Patent Application
20120085035
The invention relates generally to door operating apparatuses and door operating systems for operating swinging doors and, more particularly, to kits for retrofitting door operating apparatuses and their associated door operating systems, particularly for building ingress and egress doors.
Automatic doors are doors that are powered open or powered closed or both. If an automatic door is powered open only, then, it is conventionally spring closed or hydraulically closed. Automatic doors conventionally employ a sensor or switch to activate the door. The sensor detects approaching traffic and may be a motion sensor, infrared sensor, or pressure sensor. The switch is conventionally operated manually and may take the form of a push button, swipe card, or other available switch type access or security system. Alternatively the switch may be activated by pushing or pulling the door, so that once the door detects the movement it completes the open and close cycle. These are also known as power-assisted doors.
Swinging doors are hinged and pivot around an axis in an inward or outward direction or both. Automatic swinging doors are coupled to a source of torque, that is, a door operating apparatus, for providing the force necessary to pivot the door open or closed or both. Most commercially available door operating apparatuses are electromechanical or electrohydraulic and are positioned above the door in an overhead position for ease and economy of installation. Most commercially available door operating apparatuses are spring closed.
U.S. Pat. No. 6,176,044 (incorporated herein by reference) discloses a kit and method for retrofitting electromechanical door operating apparatuses. The retrofit kit shown in this patent is employable for converting a door operating apparatus for operating a swinging door from overhead use to underground use. The retrofit kit has had general success in the market place.
Automatic doors are differentiated from manual closers by the fact that manual closers are passive rather than active. A manual closer is a door that includes a manual door closer, that is, a passive device for closing the door. The manual door closer employs a combination of a hydraulic damping system and a spring closing system to self-close the door after a person or thing first manually pushes or pulls the door open. A manual closer is not opened automatically and therefore cannot open by itself. The hydraulic damping system regulates the force required to manually push or pull a door open and regulates the speed at which a door self-closes. Manual door closers may be mounted overhead within a door frame, or on the upper face of a door or frame, or below the door in an underground or sub-floor stratum. An automatic door operator may be employed as a door closer, but a manual door closer can not be employed as an automatic door operator. Manual door closers are passive and do not include electronic components. Some “Medium to Light Duty” manual door closers designed for use in a sub-floor stratum include a mechanism for adjusting the coupling between the door arm and the manual door closer once the manual door closer is cemented in its sub-floor stratum. More particularly, these manual door closers include a mechanism for moving the entire body of the closer in a vertical or horizontal direction to meet the location of the door arm above. The upward movement of this adjustment is constrained when the upward movement causes the closer to contact the threshold or finished floor above the closer. Lateral movements of this adjustment are similarly constrained by the height of the closer relative to the spindle height. Horizontal movement is limited by the threshold or finished floor condition above the closer. Mechanisms for independently adjusting the height of the door closer spindle without raising or lowering the entire body of the manual door closer are unknown. Also, retrofit kits for converting overhead manual door closers to underground manual door closers are unknown.
A manual closer has been converted to an automatic door operator by combining a manual door closer with a hydraulic operating system. A hydraulic operating system employable for this conversion is the Tormax™ Model TN (To ax is registered trademark of Landert Motoren AG, Bülach-Zürich, Switzerland). The Model TN is a floor mounted door operator and is manufactured as an automatic door operator. The Model TN is not an automatic door operator “conversion system” or kit, it is an automatic door operator. The Model TN is an underground hydraulic closer with a remotely mounted electric pump system that pushes hydraulic fluid within a floor closer to apply torque to a spindle that is rotationally coupled to a door. The pump system and electronics are mounted remotely and are not mounted underground. The Model TN is cemented within a sub-floor stratum and, once it is anchored within the sub-floor stratum, can not be repositioned so as to align the spindle with the door arm. The Model TN lacked a mechanism for re-aligning the spindle after the door operator has been cemented or anchored within its sub-floor stratum. The Model TN requires precise alignment of its spindle with the desired position of the door arm when the device is installed beneath the floor. Alignment adjustments for the Model TN are not available after the device is cemented in place.
The invention is directed to a kit for retrofitting door operating apparatuses from overhead use to underground use in an anchored sub-floor stratum and by facilitating this conversion by incorporating positional adjustment mechanisms covering any or all possible adjustment dimensions. The invention facilitates the alignment of the door operating apparatus with the door arm after the door operating apparatus has been cemented in place within its sub-floor stratum so that the desired door alignment can be achieved. The invention is also directed to processes that employ the positional adjustment mechanisms of the kit.
