1. Field of the Invention
The present invention relates to the field of tracks installed in garage openings to accommodate the wheels of garage doors and in particular to enable the garage door to be rolled down in a closed position and to also enable the garage door to be rolled up so that it is generally parallel to the garage floor and the garage is opened to permit entry and exit of vehicles or other items in the garage.
2. Description of the Prior Art
In general the concept of improving a garage door track has been performed. In conventional garage door tracks, the exterior edges of the track are sharp which can create a risk of a cut to an installer and a home owner. As illustrated in
One improvement is to cause the track edges to be hemmed outwardly. Another variation is to cause the track to be rolled inwardly as described in U.S. Pat. No. 5,954,111. The use is also described in U.S. Pat. No. 6,250,360. In general, the prior art garage door tracks have no stiffening ribs and no mechanism to provide extra support to the track to prevent rollout of the garage door wheels from the track as the garage door is moved upwardly toward the horizontal open position.
There is a significant need for an improved garage door track which addresses the deficiencies of the known prior art garage door tracks.
In general, the present invention relates to improvements in a track and track support structure for a sectional overhead garage door.
In general, the garage door track is an elongated piece of material such as steel, having an outer section with a wall extending at one end to an interior wall section which in turn extends to an inner section having a wall. In general, the outer section is adjacent a wall of a garage door opening, the interior wall section extends generally perpendicularly to the outer section, and the arcuate inner section is farthest from the garage door wall and is rounded and curves toward the outer section. An opening between a distal end of the outer section and the distal end of the inward curve of the inner section enables the wheels of the garage door to enter and be retained in the track area surrounded by the outer section, the interior wall section and the arcuate inner section.
In the prior art, the distal end of the outer section and the distal end of the inward curve of the outer section are sharp. Attempts to reduce the sharp ends have been made by hemming the distal ends outwardly from the track interior against an outer wall of the outer section and forming a hemmed edge and extending against an outer wall of the inward curve of the inner section. Other attempts to reduce the sharp ends were to create interior roll formed beads. However, to achieve this the material needs to be very thin which reduced the strength of the track and the garage door wheels would bind on the interior roll formed beads.
Hemming is bending in the sharp edges of the track either outwardly so that the edges are bent against adjacent outer walls of the track or bent inwardly so that the edges are bent against adjacent inner walls of the track. It has been discovered, according to the present invention, that if the outermost distal edge portions of the track which include the distal end of the outer section and the distal end of the inward curve of the arcuate inner section are respectively hemmed and bent inwardly against an adjacent inner wall section of the outer section and against an adjacent inner wall of the inwardly curved portion of the arcuate inner section, then hemming the edge of the garage door track inwardly provides increased strength and a safer smooth edge. The inward hemming will also not interfere with the roller wheels of the garage door. The entire track section has a common exterior wall and a common interior wall.
It has been discovered, according to the present invention, that hemming the edge of the garage door track inwardly provides increased strength and a safer smoother edge. An inside hemmed edge will provide a means of door roller retention with increased strength of the inward hemmed edge. This solves the problem associated with conventional garage door tracks, including: (a) edge imperfections of a steel edge which can lead to track failure; (b) an edge imperfection could be a bulge, crimp or edge stress concentration; (c) at the blade edge of the steel, edge buckling can lead to failure of the door.
It has further been discovered, according to the present invention, that a hemmed edge will provide increased resistance to track bowing. The hemmed edge solves the problem associated with sharp edges. Sharp edges can cut hands or fingers during installation of the garage door into the track or throughout its service life. The stronger design can now be now be produced in a reduced steel thickness without sacrificing the strength and integrity of the track. This also facilitates a reduced cost unit rate and a single thickness for all residential tracks. This reduces inventory for even more reduced costs of manufacturing.
