Patent Application
20150075730
The invention relates generally to flexible folding door with mini slats that is attachable to a door jamb.
Folding doors increase the usable area of room that is otherwise taken up by a hinged door that swings open. Folding doors simply fold back accordion style, with the use of many vertical folds, against the door jamb allowing the user to use all the available space in the room, without having to save a clear path for a door to swing open or close. Folding doors are typically an economical and space-saving solution where doors are needed when a standard door would impede upon the function of the room. Folding doors are commonly used as interior doors to separate rooms or for use as a closet door.
Folding doors are hung from a track attached to the header of the door jamb. A folding door needs to be sturdy and structurally sound to withstand forces from all directions when the door is being pulled open or closed along a door header. Accordingly, folding doors are often complex and not easy to install. Moreover, if the door and jamb attachment mechanisms are not sturdy, frequent use of the door can damage the attachment mechanisms and impede normal function of the door.
Therefore, there is a need in the art for a sturdy and structurally sound folding door that is easy to install on an existing door jamb. There is also a need for a folding door that contains durable and flexible attachment mechanisms that can withstand forces from all directions when the door is being pulled open or closed along the header mechanism.
There is a further need for a folding door that is made of material that is flexible, renewable and durable.
The present invention is a folding door adapted to be attached to a door jamb having a forward door jamb, a header, and a rear door jamb. There are a plurality of mini slats adapted to be hung vertically from the door header via a hanging channel track attachable to the header. Each mini slat is horizontally coupled together such that the plurality of mini slats form a flexible folding door panel. The folding door panel is adapted to substantially span and enclose a space between the forward and rear door jamb. The flexible folding door panel has a forward end near the forward door jamb and a rearward end near the rear door jamb. The folding door panel defining, in series, bounded vertical plane door segments interposed between folding seam door segments. Each bounded vertical plane segment has a first subplurality of mini slats maintained in a substantially single vertical plane by a top binder. Each folding seam segment having a second subplurality of mini slats which establish the folding panel seam segments of the folding door. The seam segments are intermediate to the plane segments. The forward end of the folding door panel has a forward edge segment adapted to be adjacent said forward door jamb. The forward edge segment has a door closure element.
The forward jamb edge piece is adapted to be fixedly attached to the forward door jamb. The forward jamb edge piece has a complementary closure element adapted to cooperate with the closure element on said forward edge segment permitting the folding door panel to open and close on the forward door jamb. The folding door panel has a rearward edge piece adapted to be attached to the rear door jamb. A plurality of caster assemblies are movably disposed in the hanging channel track, a respective caster assembly attached to a corresponding top binder. Each caster assembly includes: (1) one or more low friction wheels adapted to move in the hanging channel track and (2) a depending stem extending downward below the wheels. The depending stem forms a low friction interface with the adjacent depending track edge. The depending stem has a terminal lower end stop. Each top binder defines an aperture at its upper surface. The depending caster stem extends through the top binder aperture such that the lower stop is below the upper surface of the top binder to capture the stem and the caster assembly atop the top binder. The stem permits three dimensional movement of the vertical plane segments with respect to said hanging channel track.
In the preferred embodiment, the mini slats of the folding door are composed of bamboo. In alternate embodiments, any durable, renewable material may be used to compose the mini slats. In the preferred embodiment, the folding door will come in a package almost completely built, so that the end user will simply install the forward jamb edge piece to the forward door jamb, the hanging channel track to the header, the rear edge piece to the rear door jamb, and hang the complete folding door panel with casters.
Although the invention is illustrated and described herein in reference to a specific embodiment, it is nevertheless not intended to be limited to only the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. The construction of the invention, however, together with additional objects, features, and advantages thereof will be best understood and appreciated from the following detailed description of the embodiments thereof, selected for purposes of illustration and shown in the accompanying drawings.
a is a detailed view of the mini slats of the folding door.
b is a top view of the mini slats of the folding door panel showing an overlap in the mini slats.
c is a wood grain variation embodiment of the folding door panel.
a is a detailed side view of a dual caster assembly.
b is a cut away view of the caster assembly seated in the hanging channel track (the track attached to the heard) and showing the leg and ring cut away to reveal the position of the stem and the cap.
c is a cut away view of the caster assembly seated in the hanging channel track showing the cap and stem behind the leg.
d is a cut away front view of caster assembly seated in hanging channel track the near side wheel being but away to reveal the low friction sleeves on the depending legs of U-shaped member.
