The present disclosure generally relates to door systems and methods. More particularly, the present disclosure relates to an articulated overhead door systems and methods.
Conventional articulated overhead doors operate using devices such as counterweights, springs, lifting straps, and/or hydraulic systems. Disadvantageously, such systems are bulky and not inherently failsafe should a major component fail, such as a chain, cable, or hydraulic line. The key to operation and articulation of these types of doors is the action and forces required to start the door to fold, or articulate, as it starts to lift. Articulation of the door requires that a force be applied perpendicular to the door face, while lifting the door to start the section hinging or folding action. This action can be referred to as “Breaking the elbow.” Conventional designs utilize extended arm profiles that extend into the space in order to start this action which distracts from the aesthetic of the door and is prone to damage since they extend into the interior space. This also adds to the required clear space to he maintained in order for the door to operate without interference.
Many articulated door designs utilize heavy counterweights in order to easily operate the door. These counterweights lift up and down with the operation of the door and are most often suspended from cables and guided through the vertical structure of the door frame. The mass or weight of the counter weights are dependent on the weight of the door frame structure and all of the cladding that is mounted onto the operable door frame, Doors systems are typically shipped without cladding and pre balanced from the factory based on the frame weight only. Adding cladding and other components to the door necessitates the recalibration of the mass of the counterweights in order for the door to operate properly. On doors such as this, the counterweights can easily weigh in the hundreds of pounds. With other designs, these counterbalance forces are applied using large coil spring systems instead of counterweights.
In an exemplary embodiment, an articulated door system includes one or more door sections; a lifting block associated with a lower door section of the one or more door sections; a frame supporting the one or more door sections and engaging the lifting block; and a lead screw system including a rotatable lead screw that is configured to engage the lifting block and lift the lower door section up and down based on rotation of the lead screw. The lifting block and the frame utilize a pin system between one another to lift the lower door section responsive to the rotation of the lead screw. The pin system can include a cam slot including an angled slot and associated cam pin engaging the angled slot to start a folding action between the one or more door sections; and a lifting pin engaging a lifting pin slot. The lifting block can include the cam pin and the lifting pin slot, and wherein the frame can include the angled slot and the lifting pin. Responsive to the rotation of the lead screw, the cam pin follows the angled slot and subsequently the lifting pin engages the lifting pin slot. Responsive to the rotation of the lead screw, the lifting pin slot operates precisely with the cam slot and the cam pin such that once the cam pin disengages from the cam slot, the lifting pin has reached the bottom of the lifting pin slot and the lower door section is in a position that the lifting pin lifts the lower door section. Responsive to the rotation of the lead screw, the lifting block moves within an ovular space including the lifting pin slot until the lifting pin hits a bottom of the lifting block thereby engaging the lifting pin to start lifting the lower door section. The lead screw can have a pitch such that if the lead screw drive should fail in any way, the lower door section is held and kept in position. The lead screw system can include a lead screw follower precision machined to match the lead screw and move precisely up or down when the lead screw rotates to move the lifting block. The articulated door system does not utilize springs, strap lifting systems, or counterweights.
In another exemplary embodiment, an articulated door method includes providing one or more door sections; providing a lifting block associated with a lower door section of the one or more door sections; providing a frame supporting the one or more door sections and engaging the lifting block; and providing a lead screw system including a rotatable lead screw that is configured to engage the lifting block and lift the lower door section up and down based on rotation of the lead screw. The lifting block and the frame utilize a pin system between one another to lift the lower door section responsive to the rotation of the lead screw. The pin system can include a cam slot including an angled slot and associated cam pin engaging the angled slot to start a folding action between the one or more door sections; and a lifting pin engaging a lifting pin slot. The lifting block can include the cam pin and the lifting pin slot, and wherein the frame can include the angled slot and the lifting pin. Responsive to the rotation of the lead screw, the cam pin follows the angled slot and subsequently the lifting pin engages the lifting pin slot. Responsive to the rotation of the lead screw, the lifting pin slot operates precisely with the cam slot and the cam pin such that once the cam pin disengages from the cam slot, the lifting pin has reached the bottom of the lifting pin slot and the lower door section is in a position that the lifting pin lifts the lower door section. Responsive to the rotation of the lead screw, the lifting block moves within an ovular space including the lifting pin slot until the lifting pin hits a bottom of the lifting block thereby engaging the lifting pin to start lifting the lower door section. The lead screw can have a pitch such that if the lead screw drive should fail in any way, the lower door section is held and kept in position. The lead screw system can include a lead screw follower precision machined to match the lead screw and move precisely up or down when the lead screw rotates to move the lifting block, and wherein the articulated door system does not utilize springs, strap lifting systems, or counterweights.
