Patent Application
20110024061
Embodiments of the present invention are directed to header assemblies for movable partitions, movable partition assemblies including header assemblies, and methods of forming and installing movable partitions and header assemblies.
Movable partitions are utilized in numerous situations and environments for a variety of purposes. Such partitions may include, for example, a movable partition comprising foldable or collapsible doors configured to enclose or subdivide a room or other area. Often such partitions may be utilized simply for purposes of versatility in being able to subdivide a single large room into multiple smaller rooms. The subdivision of a larger area may be desired, for example, to accommodate multiple groups or meetings simultaneously. In other applications, such partitions may be utilized for noise control depending, for example, on the activities taking place in a given room or portion thereof. Movable partitions may also be used to provide a security barrier, a fire barrier, or both a security and a fire barrier. In such a case, the partition barrier may be configured to automatically close upon the occurrence of a predetermined event such as the actuation of an associated alarm.
One or more accordion or similar folding-type partitions may be used to enclose or subdivide a room, as a noise control, a security barrier, a fire barrier, or both a security and a fire barrier wherein each partition is formed with a plurality of panels connected to one another with hinges. The hinged connection of the panels allows the partition to fold and collapse into a compact unit for purposes of storage when not deployed. The partition may be stored in a pocket formed in the wall of a building when in a retracted or folded state. When the partition is deployed to subdivide a single large room into multiple smaller rooms, secure an area during a fire, or for any other specified reason, the partition may be extended along an overhead track, which is often located above the door in a header assembly, until the partition extends a desired distance across the room.
One or more layers of gypsum board 180 are provided between the overhead track 160 and the layers of plywood 170. The layers of gypsum board 180 also extend longitudinally along the length of the movable partition and the overhead track 160 and extend laterally across the header recess 120 to the two fire rated walls 130. Some of the layers of gypsum board 180 extend only partially across the header recess 120 in a lateral direction in order to provide a pocket for the overhead track 160. That is, some layers of gypsum board 180 extend longitudinally along a lateral side of the overhead track 160 and extend laterally between a lateral side of the overhead track and one of the two fire rated walls 130.
The layers of plywood 170 and gypsum board 180 are typically custom fitted onsite during installation of the movable partition. Because some of the measurements needed for custom fitting the layers of plywood 170 and gypsum board 180 are only obtained after other portions of a door assembly are installed, the installer often must leave the installation cite to obtain fitted plywood 170 and gypsum board 180 for installation at another time.
Various embodiments of the present disclosure comprise movable partition systems and header assemblies for movable partition systems which are more easily and efficiently installed and significantly reduce the number of required fasteners.
In one or more embodiments the present disclosure, a movable partition system may comprise a header assembly and a movable partition. The header assembly may comprise an elongated overhead track including a first channel, a second channel, and a central channel between the first and second channels. A plurality of support bracket attachment features may be included with at least one support bracket attachment feature on each of an outer surface of the first channel and an outer surface of the second channel. A track support bracket may be coupled to each of the support bracket attachment features. The movable partition may comprise a plurality of panels connected to one another with hinge-like member and may be suspended from the overhead track.
An overhead track of the present disclosure may comprise a central channel configured to receive at least one roller for a foldable partition therein. A first channel may be coupled to the central channel on a side thereof, and a second channel may be coupled to the central channel on another side opposite the first channel. A support bracket attachment feature may be included on an outer surface of the first channel and an outer surface of the second channel in some embodiments. In some embodiments, a drive member channel configured to receive a drive member therein may be included inside the central channel.
A header assembly for a movable partition according to various embodiments of the disclosure may comprise an overhead track comprising a first channel, a second channel, a central channel between the first channel and the second channel. A support bracket attachment feature may be included on each of an outer surface of the first channel and an outer surface of the second channel and a track support bracket may be coupled to each of the support bracket attachment features.
Other embodiments comprise methods for forming header assemblies for one or more embodiments of movable partitions. According to some embodiments, such methods may comprise positioning an overhead track within a longitudinally extending space between a first wall and a second wall. A track support bracket and a soffit may be attached to the overhead track.
