Patent Publication Number: US-9428908-B2

Title: Movable partition systems and methods of aligning a leading end of a movable partition

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/720,804, filed Dec. 19, 2012, now U.S. Pat. No. 8,869,867, issued Oct. 28, 2014, which application is a continuation of U.S. patent application Ser. No. 12/857,412, filed Aug. 16, 2010, now U.S. Pat. No. 8,336,597, issued on Dec. 25, 2012, the disclosure of each of which is hereby incorporated herein in its entirety by this reference. 
    
    
     TECHNICAL FIELD 
     Embodiments of the present invention are directed to the field of movable partitions used for one or more of partitioning space, as sound barriers, fire barriers, security barriers, or for various other applications. 
     BACKGROUND 
     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 barrier 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. For example, one or more accordion or similar folding-type partitions may be used as a security barrier, a fire barrier, or both a security barrier 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 movable partition in a header assembly, until the partition extends a desired distance across the room. 
     When deployed, a leading end of the movable partition, often defined by a component known as a lead post, complementarily engages another structure, such as a wall, a post, or a lead post of another door. 
     Automatic extension and retraction of the movable partition may be accomplished through the use of a motor located in a pocket formed in the wall of a building in which the movable partition is stored when in a retracted or folded state. The motor, which remains fixed in place within the pocket, may be used to drive extension and retraction of the movable partition. A motor for automatically extending and retracting a movable partition may also be mounted within the movable partition itself, such that the motor travels with the movable partition as the movable partition is extended and retracted using the motor. 
     In some cases, the lower edge of the movable partition, including the lower edge of the movable partition&#39;s lead post, may be laterally displaced relative to the top edge of the movable partition, which may be relatively fixed in a lateral sense due to engagement with an overhead track and header. Such lateral displacement of the movable partition&#39;s lower edge may be caused, for example, by a fire-induced draft, by an improperly balanced heating, ventilating, and air-conditioning (HVAC) system, by smoke evacuation systems, building air pressure systems, or simply from an occupant of a room pushing against the movable partition while it is being deployed. If the lower end of the lead post is laterally displaced relative to its upper end as the leading edge of the movable partition approaches the mating receptacle, the lead post may not be properly aligned with the mating receptacle and an appropriate seal may not be formed. In other words, the mating receptacle is conventionally installed to be substantially plumb. If the lower end of a lead post of a movable partition is laterally displaced relative to its upper end, the lead post is not plumb (or substantially vertically oriented) and, thus, may not properly engage the substantially plumb receptacle. 
     As noted above, the failure of the lead post to properly engage the receptacle may have significant consequences when, for example, the movable partition is being used as a fire or security barrier. One approach to preventing or controlling the lateral displacement of a lower end of the movable partition has included forming a guide track within the floor of a room, and then causing the movable partition or barrier to engage the track as it is deployed and refracted such that both the top and the bottom of the movable partition is laterally constrained. However, the placement of a track in the floor of a room is not an ideal solution for all applications. For example, such a track provides a place for collection of dust and debris and may, thereby, become an unsightly feature of the room. In some cases, the collection of debris may affect the proper operation of the movable partition itself. Furthermore, the existence of a track in the floor may act as a hazard or potential source of injury depending, for example, on the intended use of the area and the actual location of the floor track within that area. 
