Patent Application
20150191969
1. Field of the Invention
Embodiments of the invention relate to a rolling sheet door system. More particularly, embodiments of the invention relate to an interlocking rolling sheet door system that forms a continuous curtain of corrugated panels, which can be assembled and disassembled by rolling the corrugated panels together and apart.
2. Description of the Related Art
Sheet door manufacturers currently manufacture rolling sheet doors in accordance with the American National Standards Institute/Door and Access Systems Manufacturers Association Standard 207 (ANSI/DASMA 207). In accordance with ANSI/DASMA 207, a “rolling sheet door” is a vertically operating, coiling door typically used in commercial, industrial, or self-storage applications with a curtain consisting of formed metal sheets seamed together.
ANSI/DASMA 207 defines a “curtain” as an assembly of curtain panels seamed together. A “curtain panel” is defined as a formed metal sheeting consisting of multiple corrugations with horizontal hems. A “hem” is defined as interlocking “hooks” on the top and bottom edge of the curtain panel used to create a seam. A “seam” is defined as a method for permanently interlocking two consecutive curtain panel hems for creating a continuous sheet door curtain.
A conventional rolling sheet door is shown in
Current sheet door manufacturers use a “hem and seam”-type panel, also known as a “positive lock”-type panel, to assemble a curtain of interlockable curtain panels. One conventional process includes roll forming an upward hem and a downward hem, as shown in
Conventional rolling sheet doors formed using this process, however, are difficult to disassemble and maintenance in the field. Because the hems are seamed together, it is difficult to remove or replace a curtain panel, which may be damaged, without causing severe damage to both the astatic and structural stability of the rolling sheet door, thus making conventional rolling sheet doors of this type a “disposable door”.
For example, a curtain panel may be removed in the field by cutting the panel with a shear, snips, or a circular saw with the proper blade. The disadvantages of this process become apparent when trying to remove a curtain panel for repair, or add a new curtain panel. The new curtain panel would typically be attached by overlapping at least one rib of the corrugated curtain panel, and then using some type of fastener, such as a rivet or screw, to hold the curtain panels together. This process is not desirable when “curb appeal” is an area of concern. Overlapping the two curtain panels also adds weight to the door, which will have an adverse effect on the spring assembly, while also compromising the performance of the conventional rolling sheet door during, for example, a high wind event because of the added rigidity where the curtain panels overlap.
The curtain panel may also be removed in the field by manually opening the seam using a hammer, a flat head screw driver, a pry bar, or other tool to pry the two interlocked curtain panels apart. Once a portion of the hem is open, the claw end of the hammer or the pry bar is vigorously pulled across the door to open the rest of the seam. Due to the inconsistencies of pressure while pulling the tool across the door, such an action often results in the formation of ripples in the hems or other types of deformation. This process is not desirable when trying to add a new curtain panel. It is impossible to replicate the act of seaming in the field. In most cases, an operator attempts to seam the curtain panels using a hammer and “anvil” (e.g., another hammer, block of wood, heavy angle, etc.), and striking the hem across the length of the door. As a result, dents across the length of the door are routinely created. Forming a seam in the field between two interlocking hems is difficult because of the challenge in providing the proper amount of force or accuracy to form the seal. The major concern with both of these procedures is the effect they will have on rolling sheet door performance in certain conditions, such as high wind or impact resistance.
Another conventional rolling sheet door system includes a rolling steel or slat door, as shown in
What is needed is a rolling sheet door system that forms a continuous curtain of corrugated panels, which can be assembled and disassembled by rolling the corrugated panels together and apart without damage to the astatic or structural stability of the rolling sheet door.
Embodiments of the invention provide an interlocking rolling sheet door system that forms a continuous curtain of corrugated panels, which can be assembled and disassembled by rolling the corrugated panels together and apart without damage to the astatic or structural stability of the rolling sheet door.
In accordance with at least one embodiment, there is provided an interlocking rolling sheet door, which includes at least one curtain panel. Each curtain panel includes a first curl on a lateral end and a second curl on an opposing lateral end. One of the first curl and the second curl is an interior curl portion, and the other of the first curl and the second curl is an exterior curl portion. The first curl of one curtain panel is configured to rotationally engage an inner portion of the second curl of an adjacent curtain panel, whereby the first curl rotationally engaging the second curl until a distal end of the first curl fouls out against an inner surface of the second curl. The first curl and the second curl are configured to rotationally engage one another to form an interlocking mechanism between adjacent curtain panels to form the interlocking rolling sheet door.
According to at least one embodiment, the interlocking mechanism is arranged on an exterior surface of the interlocking rolling sheet door.
According to at least one embodiment, when the distal end of the first curl fouls out against the inner surface of the second curl, a planar surface of the first curl is positioned parallel with a planar surface of the second curl.
According to at least one embodiment, the first curl includes a planar surface and a curved portion, and the second curl includes a planar surface, a curved portion, and a return portion extending from a distal end of the curved portion of the second curl.
According to at least one embodiment, the first curl of one curtain panel is configured to rotationally engage an inner portion of the second curl of an adjacent curtain panel in a counter-clockwise direction.