Illustrations presented herein are not meant to be actual views of any particular partition or header assembly, but are merely idealized representations which are employed to describe embodiments of the present invention. Additionally, elements common between figures may retain the same numerical designation.
Referring to
To deploy the movable partition 210 to an extended position, the movable partition 210 is moved along the overhead track 240. A leading edge of the movable partition 210 may include a lead post 270 configured to engage with a door jamb or another post, which may be provided in a wall 260B of a building to which the movable partition 210 may extend in an extended state. While the embodiment of the movable partition 210 shown and described with reference to
The system 200 also includes a header structure 280. The header structure 280 may include a structural support member and a header assembly, as discussed in further detail below. The movable partition 210 may be suspended from and supported by the header structure 280. In other embodiments, the movable partition 210 may be supported by the floor below the movable partition 210, and the header structure 280 may simply serve as a guide for the movable partition 210. While the embodiment of the header structure 280 shown and described with reference to
The header structure 280 of the system 200 may include a header recess 410 (
According to various embodiments, the overhead track 240 may further include a support bracket attachment feature 340, a soffit attachment feature 350, a drive member channel 360, or one or more alignment grooves 370, as well as various combinations any of the foregoing.
The support bracket attachment feature 340 is located on an outer surface 380 of the first channel 310 and the second channel 320. In at least some embodiments, the support bracket attachment feature 340 may comprise a hook-shaped member that extends along the outer surface of the overhead track 240. In other words, the hook-shaped member may extend in the direction that would be into or out from the page as the overhead track 240 is oriented in
The soffit attachment feature 350 is also located on the outer surface 380 of the first channel 310 and the second channel 320 of the overhead track 240. In at least some embodiments, the soffit attachment feature 350 may also comprise a hook-shaped member extending along the outer surface of the overhead track 240. Like the hook shape of the support bracket attachment feature 340, the hook shape of the soffit attachment feature forms a slot 395 configured to receive a portion of a soffit therein.
The drive member channel 360 may be located within a portion of the central channel 330 and may be sized and configured to receive a drive member therein. By way of example and not limitation, the drive member channel 360 may be sized and configured to receive the chain of a chain and sprocket drive member, or the rack of a rack and pinion drive member.
The one or more alignment grooves 370 comprise a groove configured to receive and retain a rod 375 therein. In at least some embodiments of the system 200, the overhead track 240 may comprise a plurality of overhead track sections coupled together at their longitudinal ends to form an elongated overhead track 240 along which the movable partition 210 is configured to move. The one or more alignment grooves 370 for each overhead track section are located in substantially the same position. When the plurality of overhead track sections are coupled together, a rod 375 may be positioned in each of the one or more alignment grooves 370 of the two overhead track sections being coupled to aid in vertically and horizontally aligning the track sections, and all of their corresponding features. Although the alignment grooves 370 are illustrated on the outer surface 380 of the overhead track 240, one or more alignment grooves 370 may be positioned on the inner surface (e.g., in the first channel 310, the second channel 320 and/or the central channel 330) of a portion of the overhead track 240, as well as combinations thereof.
To secure sections of the overhead track 240 that are coupled together, a rigid support plate 385 shown in broken lines may be positioned over the joint where the sections of the overhead track 240 are joined. The support plate is then attached to each of the overhead track sections with one or more fasteners, such as screws or bolts.
The overhead track 240 may comprise any suitably rigid material. For example, the overhead track 240 may comprise a metal or metal alloy, a plastic, a composite or a ceramic material. In some embodiments, the overhead track 240, including the first channel 310, the second channel 320, the central channel 330 and any one or more of the support bracket attachment feature 340, the soffit attachment feature 350, the drive member channel 360 and one or more alignment grooves, may comprise an integral piece. Such an integral piece may be formed by, for example, extruding the track by conventional extrusion techniques generally known to those of ordinary skill in the art.
