Abstract:
The present invention provides a track concealment system for use with a movable wall system having movable walls, a track and a trolley. The invention includes a pair of panels, each sized to conceal a portion of the track, and a pair of brackets each having a first portion attachable to the track and a second portion configured to support an edge of a corresponding panel. When supported by the second portion, the panels are arranged such that the edge of said panel is adjacent the connecting member thereby concealing the track.

Description:
This application claims the benefit of U.S. Provisional Application No. 60/194,212, filed Apr. 3, 2000. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention pertains to operable walls movable to partition large rooms into smaller rooms, and, in particular, to the overhead track for the operable wall. 
     Operable walls or partitions, also known as movable wall panel systems, find useful application in a variety of venues, such as classrooms, offices, convention facilities and hospitals. In these venues, the operable wall panels can be moved along tracks from which they are suspended to efficiently compartmentalize a larger room of interior space into a multitude of separate, smaller rooms. In particular, the operable wall panels are typically connected to trolleys that roll within an overhead track. The track is suspended from structural supports so as to be installed at a height of, or typically slightly above, the ceiling of the room being compartmentalized. 
     One shortcoming of existing tracks of operable walls is that many people consider their appearance to detract from the aesthetics of the room in which the operable walls are installed. For example, traditional tracks include soffit portions visible within the room and which flank on both sides the slot through which extend the bolts that span the trolleys and panels. The soffit portions, which in the past have been provided in several ways, such as laterally extending flanges integrally formed with a steel channel that forms the continuous track, or as pans that are secured to the hanger brackets by which the continuous track is suspended from the structural support, frequently are quite wide and naturally run the length of the track and therefore of the room being compartmentalized. Especially when the operable panels are arranged in their stacked positions, and even when the panels are arranged in their wall-forming positions directly below the track along its length, such soffit portions often stand in noticeable contrast to the ceiling in which they are installed because along their significant width they differ in material of construction, as well as possibly color, from the ceiling. 
     Another way in which existing tracks detract from the aesthetics of a room relates to the track slot, and is most noticeable when the panels of the operable wall are arranged in their stacked positions. The slot between the track soffit portions opens into the darkened interior of the track. As a result, the track slot often appears as a dark stripe along a lighter colored ceiling of the room. 
     Thus, it would be desirable to overcome these and other shortcomings of the prior art. 
     SUMMARY OF THE INVENTION 
     The present invention provides a track concealment system for use with a movable wall system having movable walls, a track and a trolley. The track defines a passageway, in which the trolley travels, and an opening, extending the length of the passageway through which a connecting member extends to connect the movable wall to the trolley. The invention includes a pair of panels, each sized to conceal a portion of the track, and a pair of brackets each having a first portion attachable to the track and a second portion configured to support an edge of a corresponding panel. When supported by the second portion, the panels are arranged such that the edge of said panel is adjacent the connecting member thereby concealing the track. 
     In one embodiment, the bracket can include a groove between the first portion and the second portion. The groove is configured to receive and hold a light strip or illuminating element. In this configuration, the track can serve the multipurpose tasks of providing additional lighting to the area and providing a track on which the trolley can travel. 
     In another aspect of the invention, at least one sweep is provided for concealing the connecting member. The sweep can be mounted to the edge of the movable wall. When mounted to the edge of the movable wall, the sweep can extend from the edge of the wall to the second portion of the bracket, thereby covering the connecting member. In addition, a rounded ridge may be defined in the second portion of the bracket. The rounded ridge can project inwardly toward the connecting member to limit the movement of the connecting member. The rounded ridge can also engage the sweep thereby securing the sweep in a position covering the connecting member. 
     One advantage of the present invention is that it allows for the better concealment of a track above the ceiling panels or materials of the room. 
     Another advantage of the present invention is that it may be adapted for use with existing track shapes. 
     Still another advantage of the present invention is that it is relatively inexpensive to manufacture and install. 
