Patent Application
20080047672
The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.
The garage door system 140 may include a garage door 145 that is moveable between a closed and an opened positioned over the entryway 155, a track 150, a plurality of rollers or wheels 165, a track support member 185, and a garage door spring. The track 150 may include a generally horizontal and a vertical portion that are operably connected to each other. At least a portion of the track 150 may be operably connected to the floor 170. The vertical portion of track 150 may be operably connected to a bordering wall in the garage 190, for example the front sidewall 175. The horizontal portion of the track 150 may be rigidly connected to a bordering wall in the garage 190 and/or the ceiling 160, through the use of track support members 185 and/or fasteners.
The garage door 145 may be composed of a plurality of garage door panels 142 that are rotatably connected by hinge components. However, according to other embodiments, the garage door 145 may be a gate or gate panels. The sides of at least a portion of the panels 142 may be operably connected to the center axels of the wheels 165.
During operation, the wheels 165 may roll or slide against or along at least a portion of the track 150, thereby allowing the garage door 145 to move from a horizontal, open position to a vertical, closed position, over at least a portion of the entryway 155, and vice versa. Further, as the garage door 145 travels along the generally straight and curved portions of the track 150 while moving between open and closed positions, the hinged connection between the panels 142 may allow the panels 142 to rotate or pivot.
The garage door opener 100 may include a motor 105, a door activating switch 110, a main rail 115, at least one motor support member 120, a trolley component 125, a connector 130, and a drive system. As discussed below in more detail, the drive system may include a drive component a pinion. For example, in embodiments in which the drive system is a chain drive, the drive component may be a chain that is operably connected to the motor 105, while the pinion may be a gear or a sprocket. Conversely, in instances in which the drive system is a belt drive, the drive component may be a belt, and the pinion may be a pulley or a sheave, among others. In another embodiment, the drive system may be screw driven, where a motor may turn a threaded stud that is attached to a hinge system that raises and lowers the door.
As shown in
In one embodiment, the motor 105 may be operably connected to a power cord that includes a connector that is configured to be plugged into an electrical outlet in the garage 190, such as an outlet positioned on the ceiling 160. Alternatively, rather than being plugged into an outlet, the motor 105 may be wired for a direct connection with the electrical wiring of the garage 190 or a circuit that may provide electrical power to the motor 105. In another embodiment, the motor 105 may be battery powered. Alternatively, the motor 105 may be replaced with a manual system that may allow an individual to apply the physical force necessary to operate the garage door opener 100. For example, the manual system may include mechanical components that allow a user to apply force, such as cranks, ropes, handles, and/or belts. The manual system may also include components to transfer this force to the drive system 505, such as gears and/or pulleys.
Although
According to embodiments of the present invention, a wall mounted door activating switch 110 may receive electrical power through an electrical connection to the motor 105. For example, electrical wires may operably connect the wall mounted door activating switch 100 to the motor 105. Alternatively, the door activating switch 110 may have an electrical power source that is independent of the motor 105. For example, the door activating switch 110 may be equipped with an electrical plug for a direct connection to one of the electrical outlets in the garage 190, or may be wired to a electrical supply or circuit in the garage 190. As another example, the door activating switch 110 may be powered by a battery, such as alkaline batteries, nickel metal hydride batteries, and/or lithium batteries, among others. Further, these batteries may be rechargeable and/or non-rechargeable.
In order to transmit activation signals, the door activating switch 110 may be wired directly to the motor 105. Alternatively, the door activating switch 110 may contain a transmitter capable of sending wireless signals directly to a receiver that is operably connected to the motor 105. The wired and/or wireless connection between the door activating switch 110 and the motor 105 enables the user to activate the motor 105 in order to raise or lower the garage door 145 across the entryway 155.
