Patent Application
20130319623
The present invention relates to a hydraulically operated overhead bi-fold door for use with residential, retail, commercial or industrial structures.
Many buildings require large access openings to permit the ingress and egress of large equipment, merchandise or flow of people into and from the structure. Covering these large openings requires large doors. Different types of doors have been developed to cover such openings, such as top or bottom slidably mounted doors supported by a roller/track system, vertically pivotally mounted doors or top pivotally mounted (overhead) doors. Various means exist for opening and closing these doors, including man power, cables or hydraulics.
If a door opening is proportionately large with respect to the building size and there is limited available lateral space from the sides of the door opening or limited space in front of the door opening, many of these doors become impractical. Specifically, vertically pivotally mounted doors for large openings have a large arc of rotation and require significant forward or lateral space from the door opening when the doors are in the open position. Top slidably mounted doors require significant lateral extension of the horizontal support track(s) from the door opening to support the door when moved to an open position. Further, vertically pivotally mounted and top slidably mounted doors may interfere with other building operations or attributes. For example, an opaque vertically pivotally mounted or top slidably mounted door in an open position may extend in front of building viewing windows next to the door opening, blocking the view. Although transparent glass doors could be utilized, glass is quite heavy, historically requiring significant structural support for the door.
Top pivotally mounted, single panel doors are preferred, almost required, where lateral space is limited or non-existent. However, these doors still require significant space in front of the door opening to be opened. Further, these doors are susceptible to wind damage because they typically present a large impervious surface when extended in the open position, and can be damaged in strong winds.
Top pivotally mounted single panel doors also require significant structural support because they are heavy and leveraged out front of a building. Historically, the materials used on a top pivotally mounted single panel door panels are typically of light weight to address structural support issues. Transparent glass panels for such doors are historically impractical because of the enhanced weight of glass and structural support requirements.
A great deal of force is typically required to open and close top pivotally mounted single or bi-fold panel doors because of the door weight and structural support required for these doors. To aid in the opening and closing of these doors, hydraulic cylinders have been employed.
By way of example, U.S. Pat. No. 6,883,273 to Kerkvliet discloses a top mounted single panel door pivotally secured by an upper edge to a header of a building door opening so that the door can he rotated outward from the building to an open position. The door is opened and closed by a pair of hydraulic cylinders. A first end of each hydraulic cylinder is pivotally secured to a building door jamb or frame and a second end of each hydraulic cylinder is pivotally secured at a side edge of the door, about half way down the side of the door. The action of the cylinders puts significant stress on the building frame where the cylinder is mounted.
Another example of a single panel hydraulically operated door is shown in Publication No. U.S. 2011/0232196 to Robinson. This patent application discloses a number of support trusses secured to the inside of the single panel door in spaced relation along the width of the door. The trusses extend from the top to the bottom of the door. The trusses are required to give the single panel door stability and strength and prevent it from bending under its own weight or from being damaged in high wind conditions. However, adding the trusses adds weight to the door, requiring greater structural support to hold the door open. Although hydraulic cylinders are used to open and close the door, because of the mounting orientation of the hydraulic cylinders and the size of the door, Robinson requires very long and powerful hydraulic cylinders to open and close the door.
A version of a hydraulically operated top pivotally mounted/overhead. door that has reduced susceptibility to wind damage and reduced extension from the building is a bi-fold door. One such hydraulically operated bi-fold door is disclosed in Applicant's U.S. Pat. No. 7,814,957. Two hydraulic cylinders mounted on opposite sides of the door frame are used to open and close the overhead door. A first end of each hydraulic cylinder is pivotally mounted to the building door frame (the “building mount”), interior from and below the axis of rotation defined by the mounting hinges securing the top panel of the door to the building door frame. A second end of each cylinder is attached to a side edge of the top panel. In a door closed position, the hydraulic cylinders extend downward and forward from the building mount to a position close to the bottom of the top pane of the bi-fold door.