     Still another advantage of the present invention is that it provides for an illumination of the track interior, thereby reducing the contrast of the track path with a light colored ceiling so as to improve the aesthetics of a room. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above mentioned and other advantages and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following descriptions of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
     FIG. 1 is a diagrammatic perspective view of an operable wall with which the various embodiments of the track concealing system described herein may be employed; 
     FIG. 2 is a cross-sectional view, conceptually taken along line  2 — 2  of FIG. 1, further illustrating a first embodiment of a track concealing system of the present invention in use, wherein the room ceiling not shown in FIG. 1 is now shown, and wherein the trolley is connected to an abstractly shown operable wall panel; 
     FIG. 3 is a partial perspective view of a ceiling suspending bracket of FIG. 2 removed from the remainder of the track; 
     FIG. 4 is a cross-sectional view similar to FIG. 2 illustrating an alternate embodiment of a track concealing system of the present invention, and wherein one of the hanger bracket assemblies used to suspend the track from the support structure is also shown; 
     FIG. 5 is a cross-sectional view similar to FIG. 2 illustrating an alternate embodiment of a track and track concealing system of the present invention; and 
     FIG. 6 is a cross-sectional view similar to FIG. 2 of still another embodiment of a track concealing system of the present invention integrated into a trolley track, wherein a trolley is not shown. 
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the invention, the drawings are not necessarily to scale and certain features may be exaggerated or omitted in order to better illustrate and explain the present invention. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to FIG. 1, there is diagrammatically shown an operable wall which may be equipped with any of the track concealing systems of the present invention. The operable wall is shown as a paired panel system and includes operable partitions or wall panels  10 ,  11  and  13 ,  14  suspended from track  16  by trolleys  18 . The term trolley is used generally herein and is intended to encompass devices, including wheeled carriages and carriers, of all types that are operably connected to and movable along the track. Wall panel  10  is linked to panel  11 , and panel  13  is linked to panel  14 , by multiple hinges  20  arranged along the panel height. Track  16  is mountable to a support structure above the room to be compartmentalized in a well known fashion, and the track parts along which the trolleys  18  ride is located above the ceiling of the room (not shown in FIG. 1) as further described below. Panels  10 ,  11  and  13 ,  14  may be moved along the track in any known fashion in wall stacking and wall extending directions. The wall panels may be of any conventional design. Furthermore, although shown as being employed with a paired panel system, the track concealing systems described herein may be employed with different panel systems, including single panel systems, and with different or non-straight track layouts. 
     With reference now to FIGS. 2 and 3, one configuration of the track, trolley and a first embodiment of a track concealing system of the present invention is further described. Track  16  is of a known design and is made of hardened cold-rolled steel in a generally square tubed shape including a top wall  22 , vertical side walls  24  and  25 , and bottom wall portions  27  and  28 . Track  16  may be mounted to the ceiling support structure by any means known in the art, such as by not shown hanger brackets positioned at spaced intervals along the length of the track. 
     The upper surfaces of bottom wall portions  27  and  28  are the surfaces along which the wheels of trolley  18  roll when the wall panel is moved. The inward facing regions of bottom wall portions  27  and  28  are integrally formed with bend sections  30 ,  31 , respectively, that are horizontally spaced to provide a slot or gap through which vertically extends trolley bolt  44 . The lower ends of bend sections  30 ,  31  are integrally formed with laterally extending, horizontal flanges  33 ,  34 , respectively, that outwardly extend beyond the vertical plane of side walls  24  and  25 . The cross-sectional configuration of track  16  shown in FIG. 2 generally corresponds to its configuration along its entire axial length. 
