Operable walls or partitions, also known as moveable wall panel systems, find useful application in a variety of venues, such as classrooms, offices, convention facilities and hospitals. In these venues, the operable walls can be utilized to efficiently compartmentalize interior space into a multitude of separate, smaller rooms. With these wall systems, it is frequently desirable to achieve movement of multiple wall panels by application of a single force. For example, a person may wish to manually move a wall panel system from a stacked position to an extended position by pulling on a leading panel and having one or more of the remaining panels, which are connected by hinges to the leading panel and successive panels, be pulled along as well. In situations where an electric motor is used to move continuously hinged panels, a cable or chain driven by the motor is operatively attached to a leading panel to effect pulling of the leading panel in either a wall stacking or wall extending direction. The resulting movement of the leading panel effects stacking or extending movement of the hinged trailing panels. In either the manual or automatic case, the horizontal pushing or pulling forces on the trailing panels are applied via the hinges interconnecting the panels. In certain circumstances, these forces can be of a significant magnitude, especially for longer walls formed of continuously hinged panels. As a result, the hinge

and the panel structural framework to which the hinge is attached need to be specifically designed and constructed to withstand such forces.

In addition to the horizontal forces experienced by existing hinges, vertical loadings on the hinges are also present. In particular, in some continuously hinged wall panel systems, trolleys which suspend the panels from an overhead track are only mounted in alternating panels. Consequently, the wall panels without trolleys are effectively suspended from the track by their hinged connection with the adjacent trolley-suspended panels. Because these wall panels can be several stories tall, the weight of the panels required to be supported by these hinges and the framework members to which the hinges may be mounted can be significant.

Known construction techniques which account for the various horizontal and vertical forces experienced by the hinges and panel framework have taken several forms. However, these known techniques are undesirable for a number of reasons. For example, a framework side member of a panel can be roll formed of steel or aluminum with sufficient strength and rigidity along its entire length to allow direct attachment of a hinge member at a selected portion of that length. However, such a sturdy framework makes the panel relatively heavy, which results in the panel being more difficult to manually or automatically move.

Another known construction technique uses a lighter but weaker side frame member and a rigid steel backing plate to reinforce the side frame member where the hinge is attached. Fasteners extending through the hinge and side frame member attach to the backing plate to sandwich the side frame member between the hinge and backing plate. However, while the backing plate allows the side frame member to withstand the various forces acting on the hinge without yielding, the pulling forces acting on

the side frame member through the hinge still tend to pull the side frame member away from the top frame member. In addition, the top frame member, which must transfer the pulling forces to the opposite side member and hinge to achieve a pulling of the adjacent hinged panel, is pulled away from the opposite side frame member. This pulling force stresses the connection between the top frame member and side frame members. Moreover, this pulling force stretches and thereby stresses the panel skin which is attached to the opposite side frame members. To reduce these stresses, flat metal bars configured in an L-shape have been mounted over the upper corners of the structural framework and welded to the top frame member and side frame members. These additional bars help transfer the horizontal pulling forces between panels along the top frame member. The need for these additional bars and separate backing plates for the hinges complicates the assembly of the wall panel as well as adds additional weight to the panel.

Another technique for allowing the panel framework and hinges to withstand operational loadings is to use a substantial number of hinges disposed at various positions along the height of the panel and thereby better distribute the loadings within the framework. One problem with this technique is that the spacing of the hinges often results in hinges being placed near the bottom of the wall panel. These lower hinges are undesirable as they project slightly into the compartmentalized room. Such projections impair the wall aesthetics, and may create an obstruction within the room.

Thus, it is desirable to provide a moveable hinged wall panel system which overcomes these and other disadvantages of prior art systems.

