CROSS REFERENCE TO RELATED APPLICATIONS This application claims benefit of priority to U.S. Provisional Patent Application No. 61/165,215 filed on Mar. 31, 2009, which is hereby incorporated by reference, in its entirety.
TECHNICAL FIELD The present disclosure relates generally to an adjustable floor channel assembly for wall systems, and more particularly, to a low-profile, adjustable floor channel assembly for adjusting the height of a wall panel in a wall system so that the wall panel is substantially level, plumb, and square.
BACKGROUND Existing wall systems often include floor channels that are imbedded in the walls and that sit on a floor track. The floor channels allow wall panels of such wall systems to be adjusted to accommodate uneven floors. For example, FIG. 1 depicts a prior art wall system 10 having a floor track 12, which may be mounted to a floor 14, and a lower track trim 16 disposed over the floor track 12. The lower track trim 16 may house a threaded glide 18, which may extend generally perpendicular to the floor 14. The system 10 may also include a glide support assembly 20 connected to the threaded glide 18 and a structural bottom rail 22 for holding the glide support assembly 20. The structural bottom rail 22 may define a channel 24 for supporting a wall panel (not shown).
The height of the wall panel may be adjusted up and down by moving the glide support assembly 20 along the threaded glide 18. As the height of the wall panel is increased, the lower track trim 16 is raised above the floor track 12. Conversely, as the height of the wall panel is lowered, the lower track trim 16 is lowered over the floor track 12.
As shown in FIG. 1, the lower track trim 16 has a high-profile to accommodate the size of the threaded glide 18 and the range of height adjustments needed to ensure that the wall panel is level, plumb, and in square. The high-profile of the lower track trim 16 often detracts from the overall aesthetic appearance of the wall system 10.
Another common method for leveling demountable and movable wall systems includes the use of shims, which are typically pieces of wood, plastic or metal that increase in thickness from one end to the other. The shims may be placed along specific points of the wall system to level the lower base channel. This method of adjustment, however, is inefficient, generally time consuming and, like the wall system 10 described above, may detract from the overall aesthetic appearance of the wall system.
SUMMARY The invention is directed generally to an adjustable floor channel assembly that may be used to easily adjust the height of a wall panel in a wall system so that the wall is substantially level, plumb, and square. The floor channel assembly may include a floor track that defines a channel. The floor channel assembly may also include a leveling guide assembly that can be oriented within the floor channel assembly to have any one of multiple configurations. Each configuration of the leveling guide assembly provides a different height adjustment range. The floor channel assembly may further include a support track that is supported by the leveling guide assembly. The support track may be configured to receive at least a portion of the wall panel.
In one embodiment, the leveling guide assembly may include at least two supports, which may define first, second, and third sides of the leveling guide assembly. The leveling guide assembly may also include a base portion that is connected to the first and second supports. The base portion may be offset along a length of at least one of the first, second, or third sides of the leveling guide assembly. The leveling guide assembly may be configured to provide different height adjustment ranges. For example, the leveling guide assembly may provide a first height adjustment range when the assembly is positioned with the first side on the floor channel assembly and the base portion is in a first offset position, a second height adjustment range when the assembly is positioned with the second side on the floor channel assembly and the base portion is in a second offset position, and a third height adjustment range when the assembly is positioned with the third side on the floor channel assembly, and the base portion is in a third offset position. The leveling guide assembly may also include an adjustable glide that is configured to further adjust the height of the wall within each of the different height adjustment ranges.
In this manner, a gross height adjustment is achieved by placing the leveling guide assembly on one of its first, second or third sides. Fine height adjustment is achieved through use of an adjustable glide, such as a threaded glide which may be selectively advanced from and/or into one of these sides.
The features and advantages of the present invention described above, as well as additional features and advantages, will be readily apparent to those skilled in the art upon reference to the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view of a prior art demountable and movable wall system.
FIGS. 2A and 2B are perspective and front views, respectively, of an exemplary demountable and movable wall system according to an embodiment.
FIG. 2C is a perspective view of an exemplary floor channel assembly of the demountable and movable wall system shown in FIGS. 2A and 2B.
FIG. 2D is an exploded view of the exemplary floor channel assembly shown in FIG. 2C.
FIGS. 3A-3C are front, side, and top views, respectively, of an exemplary floor track of the floor channel assembly shown in FIG. 2C.