It has further been discovered, according to the present invention, that the addition of stiffening ribs into the outer section, interior inner wall, and adjacent the arcuate inner section of the track increases strength rigidity and reduces track bowing and track roll out. Track roll out is used to describe the fallout and failure of the door and door rollers. In the present invention, four stiffening ribs have been incorporated into the garage door tracks. A first stiffening rib is formed on the top sidewall of the outer track section. Two spaced apart stiffening ribs are formed on the interior sidewall section, and a fourth spaced apart stiffening rib is formed in the wall of the curl section which is the portion of the interior sidewall that curves into the arcuate inner section of the track. These roll formed channels or stiffening ribs will provide increased strength to the entire track set. These channels combined with the hemmed inward edge provide increased strength on the entire track set which would take 30-40% thicker steel to achieve the same strength, providing a weight savings of at least 30%. This in turn saves cost per set in the manufacturing. This increased strength will allow the manufacturer to run one gauge (thickness) of steel, thereby eliminating the need for multiple gauges. One gauge can now be used for light duty to heavier duty residential applications by only changing the reinforcing angle. The lower cost to the manufacturer is passed on to the user/dealer and reduced inventory cost.
It has been discovered, according to the present invention, that the addition of the top stiffening rib not only increases strength, but also provides a channel and space/area for the door rollers to ride up in. This is while the door is traveling to the raised position. Without the top stiffening rib, roller drag occurs. This is a problem with 10 inch, 12 inch and 15 inch radius track. Carriage house style doors that are 3 sections tall with 28 inch oversize sections and larger 32 inch sections have the same roller drag problem. While the door is rolling up through the radius on the top of the track, the door rollers get forced against the top of the track. This causes roller drag (binding/friction). Roller drag causes extra wear on the hinges, rollers, door sections and garage door operators. The top stiffening rib channel solves this problem. The extra space/area allows the roller to rise/raise into the channel (rib) allowing it to turn freely with no binding and dragging. This provides smooth door action throughout the entire radius transition. It works almost the same way in the down cycle. As the garage operator pushes the door through the radius position, the door is pushed against the front of the track in the vertical position. The stiffening rib channel provides the extra space to move the rollers forward and not bind in the radius. This results in a big improvement in smooth bind free performance, providing extra life for door parts including cost effective performance at no extra cost and extra strength for the life of the door track.
Another improvement is a reinforcing angle which matches the ribs on the section of the track which is the top horizontal section of track parallel to the floor. The reinforcing angle provides extra supporting strength to the horizontal track portion by having strengthening ribs which match the strengthening ribs of the track section. A reinforcing angle for the garage door track has been straight cut and has had a sharp edge since it was invented. This sharp edge has a sharp point. This has caused injury to installers and homeowners for years. Having a radius curved edge will eliminate the sharp point and provide a safer edge. There is no added cost and no loss of strength but it provides a substantial improvement over the prior art straight cut tracks for garage doors.
It should be noted that the reinforcing angle that have no stiffening ribs [industry standard design] Prior art drawing
It has further been discovered, according to the present invention, that a shorter length on the horizontal section of the track rail section will make the track stronger by reducing unsupported span. Most prior art horizontal garage door track sections are 8 feet 6 inches for a 7 foot door; or 9 feet 6 inches for an 8 foot door. Reducing the horizontal track length by 12 inches it moves the point of support (back hang) closer to the top roller of the door. The distance from the back-hang to the top roller is considered unsupported span. Unsupported span tends to let the track twist and bow. This could lead to track roll out or failure. The door roller on the top could fall out of the rack because of the bow/twist. Some prior art involves extra holes in the track. The holes are used to move the back hang forward which looks odd and unsightly. Shortening the horizontal track provides and facilitates the strongest back hang.
Sometimes the vertical section of the garage door track is damaged by the owner hitting it with his car. The present invention can be used to replace only the vertical part and inter-fit with the remainder of the existing undamaged track, even if does not have the improvements in the track as described above.
