IP Library Granted Patent US 12,305,388
Granted Patent B2
US 12,305,388 · App. 18/097,773 · Granted May 20, 2025

Cap for a temporary wall system providing fire barrier protection

Inventors: Bruce Bickford (Cushing, ME); Darrell Flagg (Turner, ME); William Randall (Brunswick, ME); Amelia Cutler (Scarborough, ME)
Assignee: STARC SYSTEMS, INC.
E04B2/821E04B2/7403E04G21/243
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Quick Facts
Patent No.
US 12,305,388
App. No.
18/097,773
Granted
May 20, 2025
Kind
B2
Abstract

A barrier system for partitioning a space includes wall panels which interlock with each other to provide a modular wall that is fire rated. The interlocking panels are assembled in the barrier in columns using a first tongue and groove assembly and a panel lock using a strike and latch supported by the tongue member and groove member, respectively. The barrier system further includes cap panel which adjoin each at a joint to provide a modular ceiling that is fire rated. The cap panels are assembled in the barrier to corresponding wall panels using a second tongue and groove assembly and a panel lock using a strike and latch supported by the tongue member and groove member, respectively.

Claims (72)

1. A barrier system for partitioning a space, comprising:

a plurality of interlocking panels forming a modular wall;

wherein the interlocking panels are assembled laterally adjacent to each other in the modular wall;

wherein a connection of laterally adjacent interlocking panels in the modular wall is made through a joint formed by a first tongue and groove assembly; and

a plurality of cap panels forming a modular ceiling;

wherein the cap panels are assembled laterally adjacent to each other in the modular ceiling;

wherein a connection of the cap panels of the modular ceiling to the interlocking panels of the modular wall is made through a joint formed by a second tongue and groove assembly;

wherein each cap panel comprises a groove extending adjacent a first edge of the cap panel, wherein said groove is configured to engage with a tongue provided on the top edge of the interlocking panel; and

wherein each cap panel further includes:

a further tongue at a second edge of the cap panel which extends perpendicular to the first edge of the cap panel; and

a further groove a third edge of the cap panel which extends perpendicular to the first edge of the cap panel.

2. The barrier system of claim 1 , wherein the first tongue and groove assembly comprises:

on a first interlocking panel, a latch plate and a connector mounted to the latch plate which includes a head; and

on a second interlocking panel, a strike plate including a slot with an end having a wider opening configured to receive the head and a middle having a narrower opening configured to engage the head.

3. The barrier system of claim 1 , wherein the second tongue and groove assembly comprises:

on a cap panel, a latch plate and a connector mounted to the latch plate which includes a head; and

on the interlocking panel, a strike plate including a slot with an end having a wider opening configured to receive the head and a middle having a narrower opening configured to engage the head.

4. The barrier system of claim 1 , wherein each cap panel comprises:

a core made of MgO material; and

opposed steel side faces encasing the core.

5. The barrier system of claim 4 , wherein the core is formed by a plurality of MgO sheets.

6. The barrier system of claim 1 , wherein the laterally adjacent assembly of cap panels to each other in the modular ceiling is provided by inserting the further tongue at the second edge of one cap panel into the further groove at the third edge of another cap panel.

7. The barrier system of claim 6 , further comprising a strip of intumescent material secured in the further groove.

8. The barrier system of claim 1 , further comprising a wall support track configured to be mounted to a wall, and wherein the wall support track includes a surface configure to support an edge of the cap panel.

9. The barrier system of claim 8 , wherein a strip of intumescent material is mounted to said surface of the wall support track.

10. A The barrier system for partitioning a space, comprising:

a plurality of interlocking panels forming a modular wall;

wherein the interlocking panels are assembled laterally adjacent to each other in the modular wall;

wherein a connection of laterally adjacent interlocking panels in the modular wall is made through a joint formed by a first tongue and groove assembly; and

a plurality of cap panels forming a modular ceiling;

wherein the cap panels are assembled laterally adjacent to each other in the modular ceiling;

wherein a connection of the cap panels of the modular ceiling to the interlocking panels of the modular wall is made through a joint formed by a second tongue and groove assembly;

wherein each cap panel comprises a groove extending adjacent a first edge of the cap panel, wherein said groove is configured to engage with a tongue provided on the top edge of the interlocking panel; and

wherein each cap panel further includes:

a first side recess in an upper surface at a second edge of the cap panel which extends perpendicular to the first edge of the cap panel; and

a second side recess in a lower surface at a third edge of the cap panel which extends perpendicular to the first edge of the cap panel.