     BRIEF SUMMARY 
     In accordance with one aspect of the invention, a movable partition system is provided. The movable partition system includes a movable partition configured to extend across a space within a building when the movable partition system is installed within a building. At least one track is configured to be coupled to an overhead structure of the building and to extend across the space when the movable partition is installed within the building. The movable partition is configured to be suspended from the at least one track when the movable partition is installed within the building. A strike plate is configured to be mounted to a wall within the building when the movable partition system is installed within the building, the strike plate being configured to engage the leading end of the movable partition when the movable partition is extended across the space within the building to an extended, closed configuration. A vertical alignment structure is coupled to the movable partition proximate a leading end of the movable partition, which comprises at least one roller element located laterally beyond a lateral side of the movable partition and at least one structural frame member coupling the at least one roller element to the movable partition, the at least one structural frame member coupled to the at least one roller element and to at least one component of the movable partition. At least one ramp is configured to be coupled to the overhead structure of the building when the movable partition system is installed within the building. The at least one ramp has at least one ramp surface configured to be orientated at an acute angle greater than zero relative to the horizontal plane. The at least one ramp surface is configured to abut against the at least one roller element as the movable partition is caused to extend across the space within the building to the extended, closed configuration and to cause the leading end of the movable partition to be aligned with the strike plate as the leading end of the movable partition engages the strike plate. 
     In accordance with another aspect of the present invention, a system for vertically aligning an automatic door is provided. The system comprises a movable partition configured to extend across a space within a building when the movable partition system is installed within a building. A drive is configured to motivate the movable partition along at least one track configured to be coupled to an overhead structure of the building. The movable partition is configured to be suspended from the at least one track. A vertical alignment structure comprising at least one roller element is coupled to an upper portion of the at least one component of the movable partition and at least one ramp is configured to be coupled to the overhead structure of the building. The at least one ramp has at least one ramp surface configured to be orientated at an acute angle greater than zero relative to the horizontal plane, the at least one ramp surface is configured to abut against the at least one roller element as the drive motivates the movable partition along the at least one track and causes the leading end of the movable partition to be at least substantially perpendicular to the horizontal plane. 
     In accordance with yet another aspect of the present invention, a method of forming a movable partition system is provided. The method includes installing at least one track to an overhead structure of a building with the at least one track extending across a space within the building. A movable partition comprising a leading end is suspended from the at least one track. A strike plate is mounted to a wall within the building and is configured to engage the leading end of the movable partition. At least one vertical alignment structure is coupled to the movable partition that includes coupling at least one structural frame member to at least one component of the movable partition and coupling at least one roller element to the at least one structural frame member such that the at least one roller element is located laterally beyond a lateral side of the movable partition. At least one ramp is installed to the overhead structure of the building when the movable partition system is installed within the building. The at least one ramp has at least one ramp surface that is orientated at an acute angle greater than zero relative to the horizontal plane. The at least one ramp is configured to abut the at least one roller element and align the leading end of the movable partition with the strike plate when the movable partition is extended across the space within the building. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       While the specification concludes with claims particularly pointing out and distinctly claiming what are regarded as embodiments of the present invention, the advantages of the embodiments of the invention may be more readily ascertained from the description of embodiments of the invention when read in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of an embodiment of a movable partition system of the present invention; 
         FIG. 2  is a simplified, schematic horizontal cross-sectional view of components of the movable partition system of  FIG. 1 ; 
         FIG. 3  is a simplified, schematic front view of the movable partition system of  FIG. 1 ; 
         FIG. 4  is a perspective view of components of the movable partition system of  FIG. 1  used for vertically aligning the movable partition as it is extended to a closed configuration; 
         FIG. 5  is a perspective view of a ramp used in conjunction with the components shown in  FIG. 4  for vertically aligning the movable partition as it is extended to a closed configuration; 
         FIGS. 6 and 7  are simplified, schematic illustrations used to illustrate how the components shown in  FIG. 4  and the ramp of  FIG. 5  may be used to vertically align the movable partition as it is extended to a closed configuration in accordance with embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-3 , an automatic movable partition system  100  is shown that includes a movable partition in the form of an accordion-type door  102 . The door  102  may be configured to extend across a space within a building when the movable partition system  100  is installed within a building. The door  102  may be used, for example, as a security and/or fire door. In other embodiments, the door  102  need not be utilized as a fire or security door, but may be used simply for the subdividing of a larger space into smaller rooms or areas. The door  102  may be formed with a plurality of panels  104  that are connected to one another with hinges or other hinge-like members  106 . The hinged connection of the panels  104  allows the door  102  to be compactly stored in a pocket  108  formed in a wall  110 A of a building when in a retracted or folded state. 
