NZ234659A - Partition panel suspension mount assembly enabling panel sway during - Google Patents

Description

w 234 65 9 Priority Dste(s):....1.1~., Compos SpaciiicaHon Filed: ? Css- & ?x{j> fr3/0^ 4nt,er the Provisions 05 .'.fL^loo^Q.^oa{7 23 Nlhe •*»»** a CpO.G? [\J.Zb3~.i.&bO<a}'>5-f&O * ' ' 23 DEC 1993 specification h«s been ante-dated publication few — ^ ,0; a...4tos.... ,9 Jl.

P.O. Jouynac, >jo: »*? . We^pcs Initiate Patents Form No. 5 This application is a divisional out of application 224906 dated 3 June 1988 NEW ZEALAND PATENTS ACT 1953 COMPLETE SPECIFICATION A WALL PANEL MOUNT ASSEMBLY V * . c- V | 26JUL1990£j WE, MODERNFOLD INC., 1711 I Avenue, New Castle, Indiana 47362, U.S.A., incorporated under the laws of the State of Indiana, U.S.A., hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: (followed by page la) la This invention relates a wall panel mount assembly for supporting movable wall panels, such as those used to partition large rooms into smaller rooms.

Four objectives of trolley and tra'.ck systems that suspend movable wall panels are: (1) to allow the walls to be moved with as little friction as possible; (2) to keep the wall panels properly centered within the track; (3) to reduce the shock caused by a trolley impacting a stationary object such as a track intersection and to allow panels to sway; and (4) to allow the panels to be moved across angular (as opposed to curved) track intersections without the trolleys dropping into gaps which usually exist in such intersections. No known system accomplishes all of these objectives.

Single puck or disc trolleys such as disclosed in U.S. Patent No. 4,084,289 generally fail to reduce friction to an acceptable level because one s.ide of the trolley rotates in a direction opposite to the direction the wall is moved. This problem was solved in U.S. Patent No. 4,141,106 by using a canted puck, but such a system allows a panel to sway to an unacceptable level( and does not keep the wall panel properly centered in its track.

Another method is to use a track having a pair of flanges, which engage two vertically spaced trolleys or pucks. In U.S. Patent No. 4,159,556, the objective of such a system was to allow the trolley to easily traverse track intersections. However, such systems require twice &s much contact between the trolley and track, increasing friction. Other systems, such "as those described in U.S. Patent Nos. 3,042,9 60, 3,879,799 and 4,401,033, provide for upper and lower discs, with only opposite sides of the upper and lower discs engaging the track. However, such systems are not only expensive to manufacture, but do not allow a standard wheeled (followed by page 2) 234(55! trolley to be used in the track if desired. Other known _ . _ systems do not adequately protect the joint of a trolley and wall panel, causing such joints tc quickly wear fro;u the shock resulting when a trolley is moyed in a track intersection or when a panel sways. In addition, wall panels become stuck in track intersections in other known systems because the trolleys are prone to dr.op into the gaps in such intersections.

This invention provides a wall panel mount assembly comprising: a housing for mounting within and supporting a movable wall panel, the housing having upper and lower walls and an aperture in the upper wall capable of receiving a shaft of a trolley which slidably supports the wall panel from a track section, said housing enclosing: a nut having internal threads for receiving a threaded portion of the shaft; a first resilient flexible block having an aperture in it retaining the nut in alignment with the aperture in the upper wall; a first washer, through which the shaft * can be inserted, that is positioned above the first resilient flexible block and that is retained thereby in contact with the upper wall of the housing; a second washer, through which the shaft can be inserted, that is aligned with the aperture in the first resilient flexible block; and that is positioned below ..and in contact with the first resilient flexible block; and a second resilient flexible block in contact with and below the second washer and contacting the bottom wall of the housing, the second resilient flexible block having an aligned cavity capable of receiving an end portion of the shaft.

The assembly may be used with a track and trolley system that allows wall panels to be moved with a minimum amount of friction. The system includes a track having arfirst rail which may be horizontal, a longitudinally parallel second.^^ rail which is higher than the first rail, and a trolley having two drive wheels that engage the rails via annular 1 '24MAri990 234(5 -2a- J track engaging surfaces of different diameters.