The objects of the present invention are to incorporate into a garage door track all of the discoveries and improvements as set forth above.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
Referring to
The outer wall section 20 extends at its proximal end 36 to an interior side wall section 40 having a wall 42 bounded by an interior wall 44 and an exterior wall 45 with a second strengthening rib 46 formed into wall 42 and extending away from the interior chamber 70. The interior side wall section 40 has a spaced apart third strengthening rib 48 formed into wall 42 and extending away from the interior chamber 70. The interior side wall section 40 extends to a curl portion 50 which is still part of wall 42 and bounded by interior wall 44 and exterior wall 45 with a fourth strengthening rib 52 formed into wall 42 and extending away from chamber 70. Second strengthening rib 46 is spaced apart from third strengthening rib 48. The length “L1” is from the proximal end of exterior wall section 20 where it joins interior side wall section 40 to adjacent the distal end of fourth strengthening rib 52. The section distance “L1-A” extends from the proximal end 36 to first space 46A of second strengthening rib 46 and a distance “L1-B” extends from a first space 46A of second strengthening rib 46 to a second space 46B of second strengthening rib 46. A length “L1-C” extends from a second space 46B of the second strengthening rib 46 to a first space 48A of third strengthening rib 48. The third strengthening rib 48 has a distance “L1-D” extending from 48A to 48B and the fourth strengthening rib 52 has a distance “L1-E”, with distances “L1-A”, “L1-B”, “L1-C”, “L1-D” and “L1-E” combining to be “L1”. Curl portion 50 extends to arcuate inner section 54 which extends to an inward curved portion 56 terminating in a distal end 58 of arcuate inner section 54 I which is hemmed inwardly with second hem section 60 pressed against interior wall 57 and having a rounded end 62. A gap “G1” is between first hem section 28 and second hem second 60 leading interior chamber 70 bounded by outer section 20, interior side wall section 40 and arcuate inner section 54 so that wheels of a garage door can be inserted through the gap “G1” and into chamber 70.
Referring to
As illustrated in
Referring to
The rear track section 10A has the same innovations of the hemmed ends 28 and 60 and supporting ribs 34, 46, 48 and 52. Adjacent the distal rear end 8A of horizontal track section 10A at a distance beyond the reinforcing angle section 106 of reinforcing angle 100 and affixed to the back of track section 10A are backing members 200 having a multiplicity of openings 202, 210 having a multiplicity of openings 212 and 220 having a multiplicity of openings 222. The rear track section 10A is affixed to a ceiling of a garage by affixation members such as one way bolts or one way screws respectively extending through one or more of the multiplicity of openings 202, 212 and 222 of the respective backing members 200, 210 and 220. A stop bolt 230 extends through an opening in the back wall 24 of interior side wall section 40 of the track section 10A adjacent the distal end 8A and extends into opening 70 to prevent the wheels of the door from moving past the distal end 8A and off the track 10A.
The angle support 100 is only on the horizontal portion of the track 10A and supports only a portion of the track section 10A. A flag bracket 300 is mounted to the garage wall. The flag bracket 300 has a first section 320 with mounting members 330 affixed to an extended portion of the reinforcing angle 100 with a coiling spring member 340 having a coil 342 to help raise the garage door. The flag bracket 300 has a multiplicity of slotted openings 350, 360, 370 and 380 to adjustably mount the distal end 102 of the reinforcing angle 100 to one or more affixation members 390 such as mounting bolts which extend through the proximal section 400.
The track section 10A extends from its horizontal position around a curved section before it is joined to a vertical section 10B of track 10. A flag 410 located at a distal end 420 of the flag bracket 300 has mounting members 430 which affix the flag 410 to the distal end 10A-D of track section 10A. The flag 410 also has mounting members 440 which affix the flag 410 at an upper or distal end 10B-D of vertical track section 10B. In this way, the track sections 10A and 10B of track 10 are supported.
Another innovation of the present invention is to reduce the distance from the distal end 8A to distal end 10A-D of horizontal track section 10A by 12 inches. This section is known as unsupported span covering the distance from the back hangers 200, 210 and 220 to distal end 10A-D. In the prior art, the span of 8 feet 6 inches or more enables the track section 10A to twist and bow leading to track roll out. The reduction of span length to 7 feet 6 inches for a 7 foot tall door (or reduction to 8 feet 6 inches for a eight foot tall door) provides for a much stronger unsupported span reducing the track twisting and bowing and reducing the incidence of rack roll out.
Referring to
The wheels of the garage door ride on the vertical track sections until they arrive at the horizontal track sections so that the garage door is horizontal adjacent the ceiling 700 and generally parallel to the floor 900. The garage door 700 is rolled down the vertical track sections to close the garage.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.
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