U.S. Pat. No. 5,020,580 to Dalman discloses a hydraulically actuated bi-fold door with the hydraulic cylinder and structural support mounted on the outside of the door to help reduce the force required to open (lift) the door. This exposes all the hydraulics to the elements. It also requires an extremely long hydraulic. The force imparted by the hydraulic cylinders When opening the door is communicated to the ground and not to the building. The door also includes a leveling mechanism that causes the lower bi-fold panel to fold horizontally and adjacent to the upper panel when the door is in its opened position. However, the top panel of Dalman, in the open door position, is angled back towards the building structure. In a rainfall, the water is directed back towards the building, which is a detraction.
UK Patent Application GB 2150965A to Hindley discloses an overhead bi-fold door that is opened or closed with hydraulic cylinders. Both the external mount system of
There remains a need for an easily installed hydraulic operated door system that requires no space lateral of the door opening and limited space in front of the door opening for the door to open, that absorbs many of the load forces created from opening and closing the door within the door system, and that requires smaller, less expensive hydraulic cylinders to open and close a door even with heavy, non-traditional door panels, such as panels composed of glass.
The present invention is a hydraulic operated top pivotally mounted overhead door assembly for a doorway defined in an interior or exterior door opening. The hydraulic operated door assembly includes a three sided door frame, a multi-panel door and at least one hydraulic cylinder assembly for moving the door between an open and closed position. The entire assembly is mounted within a rough opening of a building doorway.
The frame includes a top horizontal frame member and first and second vertical members secured on opposite ends of the top horizontal frame member. Tracks are formed in the first and second vertical frame members to guide movement of a lower panel of the door as the door is opened and closed. Mounted on opposite sides and near the top of a back side of the frame are one or more hydraulic cylinder supports for receiving a first, upper end of a hydraulic cylinder assembly. (A cylinder assembly includes a cylinder and extendable/retractable piston of a type known in the industry.)
The multi-panel door has at least an upper and lower panel horizontally pivotally coupled together. A top edge of the top panel of the door is horizontally pivotally secured to the top horizontal member of the door frame.
The top and lower panels have a front (typically exterior facing) surface and a back (typically interior facing) surface. One or more cylinder supports are mounted on the back surface of the top panel, generally near the middle of the top panel, for pivotally receiving a second, lower end of a hydraulic cylinder assembly.
Along the sides of a bottom edge of the lower panel are laterally extending rollers capable of traveling in the tracks formed in the first and second vertical frame members to guide movement of the lower panel as the door is opened and closed.
The door is opened and closed by a hydraulic control system.
In one preferred embodiment, the overhead door includes two hydraulic cylinder assemblies positioned on opposite sides of the door. Each hydraulic cylinder assembly is pivotally mounted at a first end to a vertical frame member cylinder support and at a second, opposite end to the top panel hydraulic cylinder supports.
A hydraulic manifold is in fluid communication with the hydraulic cylinder assemblies to move the piston between a retracted position and an extended position. When the pistons are in the retracted position, the door is in a closed position and when the pistons are in the extended position, the door is in an open position.
In the door closed position, due to the rearward extension of the hydraulic cylinder support from the back side of the top panel, the hydraulic cylinder assemblies are oriented inward at an acute angle away from the vertical frame members. In the open door position, the hydraulic cylinder assemblies extend generally horizontally outward from the door opening.
Because one end of each cylinder is pivotally secured to and in spaced relation from the door panel by the cylinder supports when the door is in the closed position, the cylinders are relatively short compared to cylinders typical found in the prior art. Further, the mechanical advantage provided by the orientation of the hydraulic cylinder assemblies permits the doors to be opened with greater ease and to support greater weight. This allows the doors to be made of heavier material, such as glass. Glass doors are particularly attractive in store front or interior strip mall settings, where space in front of a door is limited, lateral space does not exist because of adjoining shops and viewing of merchandise behind the door is desired.
The self-framed door system is easy to install in a framed doorway. Because the hydraulic cylinder assemblies are secured to the door frame and not the building, the load forces created from opening and closing the door are better distributed throughout the door frame, resulting in less wear and tear on the building.
The above summary of the invention is not intended to describe each and every embodiment of the invention. The Figures in the detailed description that follow more particularly exemplify these embodiments.
