Patent Application
20230250692
The present disclosure relates to the field of tracks and track assemblies for motorized retractable screens, and more particularly, to self-adjusting tracks and track assemblies.
Over the past twenty-five plus years, motorized retractable screens have gained popularity due to their utility and versatility for temporarily enclosing spaces. For example, many restaurants and other businesses having patios/outdoor areas utilize retractable screens to temporarily enclose these areas, thereby creating environmentally controlled areas that are shielded from inclement weather conditions (ex: windy, sunny and/or wintry weather conditions).
Current methods primarily have fixed tracks and the screens are positioned therein such that they are taught. Many problems exist with such fixed designs, as they are intolerant to high winds and screen shrinkage, etc., thereby making the screens inoperable under high wind conditions and/or having a tendency to bind and wrinkle and tear over time. As such, the screens and tracks require regular maintenance and adjustments to overcome the above issues.
U.S. Pat. No. 9,719,292 B1, which is hereby incorporated by reference in its entirety herein, is an example of an attempt to overcome some of these issues, but is still limited. Like the fixed track systems, the ‘292 patent does not provide any dimensional tolerance accommodation for installation for the distance between the tracks that are on each side of the screen making the installation equally difficult. All the magnets may not be engaged and is basically two positions for the screen with magnets engaged and with magnets disengaged, also creating annoying clicking noise each time the magnets engage and disengage.
While these retractable screens have great versatility and utility, several problems exist with the currently marketed products. As examples, the currently marketed tracks and track assemblies are fixed tracks that maintain the screen in a tight, aesthetically pleasing manner once the screen is installed. These fixed tracks allow for extraordinarily little play for expansion or contraction due to shrinkage or under wind load conditions when the screen wants to deflect in the out of plane direction a little looking like a bulging shape. Consequently, during high wind conditions, these screens may twist, buckle, and/or warp the fixed tracks and track assemblies permanently; can damage the screen by tearing or stretching; screen edges, i.e., the zipper edge or the keder edge can slip off the tracks; or combination of all of these. These problems lead to frequent and costly repairs and at some point, may require replacement of the fixed tracks and track assemblies and the screens.
It is an aspect of this disclosure to provide a track assembly which includes: a track configured to be fixed to a structure, the track having an elongate channel having an open side, an end wall, an interior, and two side walls. The interior of the elongate channel has a first region and a second region each provided within the two side walls. The first region is defined between the end wall and an interior partition wall that extends between and connects to the two side walls. The second region is defined from the interior partition wall towards the open side, and the two side walls extending from at least the interior partition wall to the open side. A screen receiver and at least one spring are positioned in the elongate channel. The screen receiver is configured to receive a portion of a screen therein. The at least one spring is designed for (a) compression during movement of the screen receiver in the second region in a first direction upon application of sufficient force thereto and (b) expansion to force the screen receiver towards a second direction opposite the first direction when the application of force is reduced. The at least one spring has a spring rate between 5 lbs / inch and 300 lbs / inch.
In another aspect, the at least one spring of the aforementioned track assembly is configured to compress or deflect a minimum of approximately 0.25 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 6.0 inches under wind pressure as a result of high wind speed thereto.
Other features and advantages of the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
These and other features, aspects and advantages of the present disclosure are better understood when the following detailed description of the disclosure is read with reference to the accompanying drawings, in which:
This disclosure relates generally to the field of tracks and track assemblies for retractable screens used for sunshade, privacy, wind, and other weather protection.
As noted in the background, several prior art systems are intolerant to high winds and screen movement, and lack dimensional tolerance. The disclosed track assembly is designed to eliminate and/or reduce many of these aforementioned problems by allowing for flexion relative to and in and out in the plane of the screen as needed under wind or shrinkage conditions, and reduce edge force on the screens, as well as friction, to make the screen and assembly operable at higher wind force conditions, while also keeping the screen wrinkle free and aesthetically pleasing and extending the life of the screens and the associated motor. As disclosed herein, such is achieved by having a moveable track portion, also called a spring track keder guide or a “screen receiver” throughout this disclosure, under spring-loaded condition within a fixed, elongate track (also called a track housing. Such a fixed track may be used alone, connecting to one side (or a single side) of a screen, or with another track (of similar or different construction) to connect to both sides of a screen. At least one spring is provided in the track assembly and designed for compression during movement of the screen receiver in the fixed track in a first direction upon application of force thereto, and expansion to force the screen receiver back in a direction opposite to the first direction when the application of force is reduced.
