System and method of interlocking wall panels
An interconnectable wall panel system and method of forming and assembling the same are provided. A plurality of wall panels are provided that are interconnectable in a predetermined manner and arrangement, and wherein the wall panels comprise features for enhancing ease and accuracy of assembly. Wall panel members of the present disclosure are suitable for use in constructing modular building units, such as bathroom pods.
1. A method of forming a modular building unit, comprising:
providing a plurality of pre-formed wall panels operable to be interconnected;
wherein a first pre-formed wall panel of the plurality of pre-formed wall panels comprises a first end and a second end and a planar surface extending between the first end and the second end;
the planar surface of the first pre-formed wall panel comprising a plurality of female receiving members comprising a predetermined distribution along the planar surface;
the first pre-formed wall panel comprising a plurality of metal studs on an opposing side of the first pre-formed wall panel from the planar surface and wherein at least one of the plurality of female receiving members is provided adjacent to a metal stud of the first pre-formed wall panel;
a second pre-formed wall panel of the plurality of pre-formed wall panels comprising a first end and a second end and a planar surface extending between the first end and the second end, the first end of the second pre-formed wall panel comprising a plurality of male extensions, the male extensions being sized and operable to be received within the plurality of female receiving members, and wherein the male extensions comprise substantially the same predetermined distribution as the female receiving members;
providing a plurality of support elements on the first second preformed wall panel, wherein each of the plurality of support elements comprises a metal stud provided on an opposing side of the second preformed wall panel from the planar surface of the second preformed wall panel;
wherein at least one of the plurality of male extensions comprises a rectilinear member having at least one vertical member and a pair of horizontal members, and wherein the at least one of the plurality of male extensions members is joined to or co-formed with at least one metal stud of the second pre-formed wall panel and wherein the pair of horizontal members are connected to the at least one metal stud;
inserting the plurality of male extensions of the second pre-formed wall panel into the plurality of female receiving members in the first pre-formed wall panel to secure the first pre-formed wall panel and the second pre-formed wall panel to form at least one of an interior corner and an exterior corner; and
wherein the method is devoid of taping and mudding the first pre-formed wall panel and the second pre-formed wall panel.
2. The method of claim 1 , wherein the plurality of pre-formed wall panels are at least partially comprised of a gypsum material.
3. The method of claim 1 , wherein at least one of the plurality of female receiving members and at least one of the plurality of male extensions are formed with an accuracy of plus-or-minus 0.001 inches relative to a desired dimension.
4. The method of claim 1 , wherein at least one of the plurality of pre-formed wall panels comprises a thickness of between 0.5 inches and 0.625 inches.
5. A method of forming a modular building unit, the method comprising:
providing a first wall panel member comprising a first portion and a second portion;
wherein the first portion of the first wall panel member comprises a wall surface member, and wherein the second portion of the first wall panel member comprises a first metal stud;
providing a second wall panel member comprising a plurality of metal studs on a first side and a planar surface on a second, opposing side;
forming a plurality of apertures in the second wall panel member, wherein the plurality of apertures are formed using a computer-numeric controlled process and wherein at least one of the apertures is provided adjacent to one of the plurality of metal studs;
forming an extension on the first portion of the first wall panel member, wherein the extension is formed using a computer-numeric controlled process and wherein at least a portion of the extension is provided co-planar with a surface of the first portion;
wherein the second portion of the first wall panel member comprises a rectilinear member having at least one vertical member and a pair of horizontal members, and wherein the extension is joined to or co-formed with the first metal stud;
securing the first portion of the first wall panel member to the second portion of the first wall panel member; and
inserting the rectilinear member into an aperture of the plurality of apertures in the second wall panel member to secure the first wall panel member and the second wall panel member and at least partially define an interior volume of a room.
6. The method of claim 5 , wherein the first and second wall panel members are provided and secured at a perpendicular angle to one another.
7. The method of claim 5 , wherein the method is devoid of taping and mudding the first and second wall panel members.
8. The method of claim 5 , wherein the first portion of the first wall panel member comprises gypsum.
9. The method of claim 5 , wherein the rectilinear member is joined to or conformed with the rigid structural member.
10. The method of claim 5 , wherein the first portion of the first wall panel member comprises a thickness of between 0.5 inches and 0.625 inches.