Referring to
The header assembly 410 comprises an overhead track 240 including the first channel 310, the second channel 320 and the central channel 330. The overhead track 240 may be attached to the overhead support member 450 by fastener elements such as rods 460. One end of each of the rods 460 may be attached to the overhead support member 450. Each rod 460 may comprise a threaded rod that extends through the overhead support member 450, and a nut may be threaded onto the end of the overhead support member 450 on a side thereof opposite the overhead track 240 to retain the rod 460 in position relative to the overhead support member 450. The overhead support member 450 may be, for example, a wood or metal beam, a truss structure, floor joists, etc.
The overhead track 240 is coupled to (directly or indirectly) and suspended from the rods 460. As shown in
In some embodiments, the rods 460 may be threaded and may be anchored to an overhead support member 450. The rods 460 extend from the overhead support member 450 to the support brackets 470 and may be coupled thereto. The rods 460 may be coupled or fastened to the overhead support member 450 by any suitable manner such as, for example, using conventional nuts. In some embodiments, the rods 460 may be located at set distances along the overhead track 240 to attach the support brackets 470 to the overhead support member 450. For example, the rods 460 may be spaced at set intervals along the overhead track 240, each interval being spaced a set distance such as 18 inches (45.72 centimeters) apart. Further, in some embodiments, when the movable partition 210 is retracted (i.e., opened), the weight of the movable partition 210 will be concentrated in the area of the overhead track 240 located above the retracted movable partition 210 (e.g., the section of the overhead track 240 located in the pocket 250). Therefore, the rods 460 may be spaced at shorter intervals such as 12 inches (30.48 centimeters) in the area where the movable partition 210 is stored in a retracted state. It is noted that while overhead track 240 of
As shown in
Referring to
In some embodiments, the track support brackets 470 may comprise a single piece extending substantially the entire length of the overhead track 240 along each side thereof. In other embodiments, a plurality of track support brackets 470 may be employed on each side of the overhead track 240, the track support brackets 470 being evenly spaced along the length of the overhead track 240. By way of example only, each track support bracket 470 may comprise a length of between 4 in. (10.16 cm) and 12 in. (30.48 cm) and maybe spaced from each adjacent track support bracket 470 along a both sides of the overhead track 240 by about 3 in. (7.62 cm) to 12 in. (30.48 cm).
With continued reference to
The soffit 490 may further include a second extension 570 extending from the vertical member 530 and comprising a second attachment feature 580. The second attachment feature 580 is configured to mate with the soffit coupling feature 515 of the track support bracket 470. Mating the second attachment feature 580 of the soffit 490 and the soffit coupling feature 515 of the track support bracket 470 may aid in aligning the header assembly 410 as well as reducing or inhibiting lateral displacement of the header assembly 410 or its various components (e.g., the overhead track 240). In some embodiments, a clip 590 may be employed to fixedly join the second attachment feature 580 and the soffit coupling feature 515 together. In at least some embodiments, the clip 590 may comprise any conventional s-clip.
As shown in
The header assembly 410 illustrated in
Referring again to
A track support bracket 470 may be attached to the overhead track 240. As discussed previously, attaching the track support bracket 470 to the overhead track 240 may include attaching a track attachment feature 510 of the track support bracket 470 to a support bracket attachment feature 340 of the overhead track 240. In some embodiments attaching the track attachment feature 510 to the support bracket attachment feature 340 comprises disposing a hook-shaped track attachment feature 510 into a slot 390 defined by a hook-shaped support bracket attachment feature 340.
A soffit 490 may also be attached to the overhead track 240. As discussed previously, attaching the soffit 490 to the overhead track 240 may include attaching a first attachment feature 550 of the soffit 490 to a soffit attachment feature 350 of the overhead track 240. In some embodiments attaching the first attachment feature 550 to the soffit attachment feature 350 comprises disposing a hook-shaped first attachment feature 550 into a slot 395 defined by a hook-shaped soffit attachment feature 350. The soffit 490 may also be coupled to the track support bracket 470.