A spring arrangement of many different varieties may be sized for range of wind forces and screen strength conditions and appropriate amount of flexing for any size screens. In addition to solving many of the prior art problems, use of these track assemblies will also extend the range of current widths and height of current retractable screen designs. In addition to improving the operation of the retractable screen and its life, this disclosure makes installation a bit easier by being able to have a larger tolerance for the distance between the end tracks having a range of preload on the added spring(s) and reduces maintenance issues.
Therefore, it is an object of the disclosure to provide tracks and track assemblies that overcome the problems of currently marketed fixed tracks and fixed track screen assemblies. The disclosed tracks and track screen assemblies utilize a track that is designed to assist in keeping an attached or connected screen taught with the help of one or more springs that are configured to compress to a particular level (or within a particular range) depending on the loading (force) on the screens and allowing for expansion or contraction, as necessary. When compared to currently marketed fixed tracks and fixed track screen assemblies, this spring-loaded movable arrangement advantageously results in less frequent maintenance of the disclosed tracks/track assemblies while simultaneously increasing screen operating range under various wind conditions and increasing lifespan.
In the case where two track assemblies are utilized together, for example, the disclosed assemblies utilize a novel arrangement of springs that allow a screen attached thereto to compress while under high wind pressure conditions bringing the moveable track portions (or screen receivers) closer to each other within their respective fixed tracks and, as the high wind pressure on the screen subsides, the screen receivers move relatively apart constantly tensioning the screen to provide for an aesthetically pleasing, tight screen at all times. Of course, as one having skill in the art would understand, similar effects may be obtained when utilizing a single disclosed track assembly to hold one side of a screen along with another track to hold the other side of the screen.
As another advantage and in direct contrast to the currently marketed fixed tracks and fixed track assemblies, the disclosed tracks and track assemblies do not have dimensional limitations of screens that can be used in these tracks/track assemblies, and screens covering extremely wide and tall openings, including dimensions of up to 36 feet wide by 30 feet high, may be used with the disclosed tracks and track assemblies.
Specifically disclosed is a spring-loaded track assembly including a track configured to be fixed to a structure (referred to herein as a “fixed track” for explanatory purposes), the track having an elongate channel having an open side, an end wall, an interior, and two side walls. The elongate channel of this track is fixed once attached to a structure or wall. At least one spring is secured or held within the interior of the elongate channel. A compartment or region is defined within the elongate channel. A screen receiver, which is configured to receive a portion (e.g., keder) of a screen therein, is disposed within the compartment or region and may apply a preload on the one or more springs, e.g., due to application of force to the received/attached screen. As understood by one of skill in the art, a screen keder (or “keder”) is a mechanical attachment that is attached to (e.g., welded or sewn) and/or formed along an edge of the screen fabric or mesh, for attaching the screen to a track or rail, and thus such is not explained in detail herein. The screen receiver may be an elongate track that extends within a length of the elongate channel of the fixed track. The at least one spring has a pre-defined spring rate which is designed to allow movement of the screen receiver in the channel in a first direction, e.g., between a first position and a second position, depending upon an amount of force applied thereto.
Throughout this disclosure, there is reference to wind speeds, wind pressure, and the effects of the same on the disclosed track assembly. Wind speeds are typically categorized in ranges, which result in a varying wind pressure. Depending upon placement of a screen and the disclosed track assembly in or on a building, the wind pressure that is applied thereto is reduced. Factors such as velocity pressure coefficient (0.85 to 0.98), topographic factor (0.85 to 0.98), and directionality factor (0.85 to 0.95) affect the actual wind pressure that may be applied to the disclosed track assembly (and an attached screen).
For illustrative purposes, the following chart represents examples of wind speed, wind pressure, and actual wind pressure (applied to the screen) considered throughout this disclosure:
As evidenced by the chart, the wind pressure P is determined based on the wind speed, and the actual wind pressure is approximately 25% to 35% less than the wind pressure P, once the factors and coefficients are applied.