FIGS. 4A-4C are front, side, and top views, respectively, of an exemplary support track of the floor channel assembly shown in FIG. 2C.
FIGS. 5A-5E are front, side, top, bottom, and rear views, respectively, of an exemplary leveling guide assembly of the floor track assembly shown in FIG. 2C.
FIGS. 6A-6C are perspective views of the floor channel assembly shown in FIG. 2C oriented in three different configurations.
FIGS. 7A and 7C are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in a first configuration, at its minimum height.
FIGS. 7B and 7D are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in the first configuration, at its maximum height.
FIGS. 8A and 8C are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in a second configuration, at its minimum height.
FIGS. 8B and 8D are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in the second configuration, at its maximum height.
FIGS. 9A and 9C are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in a third configuration, at its minimum height.
FIGS. 9B and 9D are front and perspective views, respectively, of the floor channel assembly shown in FIG. 2C with the leveling guide assembly oriented in the third configuration, at its maximum height.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS The disclosed embodiments are directed to a demountable and movable wall system having walls or wall panels for dividing or partitioning areas within a building into individual rooms. The walls or wall panels may extend substantially from floor to ceiling or only partially from floor to ceiling. The wall system includes a floor channel assembly that facilitates controlled height adjustments to the walls or panels to ensure that they are substantially level, plumb, and square. As used herein, the terms “walls” and “wall panels” include any type of unitary and composite structure, either framed or unframed, made from any suitable material, such as glass, metal, gypsum board, plastic, composites, and the like, painted or unpainted, or covered in natural or synthetic materials, such as paper, fabric, vinyl, wood veneer, and the like. In one embodiment, the wall system comprises a plurality of demountable and movable wall panels.
In one embodiment, the walls may be installed in the system by inserting them into a U-shaped ceiling channel assembly that is attached to a ceiling grid via one or more caddy clips, which may be removably attached to the ceiling grid. For example, the caddy clips may be attached to the ceiling grid by turning them clockwise, and may be disengaged from the ceiling grid by turning them counter-clockwise. The walls may be lifted into the ceiling channel assembly and then lowered into a U-shaped floor channel assembly. The floor channel assembly may encapsulate the lower portions of the walls on each lateral side and absorb their weight. To accommodate uneven floor surfaces, the disclosed floor channel assembly may be used to easily adjust the height of the walls so that the walls are level, plumb, and square. In one embodiment, the disclosed floor channel assembly includes a leveling guide assembly that can be oriented within the floor channel assembly to have any one of multiple configurations, each configuration providing a different range of height adjustments to the walls.
FIGS. 2A and 2B are perspective and front views, respectively, of an exemplary demountable and movable wall system 50 according to one embodiment of the present invention. As shown in FIGS. 2A and 2B, the wall system 50 includes a wall panel 100 mounted to a ceiling channel assembly 150 and a floor channel assembly 200. As will be appreciated by one skilled in the art, the floor channel assembly 200 has a lower profile than the prior art assembly depicted in FIG. 1. (It should be noted that FIGS. 2A and 2B are not shown to scale. For example, in typical arrangements, the overall height is at least 8 feet, where the majority of the height is occupied by the all panel leg. The upper track 150, when present, and the lower track assembly 200, in most embodiments, occupies a selectively small portion of the overall height).
FIG. 2C is a perspective view of the floor channel assembly 200 of FIGS. 2A and 2B. As shown in FIG. 2C, floor channel assembly 200 includes a floor track 300, a leveling guide assembly 400, a support track 500, and a low-profile trim 600. The floor track 300, the leveling guide assembly 400, and the support track 500 may be made from any suitable material that is able to support the load of the wall panel 100. In one embodiment, the floor track 300, the leveling guide assembly 400, and the support track 500 may be shaped and/or molded from a metal such as aluminum. The low-profile trim 600 generally may be used for aesthetic purposes and, therefore, may not be a load bearing component. As such, the low-profile trim 600 may be made from any suitable material that provides a desired physical appearance and/or finish. In one embodiment, the low-profile trim 600 may also be shaped and/or molded from a metal such as aluminum to match the other components of the floor channel assembly 200. In some embodiments, the low-profile trim 600 may be integrally formed with the support track 500.
