Modular Wall Systems and Related Methods

This application is a continuation of U.S. patent application Ser. No. 18/106,264, filed Feb. 6, 2023, which is a continuation of U.S. patent application Ser. No. 17/361,398, filed Jun. 29, 2021, now U.S. Pat. No. 11,572,698, which is a continuation of U.S. patent application Ser. No. 17/098,364, filed Nov. 14, 2020, now U.S. Pat. No. 11,505,948, the contents of each of which is herein incorporated by reference in its entirety.

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

During installation of wall panels for a wall system, the wall panels may not all align with studs such that the wall panels can be fastened to the studs, which can result in re-forming of the wall panels. The re-forming can cause installation delays and increased installation costs.

Additionally, gaps can occur in the wall system near wall panels, such as between panels, near an edge of the wall system, and/or near a corner of the room. The gaps can not only hinder aesthetics of the room, but can compromise the hygiene of the room. For example, the gaps can be areas in which bacteria grows. The gaps can also be difficult to sanitize. The gaps can also be non-uniform, thereby hindering ease of installation and hindering aesthetics of the room. The gaps can define protrusions that protrude into the room relative other portions of the wall.

Moreover, wall systems can involve progressive installation where a first panel is installed in a corner of an area, and subsequent panels are installed from the location of the first panel. The progressive installation can make installation complicated, expensive, and time-delayed. Additionally, progressive installation can make it difficult to remove individual installed panels from the wall system, rendering maintenance and further work on the wall system difficult and expensive.

Therefore, there is a need for improved modular wall systems and methods of installation thereof that facilitate panel alignment, covering gaps, and non-progressive installation to reduce installation time, installation costs, and installation complexity while maintaining enhanced aesthetics and hygiene of the hygienic environment.

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

In one implementation, a modular wall system for medical treatment environments includes a plurality of backplates. Each of the plurality of backplates includes a length that is larger than a width, and a longitudinal axis extending along the length. The longitudinal axis includes a center. The modular wall system includes a plurality of modular wall units configured to be arranged together as a wall. Each of the plurality of modular wall units includes a non-metallic inner panel and an outer panel disposed about a front face of the non-metallic inner panel. Each of the plurality of modular wall units includes one or more first flanges extending relative to a first side of the outer panel and having a plurality of first fastener openings formed therein, and one or more second flanges extending relative to a second side of the outer panel and having a plurality of second fastener openings formed therein. The second side opposes the first side.

In one implementation, a method of installing a modular wall system for a medical treatment environment includes fastening a plurality of backplates to a plurality of studs. Each of the plurality of backplates includes a length that is larger than a width and a longitudinal axis extending along the length. The longitudinal axis includes a center. The method includes forming one or more first fastener openings in each of the plurality of backplates on a first side of the center, and forming one or more second fastener openings in each of the plurality of backplates on a second side of the center. The method includes fastening a plurality of modular wall units to the plurality of backplates in an arrangement as a wall. Each of the plurality of modular wall units includes a non-metallic inner panel, and an outer panel disposed about a front face of the non-metallic inner panel.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

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

is a schematic isometric view of a modular wall systeminstalled in a hygienic environment, according to one implementation. The hygienic environment is a medical treatment environment. The medical treatment environment is shown as an operating roomin. The medical treatment environment can be, for example, a sterilizing processing area. Although medical treatment environments are described herein, the present disclosure contemplates that aspects described can be used in other hygienic environments and other environments, including but not limited to public corridors and hallways, common areas, hospitals, clean rooms, pharmacies, cafeterias, radiological environments, and other environments or settings.

Three walls,,of the modular wall systemare shown in. The operating roomincludes equipment, such as medical treatment equipment, disposed therein. The equipment includes a patient chair, movable lights,, movable screens, and surgical equipmentdisposed on a flooring materialof the operating room. The walls-include a plurality of modular wall units-arranged together as the walls-.