     The trolley  18  shown is of a conventional, four-wheel design and is intended to be illustrative and not limiting, as other trolleys may be employed. Trolley  18  includes a pair of wheels  38  that roll along track portion  27  and a pair of wheels  39  that roll along track portion  28 . Portions of the axles that mount the wheels are not shown to facilitate illustration. Wheels  38  and  39  are rotatably mounted on a U-shaped base plate  42  with a central bore through which rotatably extends a steel trolley bolt  44 . The enlarged head  46  of trolley bolt  44  extends through a thrust bearing assembly  48  which is sandwiched between the underside of bolt head  46  and the upper surface of base plate  42 . In FIG. 2, the bolt head is shown as a nut which is attached to a threaded section of a rod that serves as the bolt, which nut is shown secured with a transversely extending pin. Other bolt heads can be formed as well. Thrust bearing assembly  48  permits relative rotation of trolley bolt  44  to base plate  42 . A pair of rotatable wheel assemblies  50  are mounted to the underside of plate  42  so as to flank bolt  44  on its leading and trail sides, and serve to rollingly engage track bend sections  30 ,  31  during trolley movement. The distal or lower end of trolley bolt  44  is attached to the top end of operable partition  10 , which is abstractly shown. The method of attachment of trolley bolt  44  to panel  10  is not shown or fully described herein as it may be of any type that is known in the art, as the particular form of the connection is not material to the present invention. Panel  10  is shown including an automatic operable top seal  8  that moves vertically from a lowered or retracted position to the operable position shown in which the resilient sweeps  9  engage for acoustical reasons the ceiling mounting brackets described further below. 
     Attached to track flanges  33 ,  34 , respectively, are ceiling mounting brackets or soffit portions generally designated  52  and  54 . Brackets  52  and  54  extend the entire length of track  16 , and the shown cross-sectional configuration of brackets  52  and  54  generally corresponds to the configuration of each bracket along its entire axial length. In the partial perspective view of FIG. 3, bracket  54  is shown removed from track  16  and alone. As brackets  52  and  54  are mirror images of one another, the following description of bracket  54  will be recognized as having equal application to bracket  52 . Bracket  54  is formed in one-piece from a lightweight but strong material, such as of aluminum, in an extrusion molding process. Bracket  54  is installed along the entire track length in segments that are assembled end-to-end. Although the length of the bracket segments may vary, such segments are typically about ten feet long so as to be easily worked with by an installer. 
     Bracket  54  includes a plate shaped body section  56  with a generally uniform thickness of about ⅛ inch. Bracket  54  is mounted to track flange  34  via self-tapping screws  55 , or other fasteners such as rivets, that pass through axially spaced holes  57  in body section  56  and which insert through aligned holes in track flange  34 . The laterally outward edge of body section  56  is bent upward and tapered in thickness at  58 . Edge  58  flanks and is in close proximity to, or alternatively directly abuts, the outside face of the bottom edge of a sound baffle  59 , such as a panel of plasterboard, that is frequently attached at its upper, not shown end to the ceiling support structure in an effort to prevent sound from traveling over the track between rooms formed by the operable wall. Upturned bracket edge  58  aids in locating the sound baffle and in preventing sound from passing underneath sound baffle  59 , and is shown as being about ¼ inches in height. Other heights of bracket edge  58 , such as within the range of {fraction (3/16)} to {fraction (5/16)} inches, may alternatively be employed. 
     Upwardly projecting from the top surface of body section  56  is a rectangular ridge  60  that serves as a lateral stop member during bracket installation. Ridge  60  is designed to extend slightly above flange  34 , and typically is about ⅛ to {fraction (3/16)} inches in height. Ridge  60  is spaced from the laterally inward extent of bracket  54  based on the horizontal width of flange  34  with which bracket  54  will be employed, and is designed to abut the end of flange  34  at a point where bracket  54  is properly located under track  16  and trolley  18 , such as where the minimum spacing between brackets  52  and  54  equals or is slightly greater than the spacing between track bend sections  30  and  31 . Although ridge  60  is shown as continuous along the axial length of the bracket, such a configuration is a result of the extrusion molding process, as the stop could be provided in other manners, such as in the form of detents positioned at axial intervals along the bracket length. 
     The inward edge of body section  56  is integrally formed with a downwardly and inwardly extending arcuate section  64  that terminates in the vertical leg  66  of an L-shaped panel support, generally designated  68 . Arcuate section  64  defines an inward facing hollow  70  into which is preferably installed a strip light or illuminating element, abstractly shown at  72 , that is electrically attached to a not shown power source at a track end, such as at the location where the panels are stacked or at the lead end of the track. The strip light is optional. Arcuate section  64  preferably extends upward at its inward end  65  a sufficient distance above the bottom of hollow  70  so that a shallow groove  71  spanning greater than 180° is formed in which illuminating element  72  may be captured without the use of additional fasteners. Fasteners also may be used. 