The main rail 115 may include a distal end 116 and a proximate end 117. The distal end 116 of the main rail 115 may be operably connected to the motor 105. For example, the distal end 116 of the main rail 115 may be rigidly connected to motor 105 through the use of mechanical fasteners, including, but not limited to, a bolt(s) and nut(s) connection or pins, among others. The proximate end 117 of the main rail 115 may be attached to an adjustment system, as discussed in more detail below. Further, the main rail 115 may be aligned to have an generally horizontal orientation.
The main rail 115 may be configured to reduce the potential for friction and/or wear of the trolley component 125 and the drive component of the drive system that may result from contact with the main rail 115. For example, the drive channels 118a, 118b and the trolley channels 119 may be sized for no or minimal contact with the drive component and the trolley component 125, respectively. Further, the main rail 115 may include rounded, beveled, and/or or chamfered corners and edges. Such shapes may reduce friction and/or wear at the connection between the main rail 115 and the trolley component 125. Similarly, these alternative shapes may reduce friction and/or wear at the connection between the main rail 115 and the drive component, such as a chain or belt drive, of the drive system.
The motor 105 may be operably connected to the adjacent end of the first main rail segment 310. The opposite end of the first main rail segment 310 may be pivotally coupled to one end of a second main rail segment 320. That is, a pivotable connection between the first and second main rail segments 310, 320 may allow the first and second main rail segments 310, 320 to pivot and rotate with respect to one another, as discussed below in more detail. Similarly, the opposite end of the second main rail segment 320 may be pivotally coupled to the third main rail segment 330.
The pivotal connections between the main rail segments 310, 320, 330 may allow the main rail 115 to be kept in a folded or collapsed position, as shown in
One end of the third main rail segment 330 may be movably connected to the adjustment system 500. In one embodiment, the adjustment system 500 may move forward or backward along at least a portion of the length of the third main rail segment 330 in order to reduce or increase slack in the drive component. Alternatively, at least a portion of the adjustment system 500 may move toward or away from the adjacent end of the third rail segment 330.
The hinge 410 may pivotably couple main rail segments 320, 330 together. For example, the hinge 410 may be connected to one end of the second and third main rail segments 320, 330, thereby allowing the second and third rail segments 320, 330 to pivot and rotate with respect to one another around the center axis of the hinge 410.
In operation, when the second and third rail segments are connected to the hinge 410, and in a folded position, one of the rail segments 320, 330 may be pivoted to a non-folded orientation with respect to the other main rail segment 320, 330, as shown in
In an alternative embodiment, the locking plate 420 may be rigidly connected to the main rail segments 310, 320, 330 by other fasteners, such as screws, nails, rivets, and/or adhesives. Further, in certain embodiments of the present invention, the main rail segments 310, 320, 330 may be pivotally coupled to allow for vertical rotation, as opposed to the embodiment illustrated in
The main rail 115 and the motor 105 are operably connected to the drive system 505. The operable connection between the main rail 115 and the drive component is made such that when the motor 105 is activated, the drive component 135 is moved in a path around the motor 105, the pinion 507, and the main rail 115.
The pinion 507 may be operably connected to shaft or axel 511. According to one embodiment, the pinion 507 may rotate around the axel 511. In such an embodiment, the pinion 507 may include a bore having a diameter larger than that of the adjacent portion of the axel 511, which thereby allows for the pinion 507 to rotate about the axel 511. In another embodiment, the axel 511 may be operably connected to a bearing, the outer diameter of the bearing mating with a bore or counter bore in the pinion 507, and which assists in the rotation of the pinion 507 about the axel 511. Alternatively, the axel 511 and the pinion 507 may rotate together. For example, the axel 511 and pinion 507 may be operably connected to each other, such as through the use of a set screw, pin, key, or spline connection, among others. Alternatively, the pinion 507 and axel 511 may have a unitary structure.
The pinion 507 may be configured to operably engage the drive component 135 of the drive system 505. For example, in embodiments in which the drive component 135 is a chain drive, the pinion 507 may include teeth that engage surfaces of the chain, and which assist in guiding the chain along a looped path through the main rail 115 and the motor 105. Alternatively, the pinion 507 may have a generally cylindrical configuration that allows the drive component 135 to move with or against the pinion 507.