The modular wall systemalso includes a first gap cover apparatus, a second gap cover apparatus, and a third gap cover apparatusdisposed at three corners of a first wall. A fourth gap cover apparatusis disposed along the second wall. A plurality of seals-are disposed between adjacent modular wall units-. A plurality of seals-are disposed between the gap cover apparatus-and adjacent modular wall units. The seals-can be gaskets, and can be formed of a silicone material. The seals-can include flat gaskets, caulk (such as a single line of caulk), and/or foam. The seals-can be formed of an elastomeric material. The seals-can be formed of ethylene propylene diene monomer (EPDM) (M-Class) rubber and have a watertight seal. The watertight seal can make the seams of the seals-monolithic. The seals-, in a set position, can seal gaps that are within a range of 6 mm to 10 mm, for example. The seals-can be compression-only seals. The seals-can be pushed in manually between installed modular wall units-and/or installed gap cover apparatus-to create the watertight seals.

One or more openings are formed in the plurality of modular wall units-and/or the gap cover apparatus-. One or more first openingsare formed in a first modular wall unitto receive one or more utility modules, such as electrical modules, therein. One or more second openingsare formed in a second modular wall unitto receive one or more utility modules, such as gas supply modules. The openings may also receive control panels. The fourth gap cover apparatusincludes an openingto receive a viewing window, such as a glass viewing window, therein. The viewing window can allow viewing of a television screen, a white board, another room or hallway, and/or a supplies storage unit that has supplies stored therein. The modular wall systemcan have one or more doors formed therein. The doors can include flush-mounted doors and/or fully integrated solid core doors for increased infection control and durability. The doors are not only durable and easy to clean but are built to fit active spaces. The doors may be provided in both swing and slide styles.

is a side cross-sectional view of the second wallshown in, with the view running parallel to the second wall, according to one implementation. The second wallseparates the operating roomfrom a second area. The second area, can be for example, a second operating room, a hallway, or a patient waiting room.

A ceiling slabis disposed above a floor slab. Each of the ceiling slaband the floor slabis a concrete slab. The ceiling slabcan be considered a floor slab for a floor above the operating room. The floor slabcan be considered a ceiling slab for a floor below the operating room. A first piece of drywallextends between the ceiling slaband the floor slab. A plurality of ceiling support assembliesA,B are disposed on opposing sides of the second walland the first piece of drywall. The ceiling support assembliesA,B are fastened to the ceiling slabusing fastenersA,B. The ceiling support assembliesA,B define a ceiling profile for the second wall. A plurality of ceiling panelsA,B are fastened to the respective ceiling support assembliesA,B using fastenersA,B. Lower flangesof the studsare fastened to the floor slabusing a plurality of fasteners. One or more base framesare fastened to the studsand define a floor profile for the second wall. A single base frameis shown in.

Terms such as “fasten(s),” “fastener(s),” “fastened,” and “fastening,” may include use of bolts, nuts, studs, clamps, threaded connections, screws, and/or other fasteners. Terms such as “fasten(s),” “fastener(s),” “fastened,” and “fastening,” may include use of interference fitting, such as friction interference fitting, guide and slot interference fitting, and/or dovetail interference fitting. Terms such as “fasten(s),” “fastener(s),” “fastened,” and “fastening,” may include direct fastening and/or indirect fastening.

A lower backplateis fastened to the studs. The lower backplateis formed of a wood material. The flooring materialis formed on the floor slaband an inner face of the lower backplate. A plurality of studsare disposed between the first piece of drywalland the second wall. The studsare formed of a metal. The studsare fastened to the ceiling slabusing a plurality of upper flangesof the studs. The upper flangesare fastened to the ceiling slabusing fasteners. The studshave a plurality of openingsformed therein. The openingscan be longitudinal slots. The openingscan be through-holes. The openingscan have a diameter ofmm, for example.