Alternatively, the slanted rail of the track may include a short horizontal surface, to allow tjie track to be used with standard wheeled trolleys in addition to horizontal drive trolleys.

The trolley utilizes a vertical shaft having an outer drive wheel having an annular track engaging surface which is rotatably mounted on the shaft. An inner drive wheel, also rotatably mounted on the shaft, has .an annular track engaging surface with a smaller diameter than the diameter of the outer drive wheel's annular track engaging surface. The inner drive wheel may have either a horizontal lower surface or a substantially tapered lower surface, whereby its annular surface closest to the shaft is below its annular surface furthest from the shaft. If the lower surface of the inner drive wheel is tapered, it may be either conical or spherical. The inner drive wheel's annular track engaging surface is below the annular track engaging surface of the outer drive wheel. Each drive wheel may be independently rotatable in opposite directions. This eliminates the additional friction created by some prior art trolleys using M (followed by page 3) • 234659 / a single rotatable bearing which engages both rails . .. -simultaneously.

A major advantage of the trolley is that its inner and outer drive wheels contact their respective tracks via 5 annular surfaces of different diameters. This is important because it allows a more compact construction and because it reduces the vertical elevational drop when a trolley is moved through a track intersection. As long as the radius of the outer drive wheel track engaging surface is greater than the 10 diameter of the inner drive wheel track engaging surface,.the outer drive wheel will engage a track across an intersection gap before the inner drive wheel begins to drop into the gap. This is a significant improvement over the prior art, in which the engaging surfaces of counter-rotating drive wheels 15 typically have equal radii.

The track and trolley system may also include slide pads at track intersections to reduce the vertical elevational drop of a trolley when it moves across an intersection. An intersection may be an X, T, L or Y intersection. When a troliey is positioned in a track, there are vertical spaces between each drive wheel and 30 the track. The slide pads occupy these spaces in a track intersection to keep the trolley at substantially same elevation and to prevent the trolley from dropping. The slide pads may be mounted to support- just the outer drive wheel, or both inner and outer drive wheels. Also in the 35 preferred embodiment, the outer drive wheel has a substantially horizontal lower surface to increase the 234659 -4- V DESCRIPTION OF THE DRAWINGS FIG. 1 is a vertical section of a 'movable wall panel system.

FIG. 2 is a vertical section of the track and trolley system taken in the line of 2-2 of FIG. 1.

FIG. 3 is a vertical section of the flexible wall panel *« mount assembly showing how swaying of a panel is absorbed by the mount. •.

FIG. 4 is a vertical section of the flexible wall panel . mount assembly showing how the mount absorbs shock resulting from moving the trolley against a stationary object.

FIG. 5 is a perspective section of the flexible wall panel 15 mount assembly.

FIG. 6 is a perspective section of the trolley and track, showing the points at which the inner and outer drive wheels of the trolley engage the track.

FIG. 7 is a section of the trolley.' FIG. 8 is an exploded partial section of the trolley.

FIG. 9 is a perspective view of th£ track.

FIG. 10 is a vertical section of tjie trolley showing an alternate bearing and outer drive wheel i. configuration.

FIG. 11 is a vertical section of the track ■ . .• showing how it may be useij with a conventional wheeled dolley. 7 FIG. 12 is a vertical section of a- track intersection 30 showing the slide pads which reduce both friction and the vertical elevationai drop in such intersections. .r FIG. 13 is a cut-away perspective 'yiew of the slide pads mounted in a track X intersection.

FIG. 14 is a perspective view showing how a slide pad may be fastened to the track.- FIG. 15 is a detail of a slide pad'. for use on track corners where horizontal rails intersect. FIG. 16 234659 is a detail of a slide pad for use on track- corners where slanted rails intersect.

FIG. 1 is a vertical section of a movable wall panel system with which the invention may be used* Movable panels 1 are suspended from trolleys 2 by pendant bolts 3. The trolleys 2 travel in track 4. One problem with prior systems is that when trolleys 2 are moved against stationary objects such as 10 track intersections, trolleys 2 are pubject to shock, thus, causing them to wear. The present invention solves this problem as described below by connecting trolleys 2 to panels 1 using flexible mountings.