As shown in FIGS. 2C and 2D, the floor track 300 is generally U-shaped, and may be placed and/or secured to a surface 105, such as a floor, though it will be appreciated that the floor channel assembly 200 may also be used as the ceiling channel assembly 150. In one embodiment, the leveling guide assembly 400 may be slidably disposed within the U-shaped floor track 300. To adjust the height of the wall panel 100, the leveling guide assembly 400 may be oriented in the floor track 300 in multiple configurations, each configuration providing a different range of height adjustments. The support track 500 may be disposed over, and a portion of the support track 500 may be disposed within, the floor track 300. Thus, the support track 500 may cover the leveling guide assembly 400 in the floor track 300. The support track 500 may include a channel for receiving and supporting the wall panel 100. The low-profile trim 600 may be connected to or formed on each side of the support track 500 to conceal at least a portion of the support track 500 and the floor track 300, thereby improving the aesthetic appearance of the floor channel assembly 200.
FIGS. 3A-3C are front, side, and top views, respectively, of the floor track 300. The floor track 300 includes sidewalls 305 and 310 and a bottom portion 315 that connects the lower portions of the sidewalls 305 and 310 to one another. Thus, the sidewalls 305 and 310 and the bottom portion 315 define a channel 320, which extends along a length of the floor track 300. The bottom portion 315 may include T-shaped molds 325 and 330 that extend along the length of the floor track 300. The T-shaped mold 325 and the adjacent sidewall 305 define a track 335, and the T-shaped mold 330 and the adjacent sidewall 310 define a track 340. The T-shaped molds 325 and 330 define a track 345. The tracks 335, 340 and 345 extend along the length of the floor track 300, within the channel 320.
The floor track 300 may be secured to the surface 105 via any suitable means. For example, as shown in FIG. 3A, the bottom portion 315 includes carpet grippers 350, which extend generally perpendicular to a planar surface of the bottom portion 315, to help secure the floor channel assembly 200 to a carpeted surface. In another embodiment, the floor track 300 may be taped (e.g., using double-sided tape) and/or glued to the surface 105. In yet another embodiment, cement screws may be inserted through pre-drilled holes in the bottom portion 315 and into a cement surface. The floor track 300 may then be bolted to the cement surface via the cement screws. Any suitable fastener may be used, depending upon the particular application, including nails or screws.
FIGS. 4A-4C are front, side, and top views, respectively, of the support track 500. The support track 500 has sidewalls 505 and 510 and a top portion 515, which connects the upper portions of the sidewalls 505 and 510 to one another. Thus, the sidewalls 505 and 510 and the top portion 515 define a channel 516, which extends along a length of the support track 500. The top portion 515 has upper sidewalls 520 and 525, which define a channel 530. The top portion 515 also has lower sidewalls 535 and 540, which define a track 545. The lower sidewall 535 and the adjacent sidewall 505 define a track 550, and the lower sidewall 540 and the adjacent sidewall 510 define a track 555. One purpose of side walls 505 and 510 is to hide the leveling guide when taken in a raised position. Accordingly, in some embodiments, the support track 500 may not include the sidewalls. The main purpose of support track 500 is to support the wall panel on the leveling guide(s).
FIGS. 5A-5E are front, side, top, bottom, and rear views, respectively, of the leveling guide assembly 400. As shown in FIG. 5A, the leveling guide assembly 400 includes a base portion 405 and legs 410 and 415, each connected to the base portion 405 via respective beams 420 and 425. In some embodiments, the base portion 405 maybe connected directly to the legs. The base portion 405 defines a threaded hole 430, which extends through at least a portion of the base portion 405, generally parallel to its longitudinal axis. As shown in FIGS. 5B-5D, the base portion 405 also defines a threaded hole 435, which extends through at least a portion of the base portion 405, generally perpendicular to its longitudinal axis. The glide assembly 400 includes an adjustable glide 440 having a threaded shaft 445 and a support member 450 at an end thereof. Each of the threaded holes 430 and 435 are sized to receive the threaded shaft 445 of the adjustable glide 440. As shown in FIG. 5B, the legs 410 and 415 have a height H and a length L which is greater then the height H. Thus, the legs 410 and 415 define short sides 460 and 462 and long sides 464 and 466 of the leveling guide assembly 400.