A plurality of backplates-are fastened to the studs. The plurality of backplates-are disposed above the lower backplate. A gap cover apparatusand the one or more base framesare formed of a metal. The modular wall units-are arranged together as the second walland fastened to backplates that are fastened to the studs.shows a modular wall unitas fastened to the plurality of backplates-, the gap cover apparatus, and the one or more base frames, each of which are fastened to the studs. Each of the modular wall units-includes a non-metallic inner paneland an outer paneldisposed about a front faceof the non-metallic inner panel. In one embodiment, which can be combined with other embodiments, a glass panelis adhered, using a first adhesive, to a front faceof the outer panelof each of the modular wall units-. In one example, which can be combined with other examples, the first adhesive includes silicone, such as a silicone rubber sealant. In one example, which can be combined with other examples, the first adhesive includes a material meeting the ASTM C920, Class 50 standard. An aesthetic design is printed (e.g., painted) on a front exterior surfaceof the glass panelthat faces the operating room. The glass panelis a second outer panel that is adhered to the outer panel(which is a first outer panel).

The modular wall unitis disposed at least partially in the gap cover apparatus. The gap cover apparatuscovers a ceiling corner gap disposed above the modular wall unit. A second piece of drywallextends between the gap cover apparatusand the ceiling slab.

is a top cross-sectional view of the second walland the first piece of drywallshown in, along Section-, according to one implementation. The outer panelof each of the modular wall units-is fastened to the same backplateusing a plurality of first fastenersextending through a plurality of first fastener openingsand a plurality of second fasteners extending through a plurality of second fastener openings(shown in). The plurality of second fasteners are similar to the plurality of first fasteners. The first fastenersand the second fasteners can be screws, such as T-10 stainless steel screws. Other fasteners, such as bolts, nuts, and/or studs, are contemplates. Each of the modular wall units-includes an overall thickness OTthat ⅞ inches (22.225 mm) relative to a front face of the studs, including a thickness Tof the backplate. The thickness Tof the backplateis within a range of 1 mm to 2 mm, such as 1 mm (0.0394 inches). The non-metallic inner panelof each modular wall unit-includes a thickness Tthat is ¼ inches (6.35 mm). The outer panelof each modular wall unit-includes a thickness Tthat is ⅜ inches (9.525 mm). The present disclosure contemplates that the thickness Tcan be within a range of 1 mm to 2 mm. The glass panelof each modular wall unit-includes a thickness Tthat is ¾ inches (19.05 mm). In an implementation where the glass panelsare omitted from the modular wall units-, the thickness Tof each non-metallic inner panelis ⅝ inches (15.875 mm), and the thickness Tof each outer panelis ¾ inches (19.05 mm). The first piece of drywalland the second piece of drywalleach has a thickness Tthat is ⅝ inches (15.875 mm).

The backplateincludes one or more first fastener openingsconfigured to fasten to one or more first studs (two are shown in) of the studs.

is a schematic back view of the modular wall units,shown in, according to one implementation. The respective outer panelof each modular wall unit,includes five walls (a front wall and four side walls) disposed about the front faceof the respective non-metallic inner panel. During a method of forming the modular wall units,, the outer panelis a flat sheet of metal having the thickness T, and flat sheet of metal is bent into the shape of a rectangular prism that has the front wall and the four side walls. The non-metallic inner panelis adhered, using a second adhesive, to an inner surfaceof a back faceof the respective outer panel. The second adhesive includes one or more hydrofluoroolefins, such as trans-1,3,3,3-Tetrafluoroprop-1-ene (HFO-1234ze), and the second adhesive is water based. The second adhesive is pressure sensitive. In one example, which can be combined with other examples, the second adhesive is applied with a spray-gun and the second adhesive dries and tacks in less than 1 minute, such as about 20 seconds. Each of the modular wall units,includes one or more first flanges(two are shown) extending relative to a first sideof the outer panel and having the plurality of first fastener openingsformed in the one or more first flanges. The modular wall units,each include one or more second flanges(three are shown) extending relative to a second sideof the respective outer paneland having the plurality of second fastener openingsformed in the one or more second flanges. For each modular wall unit,the second sideopposes the first side.