Generally, the larger the wind speed, the larger the distance for travel (i.e., compression or depression) for the spring(s). Further, the larger the opening or doorway which the screen extends across, the larger the compression or deflection. In this case, any change of wind speed (V, in mph), wind pressure (P, in psf), screen width (ft) and/or screen height (ft), screen stretch (%), spring travel (inches), and/or spring length (ft) affects a pull force on the screen receiver/keder (lbs), screen bulging amount (ft), and a desirable spring rate for the disclosed design. Accordingly, it has been observed that at a given pressure on screen, as the stretch increases, the force on the keder and screen receiver reduces (as does the force on the track). As the force on the keder is lowered, then damage to the track(s) and screen are lowered, and the screen itself operates more easily. Herein, in order to further reduce the force on the keder and thus the screen receiver, spring(s) are added in the track as part of the assembly to compensate for wind pressure and thus force applied to the keder and frame. The spring travel -e.g., compression or deflection amount of the spring(s) - further affects the force on the screen and its keder, and thus the screen receiver and track. It has been determined that as spring travel increases, the force on the keder is reduced. Also, it has been determined that as wind speed increases, the force on the keder may be maintained (or reduced; i.e., such that keder force is similar to a force applied at lower wind speeds) by increasing the spring travel. Additionally and/or alternatively, as a screen width (measured in a horizontal direction) is increased, the force on the keder may also increase, but the keder force may similarly be maintained (or reduced) by increasing spring travel with the screen width.
As a result, this disclosure focuses on reducing force that is applied to the screen receiver (and keder) under extreme wind conditions and/or higher (i.e., hurricane winds), via one or spring(s) placed into the track assembly, and considers these aforementioned factors with regards to selecting spring rate and the compression / deflection of the spring(s) used as part of the disclosed track assembly.
In accordance with embodiments herein, the interior of the elongate channel of the track assembly has a first region and a second region each provided within two side walls. The first region may be defined between an end wall and an interior partition wall that extends between and connects to the two side walls. The second region may be defined from the interior partition wall towards an open side of the elongate channel, and the two side walls extend from at least the interior partition wall to the open side. In an embodiment, the screen receiver is positioned in the second region. In an embodiment, the at least one spring is positioned in the second region. In an embodiment, the at least one spring is positioned in the first region. In an embodiment, both the screen receiver and the at least one spring are positioned in the second region. In an embodiment, the screen receiver is positioned in the second region and the at least one spring is positioned in the first region.
As described herein, during operation, i.e., when the track assembly is installed and has a screen attached thereto, the spring(s) may be compressed as force (e.g., wind pressure as a result of wind speed/wind load thereon) on a screen increases. The movable screen receiver is disposed within the compartment or region such that as the wind load increases, the spring(s) compress in proportion as the movable track moves closer towards the open side of the elongate channel due to the applied force, and vice versa. That is, the screen receiver is moved in the first direction (e.g., from a first (or normal/default) position to a second (or active) position) during application of force [to the screen]. In the second position, the spring(s) is compressed upon application of sufficient force (to overcome the spring rate). Based on the amount of compression, the spring force of the spring(s) is designed to force the screen receiver back to its first position. That is, when the application of force is reduced, the compressed spring(s) expands to force the screen receiver towards a second direction that is opposite the first direction.
The spring rate, also referred to as spring constant, is the amount of weight or force (in this case, in pounds (lbs)) needed to compress a spring by one inch. Spring rate can also be defined as the estimation of the amount of force needed to compress a spring to a specific distance. In this disclosure, the spring rate of the spring(s) as defined herein allows for flexibility and movement of the screen receiver and attached screen within the elongate channel during application of force (e.g., during inclement weather), while also applying a counteracting force to position the screen receiver and screen into a normal or default position. In embodiments herein, the spring(s) may utilize a lower spring rate (or softer spring) and include longer spring travel to accommodate and counteract forces applied to the screen and track.