Summary of the Invention The present invention provides an operable wall panel which incorporates a backing plate for a hinge into a gusset assembly extending between the side and top frame members of a wall panel structural framework. The gusset assembly aids in transferring the vertical and horizontal forces experienced by the hinge during operation directly to the top frame member of the wall panel. As a result, the forces experienced by the side frame members are reduced, thereby allowing the side frame members to be made lighter. The need for separate backers for the hinges is also eliminated.

In one form thereof, the present invention provides an operable wall panel moveable along a track in a wall stacking direction and a wall extending direction. The wall panel includes a structural framework having a generally horizontal frame member and a generally vertical frame member. The wall panel includes gusset means for bracing the horizontal frame member and the vertical frame member, and the gusset means includes a hinge supporting backer. The wall panel also includes a hinge member, which is operably poεitionable outward of the vertical frame member and engagable with a mating hinge member of a second operable wall panel, and at least one fastener for interconnecting the hinge member to the hinge supporting backer.

In another form thereof, the present invention provides an operable wall panel that includes a structural framework that has a generally horizontal frame member and a side frame member extending downwardly below the horizontal frame member. The wall panel includes gusset means, connectable to the horizontal and side frame members, for bracing the horizontal frame member and the side frame member. The gusset means includes a backer disposed inward of the side frame member. The wall panel also includes a hinge member,

which is mountable to the side frame member and engagable with a mating hinge member of a second operable wall panel, and at least one fastener extending through an aperture in the side frame member for interconnecting the hinge member to the gusset means backer.

In still another form thereof, the present invention provides an operable wall panel system for use with a track and moveable to compartmentalize a room. The system includes a plurality of wall panels, which includes a first wall panel and a second wall panel, and at least one hinge means for hingedly connecting the first wall panel and the second wall panel. The hinge means includes a first hinge member mounted on the first wall panel and a second hinge member, engagable with the first hinge member, mounted on the second wall panel. The first hinge member also includes a mounting flange having a hole. The first wall panel also includes a structural framework comprising a generally horizontal frame member and a side frame member, wherein the first hinge member mounting flange is mountable to the side frame member. The first wall panel includes gusset means for bracing the horizontal and side frame members. The gusset means includes a backer disposed inward of the side frame member. The backer includes a hole alignable with the hole in the first hinge member mounting flange. The first wall panel also includes a fastener extending through the hole in the first hinge member mounting flange, through a hole in the side frame member, and through the hole in the backer for interconnecting the first hinge member to the gusset means backer.

One advantage of the present invention is that the interconnection of a hinge with a gusset assembly allows lighter materials to be used for the wall panel structural framework. Another advantage of the present invention is that the gusset assembly/hinge interconnection permits usage

of fewer hinges, thereby allowing hinges to be positioned only near the upper portions of the wall panel so as to improve wall aesthetics.

Still another advantage of the present invention is that a separate backer plate is not required for hinges of the wall panel.

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 description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein: Fig. 1 is a diagrammatic view of a operable wall panel system suitable for use with the present invention,- Fig. 2 is a fragmentary front elevational view of one of the wall panels of the system of Fig. 1, wherein a portion of the wall panel structural framework and an embodiment of the interconnected corner gusset and hinge are shown;

Fig. 3 is an exploded perspective view of Fig. 2; Fig. 4 is a cross-sectional view taken along line 4-4 of Fig. 2; and

Fig. 5 is a cross-sectional top view conceptually taken along line 5-5 of Fig. 2 of a fully assembled operable wall panel.

Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent an embodiment of the invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention.

Description of the Preferred Embodiment The embodiment disclosed below is not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather,

the embodiment is chosen and described so that others skilled in the art may utilize its teachings.