The objects, advantages, and features of the invention, as shown in the exemplary embodiments, will be more clearly perceived from the following description, when read in conjunction with the accompanying drawing, in which:
One aspect of the invention is directed to a retrofit conversion kit with vertical adjustment for coupling a door (2) to an automatic door operator (4) from a sub-floor stratum (6) or from an above door position. The conversion kit comprises an enclosure (8), a sled (10), a spindle (12), and a spindle housing (14). The enclosure (8) is for containing the automatic door operator (4) and is anchorable within the sub-floor stratum (6) or securable in the above door position. The sled (10) serves for mounting and securing the automatic door operator (4) thereonto. The sled (10), in turn, is mountable and enclosable within the enclosure (8). The spindle (12) is adapted for rotationally engaging the automatic door operator (4) within the enclosure (8) and for vertically and rotationally engaging the door (2) both for providing vertical support to the door (2) and for transmitting torque from the automatic door operator (4) to the door (2). The spindle housing (14) is also attached to the sled (10) and serves to secure the spindle (12). The spindle housing (14) includes a front vertical plate (16) attached to the sled (10), aback vertical plate (18) attached to the sled (10), a bearing plate (20) secured by the front and back vertical plates (16 and 18) for bearing the spindle (12), and a top plate (22). The top plate (22) defines a passage (24) therein adapted for passage (24) of the spindle (12) therethrough. The passage (24) has a bushing (26) therein for providing lateral support to the spindle (12). The bearing plate (20) is slideably secured by the front and back vertical plates (16 and 18) and has an adjustable vertical position within the spindle housing (14) for adjusting the vertical position of the spindle (12) borne thereon. Adjusting the vertical position of the spindle (12) facilitates the vertical and rotational engagement of the spindle (12) to the door (2).
In a first preferred embodiment of this first aspect of the invention, the bearing plate (20) defines one or more threaded screw holes and the spindle housing (14) further includes one or more vertical adjustment screws (28). Each vertical adjustment screw (28) is engagable to a corresponding threaded screw hole defined by the bearing plate (20) and is rotatable therein for adjusting the vertical position of the bearing plate (20) and the spindle (12) borne thereon. In a variant of the first preferred embodiment, the spindle housing (14) further includes one or more horizontal fasteners (30) for securing and de-securing the bearing plate (20) to the front and back vertical plates (16 and 18). The horizontal fasteners (30) are or a type that is capable of being fastened and unfastened for securing and de-securing the bearing plate (20) to the front and back vertical plates (16 and 18) when adjusting the vertical position of the bearing plate (20) by means of the vertical adjustment screws (28).
In a second preferred embodiment of this first aspect of the invention, the enclosure (8) has a conformation with a longitudinal dimension, the longitudinal dimension extending in a horizontal direction from a first end (32) to a second end (34). The sled (10) is slideably securable within the longitudinal dimension of the enclosure (8) for longitudinal adjustment of the spindle (12). The retrofit conversion kit further comprises an optional shim (36) and a longitudinal adjustment rod (38). The optional shim (36) is selected from a group of variably sized shims having a composition of plastic or other common shim material for wedging between the spindle housing (14) and the first end (32) of the longitudinal dimension of the enclosure (8). The longitudinal adjustment rod (38) is attached to the sled (10) and has an adjustable length for contacting the second end (34) of the longitudinal dimension of the enclosure (8). The longitudinal position of the sled (10), the spindle housing (14) and spindle borne thereon can be secured within the enclosure (8) by selecting one of the optional shims (36) of desired size, wedging the shim (36) between the spindle housing (14) and the first end (32) of the longitudinal dimension of the enclosure (8), and then adjusting the length of the longitudinal adjustment rod (38) for contacting the second end (34) of the enclosure (8) for tightening the spindle housing (14) against the shim (36) and the shim (36) against the first end (32) of the enclosure (8).
In a third preferred embodiment of this first aspect of the invention, the enclosure (8) has a conformation with a lateral dimension, the lateral dimension extending in a horizontal direction from a first side (40) to a second side (42). The sled (10) is slideably securable within the lateral dimension of the enclosure (8) for lateral adjustment of the spindle (12). The retrofit conversion kit further comprises a first lateral adjustment screw (44) and a second lateral adjustment screw (46). The top plate (22) defines a first threaded screw hole adapted for accepting the first lateral adjustment screw (44) and a second threaded screw hole adapted for accepting the second lateral adjustment screw (46). The first lateral adjustment screw (44), when screwed into the first screw hole is adapted for contacting the first side (40) of the lateral dimension of the enclosure (8). The second lateral adjustment screw (46), when screwed into the second screw hole is adapted for contacting the second side of the lateral dimension of the enclosure (8). The lateral position of the sled (10), the spindle housing (14) and spindle (12) borne thereon are securable within the enclosure (8) by adjustment of the first and second lateral adjustment screws (44 and 46).