FIGS. 6A-6C are perspective views of the leveling guide assembly 400 oriented in three different configurations. The leveling guide assembly 400 may be inserted into the channel 320 of the floor track 300 in any one of the three depicted configurations. Thus, each configuration the leveling guide assembly 400 provides a different height adjustment range for the wall panel 100 within which the adjustable glide 440 may be raised or lowered in order to make further adjustments to the height of the wall panel 100.
A fourth configuration, providing even greater height adjustment is also possible. Although not shown in the figures, base portion 405 could be provided with an additional threaded hole (which may be an extension of treated hole 430) on the remaining short end. Where, as seen in FIGS. 5B, 5D, and 6A-6C, the base is offset from the midpoint between short ends 460, 462, placing the leveling guide the short end 464 provides a fourth height adjustment.
Thus, gross height adjustment is achieved by placing the leveling guide on one of its four sides. Fine height adjustment is then achieved by the adjustable glide 450.
For example, as shown in FIG. 6A, the leveling guide assembly 400 is oriented in a first configuration in which the assembly 400 rests on its long side 466. In the first configuration, the base portion 405 of the leveling guide assembly 400 is in a low offset position, i.e., the base portion 405 is offset towards the surface on which the assembly 400 is resting. In addition, the threaded shaft 445 of the adjustable glide 440 is inserted into the threaded hole 435 so that the support member 450 is positioned at a desired height. In one embodiment, the first configuration may provide a height adjustment range of approximately 2 inches (i.e., with the adjustable glide 440 fully inserted into the base portion 405) to approximately 3 inches (i.e., with the adjustable glide 440 fully raised from the base portion 405). This arrangement is depicted in FIGS. 7A and 7B.
As shown in FIG. 6B, the floor channel assembly 400 is oriented in a second configuration in which the floor channel assembly 400 is rotated 180-degrees around its longitudinal axis (with respect to the first configuration) so that the leveling guide assembly 400 is resting on its long side 464. In the second configuration, the base portion 405 of the leveling guide assembly 400 is in a high offset position, i.e., the base portion 405 is offset away from the surface on which the assembly 400 resting. The threaded shaft 445 of the adjustable glide 440 is inserted into the threaded hole 435 so that the support member 450 is at a desired height. In one embodiment, the second configuration may provide a height adjustment range of approximately 2.5 inches (i.e., with the adjustable glide 440 fully inserted into the base portion 405) to approximately 3.5 inches (i.e., with the adjustable glide 440 fully raised from the base portion 405).
As shown in FIG. 6C, the leveling guide assembly 400 is oriented in a third configuration in which the assembly 400 rests on its short side 462. In the third configuration, the threaded hole 430 is positioned so that it extends generally perpendicular to the surface on which the assembly 400 is resting. The threaded shaft 445 of the adjustable glide 440 is inserted into the threaded hole 430 so that the support member 450 is at a desired height. In one embodiment, the third configuration provides a height adjustment range of approximately 3 inches (i.e., with the adjustable glide 440 fully inserted into the base portion 405) to approximately 4 inches (i.e., with the adjustable glide 440 fully raised from the base portion 405).
FIGS. 7A and 7C show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the first configuration (see FIG. 6A) at its minimum height. FIGS. 7B and 7D show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the first configuration at its maximum height. The leveling guide assembly 400 is oriented within the channel 320 of the floor track 300 so that its long side 466 is resting on the bottom portion 315 and the base portion 405 is in its low offset position. The legs 410 and 415 are received within the tracks 335 and 340, respectively. To improve stability and prevent the leveling guide assembly 400 from tipping over while in the floor track 300, at least one of the legs (e.g., the leg 410) may include a protrusion (e.g., a protrusion 455), which may extend into one of the recesses defined by molds (e.g., a mold 325). The leveling guide assembly 400 may be slidably disposed within the channel 320. As such, the leveling guide assembly 400 may be positioned and repositioned anywhere along the length of the floor track 300.
As shown in FIGS. 7A and 7B, adjustable glide 440 extends into the channel 545 of the support track 500, with the top portion 515 of the support track 500 resting on the support member 450 of the adjustable glide 440. The sidewalls 505 and 510 of the support track 500 are slidably disposed within the channel 320, adjacent to the sidewalls 305 and 310, respectively. The low-profile trim 600 is connected to the top portion 515 and the upper sidewalls 520 and 525 of the support track 500.