According to at least one embodiment, an inner surface of the return portion of the second curl is configured to foul out the first curl, thereby preventing adjacent curtain panels from hinging more than 180° in an opposite direction.
According to at least one embodiment, the first curl includes an inside leg extending from one distal end and a planar portion extending from another distal end, and the second curl includes an outside leg extending from one distal end, and a planar portion extending from another distal end, wherein the inside leg of the first curl is configured to be inserted into the inner portion of the second curl, when an angle between the planar portion of the first curl and the planar portion of the second curl is approximately 55°-75°.
In accordance with at least one embodiment, there is provided a method for assembling an interlocking rolling sheet door. The method includes rotationally engaging at least one curtain panel. Each curtain panel includes a first curl on a lateral end and a second curl on an opposing lateral end. One of the first curl and the second curl is an interior curl portion, and the other of the first curl and the second curl is an exterior curl portion. In accordance with at least one embodiment, the step of rotationally engaging the at least one panel includes rotationally engaging the first curl of one curtain panel with an inner portion of the second curl of an adjacent curtain panel. The first curl rotationally engages the second curl until a distal end of the first curl fouls out against an inner surface of the second curl. The first curl and the second curl are configured to rotationally engage one another to form an interlocking mechanism between adjacent curtain panels for assembling the at least one curtain panel of the interlocking rolling sheet door.
According to at least one embodiment, the step of rotationally engaging the first curl and the second curl includes forming the interlocking mechanism on an exterior surface of the interlocking rolling sheet door.
According to at least one embodiment, when the distal end of the first curl fouls out against the inner surface of the second curl, a planar surface of the first curl is positioned parallel with a planar surface of the second curl.
According to at least one embodiment, the first curl includes a planar surface and a curved portion, and the second curl includes a planar surface, a curved portion, and a return portion extending from a distal end of the curved portion of the second curl.
According to at least one embodiment, the first curl of one curtain panel is configured to rotationally engage an inner portion of the second curl of an adjacent curtain panel in a counter-clockwise direction.
According to at least one embodiment, an inner surface of the return portion of the second curl is configured to foul out the first curl, thereby preventing adjacent curtain panels from hinging more than 180° in an opposite direction.
According to at least one embodiment, the first curl includes an inside leg extending from one distal end and a planar portion extending from another distal end, and the second curl includes an outside leg extending from one distal end, and a planar portion extending from another distal end, wherein the inside leg of the first curl is configured to be inserted into the inner portion of the second curl, when an angle between the planar portion of the first curl and the planar portion of the second curl is approximately 55°-75°.
Various objects, advantages and features of the invention will become apparent from the following description of embodiments with reference to the accompanying drawings.
These and other features, aspects, and advantages of the invention are better understood with regard to the following Detailed Description, appended Claims, and accompanying Figures. It is to be noted, however, that the Figures illustrate only various embodiments of the invention and are therefore not to be considered limiting of the invention's scope as it may include other effective embodiments as well.
a)-(c) are side views of a conventional rolling sheet door, including a seam formed to interlock two consecutive curtain panel hems to create a continuous door curtain.
a) is a side view of a conventional rolling steel or slat door.
b) is a front view of the conventional rolling steel or slat door shown in
c) is another side view of the conventional rolling steel or slat door, illustrating the full range of angular rotation required to wrap the door shown in
a) and 3(b) are a graphical comparison between an interlocking rolling sheet door, in accordance with an embodiment of the invention, and a conventional slat door, as shown in
a) and 5(b) are perspective views of an interlocking mechanism of the interlocking rolling sheet door, as shown in
a), 7(b), and 7(c) are detailed perspectives of a process for engaging the male portion (inside curl) and the female portion (outside curl) of the interlocking mechanism, as shown in
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, which illustrate embodiments of the invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. Prime notation, if used, indicates similar elements in alternative embodiments.
Embodiments of the invention provide an interlocking rolling sheet door system that forms a continuous curtain of corrugated panels, which can be assembled and disassembled by rolling the corrugated panels together and apart without damage to the astatic or structural stability of the rolling sheet door. It would be contemplated by one of ordinary skill in the art of rolling sheet doors that the embodiments described herein could be used in other applications, such as roofing/wall panels, slat doors, storm shutters, sectional doors, truck bedcovers, as non-limiting examples.
Embodiments of the invention provide an interlocking rolling sheet door system that is characterized by the interlocking of curtain panels, which can be assembled and disassembled by easily rolling or folding out a curtain panel from its connection to an adjacent curtain panel. Embodiments of the invention eliminate the conventional “hem and seam” process used by many conventional rolling sheet doors. Embodiments of the invention also do not require lateral space adjacent to the rolling sheet door, and therefore the interlocking rolling sheet door can be assembled and disassembled more conveniently in a manufacturing facility and in the field. As a result, less equipment and manufacturing and repairs costs are necessary to manufacture and repair the interlocking rolling sheet door according to various embodiments of the invention.
a) and 3(b) are a graphical comparison between an interlocking rolling sheet door, in accordance with an embodiment of the invention, and a conventional steel or slat door, as shown in
As shown in
The configuration of the interlocking rolling sheet door, in accordance with an embodiment of the invention, being hinged in a direction opposite to the conventional steel or slat door prevents it from hinging or passing 180° in the opposite direction (i.e., the interlocking rolling sheet door, cannot be hinged or passed more than 180° in the direction that the conventional steel or slat door is hinged).