The invention will be better understood when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
Although the present disclosure is described in connection with exemplary embodiments, the present disclosure is not intended to be limited to the specific forms set forth herein. Other embodiments not disclosed or directly discussed are also considered to be within the scope and spirit of the invention. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present disclosure. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
The present invention, as shown at 10 in
For exemplary purposes only, and not by way of limitation, the door assembly 10 will be described using a bi-fold door and two hydraulic cylinder assemblies, even though multiple door panels and any number of hydraulic cylinder assemblies are anticipated with the present invention. Further, other components and features, such as alarms, sensors, windows and doors-within-a-door can also be used with the invention and should be considered to be within the spirit and scope of the invention.
Referring to
When installed in a doorway 50 (
One skilled in the art will understand that the frame or door support 20 can be secured to the structure or ground by numerous techniques and devices such that those suggested herein would not he considered limiting. One skilled in the art will also appreciate that the frame or door support 20 can be made from any type of material including steel plating that is either welded together or coupled together with any type of fastener. The frame or door support 20 can also be manufactured from other light, generally rigid, materials such as aluminum or other composite materials.
Roller guide tracks or channels 60 are formed in or installed on surfaces the first and second vertical frame members 24 and 26, respectively, to receive rollers carried by the bi-fold door 30 to guide movement of the door as it is opened and closed. As shown in
As shown in
Similarly, a top edge 34T of lower or bottom panel 34 is pivotally secured to a lower or bottom edge 3213 of top panel 32 by hinges 38. As with hinges 36, hinges 38 can be spaced at desired intervals along the lower edge 32T of the upper panel 32. One skilled in the art will understand that the placement of the hinges 36 and 38 can be varied to maximize the strength and integrity of the bi-fold door 30 on frame 20.
The lower panel 34 includes at least one pair of rollers 62 disposed proximate a lower edge 34B of the lower panel 34 of the door 30, which extend laterally into operative engagement with roller guides or guide tracks 60 to guide movement of the lower panel as the door 30 is opened and closed. In one embodiment, the tracks 60 are formed by attaching an angled member 64 to the vertical frame members 24 and 26 (
In one embodiment, the upper panel 32 and the lower panel 34 have the same dimensions such as height and length. In other embodiments, the upper panel 32 and the lower panel 34 have different dimensions such as different heights. As discussed above, additional panels can be added as part of door 30.
As shown in
The top and bottom panels have a front (exterior facing) surface 42 and a back (interior facing) surface 44. Two cylinder supports 72 are mounted on opposite sides of the back surface 44 of the top panel 32. The door hydraulic cylinder support 72 is generally located near the middle of a side edge of the top panel 32 as shown in
The top panel cylinder support 72 can be solid or a skeletal frame extending from the back side of the top panel 32 to position the cylinder mount in a preferred spaced relation with the top panel 32. The cylinder support can be made of any material that can bear the stresses imposed on it by repeated opening and closing of the door 30.
The door is opened and closed by a hydraulic control system 90 known in the art that in one preferred embodiment includes two hydraulic cylinder assemblies 40. The two hydraulic cylinder assemblies 40 are, in one preferred embodiment, positioned on opposite sides of the door 30. Each hydraulic cylinder assembly 40 is pivotally mounted by a first end 96 to a frame hydraulic cylinder support 100 and is further pivotally mounted at a second end 98, opposite end 96, to a door hydraulic cylinder support 72. The hydraulic cylinder supports are located roughly midpoint of the height of the top panel, although other locations are possible. Although the door and frame hydraulic cylinder supports are described in one preferred embodiment as being located on opposite sides of the top panel 32, for large doors, more hydraulic cylinders and supports may be required. These additional hydraulic cylinders and cylinder supports may be added at desired spacing along the width of the door 30.
When the pistons are in the retracted position, the door is moved to a closed position as shown in
If power to the hydraulic control system fails, a system operator can manually actuate a control valve to slowly lower the door 30 from the open position toward the closed position. Additionally, in one embodiment, the pump 120 can be operated by a DC backup system. Other safety components and features are also possible and should be considered to be within the spirit and scope of the invention.