For illustrative purposes only, the chart below shows exemplary calculations for selected wind speeds, screen widths and heights, spring rates, and selected amounts of spring compression:
indicates text missing or illegible when filed
Altering a maximum spring compression amount in turn affects a highest value of the spring rate at which movement is affected at a particular wind pressure/wind (in this case, the spring compression and spring rate are inversely proportional, i.e., as the spring compression is lowered, the spring rate is increased). While the spring rate (lbs/in) could be set to a highest value in order to fully withstand the wind speed and wind pressure [with little to no movement/compression of the spring], in a practical application as disclosed herein, the spring rate is designed to be set a lower rate, so that the spring(s) are designed to effectively “bottom out” (i.e., hit a maximum compression) at lower wind speeds and wind pressures. Accordingly, at a lower set spring rate, the disclosed design allows for the spring(s) to effectively compress /deflect between rest, minimum, and maximum positions at lower wind pressures (wind speeds) thereby reducing forces applied to the screen receiver (keder) and screen as well as the track itself, even if higher wind pressure (speed) is applied. This in turn reduces friction and noise that is caused by movement of the screen receiver within the elongated track, since the spring(s) is /are activated to absorb or dampen motion and applied force.
In accordance with embodiments herein, the spring rate and the minimum /maximum spring compression for the spring(s) in the track assembly may be selected based on nominal (e.g., up to ~15 mph) and high wind conditions (e.g., ~40 mph), while considering the aforementioned wind speed, wind pressure, screen with and height, etc. factors. That is, as noted previously, the maximum movement / compression or bottoming out of the spring(s) may be set based on a relatively lower wind speed and wind pressure, i.e., in this case, pressure as a result of high wind speed (over 25 mph and up to ~40 mph), yet it should be understood that this max/bottoming out at at least high wind speed allows for compensation and movement at higher winds (e.g., extreme wind speed, or more) as well. A skilled person in the art will understand that wind pressure and speeds may vary, thus varying movement of the spring(s).
The at least one spring has a spring rate between 5 lbs / inch and 300 lbs / inch (both inclusive), in accordance with embodiments herein. In accordance with another embodiment, the at least one spring has a spring rate between 5 lbs / inch and 100 lbs / inch. In accordance with another embodiment, the at least one spring has a spring rate between 10 lbs /inch and 100 lbs / inch. In yet another embodiment, the at least one spring has a spring rate between 5 lbs / inch and 25 lbs / inch.
In an embodiment, the spring(s) are configured to compress or deflect a minimum of approximately 0.25 inches +/- 0.1 inches under wind pressure as a result of nominal wind speed and a maximum of approximately 8.0 inches +/- 0.25 inches under wind pressure as a result of high wind speed (and/or higher / more). In one embodiment, the at least one spring allows compression or deflection of a minimum of approximately 0.25 inches +/- 0.1 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 6 inches +/- 0.25 inches under wind pressure as a result of high wind speed (and/or higher / more). In another embodiment, the at least one spring allows compression or deflection of a minimum of approximately 0.5 inches +/- 0.1 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 3 inches +/- 0.25 inches under wind pressure as a result of high wind speed (and/or higher / more). In yet another embodiment, the at least one spring allows compression or deflection of a minimum of approximately 0.25 inches +/- 0.15 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 0.75 inches +/-0.15 inches under wind pressure as a result of high wind speed (and/or higher / more). However, such distances are exemplary only and not intended to be limiting.
In embodiments herein, when spring(s) are installed in the elongate channel, they are secured with minimal (if any) compression. In an embodiment, when no force is applied to the screen receiver, the spring(s) may be interference fit within the elongate channel, without any preload thereon. In one embodiment, the spring(s) may be minimally compressed about approximately 0.005 inches when installed.
When wind pressure (force) is applied to the screen, and thus the screen receiver(s), the screen receiver(s) is moved in the channel and acts to compress the spring(s) therein. Thus, the spring(s) are compressed or deflected a distance from a neutral or normal position (i.e., position under no load).
In an embodiment where wave springs are employed, the maximum deflection amount may be defined as the free height of a wave minus the spring strip thickness.
In accordance with an embodiment, besides the wind pressure (and resulting force) that is applied to the screen and keder and thus the track assembly, the minimum/maximum compression or deflection amount of the spring(s) is dependent upon at least a size of the elongate channel, the size of the screen attached therein, and the spring(s) mounting therein. A person having ordinary skill in the art understands that factors such as screen width, height, wind speed, screen fabric stretch, spring rates and travel distances may affect the compression/deflection of the spring. In an embodiment, in addition to the wind pressure and forces applied thereto, the minimum/maximum compression or deflection amount of the spring(s) is dependent upon placement of the spring(s) and the screen receiver within the elongate channel. In an embodiment, the minimum/maximum compression or deflection amount of the spring(s) is dependent upon a depth (or width) of the second region formed in the elongate channel. In one embodiment, the minimum/maximum compression or deflection amount of the spring(s) is dependent upon a size of a pocket formed in the second region of the elongate channel that the spring(s) are mounted or secured in. In an embodiment, the minimum/maximum compression or deflection amount of the spring(s) is dependent upon a depth (or width) of the first region formed in the elongate channel.