A second aspect of the invention is directed to a retrofit conversion kit with longitudinal adjustment for coupling an automatic door operator (4) to a door (2) for operating the door (2) from a sub-floor stratum (6) or from an above floor position. The retrofit conversion kit comprises an enclosure (8), a spindle (12), a spindle housing (14), and a sled (10). The enclosure (8) serves to contain the automatic door operator (4). The enclosure (8) is anchorable within the sub-floor stratum (6) or is securable in the above door position and has a conformation with a longitudinal dimension. The longitudinal dimension extends in a horizontal direction from a first end (32) to a second end (34). The spindle (12) is adapted for rotationally engaging the automatic door operator (4) within the enclosure (8) and for vertically and rotationally engaging the door (2) both for providing vertical support to the door (2) and for transmitting torque from the automatic door operator (4) to the door (2). The spindle housing (14) serves to support the spindle (12). The sled (10) is enclosable within the enclosure (8) and serves to secure the automatic door operator (4) and the spindle housing (14) therein. The sled (10) has a first end for orienting with the first end (32) of the enclosure (8) and a second end (34) for orienting with the second end (34) of the enclosure (8). The spindle housing (14) is attached proximal to first end of the sled (10). The automatic door operator (4) is attached proximal to the second end (34) of the sled (10). The sled (10) is slideably securable within the longitudinal dimension of the enclosure (8) for adjusting the longitudinal position of the spindle (12).
In a preferred embodiment of this second aspect of the invention, the retrofit conversion kit further comprises an optional shim (36) and a longitudinal adjustment rod (38). The optional shim (36) is selected from a group of variably sized shims having a composition of plastic or other common shim material for wedging between the spindle housing (14) and the first end (32) of the longitudinal dimension of the enclosure (8). The longitudinal adjustment rod (38) is attached to the sled (10) and has an adjustable length for contacting the second end (34) of the longitudinal dimension of the enclosure (8). The longitudinal position of the sled (10) and of the attached spindle housing (14) and spindle (12) borne thereon is secured within the enclosure (8) by selecting one of the optional shims of desired size, wedging the shim (36) between the spindle housing (14) and the first end (32) of the longitudinal dimension of the enclosure (8), and then adjusting the length of the longitudinal adjustment rod (38) for contacting the second end (34) of the longitudinal dimension of the enclosure (8) and tightening the spindle housing (14) against the shim (36) and the first end (32) of the longitudinal dimension of the enclosure (8).
A third aspect of the invention is directed to a retrofit conversion kit with lateral adjustment for coupling an automatic door operator (4) to a door (2) for operating the door (2) from a sub-floor stratum (6) or from an above door position. The conversion kit comprises an enclosure (8), a spindle (12), a spindle housing (14), and a sled (10). The enclosure (8) serves to contain the automatic door operator (4). The enclosure (8) is anchorable within the sub-floor stratum (6) and has a conformation with a lateral dimension. The lateral dimension extends in a horizontal direction from a first side (40) to a second side (42). The spindle (12) is adapted for rotationally engaging the automatic door operator (4) within the enclosure (8) and for vertically and rotationally engaging the door (2) both for providing vertical support to the door (2) and for transmitting torque from the automatic door operator (4) to the door (2). The spindle housing (14) serves to support the spindle (12). The sled (10) is enclosable within the enclosure (8) for securing the automatic door operator (4) and the spindle housing (14) therein. The sled (10) has a first side corresponding to the first side (40) of the enclosure (8) and a second side corresponding the second side (42) of the enclosure (8). The spindle housing (14) is attached to the sled (10). The sled (10) is slideably securable within the lateral dimension of the enclosure (8) for lateral adjustment of the spindle (12).
In a preferred embodiment of this third aspect of the invention, the retrofit conversion kit further comprises a first lateral adjustment screw (44) and a second lateral adjustment screw (46). The top plate (22) defines a first threaded screw hole adapted for accepting the first lateral adjustment screw (44) and a second threaded screw hole adapted for accepting the second lateral adjustment screw (46). The first lateral adjustment screw (44), when screwed into the first screw hole is adapted for contacting the first side (40) of the lateral dimension of the enclosure (8). The second lateral adjustment screw (46), when screwed into the second screw hole is adapted for contacting the second side (42) of the lateral dimension of the enclosure (8). The lateral position of the sled (10), the spindle housing (14) and spindle (12) borne thereon are securable within the enclosure (8) by adjustment of the first and second lateral adjustment screws (44 and 46).