     Illuminating element  72 , which continuously extends along the entire bracket length, functions to light up the gap between brackets  52  and  54 , as well as to partially illuminate the room. One suitable illuminating element  72  is a cord of lights available from National Speciality Lighting, Inc., of Louisville, Colo., under the product name of Light Rope 500. Rather than extending continuously, the light cord may be installed at only selected sections of the track length, but such installation may require more power source wiring. 
     L-shaped panel support  68  includes a support ledge  75  arranged perpendicular to vertical leg  66 . A rounded ridge  77  that protrudes inwardly at the bottom end of vertical leg  66  is designed to be the point of contact by panel support  68  with the trolley bolt  44  when the panel sways to maintain low the frictional resistance to trolley movement by that contact. 
     The upper surface  78  of support ledge  75  functions as a ledge that supports the edge of the ceiling element, generally designated  80 , installed thereon. Ceiling element  80  is the same material as the rest of the ceiling adjacent the track and of the room in which the operable wall is installed. For example, ceiling element  80  may be tiles of a suspended ceiling, or possibly plasterboard also known as drywall or gypsum. Ceiling element  80 , and more specifically portions of the ceiling element having bottom surface area uncovered by the ceiling mounting bracket, is directly below portions of the trolley, as well as the track. 
     Support ledge  75  has a relatively small width or horizontal profile such that its downward facing bottom surface  82  is relatively inconspicuous in the ceiling to an observer in the room. Bottom surface  82  is preferably sufficiently wide to be engaged by retractable or operable acoustical sweeps  9  mounted to the panel which may be pressed into contact with surface  82  to provide a sound seal between the panel and the ceiling. In the shown embodiment, support ledge  75  has a thickness of about ⅛ inch and horizontally juts outward beyond vertical leg  66  a distance of about ⅜ inches, and preferably juts outward within the range of about ¼ and 3.0 inches, and more preferably within the range of about ⅜ and ¾ inches. For a thickness of about ⅛ inches for vertical leg  66  and a protruding height of ridge  77  of about {fraction (5/64)} inches, surface  82  has a downward facing width of about {fraction (37/64)} inches in the shown embodiment. As a result, when the track slot or gap between ridges  77  of brackets  52  and  54  is about ¾ inches for a ½ inch diameter trolley bolt, the distance between the outward edge of support ledge  75  of bracket  52  and the outward edge of support ledge  75  of bracket  54  is about 1.9 inches. 
     Referring now to FIG. 4, there is shown a second embodiment of a track concealing system of the present invention. The track  116  and trolley  118  are identical to the track  16  and trolley  18  shown in the embodiment illustrated in FIG.  2 . Track  116  is mounted to the ceiling support structure by means of hanger brackets, such as shown at  120 , positioned at spaced intervals along the length of the track. Hanger bracket  120  includes top bar  122  to which is welded a pair of gusseted and reinforced support members  124  and  126  that fit under and support track  116 . Not shown hanger rods and securing nuts are used to mount the hanger bracket  120  to the support structure in a conventional manner. 
     Ceiling mounting brackets  130  and  132  are attached to horizontal flanges of track  116 . Bracket  130  and  132  are similar in most respects to brackets  52  and  54  described above, and therefore explanation herein is generally limited to the differences therebetween. Ceiling brackets  130  and  132  include L-shaped hooks  140  and  142 , instead of upstanding ridges  60 , that extend along the bracket length. The vertical legs  144 ,  146  of hooks  140  and  142  serve as stop members to control the lateral placement of the brackets relative to the track  116  during installation, and the horizontal legs or lip sections  148 ,  150  of hooks  140  and  142  fit over the track flanges and serve to hold the brackets in place during bracket installation prior to the fixed securement of the brackets to the track with screws  155 . The laterally outward edges  158 ,  160  of the brackets have a higher vertical profile than bracket edge  58 , and are shown extending upward a height of about {fraction (5/16)} inches. Ceiling mounting brackets  130  and  132  lack the strip light mounting recess shown in the embodiment of FIG. 2, and consequently the inward end of body section  156  of each bracket is integrally formed with the vertical leg of an L-shaped panel support, generally designated  168 . 