Embodiments of the invention are illustrated in the accompanying drawings. The present invention can be best understood by referring to the enclosed drawings and the following explanation.
The folding door, in one embodiment, is a do-it-yourself kit which the home owner or occupant can easily install. The kit includes door 1, forward jamb piece 3, track 9 and certain handle pieces and mounting fixtures (screws, nails, etc.).
The hanging channel track 9 is attached to the header 28 of the doorway. The hanging channel track 9 is the track from which the folding door panel 21 will be vertically hung. The rear edge door piece 17 of folding door 1 is permanently attached to the rear door jamb 30 with screws or other similar attachment means as shown by arrows 34. The rear edge door piece 17 is also attached to the rearward end of the folding door panel 21. Accordingly, once the rear edge door piece 17 is attached to the rear door jamb 30, that attachment will form the portion of the folding door panel 21 that will remain somewhat permanently secured to the rear door jamb 30. The fore end leading edge door piece 5 is the leading edge of the folding door panel 21. A dual caster assembly 13 is attached to the top of the fore end leading edge door piece 5. A door handle 11 is attached to the fore end leading edge door piece 5.
The terms “forward” and “rear” refer to portions of the door jamb. The “forward” region is where the folding door normally opens, permitting entry and exist into the room. “Rear” or “rearwards” refers to the somewhat permanently a fixed door region at the opposite door jamb.
When the folding door panel 21 is shut, closing the door jamb opening, the forward jamb edge piece 3 receives the fore end leading edge door piece 5 and the folding door panel 21 is removably secured in place. The forward jamb edge piece 3 has a complementary closure element 7 adapted to cooperate with the closure element 19 on the forward edge segment permitting the folding door panel 21 to open and close on the forward door jamb 26. The complementary closure system shown in the preferred embodiment is a magnetic system; however, any appropriate closure system may be used. Alternate complementary closure systems are a hook and eye system, a latch system, a loop and post system, or any other known closure system. As shown, magnetic plates 7 are seated within the forward jamb piece 3. Magnetic buttons 19 are fixed in the fore end leading edge door piece 5. When the folding door panel 21 is moved to a closed position wherein persons and items cannot pass through the door opening, the magnetic plates 7 attract the magnetic buttons 19 and the folding door panel 21 is secured in the closed position.
The folding door panel 21 is composed of a plurality of segments that are primarily divided between two segment groups: (1) a fixed or bound panel segments 25a, 25b, 25c and (2) a folding panel seam segments 23a, 23b. The segments are serially interposed such that each panel is bounded or intermediate a seam segment. These segments create the accordion style fold of the door. Bound segments fold next to each other such that 25a is next to 25b; 25b is next to 25c; when the door is in an open mode operational position.
The fixed or bound panel segments include a forward bound panel segment 25a, a plurality of mid bound panel segments 25b and rear bound panel segments 25c.
A single caster assembly 15 is attached to the vertical center line of the mid bound panel segments 25b. The folding panel seam segments include a forward folding panel seam segment 25a and a number of mid folding panel seam segments 25b.
The fixed or bound segments 25a, 25b, 25c and a folding seam segments 23a, 23b are shown in greater detail in
In the preferred embodiment, the folding door system 1 is a center mount door where each mid bound panel segment 25b is hung from the top center of that segment by a single caster assembly 15. This creates a balanced folding door panel 21 that is suspended from the hanging track channel 9. As shown in
a is a detailed view of the mini slats 53 in the folding door panel 21.
As shown in
Although cylindrical sleeves are shown, half pipe sleeves may be used to provide a low friction barrier between legs 105 and the vertical edge (defining the opening in the channel track) of the channel track.
The distal downward portion of each leg 105 is attached perpendicularly to a ring 113. A movable stem 107 sits in the ring 113 with a stem cap 108 that overhangs atop the ring 113. The caster assemblies 13, 15 provide a smooth sliding folding door panel 21 by absorbing forces put on the door through: (1) the pitch, yaw and roll created by the movement in all directions of the stem 107 within the ring 113, (2) the rotation allowed by the stem 107 in the ring 113 and (3) the use of low friction material on the sleeves 103 and the wheels 101. In this manner, the bound door segments move in a swivel manner, that is, a swivel connection, with respect to the caster, which moves longitudinally in the header channel track. Vertical movement is permitted between the ring and cap. 360 degree movement is permitted by a small diameter stem in a larger aperture in the ring. The pitch, yaw and roll allows the caster assemblies 13, 15 to move all the way around thus increasing the flexibility and stability of the folding door system 1. As used herein, pitch, yaw and roll shall have their customary meanings, namely, pitch is understood to mean the rotation around the side to side axis, yaw is understood to mean the rotation around the vertical axis, and roll is understood to mean the rotation around the front to back axis. The distance between the ring 113 and the upward leg of dual caster U-shaped base mount clip 109c is designated as h1. Distance h1 is a variable distance that fluctuates due to the yaw, pitch and roll of the stem 107 seated in the ring 113.