A fourth aspect of the invention is directed to a process with vertical adjustment for coupling a door (2) to an automatic door operator (4) from a sub-floor stratum (6) or from an above door position. The process comprises multiple steps. In an anchoring step, a lower portion of an enclosure (8) is anchored within the sub-floor stratum (6). In an attaching step, the automatic door operator (4) and a coupling device are attached to a sled (10). The automatic door operator (4) and the coupling device are rotationally coupled to one another. The coupling device includes a spindle (12) for rotationally coupling to the door (2). In an installing step, the sled (10) is installed within the lower portion of the enclosure (8). Then, in an adjusting step, the vertical height of the spindle (12) is adjusted to accommodate the coupling of the spindle (12) with the door (2). Then, in an engaging step, the spindle (12) vertically and rotationally engaged with the door (2) for providing vertical support to the door (2) and for transmitting torque from the automatic door operator (4) to the door (2) via the spindle (12).
A fifth aspect of the invention is directed to a process with horizontal adjustment for coupling a door (2) to an automatic door operator (4) from a sub-floor stratum (6) or from an above door position. The process comprises multiple steps. In an anchoring step, a lower portion of an enclosure (8) is anchored within the sub-floor stratum (6). In an attaching step, the automatic door operator (4) and a coupling device are attached to a sled (10). The automatic door operator (4) and the coupling device are rotationally coupled to one another. The coupling device includes a spindle (12) for rotationally coupling to the door (2). In an installing step, the sled (10) is installed within the lower portion of the enclosure (8). Then, in an aligning step, the spindle (12) is aligned with the door (2) by repositioning the sled (10) within the enclosure (8) and securing the repositioned sled (10) within the enclosure (8). Then, in an engaging step, the spindle (12) is vertically and rotationally engaged with the door (2) for providing vertical support to the door (2) and for transmitting torque from the automatic door operator (4) to the door (2).
In a first preferred mode of this fifth aspect of the invention, the enclosure (8) is of a type having a longitudinal dimension and, in the aligning step, the sled (10) is aligned along the longitudinal dimension.
In a variation of the first mode of this fifth aspect of the invention, after the completion of the anchoring, attaching, and installing steps, the process additionally includes an adjusting step the vertical height of the spindle (12) is adjusted to accommodate the coupling of the spindle (12) with the door (2).
In a second preferred mode of this fifth aspect of the invention, the enclosure (8) is of a type additionally having a lateral dimension and, in the aligning step, the sled (10) is additionally aligned along the lateral dimension.
In a variation of the second mode of this fifth aspect of the invention, after the completion of the anchoring, attaching, and installing steps, the process additionally includes an adjusting step the vertical height of the spindle (12) is adjusted to accommodate the coupling of the spindle (12) with the door (2).
In a further variation of the second mode of this fifth aspect of the invention, the enclosure (8) is of a type additionally having a longitudinal dimension and, in the aligning step, the sled (10) is additionally aligned along the longitudinal dimension.
A preferred example of the invention is a modified version of the retrofit conversion kit disclosed in U.S. Pat. No. 6,176,044 ('044). The '044 patent discloses a kit for converting any manufacturer's overhead mounted swinging door operating apparatus from overhead use to underground use. The present invention is directed to a similar kit except that the kit of the present invention additionally provides positional adjustment mechanisms covering any or all possible adjustment dimensions. More particularly, the present invention includes vertical or lateral or longitudinal positional adjustment mechanisms or any combination thereof for aligning the spindle (12) with the preferred location of the door (2). The spindle (12) defines a male member and the door (2) includes a door arm (48) with a female member. When the door (2) is mounted onto the door operating device, the male member of the spindle (12), which is rotationally coupled to the door operating device, inserts into the female member of the door arm (48). This insertion achieves a coupling between the spindle (12) and the door arm (48), determines the alignment of the door (2) and enables the door operating apparatus to transfer torque to the door arm (48) and hence to the door (2) via the spindle (12). Achievement of the desired alignment between the spindle (12) and the female member of the door arm (48) is essential to properly enable both of these functions. The invention provides positional adjustment mechanisms for achieving this alignment.