The one or more first flangesinclude a plurality of first flangesspaced from each other along a first pattern having first gaps. The first gapsare disposed between the first flangesand outside of the first flanges. The one or more second flangesinclude a plurality of second flangesspaced from each other along a second pattern having second gaps. The second gapsare disposed between the second flangesand outside of the second flanges. The plurality of first flangesare aligned with the second gapsand the plurality of second flangesare aligned with the first gaps.

The first pattern (of the first flangesand the first gaps) is configured to interleave with the second pattern (of the second flangesand the second gaps) in an alternating arrangement. In, the first pattern of the modular wall unitis shown as interleaved with the second pattern of the modular wall unitin the alternating arrangement. Each of the modular wall units-shown inis arranged and fastened to a plurality of backplates for the respective wall-with first and second flanges,in the alternating arrangement described for the modular wall units,shown in. The interleaving and alternating arrangement is used for the modular wall units-such that each modular wall unit-is independently detachable from the respective plurality of backplates by removing the first fastenersand second fasteners from the first fastener openingsand the second fastener openingsof the respective modular wall unit-. For example, the modular wall unitcan be independently detached from the backplates-, the one or more base frames, and/or the gap cover apparatusof the second wallwithout first removing any of the other modular wall unitsor-of the second wall. The independent detachment of individual modular wall units-from the backplates-of the modular wall systemfacilitates ease of replacement of modular wall units-, and ease of maintenance for the modular wall system. As an example, one of the modular wall units-can be independently replaced in a time that is less than 1 hour, such as 30 minutes. The independent detachment of individual modular wall units-also facilitates ease of conducting further installation of equipment. As an example, a modular wall unit-can be replaced with a modular wall unit that has a differing opening to receive equipment therein.

The interleaving and alternating arrangement also facilitates a non-progressive installation of the modular wall units-as the walls-. For example, the first modular wall unit need not necessarily be installed at a corner of the operating room. For example, the first modular wall unit installed for the second wallcould be the modular wall unitor the modular wall unitsuch that the modular wall unitor the modular wall unitis fastened to one or more of the backplates-before the other modular wall units of the second wall. Each of the modular wall units,is fastened and installed at a distance from each corner,(shown in) of the second wall. Non-progressive installation simplifies the installation and saves time and money compared to operations that use progressive installation. The interleaving and alternating arrangement of the first and second flanges,can be used for the gap cover apparatus-to facilitate the non-progressive installation and independent detachment thereof.

Each of the first and second flanges,includes a width W. The width Wcan be 6 mm or more, for example. In one embodiment, which can be combined with other embodiments, adjacent flanges,are spaced from each other by a spacing Sin the interleaving and alternating arrangement. The spacing Scan be 10 mm, for example. In one embodiment, which can be combined with other embodiments, each of the first and second fastener openings,is a longitudinal slot having two semi-circular end sections and a rectangular middle section. A length of the rectangular middle section can be 6 mm, for example, and a radius of the two semi-circular end sections can be 1.78 mm, for example. Each first and second fastener opening,can be positioned at a distance from all sides of the respective flange,, and the distance can be 3 mm, for example. In the interleaving and alternating arrangement, adjacent outer panelscan be disposed at a distance Dfrom each other, and the distance Dcan be 6 mm, for example.

is a schematic front view of the modular wall units,shown in, according to one implementation. Each modular wall unit,includes a front face. The front faceof each modular wall unit,includes a front exterior surface. The front exterior surfaceof each outer panelhas an average surface roughness that is less than an average surface roughness of a front exterior surface(shown in) of each of the plurality of backplates-. A surface hardness of the front exterior surfacesis approximately 750 HV. The outer panelshave a minimum breaking torque of 16 kg-cm, and can be bent using a minimum bending angle of 5 degrees or more.