FIG. 2 is a vertical section of the track and trolley taken in the line of 2-2 of FIG. 1.

The bottom surfaces of first rail 43 and second rail 44 are substantially coplanar so that track 4 may be held by C channel 5, which is attached to overhead structure by supporting bolts 6 and nuts 7. Height alignment bolt 8 abuts 20 the top of track channel 5 so height of track channel 5 may be controlled. Guide walls 9 extend from track 4 to provide proper alignment of the trolley 2. Flanges 10 outwardly extend from guide walls 9 to serve as a soffit and to receive wallboards 11 which act as sound baffles. 2 5 The trolley includes bolt 12, which serves as a shaft to support outer drive wheel bearing 21-, bottom spacer 14, upper spacer tube 15, washer 16, lower spacer tube 17, sleeve bearings 18, lock washer 19 and jam nut 20. Sleeve bearings 18 should be freely rotatable, so their combined 3 0 length should be less than that of lower spacer tube 17.

Outer drive wheel bearing 21 supports outer drive wheel 13, while bottom spacer 14 supports inner drive wheel bearing 22 which in turn supports inner drive wheel 23. Thus, outer drive wheel 13 and inner drive, wheel 23 may independently 35 rotate in opposite directions.

The lower portion of bolt 12 j^i^attached to movable wall panel 1. Movable wall panel 1 includes*^Saiwte24^ which act 234659 as a sound seal and which help protect the trolley assembly, from exposure to dirt and the like.

It may be appreciated that the present invention allows a wall panel to hang plumb, keeping the trolley engaged on both 5 sides of the track.

FIG. 3 is a vertical section of the flexible wall panel mount assembly showing how the mount allows swaying of a panel. Bolt 12 extends- from trolley assembly 2 5 and is secured to upper wall mount housing 26 by square 10 nut 27. Upper wall panel frame 28 includes aperture 29 through which bolt 12 extends. Bolt 12 has mounted thereon spacer tube 30; which is secured by washer 31 and lock nut 32. Distal adjustment of the wall' panel with respect to trolley assembly 25 is made by adjusting the extent to which 15 bolt 12 is screwed into square nut 2.7. The distance between the trolley assembly 25 and movable wall panel 1 should be the same for all such assemblies and panels. Once the desired distance is obtained, lock r\ut 32 is tightened against washer 31 and spacer tube 3fr to prevent bolt 12 from 20 rotating with respect to square nut -27. Aperture 29 has a diameter greater than spacer tube 30, so spacer tube 30 can move without hitting the edges of aperture 29. Spacer tube 30 abuts top washer 33, which is positioned below upper wall mount housing 26 and above washer 34. In between 25 washer 34 and center washer 35 is nut retainer 36. Nut retainer 36 is a rectangular block of resilient flexible material such as rubber with a squar'e hole in the center which holds square nut 27 and acts as a shock absorber.

Beneath center washer 35 is trolley mount retainer 37, which 30 is a square block of resilient flexible material such as rubber with a hole through the center for receiving bolt 12. Trolley mount retainer 37 acts as a gompression spring and shock absorber, and is held in place by lower wall mount housing 38. As shown more fully in ;,FIG. 4, lower wall mount 35 housing 38 is fastened to upper wall mount housing 26 by means such as welding, and supports trolley mount .. . retainer 37. 234659 The shock absorbing characteristics of the flexible wall •• panel mount assembly are demonstrated in FIG. 3. When a movable wall panel is swayed out of a plumb position, top washer 33 pivots on its leading edge;, causing a gap 39 5 between top washer 33 and upper wall'.mount housing 26. Nut retainer 36 partially absorbs the shock, and together with square nut 27, apply force on center'washer 35, which in turn, together with bolt 12, compress trolley mount retainer 37 and absorb the remainder of the shock. Trolley IQ mount retainer 37 acts like a compression spring and a shock absorber, and becomes increasingly %tiff as deformation is increased. After displacement, nut 'retainer 36 and trolley mount retainer 37 return to their normal position. The stiffness of the mount may be changed by varying the !5 durometer hardness of nut retainer 36 and trolley mount retainer 37.