     When it is desired to deploy the door  102  to an extended position, for example, to secure an area such as an elevator lobby  112  during a fire, the door  102  is driven along at least one track  114  across the space to provide an appropriate barrier. The at least one track  114  may be configured to be coupled to an overhead structure of the building and to extend across the space when the movable partition system  100  is installed within the building. The door  102  may be configured to be suspended from the at least one track  114 . When in a deployed or an extended state, a leading edge of the door  102 , shown to include a male lead post  116 , complementarily or matingly engages with a door post or strike plate  118  that may be formed in a wall  110 B of a building. The strike plate  118  may be configured to be mounted to the wall  110 B of a building when the movable partition system  100  is installed within the building. As can be seen in  FIG. 2 , an accordion-type door  102  may include a first sheet  102 A of panels  104  and a second sheet  102 B of panels  104 , which is laterally spaced from the first sheet  102 A. Such a configuration may be utilized as a fire door wherein one sheet  102 A of panels  104  acts as a primary fire and smoke barrier, the space  122  between the two sheets  102 A and  102 B of panels  104  acts as an insulator or a buffer zone, and the second sheet  102 B of panels  104  acts as a secondary fire and smoke barrier. Such a configuration may also be useful in providing an acoustical barrier when the door  102  is used to subdivide a larger space into multiple, smaller rooms. 
     A drive device, which may include, for example, a motor  124  and a drive belt or chain  125  ( FIG. 2 ), may be configured to open and close the door  102  upon actuation thereof. The movable partition system  100  may further include various sensors and switches to assist in the control of the door  102  through appropriate connection with the drive device. For example, as shown in  FIG. 1 , when used as a fire door, the door  102  may include a switch or actuator  126 , commonly referred to as “panic hardware.” Actuation of the panic hardware  126  allows a person located on one side of the door  102  to cause the door  102  to open if it is closed, or to stop while it is closing, allowing access through the barrier formed by the door  102  for a predetermined amount of time. 
     It is noted that, while the exemplary embodiment shown and described with respect to  FIGS. 1 and 2  is directed to a single accordion-type door  102 , other movable partitions may be utilized. For example, a two-door, or bi-part door, system may be utilized wherein two similarly configured doors extend across a space and join together to form an appropriate barrier. In such a two-door system, a vertical alignment system  129  as described herein may be placed on one or both doors to ensure vertical alignment of one or both doors with each other. Also, the present invention is applicable to movable partitions or barriers other than the accordion-type doors that are shown and described herein. 
     Referring still to  FIGS. 1-3 , the door  102  of the present invention further includes a vertical alignment system  129  that may be used to ensure vertical alignment of the door  102  or at least a portion thereof. The vertical alignment system  129  includes a vertical alignment structure  130  and at least one ramp  131 . For example, upon the exertion of an external force, such as by a draft or from an individual pushing on the door  102  while it is being deployed or retracted, the lead post  116  (or some other section of the door  102 ) may deviate from its intended plumb orientation, or substantially vertical orientation, as indicated by dashed lines at  116 ′ in  FIG. 3 . In other words, a lower portion of the door  102 , such as the lower edge  132 , may become laterally displaced relative to the upper edge  134  of the door  102 , which is substantially laterally fixed by virtue of its engagement with the at least one track  114 . As previously discussed, in such a case where the lead post  116  is out of plumb (e.g., not substantially vertically oriented), the lead post  116  will not properly engage the door post or strike plate  118  and will prevent the door  102  from properly closing and forming a proper barrier. However, in accordance with the present invention, the vertical alignment system  129  may be configured to correct a deviation of the door  102  from its desired course or orientation. 
     It is noted that, while embodiments of the present invention are generally discussed with respect to correcting a section of the door  102  or other partition that has deviated from a substantially plumb or vertical orientation through use of a vertical alignment system  129 , embodiments of the present invention more broadly contemplate positioning a section of the door  102  to a selected or specified orientation. 