Each outer panel(including the front exterior surface) is formed of stainless steel. In one embodiment, which can be combined with other embodiments, each outer panel(including the front exterior surface) is formed of 304 stainless steel, such as ASTM A666 304 (304L) stainless steel. The front exterior surfaceshave a Level 4 vertically brushed finish for a vertical grain. The vertical grain is applied in a vertical direction Von the front exterior surfaces.

The front exterior surfacesfacilitate hygienic properties of the operating roomand durability. For example, the modular wall units-can be used for several years (such as 3 years) without needing repair or replacement. As an example, the front exterior surfacescan withstand impacts that occur during medical treatment operations conducted in the operating room. The present disclosure contemplates that other materials (such as extruded aluminum) may be used for each outer panel(including the front exterior surface). In one embodiment, which can be combined with other embodiments, a powder coating and/or a galvanized finish is applied to the front exterior surfaces. The finish and/or the powder coating can include one or more different colors. An antimicrobial powder coating may be used. Other finishes and/or coatings are contemplated. Each non-metallic inner panelis formed of drywall, such as gypsum board. The present disclosure contemplates that other moisture-resistant and mold-resistant materials can be used for the non-metallic inner panels, such as a fiberglass-reinforced (e.g., fiberglass-backed) drywall or a honeycomb structural material. The backplates-are each formed of a metal, such as steel, for example 16 gauge steel. The metal of the backplates-can be stainless steel or carbon steel, for example. Other gauges of steel and other materials (such as aluminum) are contemplated for the backplates-. The first piece of drywalland the second piece of drywallare each formed of drywall, such as gypsum board.

The drywall referred to in the present disclosure can include Type X paneling for use on walls; can comply with ASTM C1177, C1396, C1658 and D3273; and/or can include USG Sheetrock Brand Mold Tough Panels, Firecode X, USG Brand UltraLight Panels Mold Tough Firecode X, and/or Georgia-Pacific ToughRock Fireguard X Mold-Guard Gypsum Board, for example.

The glass panels, if used, include front exterior surfaces(shown in). The front exterior surfaceof each glass panelhas an average surface roughness that is less than an average surface roughness of the front exterior surface(shown in) of each of the plurality of backplates-. A surface hardness of the front exterior surfacesis approximately 750 HV.

Each of the walls-including the modular wall units-shown inhas a fire rating that is 1 hour or more. As an example, the second walland the piece of drywalltogether form a separating wall having a fire rating that is 1 hour or more. For example, the separating wall can be fire resistant against temperatures of up to 1700 degrees for at least 60 minutes. The outer panelsof the modular wall units-have a Class A fire rating. The outer panelshave a flame spread index that is less than 10 and a smoke-developed index that is less than or equal to 25. The outer panelscan be tested in accordance with ASTM E84 for surface burning characteristics. The outer panelscan have a stretcher-leveled standard of flatness.

is a schematic front view of the plurality of backplates-of the second wallshown in, according to one implementation. In, the second wallis shown with the backplates-fastened to the studs, before the modular wall units-are fastened to the backplates-. Each of the plurality of backplates-includes a length Lthat is larger than a width W, and a longitudinal axis LAextending along the length L. Each of the plurality of backplates-has a four-sided rectangular cross-section that includes the width Wand the thickness T. The four-sided rectangular cross-section having the width Wand the Tis continuous across the respective length Lfor each backplate-. The longitudinal axis LAincludes a center. The width Wis larger than the thickness Tof the backplates-. The width Wcan be about 150 mm (5.906 inches). A backplate spacing Sbetween the backplates-can be the same across the backplates-or can vary across the backplates-. The backplate spacing Sis about 260 mm (10.236 inches). A width Wof the one or more base framesis about 77 mm (3.032 inches). A spacing Sbetween the one or more base framesand the lowermost backplateis about 298 mm (11.732 inches), and a spacing Sbetween the one or more base framesand the floor slabis about 152 mm (5.984 inches). The gap cover apparatushas a width Wand is disposed at a spacing Sfrom the backplate. The width Wcan be the same as the width W, and the spacing Scan be the same as the spacing S.