In the embodiment illustrated in
In the illustrated embodiment, the adjustment member 530 may be operably connected to the housing 520 and may mate or be operably connected to a lock-down stop assembly 541. The adjustment member 520 may include, but is not limited to, a bolt or screw, among others.
The adjustment member 530 may be rotatably connected to the top of the housing 520. That is, the adjustment member 530 may be rotated while still remaining connected to the housing 520. Since the adjustment member 530 is rotatably connected to both the housing 520 and the lock-down stop assembly 541, rotation of the adjustment member 530 moves the housing 520 towards or away from lock-down stop assembly 541, depending on the direction of rotation.
In the embodiment illustrate in
The vertical portion 542 of the flange 540 may include an orifice through which at least a portion of the adjustment member 530 may pass. The adjustment member 530 may be secured to the flange 540 through the use of a fastener, such as a mating nut, among others. For example, when the adjustment member 530 is rotated, it may move through a lock-down stop assembly 541, which may include a nut and the vertical portion 542 of the flange 540. Alternatively, the flange 540 may include a threaded aperture that mates a threaded portion of the adjustment member 530.
The operable connection between the housing 520 and the adjustment member 530, may allow for the housing 520, and the operably connected pinion 507, to be moved towards or away from the mail rail segment 330. Moreover, the movement of the pinion 507 relative to the main rail 115 may tighten or loosen the operable connection between the pinion 507 and the drive component 135. Accordingly, when the pinion is moved away from the proximate end 117 of the mail rail 115, the tension in the connection between the pinion 507 and the drive component 135 may be increased. Conversely, when the pinion is moved toward the mail rail 115, the tension in the connection between the pinion 507 and the drive component 135 may be decreased, which may increase the slack in the drive component 135.
Two attachment holes 560 may be provided by two vertical flanges 550 that extend from one end of the housing 520. The vertical flanges 550 and the attachment holes 560 are used to secure a connection between the adjustment unit 500 and a wall in the garage 190. For example, the flanges 550 and the attachment holes 560 may be used in conjunction with fasteners, such as nails, screws, nuts and bolts, and/or rivets, to secure the adjustment system 500 to a wall in the garage 190. This connection may provide added stability and support to the main rail 115 during operation of the garage door opener 100. However, in other embodiments of the present invention, the flanges 550 may extend from different positions on the housing 520. For example, the flanges 550 may extend from the horizontal edges of the housing 520, rather than from the vertical edges of the housing 520.
The trolley component 125 may be movably connected to the main rail 115 at the plurality of trolley channels 119 that run along at least a portion of the length of the main rail 115. For example, as previously discussed, according to one embodiment, a trolley channel 119 is provided on both sides of the main rail 115. Accordingly, both sides of the trolley component 125 may include sliding devices, such as wheels, which engage the trolley channels 119. Further, the trolley component 125 may be operably connected to the drive system 505. That is, when the drive component 135 moves, the trolley component 125 may be pulled along at least a portion of the main rail 115.
The connector 130 may be rotatably connected to the bottom of the trolley component 125. The bottom of the rigid connector 130 may be rotatably connected to the garage door 145. According as the trolley component 125 slides along the main rail 115, the connector 130 may rotate in a vertical plane. That is, the rigid connector 130 may rotate as it pulls the garage door 145 into its horizontal, open position or its vertical, closed position along the track 150.
In operation, when the user activates the door activating switch 110, a signal is transmitted to the motor 105. This signal activates the motor 105, which moves the drive component 135 along the looped path of the main rail 115. The movement of the drive component 135 along the main rail 115 slides the trolley component 125 along the main rail 115. When trolley component 125 moves, the connector 130 pivots at its connections with the trolley component 125 and the garage door 145. The trolley component 125 pulls the rigid connector 130 and the garage door 145 along the path of track 150. If the garage door 145 was initially in the horizontal, open position, the garage door 145 may come to rest in the vertical, closed position. Similarly, if the garage door 145 was in the closed position initially, it may come to rest in the horizontal, open position.