     For example, an existing or previously installed door  102  may be retrofitted or modified to include a vertical alignment system  129 . In certain installations, the strike plate  118 , with which a lead post  116  will engage, may have been improperly or carelessly installed such that it is out of plumb by a determined magnitude. In such a case, the vertical alignment system  129  may be configured to guide the lead post  116  of the door  102  such that it is also out of plumb by the same magnitude, and in a corresponding direction, thereby enabling the lead post  116  to engage with the strike plate  118  and effect a desired coupling or seal therebetween. 
     Referring now to  FIGS. 4 and 5 , the vertical alignment system  129  ( FIG. 1 ) includes a vertical alignment structure  130  (shown in  FIG. 4 ) and at least one ramp  131  (shown in  FIG. 5 ). The vertical alignment structure  130  shown in  FIG. 4  may be coupled to the door  102  proximate the lead post  116 . The vertical alignment structure  130  comprises at least one roller assembly  204  located laterally beyond a lateral side of the door  102 . A structural frame member  202  may be used to couple the at least one roller assembly  204  to the door  102 . 
     In some embodiments, the structural frame member  202  may be coupled to a rear surface  208   b  of an upper portion of the lead post  116 . The rear surface  208   b  of the lead post  116  is also coupled to the door  102  ( FIGS. 1-3 ) which has been omitted from  FIG. 4  for clarity. A front surface  208   a  of the lead post  116  remains unobstructed by the vertical alignment structure  130  such that the lead post  116  may properly engage the door post or strike plate  118  ( FIG. 2 ) as previously described. The vertical alignment structure  130  is also positioned so as not to obstruct a track assembly  221  from engaging with the at least one track  114  ( FIG. 1 ). The structural frame member  202  may comprise, for example, a plate as illustrated in  FIG. 4 . At least one spacer  206  may be coupled to the rear surface  208   b  of the lead post  116  and positioned between the first sheet  102 A and the second sheet  102 B ( FIG. 2 ) of panels  104  of the door  102 . In some embodiments, a short structural vertical bar  213  may also be coupled to the lead post  116  extending vertically from an upper portion of the lead post  116 . The structural frame member  202  may be coupled to the at least one spacer  206  and the vertical bar  213 . The structural frame member  202  may be secured to the vertical bar  213  via a lead post bolt  214  that extends through the structural frame member  202  and the vertical bar  213 . In additional embodiments, the vertical bar  213  may be omitted and the structural frame member  202  may be coupled to the at least one spacer  206  and the lead post  116 , or to just the lead post  116 . The lead post bolt  214  and the at least one spacer  206  not only provide a means to affix the structural frame member  202  to the lead post  116 , but also may provide lateral support to the structural frame member  202  when the at least one roller assembly  204  abuts the at least one ramp  131  ( FIG. 5 ) as described in greater detail below. The at least one spacer  206  may also provide a means to affix the structural frame member  202  to the lead post  116  without the risk of damage to the lead post  116  caused by tightly affixing the structural member  202  to the lead post  116 . In further embodiments, the structural frame member  202  may be permanently coupled to the lead post  116  by, for example, welding or chemical bonding. 
     The structural frame member  202  includes at least one roller assembly  204  coupled therewith. In one embodiment, at least one structural frame member  202  may have a generally triangular shape and the at least one roller assembly  204  may be coupled to a corner of a structural frame member  202  opposite the lead post  116 . The at least one roller assembly  204  may include a bracket  220  configured to attach at least one roller element  216  to the at least one structural frame member  202 . The at least one roller element  216  may comprise, for example, a wheel configured to rotate or roll about a first axis or a rolling axis, which may be defined by a hub or axle  218  that extends through the roller element  216  and secures the roller element  216  to the bracket  220 . While each roller assembly  204  is illustrated in  FIG. 4  as including one roller element  216 , it is understood that a plurality of wheels may be coupled to the at least one structural frame member  202 . 