Each of the plurality of backplates-includes one or more first fastener openingsdisposed on a first sideof the centerand configured to fasten to one or more first studsof the studs. Each of the plurality of backplates-includes one or more second fastener openingsdisposed on a second sideof the centerand configured to fasten to one or more second studsof the studs.

One or more of backplates-includes a plurality of third fastener openings,. One or more of the plurality of third fastener openingsare configured to align with one or more of the plurality of first fastener openingsformed in the one or more first flangesof one of the plurality of modular wall units-. One or more of the plurality of third fastener openingsare configured to align with one or more of the plurality of second fastener openingsformed in the one or more second flangesof one of the plurality of modular wall units-. In one embodiment, which can be combined with other embodiments, the fastener openings,,,are not yet formed in the backplates-when the backplates-arrive at the operating roomfor installation. In such an embodiment, the backplates-arrive at the operating roomas flat sheet metal. The fastener openings,,,can be formed in the respective backplates-at the operating roomby drilling through the backplates-with a drill bit and/or by drilling a fastener through the backplates-. In one embodiment, which can be combined with other embodiments, the first fastener openingsand the second fastener openingsare already formed in the first and second flanges,upon arriving at the operating roomfor installation.

The third fastener openingsreceive the first fastenerstherethrough, the third fastener openingsreceive the second fasteners therethrough, and the first and second fastener openings,receive a plurality of third fastenerstherethrough to fasten the backplates-to the studs. A spacing Sbetween the studscan be constant across the studs. The modular wall units-each can be fastened to the backplates-. Although the spacing Sis constant, the first and second fastener openings,may not necessarily align with one of the studsfor fastening depending on the configuration of the operating room. The backplates-facilitate quickly and accurately fastening the modular wall units-for installation in a variety of configurations for hygienic environments. As an example, the same modular wall unit designs can be used for differing configurations of the operating room.

is a schematic back view of a gap cover apparatus, according to one implementation. The gap cover apparatusincludes a length L. The length is 2,888 mm (113.701 inches). The gap cover apparatuscan be referred to as an edge trim for the respective modular wall unit-against which the gap cover apparatus 800 abuts. The gap cover apparatus-can be referred to as edge trim for adjacent modular wall units-.

is a schematic cross-sectional view of the gap cover apparatusshown in, along Section-, according to one implementation. The gap cover apparatuscan be used as the gap cover apparatus-of the modular wall systemshown in. The gap cover apparatusis configured to cover one or more gaps of the walls-. The gaps can be between modular wall units-and/or can be disposed at outer edges of the modular wall units-. The gaps can be disposed at corners and/or outer sides of the walls-.

The gap cover apparatusincludes one or more brackets,(two are shown) configured to interface with one or more of the plurality of modular wall units-. The one or more brackets,define a retaining openingthat at least partially receives the one or more of the plurality of modular wall units-therein. The gap cover apparatusincludes a plurality of first fastenersconfigured to fasten the one or more brackets,to a support structure. The support structurecan include one or more of the backplates-, the one or more base frames, and/or one or more of the studs.