As shown in FIG. 7A, the floor channel assembly 200 has a minimum height of approximately 2 inches in the first configuration when the adjustable glide 440 is fully inserted into the base portion 405 of the leveling guide assembly 400. As shown in FIG. 7B, the floor channel assembly 200 has a maximum height of approximately 3 inches in the first configuration when the adjustable glide 440 is fully raised from the base portion 405 of the leveling guide assembly 400. Moreover, the floor channel assembly 200 may be adjusted to any height between 2 and 3 inches by raising or lowering the adjustable glide 440 to any desired intermediate position. As shown in FIGS. 7B and 7D, the adjustable glide 440 lifts the support track 500 as the adjustable glide 440 is raised from the base portion 405, thereby raising the height of the wall 100 (not shown) supported in the channel 530.
FIGS. 8A and 8C show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the second configuration (see FIG. 6B) at its minimum height. FIGS. 8B and 8D show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the second configuration at its maximum height. As shown, the leveling guide assembly 400 is rotated 180-degrees around its longitudinal axis (with respect to the first configuration) so that the assembly 400 is now resting on its long side 464 and the base portion 405 is in its high offset position. Thus, the minimum and maximum height adjustments of the second configuration are greater than the minimum and maximum height adjustments of the first configuration.
For example, as shown in FIG. 8A, the floor channel assembly 200 has a minimum height of approximately 2.5 inches in the second configuration when the adjustable glide 440 is fully inserted into the base portion 405 of the leveling guide assembly 400. As shown in FIG. 8B, the floor channel assembly 200 has a maximum height of approximately 3.5 inches in the second configuration when the adjustable glide 440 is fully raised from the base portion 405 of the leveling guide assembly 400. Moreover, the floor channel assembly 200 may be adjusted to any height between 2.5 and 3.5 inches by raising or lowering the adjustable glide 440 to any desired intermediate position.
FIGS. 9A and 9C show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the third configuration (see FIG. 6C) at its minimum height. FIGS. 9B and 9D show front and perspective views, respectively, of the floor channel assembly 200 with the leveling guide assembly 400 oriented in the third configuration at its maximum height. As shown, the leveling guide assembly 400 is oriented in the channel 320 so that the assembly 400 is resting on its short side 462. Thus, the minimum and maximum height adjustments of the third configuration are greater than the minimum and maximum height adjustments of the first and second configurations.
For example, as shown in FIG. 9A, the floor channel assembly 200 has a minimum height of approximately 3 inches in the third configuration when the adjustable glide 440 is fully inserted into the base portion 405 of the leveling guide assembly 400. As shown in FIG. 9B, the floor channel assembly 200 has a maximum height of approximately 4 inches in the third configuration when the adjustable glide 440 is fully raised from the base portion 405 of the leveling guide assembly 400. Moreover, the floor channel assembly 200 may be adjusted to any height between 3 and 4 inches by raising or lowering the adjustable glide 440 to any desired intermediate position. In the embodiment shown in FIGS. 9A-9D only three positions are possible, since the base portion 405, extends substantially the entire length L of the leveling guide 400. As discussed above, other embodiments, such as in FIGS. 5A-5E include a base portion which is offset and does not extend the entire length L of the leveling guide. In those embodiments, a fourth position may be employed for even greater height adjustment.
As described above, the leveling guide assembly 400 may be oriented in different configurations within the floor channel assembly 200 and may provide overlapping height adjustment ranges within which the adjustable glide 440 may be positioned. Through choice of leg length L, leg height H, and the placement and size of the base portion and screw size, a wide range of adjustment can be achieved using a single leveling guide. In preferred embodiments, the adjustment range from one position to the next overlap to provide the ability to achieve any height between the lowest position and the highest. Thus, the floor channel assembly 200 may provide an overall height adjustment range for leveling wall panels that is much greater than the height adjustment range afforded by any single configuration.
The foregoing description of the invention is illustrative only, and is not intended to limit the scope of the invention to the precise terms set forth. Although illustrated and described herein with reference to certain specific embodiments, those skilled in the art also will appreciate that many other variations for the specific embodiments described herein are intended to be within the scope and spirit of the invention. In particular, the floor track 300, the leveling guide assembly 400, and/or the support track 500 are not limited to the specific height adjustment ranges depicted in FIGS. 7A, 7B, 8A, 8B, 9A, and 9B, but may be sized to provide any desired set of height adjustment ranges.