Exemplary positional adjustment mechanisms for providing vertical adjustments are illustrated in
Exemplary positional adjustment mechanisms for providing longitudinal adjustments are illustrated in
Exemplary positional adjustment mechanisms for providing lateral adjustments are illustrated in
All of the positional adjustment mechanisms described herein may be used to adjust the spindle position without removing the door (2).
All of the positional adjustment mechanisms described herein may be used with retrofit conversion kits employable either in a sub-floor stratum (6) or in an above door position.
All of the positional adjustment mechanisms described herein are capable of adjusting the position of the spindle (12) without moving the enclosure (8), as was required in the prior art.
All of the positional adjustment mechanisms described herein are capable of adjusting the position of the spindle (12) beyond constraints that can be practically anticipated by the threshold or finished floor condition above the door operating apparatus. For example, longitudinal adjustments can be achieved of up to 12 inches and lateral adjustments of three quarters of an inch. These constraints far exceed what is necessary from a practical basis. Vertical adjustments of up to one and one quarter inch upward or downward from center are achievable. It is important to note that vertical adjustment is extremely important in door installation. The bottom arm (48) of the door (2) (the female component that engages the male spindle (12) may be located at different depths within the bottom of the door (2) of the door panel. This depth may vary from flush to the bottom of the door (2) to as much as two inches within the bottom of the door (2). Sometimes, the bottom arm (48) protrudes beyond the bottom of the door (2) (mainly in retro-fit application). A vertically adjustable spindle (12) is critical to a successful door installation in order minimize the error factor that occurs when matching various manufacturers' door hardware. Excavation depth also affects the vertical distance required for the spindle (12) to bottom arm dimension.
The kit of the present application can also be employed with a sealing arrangement to protect the content of the enclosure. A kit having such a sealing system is described in co-pending patent application Ser. No. ______, entitled “Sealing Arrangement for Door Operating Apparatus Retrofit Kit,” filed Apr. 21, 2008, which is incorporated herein by reference.
Automatic Door Operator (4): An automated power mechanism rotationally coupled to a door (2) for providing torque for opening or closing such door (2), or both.
Enclosure (8): A container in which the door operating apparatus and automatic door operating system are enclosed. The enclosure (8) has two halves, viz., an upper portion and a lower portion. When installed, the lower portion is cemented in-place or otherwise anchored in a sub-floor stratum (6). The upper portion is a plate that attaches to the lower portion by means of fasteners. The enclosure (8) may also have a conformation with a lateral dimension extending in a horizontal direction and a longitudinal dimension also extending in a horizontal direction. The longitudinal dimension is greater than the lateral dimension. The lateral dimension extends from a first side (40) of the enclosure (8) and a second side (42) of the enclosure (8), in a horizontal direction; the longitudinal dimension extends from a first end (32) of the enclosure (8) to a second end (34) of the enclosure (8), also in a horizontal direction.
Sub-Floor Stratum (6): Any stratum that is sufficiently proximal to a floor surface so as to be subject to moisture and/or dust conditions characteristic of a floor surface.
Spindle (12): A vertical shaft protruding from a door operator (4) that engages a door arm (48) located in the bottom of the door panel (2). Conventionally, the spindle (12) serves as a “male” component mounted in the apparatus and the bottom arm (48) includes a “female” component for engaging the spindle (12). The spindle (12) is attached to an adjustable chain sprocket, a drive belt pulley, or a direct gear drive system, which, in turn, is coupled to the automatic door operator (4) drive system for the provision of torque. The spindle (12) is mounted in a tapered bearing on a base plate and is laterally secured within a bushing on a top plate (22), and additionally with a Delrin™ seal/bushing where the spindle exits the enclosure.
Spindle housing (14): An assembly comprising a top plate (22) with bushing (26), a bearing plate (20) with a tapered bearing, and front and back vertical support plates (16 and 18).
Mounting Sled (10): A structural support to which the spindle housing (14), door operating apparatus, and automatic operator (4) system are attached. The mounting sled (10) may be mounted into the enclosure (8) together with all attachments and reposition therein, if repositioning mechanisms are provided.
Door Arm (48): A structure or member attached to a door (2) and capable of being coupled to a spindle (12) for transmitting torque from the spindle (12) to the door (2). The door arm (48) includes a female bottom having any of several conventional designs to which the spindled (12) must be adapted for coupling.
This application claims priority to U.S. application Ser. No. 12/107,018, filed on Apr. 21, 2008, which claims priority to U.S. Provisional Application No. 60/925,644, filed on Apr. 20, 2007.
| Number | Date | Country | |
|---|---|---|---|
| 60925644 | Apr 2007 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12107018 | Apr 2008 | US |
| Child | 13314543 | US |