As discussed previously with reference to
With reference to
The header assembly 710 comprises an overhead track 240 including the first channel 310, the second channel 320 and the central channel 330, as described above with reference to
Referring to
The soffit 720 may comprise a substantially flat member comprising a first attachment feature 750 configured to attach to the soffit attachment feature 350 of the overhead track 240. In some embodiments, the first attachment feature 750 may comprise a hook shape configured to receive, and be received by the hook-shaped soffit attachment feature 350 of the overhead track 240. As shown in
The wall trim 730 may be configured to receive and support a portion of the soffit 720 and may be fixedly attached in-between bracket 740 and the first wall 430 or the second wall 440. The wall trims 730 may comprise a generally L-shaped cross-section, with one leg attached into the recess 780 and against walls 430 and 440. As stated, the wall trim 730 may receive and support a portion of the soffit 720. In at least one embodiment, the soffit 720 extends from the overhead track 240 and at least partially overlaps and lies on a portion of the wall trim 730.
The clipping member 740 is configured to be coupled to the track support bracket 470 and to retain the soffit 720 adjacent the wall trim 730. The clipping member 740 may comprise a support bracket leg 765 configured to be attached to the track support bracket 470. The support bracket leg 765 may be attached to the support bracket 470 with one or more fasteners 770, such as a screw, bolt, or the like. The clipping member 740 and the track support bracket 470 are configured so the clipping member 740 may be adjusted laterally in track support bracket 470 to account for walls 430 and 440 being unparallel prior to being fixedly fastened together. Attaching the clipping member 740 to the track support bracket 470 removes the need to take measurements, strike chalk lines, employ a laser line, or otherwise calculate and locate the proper height of the wall trim 730 to ensure alignment with the overhead track 240. The wall trim 730 may instead be aligned directly to the clipping member 740 that is already aligned with the overhead track 240 by virtue of being attached to the track support bracket 470 that is coupled with the overhead track 240.
The clipping member 740 may further include a retention leg 775 configured to extend away from the support bracket leg 765 to a location adjacent the portion of the soffit 720 that is overlapping the wall trim 730. The retention leg 775 is configured to exert a force on the soffit 720 to retain the soffit 720 adjacent the wall trim 730. The force exerted on the soffit 720 may be a result of the retention leg 775 being partially compressed toward the support bracket leg 765 when the header assembly 710 is assembled.
In order to keep the clipping member 740 from displacing upward due to the force of the partially compressed retention leg 775, the clipping member 740 may include a wall piercing feature 785. The wall piercing feature 785 is configured to be forced into and penetrate the wall 430, 440 until seated against the wall as the clipping member 740 is being adjusted in track support bracket 470. The fastener 770 then is fastened, coupling the track support bracket 470 to the clipping member 740 and the wall 430, 440.
Similar to the header assembly 410 in
The header assembly 710 illustrated in
Referring again to
A track support bracket 470 may be attached to the overhead track 240. As discussed previously, attaching the track support bracket 470 to the overhead track 240 may include attaching a track attachment feature 510 of the track support bracket 470 to a support bracket attachment feature 340 of the overhead track 240. In some embodiments attaching the track attachment feature 510 to the support bracket attachment feature 340 comprises disposing a hook-shaped track attachment feature 510 into a slot 390 defined by a hook-shaped support bracket attachment feature 340.
A soffit 720 may also be attached to the overhead track 240. As discussed previously, attaching the soffit 720 to the overhead track 240 may include attaching a first attachment feature 750 of the soffit 720 to a soffit attachment feature 350 of the overhead track 240. In some embodiments attaching the first attachment feature 750 to the soffit attachment feature 350 comprises disposing a hook-shaped first attachment feature 750 into a slot 395 defined by a hook-shaped soffit attachment feature 350.
A wall trim 730 is attached in-between bracket 740 and the first wall 430 or the second wall 440 and a portion of the soffit 720 is positioned over a portion of the wall trim 730. The method further includes retaining the soffit 720 in contact with the wall trim 730 with a clipping member 740 coupled to the track support bracket 470 and the wall 430, 440.
As discussed previously with reference to
While certain embodiments have been described and shown in the accompanying drawings, such embodiments are merely illustrative and not restrictive of the scope of the disclosure, and this disclosure is not limited to the specific constructions and arrangements shown and described, since various other additions and modifications to, and deletions from, the described embodiments will be apparent to one of ordinary skill in the art. Thus, the scope of the disclosure is only limited by the literal language, and legal equivalents, of the claims which follow.