In a further exemplary embodiment, a bi-fold articulated door system includes an first door section and a second door section; a lifting block associated with the second door section; a frame supporting the first door section and the second door section and engaging the lifting block; and a lead screw system including a rotatable lead screw that is configured to engage the lifting block and lift the second door section up and down based on rotation of the lead screw.
The present disclosure is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like system components/method steps, as appropriate, and in which:
In various exemplary embodiments, articulated overhead door systems and methods are described. The articulated overhead door systems and methods include a novel drive mechanism supporting the elimination of counterweights and cam action and timing to articulate a door. The drive mechanism utilizes a screw design for a fail-safe design. Additionally, the articulated overhead door systems and methods require no unsightly arm extending into the space to initiate articulation of the door. Note articulation arms also extend into unoccupied space where they may be a hazard and they limit use of adjacent space. Rather, in the systems and methods, articulation is done through the unique design of the lifting block and the cam slot design. Again, the articulated overhead door systems and methods eliminate heavy and difficult to manage and calibrate counterweights and require no stored energy systems such as counterbalances or springs.
Referring to
The drive mechanism 20 is a lead screw system for lifting and operating the door sections 12, 14. Specifically, the drive mechanism includes a lead screw 22 and a lead screw follower 24 rotatably connected to lead screw 22. The lead screw follower 24 is precision machined to match the lead screw 22 and move precisely up or down when the lead screw 22 turns. The lead screw follower 24 is attached to a lifting block 26 and moves the lifting block 26 up or down depending on the direction of the lead screw 22. By rotating the lead screw 22 clockwise or counter clockwise, the door sections 12, 14 can be made to lift up or down using the lifting block 26 and a pin system. The lifting block 26 has a mating thread system to the lead screw 22 and advances up or down the lead screw 22 as it rotates. The lifting block 26 can be extruded aluminum with heavy duty plastic sliders that allow it to slide easily up and down inside of the door frame 18. The lifting block 26 is attached to the lead screw follower 24 and moves up and down with the lead screw follower 24.
The lead screw 22 is of a certain pitch that, should a screw shaft drive (not shown in
The articulated door system 10 utilizes cam action and timing to articulate the door sections doors 12, 14. This design eliminates the need for arms to extend into space in order to start the folding action or “Breaking of the elbow.” This is achieved through the use of an angled slot within the door section 14 and also through a unique timing featured designed into the lifting block 26 that follows the lead screw 22. In other exemplary embodiments, “Breaking of the elbow” can be down through a slave cylinder, which allows the lifting block 26 and the screw 22 to begin lifting the door section 14. In another exemplary embodiment, a hand-operated level can be used to break the elbow, which allows the lifting block 26 and the screw 22 to begin lifting the door section 14.
Note,
The lifting pin 32 can be fixed in the operable door section 14. The lifting block 26 can move within the ovular space in the lifting block 26 (i.e., the lifting pin slot 30) until it hits the bottom of the lifting block 26. At that point, the lifting block 26 will engage the lifting pin 32 and start lifting it, thereby lifting the door section 14. Note, lifting of the door section 12 (or other door sections) is performed via one or more hinges.
Starting from a totally down position (
In
Note, the cam pin 28 and the lifting pin 32 apply a force to the door section 14, causing the folding/articulation action between the door sections 12, 14 via the hinge 16. The cam pin 28 is used to start the folding of the hinge 16 and the lifting pin 32 is used to completely raise the door sections 12, 14 after the hinge 16 action is started. Note, the locations of the cam pin 28, the lifting pin slot 30, the lifting pin 32, and the cam slot 34 can be either associated with the lifting block 26 or the door frame 18. For example, the cam pin 28 is illustrated in the door frame 18 and the associated cam slot 34 is on the lifting block 26. The lifting pin 32 is illustrated on the door section 14 (through the lifting block 26) with the associated lifting pin slot 30 on the door frame 18. Alternatively, the lifting pin 32 could be on the door frame 18 and the lifting pin slot 30 on the door section 14 (through the lifting block 26). That is, the systems and methods contemplated various different locations of the various components of the drive mechanism 20.