FIG. 4 is a vertical section of the flexible wall panel mount assembly taken from an angle perpendicular to that of FIG. 3, showing how the mount 20 absorbs shock resulting from moving .-.the trolley against a stationary object such as a track intersection. From the view of FIG. 4, it may be appreciated that lower wall mount housing 38 may be spot welded to upper wall mount housing 26 at weld points 40 and 41. Upon impact, top washer 33 pivots, 25 causing a gap 42 between top washer 33 and upper wall mount housing 26. Nut retainer 36 partially absorbs the shock, and together with square nut 27, apply force on center washer 35, which in turn, together with bolt 12; compress trolley mount retainer 37 to absorb the remainder of the shock. 3q FIG. 5 is a perspective section of!.the flexible wall panel mount assembly. From this view, it may be seen that upper wall mount housing 26 and lower wall mount housing 38 have mounted therein top washer 33, washer 34, nut retainer 36, square nut 27, center washer 35, andVtrolley mount f .** retainer 37. Bolt 12, which extends';from the trolley, may be screwed into square nut 27, effecting the distance between ... .the wall panel and trolley assembly.

FIG. 6 is a perspective section of the trolley and track-/ showing the points at which the inner and outer drive wheels of the trolley engage the track. Although left rail 43 and right rail 44 may appear, coplanar at first glance, closer examination reveals that right rail .44 is actually comprised of three separate longitudinal, planar surfaces, 45, 46 and 47. As the lower surface of inner drive wheel 23 extends below the planar surface of outer drive wheel 13, inner drive wheel 23 engages left rail 43 along its annular edge 48 with guide wall 9. However, planar surface 45 of right rail 44. is below the planar surface of left rail.43, so the lower surface of outer drive wheel 13 does not engage either of these surfaces or longitudinal planar surface 46. Instead, the outer annular edge 49 of outer drive wheel 13 engages right rail 44 along longitudinal planar surface 47, which is adjacent to surface 46 and which upwardly extends from the plane defined by the surface of left rail 43. Right rail 44 need not: necessarily extend towards the trolley as shown in FIG. 6, so right rail 44 need not include planar surface 45 or 46. It is sufficient to practice the present invention if right rail includes only a planar surface for engagement of outer drive wheel 13 which does not engage inner drive wheel 23. The engaging surface of inner drive wheel 23 has a radius as opposed to a conical surface. This reduces the wheel's contact area with the rail, and the resulting friction whejti the trolley is moved in the track.

FIG. 7 is a section of the trolley.

Pendant bolt 12 serves as a mounting shaft for outer drive wheel bearing 21, bottom spacer 14, and upper spacer tube 15. Outer drive wheel 13 is fitted to outer drive wheel bearing 21 to be rotatable with respect to bolt 12. The construction of outer drive wheel 13 creates a cavity in which bottom spacer 14 is fitted to inner drive wheel bearing 22, which supports inner drive wheel 23, allowing said wheel to rotate independently of both bolt 12 and outer drive wheel 13. Outer drive wheel bearing 21, bottom spacer 14, and upper spacer tube 15 are upwardly fitted against the top of bolt 12 by washer 16, which in turn is 234659 supported by lower spacer tube 17, which is secured by lock -washer 19 and jam nut 20. Sleeve bearings 18 are placed around lower spacer tube 17, and are freely rotatable thereon. The plane defined by the lower surface of said 5 outer drive wheel 13 is immediately adjacent to the outermost surface of said inner drive wheel 23.

FIG. 8 is an exploded partial section of the trolley * whereby the construction thereof as described above may be more fully appreciated,.

FIG. 9 is a perspective view of the track.