Referring to Fig. l, there is diagrammatically shown one embodiment of an operable wall panel system with which the present invention finds beneficial application. The shown system is a continuously hinged system including operable partitions or wall panels 10, 11, 12, 13 and 14 suspended from track 16 by trolleys 18. Each of wall panels 10-14 is linked to the adjacent panels by multiple hinges 20 arranged along the panel height. Track 16 is mountable in the ceiling of a room to be compartmentalized, and panels 10-14 may be moved along the track in wall stacking and wall extending directions. Trolleys 18 are shown installed in alternating panels, namely panels 10, 12 and 14, to directly suspend these panels from track 16. Panels 11 and 13 are suspended by way of hinges 20 that support panels 11 and 13 relative to suspended panels 10, 12 and 14. Although not shown, an electric drive system which is well known in the art may be employed with the shown continuously hinged wall panel system to move the panels between opened and closed orientations. In addition, although illustrated with reference to a continuously hinged system, the present invention is also useful with alternate panel systems, such as systems having paired panels that are hinged together.

With reference now to Figs. 2 and 3, which show a front elevational view and an exploded perspective view of portions of wall panel 12, the panel structural framework is defined at its top and side by horizontal frame member 25 and vertical frame member 30 respectively. In the shown embodiment, top frame member 25 is a C-shaped structural steel channel including top flange 26 and downwardly extending side flanges 27, 28. The steel construction provides sufficient strength to withstand the generally horizontal

pushing and pulling forces experienced during wall panel stacking and extending. Lighter channels made of aluminum may be substituted for the steel of frame member 25. Depending on the wall panel system with which the operable panel is to be used, these lighter channels may require reinforcement to ensure adequate strength to withstand operational loadings. For example, in a system in which a substantial number of panels are continuously hinged together, a high strength channel or beam horizontally positioned along the underside of an aluminum top flange 26 could be incorporated into the panel framework. A steel trolley block 29 attaches to the underside of top flange 26 and provides reinforcement for the attachment of trolley 18 shown in Fig. l. In the shown embodiment, vertical frame member 30 is roll formed steel with inward planar flange 32, side flanges 33, 34, and outward facing stepped lips 35, 36. Alternatively, frame member 30 may be formed from a lighter material such as aluminum. Circular holes 37 extending through inward flange 32 are arranged in a particular staggered arrangement and allow passage of hinge fasteners 75 as described further below. Vertical frame member 30 downwardly extends from top frame member 25 and can be connected thereto in any manner known in the art. The shown connection involves inserting an end of top frame member 25 through notch 38 formed in inward flange 32 of side frame member 30 and a welding of side flanges 27, 28 to side flanges 33, 34. It will be appreciated that the shown configurations and constructions of frame members 25, 30 is merely illustrative, as the invention as described further below can be employed with alternate frame members.

The preferred gusset assembly which braces top frame member 25 relative to side frame member 30 at their corner intersection is shown unassembled in the exploded view of Fig. 3. The corner gusset assembly includes a

hinge backer, which serves to connect the gussets to the side frame member as well as supports a panel hinge, and gussets effectively extending between the top and side frame members 25, 30. In the shown embodiment, the backer is a backing plate 42 made from a sheet of three- eighth inch steel . The tapering upper region 43 of backing plate 42 is shaped to fit within the opening provided in C-shaped frame member 25. Backing plate upper edge 44 includes a straight section which is welded to the underside of top flange 26 as shown in Fig. 4 to further secure the frame members. Multiple staggered holes 46 are drilled or otherwise formed in backing plate 42 in alignment with holes 37 in vertical frame member 30. Rather than a single, relatively thick backing plate, a suitable backer can be formed by stacking and welding together thinner backing plate portions with previously provided holes formed therein. Such holes could be stamped into the thinner backing plate portions rather than drilled through the single backing plate.