In an alternate embodiment, the caster assembly 13, 15 may use one or more low friction wheels 101 adapted to move in the hanging channel track 9. A depending stem 107 extends downward below the wheel(s) 101. The depending stem 107 forms a low friction interface with the adjacent depending hanging channel track edge 9. The depending stem 107 has a terminal lower end stop. Each top binder 51b has an aperture on its upper surface. The depending stem 107 extends through the top binder 51b aperture such that the lower stop is below the upper surface of the top binder 51b to capture the stem 107 and the caster assembly atop the top binder 51b. The stem 107 permits three dimensional movement of the vertical plane segments or door panels with respect to the hanging channel track 9. Additionally, the alternate embodiment may also include caster assembly wheel(s) 101 that rotate about an axis that runs through a hub 155. The hub 155 has depending legs 105 which define a ring 113. The hub legs 105 define an upper stem element 107 carrying the low friction interface. A lower stem 107 element has an upper stop 108 disposed at the lower terminal end of the lower stem 107 below the upper surface of the top binder 51b. The lower caster stem element 107 extends through the ring 113 and through the top binder aperture such that the upper stop 108 is above the ring 113 and the lower stop 125 is below the upper surface thereby permitting vertical movement of the caster assembly ring with respect to the top binder 51b. The swivel movement of the bound door segments with respect to the caster is accomplished by this simplified stem construct.
a is a detailed side view of the dual caster assembly 13 cut away to show the placement of the stem 107. This view shows the low friction wheels 101 attached to a fixed axel 157. Alternatively, the wheels could rotate on a fixed axle mounted horizontally in frame 155. U-shaped frame 155 has two depending legs 105. The low friction sleeve 103 surrounds the depending leg 105. The stem 107 is seated in the ring 113. The stem 107 proceeds through the upward leg of dual caster U-shaped base mount clip 109c. The front side of the dual caster U-shaped base mount clip 109a faces to the front of the folding door panel 21 and the rear side of the dual caster U-shaped base mount clip 109b faces to the rear of the folding door panel 21. The stem 107 contains a lateral pin hole 153 for receiving a pin, rivet, or any device capable of securing the stem 107 within the ring 113 and onto the fore end leading edge door piece 5. Three dimensional movement of the caster assembly 13 in the hanging channel track 9 is shown by arrow 135.
b and 6c both show a caster assembly 13 seated in the hanging channel track 9.
d is a cut away front view of caster assembly 13, 15 seated in the hanging channel track 9, the near side wheel 101 being cut away to reveal the low friction sleeves 103 on the depending legs 105 of the U-shaped member 155. The low friction wheel 101 is shown seated in the hanging channel track 9 with the legs 105 surrounded by sleeves 103. The low friction wheel 101 is cut away to reveal the second low friction wheel 101 sitting behind the first wheel in the hanging channel track 9. Also shown by the low friction wheel 101 being cut away is the U-shaped frame 155 that connects the two depending legs 105 and the fixed axel 157 to which the wheels are attached. Distance d8 is a variable length of distance of the low friction wheel 101 above the hanging channel track 9. The legs 105 attach to the ring 113 through which sits stem 107. The cap 108 of the stem 107 retains the stem 107 in the ring 113 as does pin 125, which secures the bottom of the stem 107 in the ring 113. The use of the cap 108 and pin 125 cause there to be a significant amount of pitch, yaw and roll within the caster assembly 13, 15.
The closing mechanism of the folding door system 1 is shown in
In an alternate embodiment, there are double folding door panels 21 that close in the middle of the door way. A double folding door would likely be designed for larger than normal door ways.
Although described above in connection with a specific embodiment, this is not meant to be limiting, as other folding door systems can be made in accordance with the description herein. As such, although the invention is illustrated and described herein, various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
STATEMENT OF PRIORITY This application is a nonprovisional application under 35 U.S.C. §111(a) and 37 CFR §1.53(b) claiming priority to provisional application No. 61/878,114 filed on Sep. 16, 2013, the contents of which is incorporated herein by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| 61878114 | Sep 2013 | US |