Track 4 may be integrally formed from commercial quality hot rolled steel or extruded aluminum, and shaped using techniques well-known in the art and which do not form a part of the present invention. Track 4. Includes left rail 43. 15 right rail 44, left wall 49, right wall 99, left guide wall 50 and right guide wall 51. Left rail 43. has a horizontal planar surface. In the preferred embodiment as shown in FIG. 9, right rail 44 includes three separate longitudinal planar surfaces, 4j>, 46, and 47. Planar surface 46 is coplanar with 20 the left rail surface 43. Planar surface 45 angularly extends below planar surface 46, while adjacent planar surface 47 angularly extends upwardly from planar surface 46. However, it is also possible to construct right rail 44 so it has no surface coplanar with left rail 43, and the entire right rail 44 25 merely angles downwardly from right wall 99. Right rail 44 may either terminate after the trolley engaging surface, or continue to right guide wall 51. Although such a construction would allow the trolley to engage the track as shown in FIGURES 2 and 6, such a construction would not be 30 capable of accommodating a wheeled trolley as shown below in FIG. 11, because right rail 44 would not contain a surface coplanar with left rail 43. Alternatively, planar surfaces 45 and 47 could be constructed to form adjacent "steps" to planar surface 46, the only requirement being that 35 planar surface 45 be below planar surface 46, and planar surface 46 be below planar surface 47.

FIG. 10 is a vertical section of the trolley showing an alternate bearing and outer drive wheel 234659 configuration. Specifically, to support heavier wall panels, outer drive wheel 52 is supported by a larger outer drive wheel bearing 53, which in turn is secured to bolt 12 by both upper spacer 54 and lower spacer 55. Lower spacer 55 also 5 supports inner drive wheel bearing 5.6. It may also be appreciated from FIG. 10 that the contact point 57 between inner drive wheel 23 and left rail 4;3 is opposed to contact point 58 of outer drive.wheel 52 and right rail 44, thus keeping the trolley level within the track. In 10 addition, it is apparent that as the trolley travels through the track, inner drive wheel 23 will rotate in a direction counter to that of outer drive wheel 52.

It may further be appreciated that because outer drive wheel 52 does not contact right rail 44 between contact 15 point 58 and right guide wall 51, this portion of right rail 44 need not necessarily be triplanar as described above. All that is necessary to practice the invention is that right rail 44 have some longitudinal surface that is above the surface of left rail 43, so that the respective surfaces may 20 be independently engaged by the inner and outer drive wheels. However, such a construction would not prove suitable for a wheeled dolley as shown in FIG. 11.

In FIG. 11, the track as describe.d above is shown using a wheeled dolley of the type well known in the art. Thus, the 25 advantage of the track . may be appreciated because the track may be used not only with a trolley having inner and outer drive wheels as described above, but also with such wheeled dolleys. Specifically, bolt '59 is secured to shaft support 60. Support 60 supports shaft 61, on which wheels 62 3 0 and 63 are mounted. Wheel 62 engages left rail 43, while right wheel 63 engages the horizontal longitudinal planar portion 46 of right rail 44, which is coplanar with left rail 43.

FIG. 12 is a vertical section of a track intersection 35 . showing the slide pads 64 and 67 which reduce the vertical elevational drop in such intersections. The slide pads reduce vertical elevational drop of the trolleys in intersections by supporting the lower surfaces of the 234659 j,nner and outer drive wheels across an intersection before •• the center of the trolley crosses the intersection. Thus, when a trolley is in the middle of an intersection, it is fully supported by the slide pads, instead of dropping and 5 being supported by the rails themselves. Left rail slide pad 64 has a flat lower surface 65, to accommodate the horizontal surface of left rail 43. The upper outer surface 66 of the pad is also horizontal, and supports outer drive wheel 13. The upper inner surface 71 is tapered, and 10 adapted to support inner drive wheel 23.

Right rail slide pad 67 has inner and outer portions. The lower outer surface 68 is horizontal, and is capable of fitting against the horizontal portion 46 of right rail 44. The lower inner portion 69 is tapered at the same angle as 15 the planar surface 45'of right rail 44. The upper outer surface 70 of the pad is horizontal and engages outer drive wheel 13. The inner upper surface 71 of the pad is angled at the same angle as inner drive wheel 23 to engage the same. Thus, when a trolley is moved into a track intersection, the 20 slide pads occupy the vertical gaps between each drive wheel and the track, providing additional support for the trolley. Although the slide pads have been described with respect to the particular upper track surfaces and lower drive wheel surfaces described above, the invention only requires that 25 the slide pads occupy sufficient space between such surfaces to support the drive wheels in a track intersection.