In the shown embodiment, backing plate 42 is planar and unbroken except for the holes therethrough. Alternate backer configurations are also within the scope of the invention. For example, the backing plate may be particularly shaped to conform to a non-planar inward flange of the vertical side frame member. In addition, provided sufficient strength is retained, the backing plate could include holes which further reduce the overall weight of the operable wall panel . The preferred gusset assembly further includes a pair of generally triangular gussets 50, 55. Gussets 50, 55 are formed from a solid sheet of twenty- one gauge steel. Along their upper edges 52, 57, gussets 50, 55 are rigidly secured directly to top frame member 25. Along their side edges 53, 58, gussets 50, 55 are rigidly secured to backing plate 42, which in turn is

secured with side frame member 30 as described below. While mechanical fasteners may be employed to secure gussets 50, 55 to the frame members, a preferred connection involves welding upper edges 52, 57 and side edges 53, 58 to top frame member side flanges 27, 28 and backing plate 42 respectively. Half-inch long welds spaced at two inch intervals have been found to provide a suitable welded connection.

It will be appreciated that alternate gussets attached to backing plate 42 and connecting the frame members can be substituted within the scope of the invention, provided the substituted gussets are strong enough to transfer to top frame member 25 the horizontal pulling forces applied to the hinge. For example, a single triangular gusset connected to a central portion of the backing plate and the top frame member top flange 26 could be substituted for the pair of gussets shown. Non-triangular shaped gussets, such as diagonally arranged bars spanning the frame members, could also be employed. Other gussets include rectangular shaped gussets that attach to the top frame member along its length and extend across the wall panel to connect to a second backer provided for the hinge mounted on the side frame member opposite side frame member 30. In addition, the gussets and backing plate may be integrally formed. The gussets could also include a cable extending between the backers on opposite side frame members of a wall panel.

Referring now to Fig. 3, a portion of a suitable hinge 20 mountable to wall panel 12 is shown. The hinge member is generally designated 65 and includes a stepped mounting flange 67 with staggered holes 68 corresponding to the holes in side frame member inward flange 32. Although shown in the Figures as a single piece, hinge member 65 may be formed by using two or more smaller hinge portions that may be more available. The end of

flange 67 is provided with cylindrical sleeves 70 conventionally shaped to mate with complementarily configured sleeves on a mating hinge member (not shown) of hinge 20 that attaches to operable wall panel 13. The inward end of mounting flange 67 is designed to install flush with the side frame member inward flange 32, and the outward end of flange 67 fits within notch 40 provided in side flange 33 and lip 35. The pivot point of hinge member 65 is closely aligned with the end face of wall panel 12.

To install hinge member 65, self-tapping screws 75 extend through hinge holes 68, through side frame member holes 37, and into and through backing plate holes 46. Rather than screws, other mechanical fasteners, such as rivets or bolts with nuts, extending between hinge member 65 and backing plate 42 may be substituted within the scope of the present invention. In addition, the fasteners could be integrated into the backer or hinge to potentially simplify assembly. Referring now to Fig. 5, there is shown a cross- sectional view of a complete wall panel as conceptually taken along the line 5-5 of Fig. 2, wherein the interconnection of hinge member 65 and backing plate 42 of the gusset assembly is more clearly illustrated. In Fig. 5, the structural framework and the interconnected gusset assembly and hinge are covered with gypsum panels 80, 81 and steel skins 82, 83 secured to vertical frame member 30. Shown astragal 85 and seal 86 may be provided to cooperate with a seal and astragal (not shown) on panel 13 to improve the sound barrier characteristics of the wall panel system. It will be appreciated that the interconnection of hinge member 65 directly to the gusset assembly eliminates the need to provide a thicker and more rigid inward flange 32 or a separate backer. In addition, in the preferred embodiment shown, screws 75 not only connect the hinge to

the gusset assembly but also connect the gusset assembly to vertical frame member 30, thereby eliminating the need for separate fasteners or welds therebetween.

Although only a single gusset assembly is shown in the Figures, it will be appreciated that the not shown side frame member of wall panel 12 opposite side frame member 30 can be outfitted with a similar gusset assembly to advantageously brace the panel framework and provide a backing plate for the hinge 20 mounted to that side frame member that connects with panel 11.

While this invention has been described as having a preferred design, 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.