As previously mentioned, and as shown in the chart, in an embodiment, the compression or deflection amount of the spring(s) is [further] dependent upon a size of the opening or doorway in which the screen extends. Generally, the larger the wind speed, the larger the distance for travel (i.e., compression or depression) for the spring(s). In an embodiment, the larger the opening or doorway which the screen extends across, the larger the compression or deflection.
As an example, when subjected to an applied sufficient force for nominal to high wind speeds, e.g., up to 40 mph, the spring(s) may be designed to have with a particular spring rate, e.g., 10 to 100 lbs/in, and to compress or deflect a minimum of approximately 0.25 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 1 inch under wind pressure as a result of high wind speed. As the wind speeds, and thus the applied wind pressure / force, increase, the selection for the desired spring rate and compression/deflection (min and max) may also increase, or may remain the same or similar. As another example, under very high wind speeds (hurricane category 1 or 2), the spring(s) may be designed to compress or deflect a minimum of approximately 0.25 inches under wind pressure as a result of nominal wind speed to a maximum of approximately 2 inches under wind pressure as a result of high wind speed, with a similar spring rate. In accordance with an embodiment, the spring rate and the spring(s) compression or deflection is proportional to the extension (width) of the screen (between two track assemblies), as well as the anticipated force (from the winds) that may be applied to the screen and track assembly. For example, for openings or doorways that are less than 20 feet which are subject to high winds, like hurricane winds, the spring(s) may be designed to have with a particular spring rate and to compress or deflect a minimum of approximately 1 inch at nominal wind speeds to a maximum of approximately 2 inches for extreme wind speeds. The same configuration of spring(s) may be used for openings or doorways that are greater than 20 feet but subject to nominal wind speeds. Such distances are exemplary only and not intended to be limiting.
In certain instances, there may be a partition wall inside the fixed track creating a partition side for the screen receiver and spring(s) and an additional or secondary channel side. The additional / secondary channel side may be used for anchoring the track to a structure of an open space where the screens are being installed, in accordance with an embodiment. On the partition side, the interior of the elongate channel includes a first interior region or compartment and a second interior region or compartment provided within the two side walls, which are optionally parallel to one another. The first interior region may be defined between the end wall and an interior partition wall that extends perpendicularly between and connects to the two side walls. The second interior region may be defined from the interior partition wall towards the open side, and may be configured to receive the screen receiver and the at least one spring therein.
In certain aspects, on the secondary channel side of the tracks, there is an opening for the full length on one of the faces to access the anchors, and the track assembly further includes a removable elongate cover covering a length of the secondary channel. As an example, in an embodiment, the secondary channel has an elongate opening that is accessible in a direction perpendicular to the open side of the elongate channel. In accordance with an embodiment, a removable elongate cover for removably covering a length of the elongate opening of the first compartment or region is provided which extends parallel to the side walls when mounted to cover the elongate opening. Such cover may add aesthetic value, for example.
The screen receiver may be of any shape, symmetric or non-symmetric, primarily having a provision to capture the screen keder and stay within the fixed track and being movable in the plane of the screen. Movement of the screen receiver is controlled via the fixed track and as a result of the lateral wind or other force on the screen balanced by the spring(s) working against the screen receiver. In accordance with an embodiment, the screen receiver includes an elongate Split-O shaped channel having an opening that is accessible through the open side of the elongate channel. That is, the opening extends along a same direction as the open side of the elongate channel, when the screen receiver is placed within the fixed track. Accordingly, the opening of the elongate Split-O shaped channel may be accessible in a direction that is through the open side and that is substantially parallel to at least one of the two side walls. In accordance with an embodiment, the opening of the screen receiver is provided in a center thereof, such that the elongate Split-O shaped channel is accessible through the open side of the elongate channel. The screen receiver, and more particularly the Split-O shaped channel opening, are in certain aspects adapted to receive a screen interlock including, but not limited to a keder interlock, a Zipper interlock, a rope, a beaded chain, or any similar interlock known in the art associated with the disclosed retractable screens.