A first bracketis configured to interface with the front face(s)of the one or more of the plurality of modular wall units-. The first bracketincludes a plurality of first fastener openingsconfigured to receive the plurality of first fastenerstherein. The first bracketincludes one or more back flanges, a front flangeparallel to the one or more back flanges, and a middle portionextending between the one or more back flangesand the front flange. The plurality of first fastener openingsare formed in the one or more back flanges. The middle portionof the first bracketintersects the one or more back flangesand the front flangeat an oblique angle A. The oblique angle is less than 90 degrees, such as 76 degrees. The front flangeof the first bracketincludes a tapered sectionthat tapers away from the front flangeand toward the one or more back flangesat a taper angle A. The taper angle Ais 5 degrees or less, such as 3 degrees. The tapered sectionat least partially defines the retaining openingin which the one or more of the modular wall units-are received. The tapered sectioncan taper toward the one or more back flangesby a taper distance TDrelative to the front flange. The taper distance TDcan be 1 mm or less, such as within a range of 0.5 mm to 0.7 mm.

A second bracketis fastened to the first bracketusing a plurality of second fasteners. The first bracketincludes a plurality of second fastener openingsformed in the middle portionand configured to receive the plurality of second fastenerstherein. The second bracketincludes a baseand an extending flangeextending relative to the base. The extending flangeof the second bracketextends relative to the baseat the oblique angle A. The extending flangeincludes a plurality of fastener openingsto align with the plurality of second fastener openingsformed in the middle portionof the first bracket. The first bracketincludes a height H, and the height His 0.887 inches (22.5 mm). The front flangehas a width W, and the width Wis 1.5 inches (38.1 mm). Each of the second fastenersincludes a PEM nutat least partially received in the respective fastener opening, and a screwdisposed through the respective second fastener openingand through the respective fastener opening. Threaded bolts may be used in place of the screws. The second bracketincludes a height H, and the height His 0.75 inches (19.05 mm). The baseincludes a width W, and the width Wis 1.164 inches (29.57 mm). Each of the fastener openingshas a diameter within a range of 0.166 inches to 0.169 inches. The one or more back flangeshave a width Wthat is 0.433 inches (11 mm).

Each of the first bracketand the second bracketof the gap cover apparatusis formed of a metal. The first bracketand/or the second bracketcan be formed of the same material as the outer panel. A front face of the front flangehaving the tapered sectioncan include a finish and/or a coating similar to the finish and/or the coating of the front exterior surfaces. The first bracketand/or the second bracketcan be formed of extruded aluminum, such as ASTM B221/B221M aluminum.

is a schematic isometric exploded view of the gap cover apparatusshown in, according to one implementation. The one or more back flangesof the first bracketinclude a plurality of back flanges(four back flangesare shown in) protruding from the middle portionand spaced from each other along the length Lof the middle portion. Each of the back flangesincludes three first fastener openingsformed therein.

is a schematic back view of the second bracketshown in, according to one implementation. The view of the second bracketshown inis from the first bracketshown inand toward the extending flangeof the second bracket.

is a schematic partial top view of a piece of flat sheet metalthat can be used to form the second bracketshown in, according to one implementation. To form the second bracket, a bendis formed between the baseand the extending flange. The fastener openingsare spaced from each other along the length Lby a spacing S. The spacing Sis 10 inches (254 mm). The two outer fastener openingsnearest the two ends of the second bracketare spaced by a spacing Sfrom the respective ends of the second bracket. The spacing Sis 1.85 inches (87 mm).

A distance D(before the second bracketis formed, while the second bracketis in the form of the flat sheet metal) between an edge of what will be the baseand an edge of what will be the extending flangeis 1.859 inches (47.22 mm). A distance Dbetween the edge of what will be the extending flangeand the bendis 0.728 inches (18.49 mm).

is a schematic isometric exploded view of the second bracketshown inand a plurality of PEM nuts, according to one implementation. As described in relation to, the second bracketcan be formed by bending the piece of flat sheet metalinto the second bracket. After forming the second bracket, the PEM nutscan be received into the plurality of fastener openings.

is a schematic partial side view of the first bracketshown in, according to one implementation. The side view inis from the right of the first bracketshown in. In the implementation shown in, the two end back flangesare disposed at a spacing Sfrom the two respective ends of the first bracket. The spacing Sis 1.732 inches (44 mm).