A down cycle is reverse of above, where the lifting block 26 now travels down the lead screw 22 due to a change in rotation of a screw drive system 40, i.e., a screw shaft drive. At a certain point, and at the same time due to the design of the lifting block 26, the cam pin 28 re-engages the cam slot 34 and the lifting pin 32 becomes unsupported by the lifting block 26.
The lifting block 26 continues down the lead screw 22, and the cam pin 28 continues exerting a horizontal force against the cam slot 34 and pushes the door sections 12, 14 closed. All of this is accomplished by the lead screw 22 travel.
The installation of the articulated door system 10 is designed to be as simple as possible and to minimize labor in the field. All mechanical assembly critical to the operation of the articulated door system 10 is done in a factory, and the components are modularized and are easily connected and installed in the field.
Referring to
The door sections 12, 14 are shown with various panels 52. In these examples, the door section 12 has a height of one panel and the door section 14 has a height of three panels, i.e., the door section 12 is about one third the size of the door section 14. Of course, other ratios are contemplated. The drive system 40 is located on one side of the door frame 18, and drives both the lead screws 22 (on each side of the door frame 18). The left and right lead screws 22 can be connected mechanically to each other through a belt, chain or other mechanical device 42. That is, the forces of the screw drive system 40 are applied on both sides of the door frame 18.
In various exemplary embodiments, the articulated door system 10 can be used for interior doors as well as for exterior doors, i.e., the articulated door system 10 can be used for any type of separation between rooms, exteriors, etc. Note, the door sections 12, 14 can include the panels 52 or any other covering for aesthetics to match the wall 50 or the like.
The articulated door system 10 can be a modular platform preconfigured to accept various different door sections 12, 14 with user-adjustable modules like lights, fans, heaters, speakers, etc. The articulated door system 10 is configurable and user-controlled, installed at the factory or optionally added after installation. For the modular platform, the door frame 18 and the lifting block 26 can be aluminum or the like and cut, welded, manufactured, etc. to a specific size and specification for the wall 50 or the like. These components have the channels, i.e., the lifting pin slot 30 and the cam slot 34 to accommodate the drive mechanism 20.
Additionally, the articulated door system 10 can include various additional features, such as electronics added to the door frame 18 (e.g., lighting, heating, cooling fans, laser lights, marquee scroll, LCD glass, LED-embedded glass, speakers, etc.) and non-electronics added to the door sections 12, 14 (e.g., cooling misters, roll-down side curtains, sound baffles, etc.). Also, these various additional features could be added after installation.
Referring to
In an exemplary embodiment, the add-on modules 70 can be lights, such as light emitting diodes (LEDs) or the like. One benefit of the door sections 12, 14 is the overhead shelter associated with the door section 14 in the open position. The add-on modules 70 can be LED downlights can be installed at the factory, or after installation, in a number of styles and configurations.
In another exemplary embodiment, the add-on modules 70 could be micro-foggers for cooling mist along with centerline LED lights to highlight the fog. For example, micro-foggers embedded in the door section 14 reduce temperatures on hot days for outside restaurants and sidewalk cafes.
In a further exemplary embodiment, the add-on modules 70 could be heaters to provide radiant heat, such as for a sidewalk cafe or a personal residence.
Referring to
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For example, for sidewalk cafes, opening the door can be a safety hazard and liability. The laser scanner 78 can “paint” a warning sign on the sidewalk while the door sections 12, 14 are in motion for safety or to add drama to the opening ceremony. Once the door sections 12, 14 are open, the laser scanner 78 can be used to provide a message, picture, etc. on the ground/floor. Also, a video screen can be embedded in or attached to one of the door sections 12, 14.
Referring to
Although the present disclosure has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present disclosure, are contemplated thereby, and are intended to be covered by the following claims.