion to be free-standing. Other suitable materials may also be used for the framemembers (e.g., aluminum, etc.), sheets, and targetdecals. In this regard, the targetimage may be painted or printed onto the sheetand need not be a decal in all implementations, and the panel material does not have to be a clear polymer in all implementations (e.g., it may be wood, metal, etc.).

In the illustrated implementation, the targetshave a mirrored image and an additional sheetof polycarbonate to provide a “two-sided” target, although just a single one-sided decal may be used in some implementations. During assembly, a clear sheetof polycarbonate is attached on one side of the frame, the targetdecals are positioned, and a second panel is slid into the frame to sandwich the decal(s) therebetween. Placing targetdecals between the first and second sheetshelps protect the decals during training and transportation. In some implementations, the front of the framemay have two slots which allow one target or two targets to be placed inside. The top of the framemay be removable to insert and remove the sheets of polycarbonate targets, for example.

An alternative approach to the above-described assembly utilizing aluminum rivets in a steel frame may also be used. In this approach, an adhesive is used for a pultrusion frame to secure to the panel of polycarbonate and foam. Corner brackets provide additional stability to the adhesive. In the above-described implementation utilizing metal (e.g., thin steel), the reinforcement or crown pieces may be advantageous for assembly because the thin steel is relatively flexible. Threaded corner supports may be beneficial for use with more rigid materials such as pultrusion, which does not bend as much as materials such as thin steel. However, it will be appreciated that either assembly approach may be used with various wall panel materials in different implementations. The threaded corner supports may be embedded into the foam coreto avoid increasing panel thickness, if desired. This approach may also reduce the need for extra fabrication and tooling costs, and may also ease final assembly.

In one example approach, as the foam is being routered into shape, pockets are milled to accept the support. During the cutting process of the polycarbonate, holes are drilled to allow bolts to pass through. During the cutting process of the pultrusion, holes are also drilled for the bolts to pass through. The threaded corner brackets may then be positioned into the recesses routered into the foam after applying glue, and both sides of the polycarbonate may be laminated. The assembly may be completed by screwing bolts into the threaded corner brackets from the opposite side of the panel.

Referring additionally to, another example implementation is provided. In the illustrated approach, 4″ wide pultrusion frames (similar to those described above for targets) with a high density Styrofoam core are used instead of steel frames. Moreover, an example door assemblyconfiguration advantageously provides a removable doorand hinge panelthat may be flipped and installed on either the left or right side of the door frame, and which can open either in or out. The dooris coupled to the hinge panel via hingesand has a handle. The door framehas a plurality of “key hole” openings or slotson the front and back side of the frame, which are configured to receive a 1″ flange of a support member(e.g., a bolt) to lock the hinge paneland doorinto an adjacent wall panel(which may be similar to the panelsdescribed above but with a pultrusion frame). More particularly, the head of each support memberis inserted into the large portion of the corresponding key hole slot, and then the hinge panelmay be slid down so that the support member engages the narrow portion of the corresponding key hole slot to hang or be carried on the hinge panel and dooron the frame.

Turning to, in some implementations the door framemay also include an adjustable thresholdthat may be used to keep the doorlevel despite uneven ground. The frameillustratively includes a respective trackand associated track knobat the bottom of each side of the frame which may be used to allow the thresholdto slide up or down for leveling the door frame to the terrain and then locked in place, as shown in. By way of example, the tracksmay be aluminum, although other suitable materials and configurations may be used to allow telescoping of the lower frameportions for leveling in different implementations.

Other modifications and implementations will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the disclosure is not to be limited to the specific implementations disclosed, and that modifications and implementations are intended to be included within the scope of the appended claims.