It may thus be appreciated that both sides of the inner and outer drive wheels are engaged by the slide pad when the r trolley is moved into a track intersection. This has the 30 shortcoming noted above of the the opposite sides of each drive wheel rotating in a direction counter to the direction the panel is being moved, thus creating additional friction. Therefore, it is preferable for the slide pads to be made of a hard, low-friction material.such as powdered metal, nylon 35 or molydisulfide oil-impregnated nylon.

FIG. 13 is a cut-away perspective View of the slide pads mounted in a track X intersection. It may be appreciated that in such track intersections, multi-planar 234659 rails 72, 73, 74 and 75 (referred to as the right rail above) are joined only with other multi-planar rails, while horizontal rails 76, 77, 78 and 79 (referred to as the left rail above) are joined only with other horizontal rails. As 5 described above, the slide pads are shaped differently depending on whether they are mounted on a multi-planar rail or a horizontal rail. The slide pads may be square in shape, and are usually symmetrical with respect to their diagonal extending towards the center of the intersection when rails 10 of identical shape are joined.

FIG. 14 is a perspective view showing how a slide pad may be fastened to the track. Slide pad 98 may be secured to track intersection 80 by screw 81. The screw is placed through screw hole 82 drilled through track 80. 15 Rotation of slide pad 79 around screw hole 82 may be prevented by placing lug (not shown) on the slide pad into a second hole 83 drilled through track 80.

FIG. 15 is a detail of a slide pad . for use on track corners where slanted rails' intersect. The upper 2o surface includes a horizontal portion 84 for engaging the outer drive wheel, and a slanted portion 85 for engaging the inner drive wheel. The lower surface also has a horizontal surface 86 to fit the horizontal pla:nar portion of the rail, and a slanted surface 87 to fit the inner slanted surface of 25 the rail. The pad also includes hol.e 90, which is capable of receiving a screw or other fastener to secure the pad to the track. Screw receiving wall 89 and lug 88 also serve to prevent the lug from moving on the track.

FIG. 16 is a detail of a slide pad * - for use on track corners where horizontal rails intersect. The entire lower surface 92 and 94 of the pad is horizontal. Upper surface portion 91 is also horizontal to provide support of the outer drive wheel, while upper surface portion.93 is slanted to support the. slanted inner drive 35 wheel. The pad also includes hole 96, which is capable of receiving a screw or other fastener to secure the pad to the • track. Screw receiving wall 95 and lug 97 also serve to prevent the lug from moving on the track. 234 6 5 -i3- ; Although the present invention has. been described with reference to the accompanying drawings, it is not limited to that precise embodiment, and various- changes and modifications can be effected therein without departing from 5 the scope or spirit of the invention'. 1 23465

Claims (5)

WHAT WE CLAIM IS;

1. A wall panel mount assembly comprising: a housing for mounting within and supporting a movable wall panel, the housing having upper and lower walls and an aperture in the upper wall capable of receiving a shaft of a trolley which slidably supports the wall panel from a track section, said housing enclosing: a nut having internal threads for receiving a threaded portion of the shaft; a first resilient flexible block having an aperture in it retaining the nut in alignment with the aperture in the upper wall; a first washer, through which the shaft can be inserted, that is positioned above the first resilient flexible block and that is retained thereby in contact with the upper wall of the housing; a second washer, through which the shaft can be inserted, that is aligned with the aperture in the first resilient flexible block; and that is positioned below and in contact with the first resilient flexible block; and a second resilient flexible block in contact with and below the second washer and contacting the bottom wall of the housing, the second resilient flexible block having an aligned cavity capable of receiving an end portion of the shaft.

2. An assembly according to claim 1 in which the first washer has a circular aperture and further comprising a third washer having an outer diameter greater than that of the first washer and positioned between the first washer and the first resilient flexible block.

3. An assembly according to claim 1 or claim 2 in which the bottom wall of the housing has a circular aperture in it of a diameter greater than the diameter of the shaft.

4. A wall panel mount assembly as claimed in claim 1 and substantially as described in this specification ,-^th reference to figures 1 to

5. % ~—-