In certain aspects, the first and/or second interior region(s) of the elongate channel has a depth of approximately one inch. In embodiments, a second region 120 (see, e.g.,
In accordance with an embodiment, the overall thickness OT (i.e., a distance between outer portions of side walls 143 and 144, defined in a perpendicular direction to an extension direction of the screen) of an elongate channel 140 may be from approximately one inch to approximately six inches. In an embodiment, the total depth TD (or overall width) of the track (i.e., where total depth is defined as a distance between an outer edge/wall of an end wall (142 in
The at least one spring of the track assembly may be provided in the form of a wave spring, a coil spring, or a compression spring, in accordance with embodiments herein. In one embodiment, the track assembly includes at least two springs. For example, the screen receiver may include two sides, and each of the at least two springs may be positioned on either side of the screen receiver, within the fixed track, according to exemplary embodiment.
In one illustrative embodiment shown in the Figures, wave springs are used. Each wave of a wave spring has a “free height” or “free wave height” which is a distance that is defined between two planes along a wave; that is, the distance between a plane along a bottom portion of the wave and a plane along a top portion (i.e., along a curved portion) thereof. In an embodiment, the free height is between 0.4 inches and 0.7 inches. In certain aspects, the wave springs free wave height can be up to approximately 1 inch, approximately 2 inches, approximately 3 inches, approximately 4 inches, approximately 5 inches, or approximately 6 inches, e.g., to match with the size of a pocket (described briefly above and later below) within the track. That is, the free height of the waves of the wave spring (extending within the length of the track) may be proportional to a depth PD (see
In certain aspects, the wave springs can be pre-mounted on the receiver with a rivet or clip or similar accessary to hold them in place during assembly.
In certain aspects not limiting to wave springs, as alternate designs to wave spring design described here, one or multiple coil springs attached to the screen receiver or one or multiple flat springs attached to the screen receiver can be used to provide the necessary compression and movement of the screen receiver.
In accordance with embodiments herein, the free height of the spring(s) may be proportional to a distance that a screen extends between two track assemblies when covering an opening or doorway, as previously discussed above. In embodiments, the free height of the spring(s) may be determined based upon anticipated forces that may be applied to the track assembly (and screen).
In certain aspects, the screen receiver is adapted to move in the plane of the screen horizontally within the region or compartment toward and away from the open side channel legs.
In certain aspects, a width of the screen receiver is less than a width of the region or compartment such that the screen receiver can be installed by sliding in from either end of the elongate channel.
In certain aspects, the elongate channel is open at a top and a bottom thereof, and the top and the bottom are covered with removable top and bottom covers, respectively.
Embodiments of the disclosure can include one or more or any combination of the above features and configurations. Additional features, aspects and advantages of the disclosure will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the disclosure as described herein. It is to be understood that both the foregoing general description and the following detailed description present various embodiments of the disclosure and are intended to provide an overview or framework for understanding the nature and character of the disclosure as it is claimed. The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification.
The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which exemplary embodiments of the disclosure are shown. However, the disclosure may be embodied in many different forms and should not be construed as limited to the representative embodiments set forth herein. The exemplary embodiments are provided so that this disclosure will be both thorough and complete and will fully convey the scope of the disclosure and enable one of ordinary skill in the art to make, use and practice the disclosure. Like reference numbers refer to like elements throughout the various drawings.
Disclosed are movable screen receivers and track assemblies that utilize a novel spring arrangement in the track assemblies that allow one or more springs to compress and flatten and allow the screen receiver to move closer to an open end or open side of fixed track thereby allowing an attached screen to expand out of plane to a bubble like shape or a slight bulge in the middle of the screen while under high wind pressure, and after the high wind pressure subsides, the load on the one or more springs (applied via the screen receiver) is relieved cause said spring(s) to expand and push away the screen receiver thereby tensioning the attached screen to provide an aesthetically pleasing, tight screen. Thus, the novel spring arrangement within the tracks/track assemblies provide a self-tensioning system that operates effectively while accounting for fluctuations in wind conditions that advantageously ensures increased screen and track assembly lifespan while reducing frequent maintenance (and/or replacement) associated with currently marketed screens, track/track assemblies, or a combination thereof.