In use, the manifold can control the flow of fluid into the cylinders 106. The fluid forces the piston rod 104 to move from the retracted position toward the extended position. As the piston rod 104 moves toward the extended position, a central portion of the bi-fold door 30, where the upper panel 32 and the lower panel 34 are pivotally coupled together, moves outwardly away from the doorway 50. As the piston rod 104 continues toward its extended position, the upper panel 32 is lifted upwardly causing the rollers 62 connected to the lower panel 32 to travel upward in channels 60.
When the piston rod 104 reaches its permitted outermost extended position, the upper panel 32 and the lower panel 34 form a wedge with the opening 140 of the structure 52 being generally unobstructed.
In
As shown in
As shown by the cylinder angle of orientation 158, the cylinder assembly 40, in the door closed position, is angled away from the back surface 44 of door 30. The cylinder angle of force 160 applied by the hydraulic cylinder assembly 40 to the panel cylinder support 72 causes the top panel 32 to rotate outward from the door frame 20 as the piston rod 104 is extended from the cylinder 106. The cylinder angle of orientation 158 remains at an acute angle as the cylinder rotates with the opening of the door, as shown in
By way of example, one preferred embodiment of the invention, as shown in
WW, the vertical distance between the upper panel/frame pivot axis 50 and the cylinder upper pivot axis 152 is 12 inches;
YY, the horizontal distance between the upper panel pivot axis 150 and the cylinder upper pivot axis 152 is 6.5 inches;
XX, the vertical distance between the upper panel/frame pivot axis 150 and the cylinder lower pivot axis 154 is 43.5 inches; and
ZZ, the horizontal distance between the upper panel/frame pivot axis 150 and the cylinder lower pivot axis 154 is 8.5 inches.
The angle of orientation of the cylinder axis (line E-E) with respect to a plane defined by the pivot axis of the top panel and frame and the cylinder top panel pivot axis (line D-D), when the door is in its closed position, is shown in
Although wider and narrower angles of orientation are anticipated by the present invention, in one preferred embodiment, the angle of orientation of line D-D and EE remains relatively small throughout the door opening process, starting at about 7.8 degrees when the door is in the closed position, to about a high of about 18 degrees as the door is partially open to 15.8 degrees when the door is in the fully open position.
The doors of the present invention can be constructed of larger or small size, if the component orientation is maintained as described above. This orientation can be maintained by spacing the cylinder lower axis of rotation 154 sufficiently from the back surface 44 of door 30 to orient the hydraulic cylinder assembly as described above. Of course, proportionately smaller and larger doors require proportionately small and larger cylinders to maintain the proper configuration of the door components.
In another preferred embodiment, the first end 96 of the hydraulic cylinder assembly 40 is attached over center of the edge 162 for direct application of force to the cylinder support 72.
Other configurations of a cylinder support 72 are possible, by way of example, a triangular or rectangular truss extending along part or all of the top panel height. However, if other configurations of the cylinder support are utilized, the cylinder may need to be attached to one side of the cylinder support to avoid operational interference.
This disclosed configuration of the cylinder support and orientation of the hydraulic cylinder assemblies facilitates use of a short hydraulic cylinder assembly with reduced rod extension to open and close the door. The cylinder support further provides strength to the door. Further, the mechanical advantage provided by the orientation of the hydraulic cylinder assemblies permits the doors to be opened with greater ease and to support greater weight. This allows the doors to be made of heavier material, such as glass. Glass doors are particularly attractive in store front or interior strip mall settings, where space in front of a door is limited, lateral space does not exist because of adjoining shops and viewing of merchandise behind the door is desired.
As shown in
Because the hydraulic cylinder assemblies are secured to the door frame and not the building, the load forces created from opening and closing the door are better distributed throughout the door frame, resulting in less wear and tear on the building structure. Additionally, the self-framed door system is easy to install in a framed doorway.
The invention may be embodied in these and other specific finis without departing from the spirit or attributes thereof, and it is therefore desired that the embodiments be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