     Referring now to FIG. 5, there is shown still another embodiment of a track concealing system of the present invention for use with a differently configured track. Track  180  is similar to track  16  and includes a top wall  182 , vertical side walls  184  and  185 , and bottom wall portions  187  and  188 . Bottom wall portions  187 ,  188  are integrally formed with bend sections  190 ,  191  that turn out into laterally extending, horizontal flanges  193 , 194 , respectively, that include upturned ends  196 ,  197 . The cross-sectional configuration of track  180  shown corresponds to its configuration along its entire axial length. 
     Track  180  is mounted to the ceiling support by hanger brackets, such as shown at  200 , positioned at spaced intervals along the track length. Hanger bracket  200  includes top bar  202  to which is welded a channel segment  204  that supportably extends under track  180 . Screws  206  that insert through tapped holes in channel segment  204  are tightened against top wall  182  to retain track  180  within channel segment  204 . A pair of hanger rods  207  and associated securing nuts  208  are used to mount the hanger bracket  200  to the support structure in a conventional fashion. Sound baffling panels  210  and  212  that extend along the track length are mounted to the support structure and abut the upper surface of track flanges  193  and  194  to limit sound transmission over the track. 
     Trolley  215  is similar to trolley  18  of FIG.  2  and includes a pair of wheels  218 , a pair of wheels  219 , a U-shaped base plate  222  through which extends a trolley bolt  224 , a thrust bearing assembly  228  around bolt  224 , and wheel assemblies  230  flanking bolt  224 . The lower end of trolley bolt  224  is attached to the upper end of an abstractly shown operable partition  10  in a conventional fashion. Panel  10  includes a pair of operable acoustical sweeps or seals  235  that are rotatable from the retracted position shown to a sealing position in which their elastomeric structure achieves a sound barrier seal with the bottom surface of the ceiling mounting brackets  240  and  242 . 
     Attached to track flanges  193 ,  194 , respectively, are mirror image ceiling mounting brackets  240  and  242  that extend the entire length of the track  180  in the configuration shown. Each bracket is formed in one-piece of aluminum in an extrusion molding process. Bracket  240  includes a plate shaped body section  244  with axially spaced holes therethrough that accommodate self-tapping screws  246  insertable into holes in track flange  193  to mount bracket  240  to the track. The laterally outward edge  248  of body section  244  is bent upward about ½ inches and is of a reduced thickness and directly abuts the upturned track end  193  to serve as a lateral stop member during bracket installation. The inward edge of body section  244  is integrally formed with arcuate section  250  that provides a seat for electrical strip light  252 . Bracket arcuate section  250  terminates in an L-shaped panel support  255  that extends under and supports the edge of the ceiling element shown at  270 . 
     Bracket  242  similarly includes plate shaped body section  260 , an upward bent end  262  that serves as a lateral stop member during installation of bracket  242 , arcuate section  264  with strip light  266 , and an L-shaped panel support  268  that supports ceiling element  272 . 
     Referring now to FIG. 6, there is shown still another embodiment of a track concealing system of the present invention integrated into a trolley track. In this embodiment, which requires a custom made track part as opposed to the tracks shown in the other figures which are already known in the art, the track includes a top wall  300 , vertical side walls  302  and  304 , and bottom wall portions  306  and  308  upon which the not shown trolleys ride. Bottom wall portions  306  and  308  are integrally formed with depending flanges  310  and  312  that at their lower ends terminate in L-shaped panel support portions  314  and  316  similar to the supports  68  of the embodiment shown in FIG.  2 . Support portions  314  and  316  suspend ceiling panels  320  and  322  directly below the track and the not shown trolley. 
     Although this invention has been shown and described as concealing a track installed in a ceiling support structure, it is contemplated that this invention can also be used to conceal tracks installed in other structures, such as walls and floors. 
     While this invention has been shown and described as having multiple designs, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.