     In some embodiments, the at least one roller assembly  204  is adjustably coupled to the at least one structural frame member  202 . For example, as shown in  FIG. 4 , the at least one structural frame member  202  may include at least two holes  210  at differing heights on the at least one structural frame member  202 . In one embodiment, the structural frame member  202  may include three holes  210 . The holes  210  may be spaced close together so that the height of the roller assembly  204  may be acutely adjusted. In one embodiment, an inside diameter of one hole of the at least two holes  210  may be about one-quarter (¼) inch from an inside diameter of an adjacent hole. The at least one roller assembly  204  may be attached to the at least one structural frame member  202  using a fastener  212 , such as a bolt and nut, extending through one of the at least two holes  210  having the desired height. By adjustably coupling the at least one roller assembly  204  to the at least one structural frame member  202 , the at least one roller assembly  204  may be adjusted to a desirable height to move the lead post  116  to a plumb position as described in greater detail below. 
     The horizontal distance from a center of the lead post  116  to the at least one roller assembly  204  may be about one-half (½) foot to about three (3) feet. In one embodiment, the horizontal distance may be about eight (8) inches long. In another embodiment, the vertical alignment structure  130  includes at least two roller assemblies  204  disposed substantially symmetrically about a vertical centerline of the lead post  116 . The at least two roller elements  216  may have a distance D 204  ( FIG. 7 ) between the two roller assemblies  204  of about two (2) feet to about four (4) feet. The greater the distance between the center of the lead post  116  and the at least one roller assembly  204 , the greater the force that will be applied to vertically align the lead post  116  as described in greater detail below. If, for example, a force causing the lead post  116  to be out of plumb is expected to be large, such as a strong draft, then the distance between the center of the lead post  116  and the at least one roller assembly  204  may be increased to overcome the force. 
       FIG. 5  illustrates an enlarged lateral view of at least one ramp  131  of an embodiment of the present invention. As shown in  FIG. 5 , the at least one ramp  131  is configured to be coupled to an overhead structure of the building, such as to a ceiling  222  of the room adjacent the wall  110 B housing the door post or strike plate  118  as described above regarding  FIG. 1 . The at least one ramp  131  is provided for each roller assembly  204  ( FIG. 4 ). For example, if the vertical alignment structure  130  includes two roller elements  216 , as shown in  FIG. 4 , then two ramps  131  may be provided. The at least one ramp  131  may be placed adjacent the at least one track  114  ( FIG. 1 ) such that the at least ramp  131  abuts the at least one roller assembly  204  as the door  102  is caused to extend across the space within the building to the extended, closed configuration. The at least one ramp  131  may be formed of, for example, a metal (e.g. steel). In other embodiments, the at least one ramp  131  may be formed of, for example, a plastic, a composite material, and a ceramic. 
     In some embodiments, the at least one ramp  131  includes a beveled portion  224  where the at least one roller assembly  204  first engages the at least one ramp  131  upon closing of the door  102 . The at least one ramp  131  includes a ramp surface  226  configured to be orientated at an acute angle α greater than zero relative to the horizontal plane. As used herein, the phrase “the horizontal plane” refers to a plane perpendicular to earth&#39;s gravitational field. For example, the angle α may be between about five degrees (5.degree.) and about 30 degrees (30.degree.). 
     In one embodiment, the at least one ramp  131  may be generally triangular such that the at least one ramp  131  is flush with the ceiling  222 . In another embodiment, at least one shim  228  may be optionally placed between a generally planar at least one ramp  131 ′ and the ceiling  222  causing the generally planar at least one ramp  131 ′ to gradually slope downward toward the wall  110 B. The thickest portion of the shim  228  may have a thickness of, for example, about one-quarter (¼) inch. 
     The at least one ramp  131  may have a total length L 1  such that when the vertical alignment structure  130  engages the at least one ramp  131 , a gradually increasing downward pressure is applied from the at least one ramp  131  to the vertical alignment structure  130 . 