11. The barrier system of claim 10 , wherein the laterally adjacent assembly of cap panels to each other in the modular ceiling is provided by a shiplap joint formed by a first half lap at the first side recess of one cap panel and a second half lap form by the second side recess of another cap panel.

12. The barrier system of claim 11 , further comprising a joiner plate secured to said one cap panel and said another cap panel across the shiplap joint.

13. The barrier system of claim 10 , further comprising:

a groove in a bottom of one of said first and second side recesses; and

a strip of intumescent material secured in the groove.

14. A barrier system for partitioning a space, comprising:

a plurality of interlocking panels forming a modular wall;

wherein the interlocking panels are assembled laterally adjacent to each other in the modular wall;

wherein a connection of laterally adjacent interlocking panels in the modular wall is made through a joint formed by a tongue and groove assembly; and

a plurality of cap panels forming a modular ceiling mounted to the interlocking panels of the modular wall;

wherein the cap panels are assembled laterally adjacent to each other in the modular ceiling;

wherein a connection between two laterally adjacent cap panels of the modular ceiling is made through a shiplap joint; and

wherein each cap panel comprises a groove extending adjacent a first edge of the cap panel, wherein said groove is configured to engage with a tongue provided on the top edge of the interlocking panel.

15. The barrier system of claim 14 , wherein the tongue and groove assembly comprises:

on a first interlocking panel, a latch plate and a connector mounted to the latch plate which includes a head; and

on a second interlocking panel, a strike plate including a slot with an end having a wider opening configured to receive the head and a middle having a narrower opening configured to engage the head.

16. The barrier system of claim 14 , wherein each cap panel comprises:

a core made of MgO material; and

opposed steel side faces encasing the core.

17. The barrier system of claim 16 , wherein the core is formed by a plurality of MgO sheets.

18. The barrier system of claim 14 , further comprising a joiner plate secured between said two laterally adjacent cap panels across the shiplap joint.

19. The barrier system of claim 14 , further comprising a wall support track configured to be mounted to a wall, and wherein the wall support track includes a surface configure to support a rear edge of the cap panel.

20. The barrier system of claim 19 , wherein a strip of intumescent material is mounted to said surface of the wall support track.

21. A barrier system for partitioning a space, comprising:

a plurality of interlocking panels forming a modular wall;

wherein the interlocking panels are assembled laterally adjacent to each other in the modular wall;

wherein a connection of laterally adjacent interlocking panels in the modular wall is made through a joint formed by a tongue and groove assembly; and

a plurality of cap panels forming a modular ceiling mounted to the interlocking panels of the modular wall;

wherein the cap panels are assembled laterally adjacent to each other in the modular ceiling;

wherein a connection between two laterally adjacent cap panels of the modular ceiling is made through a shiplap joint; and

wherein each cap panel further includes:

a first side recess in an upper surface at one lateral edge of the cap panel to form a first half lap for the shiplap joint; and

a second side recess in a lower surface at another lateral edge of the cap panel to form a second half lap for the shiplap joint.

22. The barrier system of claim 21 , further comprising:

a groove in a bottom of one of said first and second side recesses; and

a strip of intumescent material secured in the groove.

Assignments (3)
RELEASE OF SECURITY INTEREST Recorded Sep 10, 2026
From: BYLINE BANK, AS AGENT
To: STARC SYSTEMS, INC.
Reel/Frame 075962/0764 →
SECURITY INTEREST Recorded Sep 9, 2026
From: STARC SYSTEMS, INC.
To: CHURCHILL AGENCY SERVICES LLC
Reel/Frame 075945/0972 →
SECURITY INTEREST Recorded Jul 26, 2023
From: STARC SYSTEMS, INC.
To: BYLINE BANK, AS AGENT
Reel/Frame 064385/0547 →
Continuity (2)
Provisional Application 63389461 · Jul 15, 2022
Related Publication 20240018777A1 · Jan 18, 2024
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