Exemplary screen receivers and track assemblies 100 are depicted, for example, in an embodiment as shown in
In accordance with an embodiment, a direction of mounting each track assembly may be such that the elongate track extends in a vertical direction. According to an embodiment, in certain aspects, all portions of the assembly remain vertically stationary during screen deployment and retraction.
The track assembly 100 has a fixed track including an elongate channel 140 having a length to configured to extend vertically, in accordance with an embodiment. In the illustrated exemplary embodiment of
As shown in
As further shown in
As previously noted, the springs 102 and 104 are configured to be compressed during movement of the screen receiver 110 in the channel in a first direction (from its first position). Per
For example, in embodiments, the screen receiver 110 includes an elongate Split-O shaped channel 111 formed thereon that has an opening 112 that receives the screen 200 (e.g., a screen keder interlock, a Zipper interlock, a rope, a beaded chain, or any similar interlock known in the art) while providing sufficient clearance such that the screen may easily move through the Split-O shaped channel. As previously described, the opening 112 extends along the screen receiver 110 in a same direction as the open side 141 of the elongate channel 140 and may be in the center of the screen receiver for accessibility. The screen is designed to be easily deployed and retracted as desired through the Split-O shaped channel via the open side 141 or end.
In an embodiment, the interior of the elongate channel 140 includes a first compartment 160 and a second compartment 120 each provided within the two side walls 143 and 144, such as shown in
In one embodiment, the elongate channel 140 further includes at least one optional partition stop wall extending from at least one of the two side walls 143 and/or 144 towards a center of the elongate channel 140 while still allowing access to the screen receiver 110. Accordingly, in such instances, the screen receiver 110 is adapted to move between the interior partition wall 138 and the partition stop wall(s). That is, screen receiver 110 is configured to move towards the open side 141 of the elongate channel 140 to compress the at least one spring relative to/against the partition wall, and configured to move back towards and against the interior partition wall 138 based on a spring force from the at least one spring. As shown in
In an non-limiting embodiment, for the example shown in
In accordance with an embodiment, a depth or width of the leg portions 136 (i.e., a distance extending in the same direction as the screen, generally parallel to walls 143, 144) is approximately ¼ to ½ of the depth D1 of the second region 120. In an embodiment, the depth or width of the leg portions 136 is approximately ⅓ of the depth D1 of the second region 120. However, such distances are exemplary only and not intended to be limiting.
When the screen is under wind pressure and wants to collapse putting tension on the edges, the screen receiver 110 moves and its lateral back walls push on the wave springs 102, 104 and starts compressing them and moving closer to the partition walls 147, 148 and open side 141 or end. The legs are separated from the interior partition wall 137 as the wind pressure increases on the screen. The leg portions 136 assist in keeping the screen receiver 110 straight and parallel, while the screen is subject to forces (e.g., wind forces) which result in the receiver 110 moving in and out, and without twisting within the elongate channel 140. However, such is meant to be illustrative only. The springs 102 and 104 may be provided in the second region 120, between the screen receiver 110 and one of the partition stop walls, in accordance with an embodiment. Specifically, in an embodiment, the wave spring 102 is captured in a pocket (or compartment area) formed by the back wall of the leg portions 136 of screen receiver 110 and partition wall 148 of the elongate channel 140 and wall 144 and the Split-O shaped channel 111. Similarly, the wave spring 104 is captured in a pocket (or compartment area) formed by the back wall of the leg portions 136 of the screen receiver 110 and partition wall 147 of the elongate channel and wall 143 and the Split-O shaped channel (i.e., on an opposite or other side). The depth PD of each pocket - and thus the spring(s) - is dependent upon a depth (or width) of the extension leg of the leg portions 136 and the depth D1 of the second region 120 (in this illustrated case, the depth D1 is defined between the partition wall 138 and partition wall 147 or 148), i.e., D1 minus depth of leg portion 136. Accordingly, movement of the screen receiver 110 towards the partition stop wall(s) 147 and/or 148 is configured to compress the spring(s) 102 and/or 104 with the pocket(s). As the screen receiver 110 moves within the elongate channel 140 during inclement weather due to the pressure load on the screen 200, these two pockets get smaller or larger simultaneously compressing the wave springs 102, 104. For example, and as shown in
As noted previously, the minimum/maximum compression or deflection amount of the spring(s) may be dependent upon a number of factors, including the placement of the spring(s) and the size of the features of the elongate channel. In an embodiment, wherein the spring(s) are provided in a pocket(s) (e.g., formed between the screen receiver 110 and one of the partition stop walls 147, 148 in the second region 120 of the elongate channel 140 (as described above with reference to
The screen receiver 110 can be stable at any point along its range of full motion defined by freely or slightly preloaded state installed spring position and fully compressed spring position depending on the pull force of screen and the balancing compressive resistance of the wave springs resulting in partial or full compression of the springs.