     In one embodiment, the length L 1  of the at least one ramp  131  may be at least about three (3) ft. The beveled portion  224  of the at least one ramp  131  may have a length L 2  of about one (1) inch to about twelve (12) inches. A maximum height h 2  of the at least one ramp  131  may be from about one-quarter (¼) inch to about five (5) inches. The generally planar at least one ramp  131 ′, excluding the beveled portion  224 , may have a height h 1  of about one-tenth ( 1/10) inch to about three (3) inches. Thus, a maximum height h 2  from a ramp surface  226  of the at least one ramp  131  to the ceiling  222  may be from about one-quarter (¼) inch to about five (5) inches. 
     In some embodiments, when the at least one ramp  131  is installed and mounted to the ceiling  222 , the ramp surface  226  may have a pitch (i.e., the ratio of change in height to change in length, .DELTA./.DELTA.L) of between about one-sixteenth inch per foot ( 1/16 in./ft.) and about two inches per foot (2 in./ft.). 
     The at least one roller assembly  204  of the vertical alignment structure  130  ( FIG. 4 ) is configured to engage or abut the at least one ramp  131  ( FIG. 5 ) such that if the lead post  116  of the door  102  ( FIG. 1 ) is out of plumb, the at least one ramp  131  will provide a gradually increasing downward pressure on the vertical alignment structure  130  forcing the lead post  116  into the plumb position.  FIG. 6  is an enlarged schematic of the vertical alignment structure  130  when the door  102  is out of plumb and before the vertical alignment structure  130  has engaged the at least one ramp  131 .  FIG. 7  is an enlarged schematic of the vertical alignment structure  130  after the vertical alignment structure  130  has engaged the at least one ramp  131  and the at least one ramp  131  has provided a downward pressure on the vertical alignment structure  130  thus forcing the door  102  into the plumb position. As shown in  FIG. 6 , when the lead post  116  is out of plumb, a first distance D 1  between the at least one roller assembly  204  and the ceiling  222  on a first side  301  of the vertical alignment structure  130  is less than a second distance D 2  between the at least one roller assembly  204  and the ceiling  222  on a second side  302  of the vertical alignment structure  130 . As shown in  FIG. 7 , when the at least one roller assembly  204  on the first side  301  of the vertical alignment structure  130  engages or abuts the at least one ramp  131 , the at least one ramp  131  provides a downward pressure on the at least one roller assembly  204  causing the first distance D 1  to gradually increase to a third distance D 3 . As the first distance D 1  increases, the lead post  116  becomes plumb and the second distance D 2  decreases to also equal the third distance D 3 . 
     As shown in  FIG. 7 , at least one ramp  131  may be provided for each roller assembly  204 . For example, as illustrated in  FIG. 7 , the vertical alignment structure  130  includes two roller assemblies  204  and two ramps  131 . The two ramps  131  flank each side of track  114  in the ceiling  222 . It is noted that, while the exemplary embodiments described hereinabove include a pair of roller assemblies  204  and ramps  131 , the invention may be practiced with a single roller assembly  204  and ramp  131 . For example, if the door  102  illustrated in  FIG. 6  is expected to be consistently out of plumb in one direction, such as if that the first distance D 1  is consistently less than the second distance D 2 , then the at least one roller assembly  204  and the at least one ramp  131  may be placed on only a first side  301  of the vertical alignment structure  130  of the door  102 . 
     The vertical alignment system  129 , as illustrated in  FIG. 1 , of the present invention may offer any number of advantages over the prior art. For example, because the vertical alignment system  129  is coupled to the lead post  116 , the floor of a room is unobstructed unlike when a track is placed in the floor of the building to maintain the lead post  116  plumb. Also, previously installed movable partitions or doors  102  may be easily retrofitted with the vertical alignment system  129 . Furthermore, because the vertical alignment system  129  does not require any electronics, the vertical alignment system  129  requires minimal upkeep. Other advantages may also be provided by embodiments of the invention. 
     While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.