According to at least one embodiment of the invention, the interlocking rolling sheet door 400 includes flat surfaces that are parallel to each other where two adjacent curtain panels come together, thereby causing radiuses of a male portion and a female portion of the interlocking mechanism 420 to engage and foul out against one another, as shown in more detail in
a) and 5(b) are perspective views of an interlocking mechanism of the interlocking rolling sheet door, as shown in
As further shown in
Embodiments of the invention provide an interlocking rolling sheet door system 600 that is characterized by the interlocking of curtain panels that are rolled together, rather than laterally slid together, such as curtain panels used in conventional steel or slat doors, as discussed above. This is achieved by reducing the length of the inside leg (e.g., the male inside curl portion) and adding a small return to the outside leg (e.g., the female outside curl portion), as shown in
a), 7(b), and 7(c) are detailed perspectives of a process for engaging the male portion (inside curl) and the female portion (outside curl) of the interlocking mechanism, as shown in
In particular,
b) illustrates a second step of engaging the male portion 722 and the female portion 724. As shown in
c) illustrates the male portion 722 engaged and fouled out against the female portion 724. As shown in
As briefly discussed above, with respect to conventional steel or slat doors, when the male portion of the hinge is slid laterally into the female portion, the two portions, and therefore the two slats, are locked together, as shown in
The interlocking rolling sheet door, in accordance with various embodiments of the invention, is only similar in appearance to a conventional steel or slat door. The interlocking mechanism, according to various embodiments, of the interlocking rolling sheet door as described herein, is distinctly unique from the interlocking mechanism used to interlock two adjacent slats on a conventional steel or slat door. As shown in
Furthermore, the interlocking mechanism, according to various embodiments of the invention, is distinct from the interlocking mechanism of a conventional steel or slat door in that slats of a conventional steel or slat door are assembled typically using 2″ or 3″ slats that hinge as the conventional slat door rolls up. This is in accordance with ANSI/DASMA 203 Section 6, 6.1. The slats of a conventional slat door cannot be rolled together due to the design and dimensions of their hinge. In assembly of the conventional slat door, the individual slats have to be slid together from end to end (i.e., laterally slid together). They cannot be rolled together like the curtain panels according to various embodiments of the invention. If one were to assemble two slats of a conventional slat door and attempt to roll them together, the two slats would foul out by the opposite sides hitting each other.
For conventional steel or slat doors for a 12′ wide doors in a 15′ wide building, there is clearly insufficient lateral space to slide a 12′ slat out to disengage it from an adjacent curtain panel, nor could one add a new slat for the same reason. In order to repair or maintenance the rolling slat door, the technician would have to remove the entire door from the drum and have it serviced outside of the building where sufficient space would be available to disassemble the slats. This would be time consuming, dangerous to the technician, and increase maintenance expenses.
The interlocking rolling sheet door, according to various embodiments of the invention, overcomes these challenges of conventional rolling sheet or slat doors. As generally discussed above, various embodiments of the invention provide an interlocking rolling sheet door including an interlocking mechanism arranged on an exterior side of the door and inverted to prevent the door from hinging or passing 180° in the opposite direction, thereby locking adjacent curtain panels together in a secure manner. The interlocking mechanism includes a first curl that engages a second curl, such that the radiuses of the male and female portions of the interlocking mechanism engage and foul out against one another. The interlocking mechanism allows for the assembly, repair, and/or replacement of curtain panels without requiring a seaming process or lateral space. Accordingly, the curtain panels, according to various embodiments of the invention, are connected in a manner, which allows the curtain panels, when connected, to curve around a drum of the door mechanism, rather than hinge.
Embodiments of the present invention may suitably comprise, consist or consist essentially of the elements disclosed and may be practiced in the absence of an element not disclosed. For example, it can be recognized by those skilled in the art that certain steps can be combined into a single step.
The terms and words used in the present specification and claims should not be interpreted as being limited to typical meanings or dictionary definitions, but should be interpreted as having meanings and concepts relevant to the technical scope of the present invention based on the rule according to which an inventor can appropriately define the concept of the term to describe the best method he or she knows for carrying out the invention.
The singular forms “a,” “an,” and “the” include plural referents, unless the context clearly dictates otherwise.
As used herein and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.
Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.
Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.
This application relates to, claims priority to and the benefit of, and incorporates by reference herein in its entirety U.S. Provisional Patent Application Ser. No. 61/923,990, titled, “INTERLOCKING ROLLING SHEET DOOR SYSTEM,” filed on Jan. 6, 2014.
| Number | Date | Country | |
|---|---|---|---|
| 61923990 | Jan 2014 | US |