At step 710, the user may un-package the garage door opener 100 in the configuration shown in
At step 720, after the motor support members 120 are attached to the ceiling 160 and the garage door opener 100 is flipped into the correct position, the user may attach the motor 105 to the motor support members 120 using fasteners, such as screws, nails, rivets, and/or nuts and bolts. Once these motor support members 120 are secured to the motor 105, the garage door opener 100 may be self-supported, and the user may not need to exert physical force to keep the motor 105 from falling. Further, the connection between the motor 105 and the first main rail segment 310 may be sufficient to support the weight of the other pivotally coupled main rail segments 320, 330, such that the user may not need to physical exert force to keep the main rail segments 310, 320, 330 from falling.
At step 730, the user may position a ladder directly underneath the hinge 410 at the joint between the first and second main rail segments 310, 320. Once in position, the user may pivot the second main rail segment 320 into a non-folded orientation with respect to the first main rail segment 310. After positioning the first and second main rail segments 310, 320 in a non-folded orientation, the user may secure a locking plate 420 to the first and second main rain segments 310, 320 with nuts 430 and bolts 440. The rigid connection created by the locking plate 420 may be sufficient to support the weight of the second and third main rail segments 320, 330, such that the user may not need to exert force to keep the main rail segments 320, 330 from falling.
At step 740, the user may position a ladder directly underneath the hinge 410 at the joint between the second and third main rail segments 320, 330. Once in position, the user may pivot the third main rail segment 330 into a non-folded orientation with respect to the second main rail segment 320. After positioning the second and third main rail segments 320, 330 in a non-folded orientation, the user may secure a locking plate 420 to the second and third main rail segments 320, 330 with nuts 430 and bolts 440. Once the locking plate 420 is secured, the main rail 115 may be completely assembled. The rigid connections created by the two locking plates 420 may be sufficient to support the weight of the main rail 115, such that the user may not need to exert force to keep the main rail 115 from falling.
At step 750, the user may slide the trolley component 125 onto the trolley channels 119 of the main rail 115. After the trolley component 125 is connected to the main rail 115, the trolley component 125 may be connected to the drive component 135.
At step 760, the adjustment system 500 may be affixed to a wall in the garage 190. This may be accomplished by using fasteners, such as nails, screws, nuts and bolts, and/or rivets through attachment holes 560.
At step 770, the user may connect the rigid connector 130 to the trolley component 125 and to the garage door 145. These connections may be made with rotational connection pieces, such as hinges and/or ball joints, and fasteners, such as nails, screws, rivets, and/or nuts and bolts.
At step 780, the user may rotate the adjustment member 330 to take any excess slack out of the drive component 135. Rotating the adjustment member 330 increases the tension in the drive component 135 and may result in smoother operation of the garage door opener 100.
At step 790, the motor 105 may be plugged into an electrical outlet on ceiling 160. However, as previously discussed, the motor 105 may be operably connected to an electrical power supply or source through a variety of different connections.
At step 795, the user may affix the door activating switch 110 onto the garage 190 wall 180 using fasteners, such as nails, screws, nuts and bolts, and/or adhesives. A wiring connection may be made between the motor 105 and the door activating switch 110. If a hard-wired door activating switch 110 is used, a signal wire connection may be made between the motor 105 and the door activating switch 110. If a wireless wall switch is used, a signal wire connection need not be made between the motor 105 and the door activating switch 110. Alternatively, as previously discussed, the door activation switch 110 may be a portable or wireless device.
Certain embodiments of the present invention may omit one or more of these steps and/or perform the steps in a different order than the order listed. For example, some steps may not be performed in certain embodiments of the present invention. As a further example, certain steps may be performed in a different temporal order, including simultaneously, than listed above.
While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
This application claims the benefit of U.S. Provisional Application No. 60/823,553, filed Aug. 25, 2006, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60823553 | Aug 2006 | US |