As further shown in
As further depicted in
The elongate channel 140 further includes a top end 180 and a bottom end 181 positioned at ends of the two side walls 143 and 144, shown generally (not to scale) in
The aforementioned ranges of spring rates similarly apply to the coil springs 102A 104A of
Flat springs is another option for the spring(s) used in the track assembly.
Although not explicitly shown in each of the Figures, it should be understood that the exemplary embodiments of the spring(s) as shown in
The aforementioned ranges of spring rates similarly apply to the spring 102B of
Further, as noted previously, the springs 102B and studs 106 of
The screen receiver 110, the elongate channel 140, elongate cover 170, and/or top cover 182 and the bottom cover 183 may be formed of metal, a thermoplastic resin, or a combination thereof. For example, in certain aspects, the screen receiver 110, the elongate channel 140, elongate cover 170, and/or top cover 182 and bottom cover 183 may be formed of metal, a molded thermoplastic resin sufficient to withstand harsh weather conditions and the movements disclosed herein. Such materials are not intended to be limiting, however. It should be further noted that the screen receiver 110 disclosed herein may be adapted to receive a screen keder through, for example, a Split-O shaped channel 111. However, the screen receiver 110 may have any desired predetermined shape (e.g., triangular, square, rectangular shape) that can receive screen 200 there-through. As alluded to above, the screen receiver 110 may be adapted to receive a zipper interlock, a rope, a beaded chain, or any similar interlock known in the art associated with the disclosed retractable screen.
In addition to the improvements and advantages described throughout this disclosure, the use of the at least one spring in a track assembly as disclosed herein reduces noise with regards to movement of the screen receiver within the track. That is, unlike the prior art systems which use magnets that disconnect with nominal wind variations - and thus cause noise and friction as a result of movement of part(s) within a track or rail - the disclosed designs further provide limited to zero noise during applied wind pressure, since the spring(s) not only provides absorption with regards to force and noise, but also less friction between parts within the track assembly [as they move]. Further, by using a lower spring rate, the disclosed designs allow for compression at lower (e.g., nominal) wind speeds and bottoming out at higher (e.g., high, extreme and/or higher) wind speeds, which reduces forces applied to the screen receiver (and keder) and allows the screen to better operate while remaining aesthetically pleasing with limited to no wrinkles. Furthermore, installation of the disclosed track assembly is easier as the spacing between track assemblies (e.g., when using two on either side of a doorway or opening) & tolerances may be increased by having some small compression in the springs at installation, if needed.
The foregoing description provides embodiments of the disclosure by way of example only. It is envisioned that other embodiments may perform similar functions and/or achieve comparable results. Any and all such equivalent embodiments and examples are within the scope of the present disclosure and are intended to be covered by the appended claims. Also, while the track assembly 100 has a fixed track including an elongate channel 140 with a length that is configured to extend vertically, in accordance with an embodiment, it is envisioned that the track assembly 100 may be positioned horizontally. Further, while a motorized screen (i.e., motor and screen) is noted for use with said track assembly 100, such is not intended to be limiting. That is, a manual screen, i.e., secured and pulled by hand, may be used with the disclosed track assembly.
While the principles of the disclosure have been made clear in the illustrative embodiments set forth above, it will be apparent to those skilled in the art that various modifications may be made to the structure, arrangement, proportion, elements, materials, and components used in the practice of the disclosure.
It will thus be seen that the features of this disclosure have been fully and effectively accomplished. It will be realized, however, that the foregoing preferred specific embodiments have been shown and described for the purpose of illustrating the functional and structural principles of this disclosure and are subject to change without departure from such principles. Therefore, this disclosure includes all modifications encompassed within the spirit and scope of the following claims.
