Abstract:
An adjustable door hanger for a sliding door assembly comprises an operator interface and door panel interface connected to the operator interface. The door panel interface is adapted to adjustably engage a door panel such that the door panel is pivotable about the door panel interface. The door panel interface may then be pivoted to a desired resting position. The hanger may include a door panel top rail for receiving the door panel interface. The door panel may be fixed to the door panel interface after pivoting to the desired resting position. A method of hanging a sliding door panel includes providing a door hanger having a door panel interface, attaching a door panel to and pivoting the door panel about the door panel interface to a desired resting position and securing the door panel to the door panel interface.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a hanger assembly, and, more particularly, to a hanger for a sliding door and a method of hanging a sliding door. 
         [0003]    2. Description of Related Art 
         [0004]    Sliding doors are those that open horizontally by sliding. Sliding doors are typically mounted to an overhead door operator, such as track, drive or actuator assembly, such as the doors on a people mover vehicle or light rail car. Oftentimes, during assembly, the sliding doors can become misaligned with the overhead track, drive or actuator assembly. The amount a door, or door panel, can be adjusted to account for the misalignment is often limited by the amount of tolerance stack-up between the door panel and the overhead operator. Further, a sliding door and overhead track, drive or actuator assembly may not be correctly dimensioned prior to installation such that the door and overhead operator are optimally aligned. In some cases, tapered shims must be installed into the overhead assembly to achieve acceptable alignment between the door and the overhead assembly. Once the door is fixed in position, and the vehicle has been fully setup, it becomes laborious and expensive to correct any door misalignments. Further, any misalignment can result in damage to door operators due to excessive force and wear to the door operator. 
         [0005]    Therefore, there exists a need for a hanger assembly for a sliding door that is capable of adjustable during installation. 
       SUMMARY OF THE INVENTION 
       [0006]    Provided herein is an adjustable door hanger. The door hanger includes a door operator interface and a door panel interface that is connected to the door operator interface. The door panel interface is adapted to adjustably engage a portion of a door panel such that the door panel swivels about the door panel interface. 
         [0007]    Also provided herein is a method of hanging a sliding door panel. The method includes providing a door hanger having an operator interface and a door panel interface connected to the operator interface. Other steps include connecting the operator interface to an overhead door operator assembly and subsequently attaching the door panel such that the door panel swivels about the door panel interface. The door panel is then pivotally adjusted about the door panel interface until a desired resting position of the door panel is determined and secured in place. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    These and other features, aspects, and advantages of the present invention may become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures. 
           [0009]      FIG. 1  is a diagrammatical representation of a door hanger according to one embodiment of the present invention; 
           [0010]      FIG. 2  is a diagrammatical representation of a cross-section of the door hanger and a corresponding door panel top rail portion in accordance with another embodiment of the present invention; 
           [0011]      FIG. 3  is a diagrammatical representation of the door hanger as shown in  FIG. 1 , illustrating a plurality of apertures on both the door operator interface and the door panel interface in accordance with another embodiment of the present invention; 
           [0012]      FIG. 4  is a diagrammatical representation of the door hanger and the door panel top rail portion illustrating the matching patterns between the pairs of plurality of apertures in the door panel top rail portion and the plurality of apertures in the door panel interface in accordance with yet another embodiment of the present invention; 
           [0013]      FIG. 5  is a diagrammatical representation of a cross-section of the door hanger and the door panel top rail portion illustrating a fastening means in accordance with yet another embodiment of the present invention; 
           [0014]      FIG. 6  is a diagrammatical representation of the swiveling motion of the door panel top rail portion about the door hanger in accordance with yet another embodiment of the present invention; and 
           [0015]      FIG. 7  is a diagrammatical representation of an exemplary engagement between the door hanger and a portion of a door panel including a top rail portion in accordance with another embodiment of the present invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    For purposes of the description hereinafter, spatial orientation terms, if used, shall relate to the referenced embodiment as it is oriented in the accompanying drawing figures or otherwise described in the following detailed description. However, it is to be understood that the embodiments described hereinafter may assume many alternative variations and embodiments. It is also to be understood that the specific devices and methods illustrated in the accompanying drawing figures and described herein are simply exemplary and should not be considered as limiting. 
         [0017]    Turning now to the drawings and referring first to  FIG. 1 , one embodiment of adjustable door hanger  10  in accordance with one aspect of the present invention is illustrated. The door hanger  10  includes a door operator interface  20  and a door panel interface  30 . Optionally as shown, the door operator interface  20  and door panel interface  30  may be a single integrally formed door hanger  10 , or, alternatively, the door operator interface  20  and door panel interface  30  may comprise two separate components. The door panel interface  30  is adapted to adjustably engage a door panel  70  (shown in  FIG. 2 ) such that the door panel swivels about the door panel interface  30  of the hanger  10 . The door operator interface  20 , in one embodiment, may be ‘L’ shaped, with two legs  40 ,  50  each including first and second ends, wherein the second end of the first leg  40  and the first end of the second leg  50  are connected. In one embodiment, the first and second legs  40 ,  50  may be substantially perpendicular to each other, while in another embodiment, as shown in  FIG. 1 , the door operator interface  20  may include legs  40 ,  50  that are not perpendicular to each other. The angle between the legs  40 ,  50  is purely a function of arrangement to allow a successful interface between the door hanger  10  and the door panel. Furthermore, in the present embodiment, the door operator interface  20  is shown as being monolithic or made from a single substance, steel or aluminum for example. In an alternative embodiment, the door operator interface  20  may be composed of dissimilar materials that are fastened together appropriately. 
         [0018]    The door hanger  10  further includes a neck portion  60  that extends from one of the two legs of the door operator interface  20 . In the illustrated embodiment, the neck portion  60  extends from the second end of the leg  50 . The neck portion  60  bridges and connects the door operator interface  20  and the door panel interface  30 . In one embodiment, the neck portion  60  is merely an extension of the leg  50  that is bent in order to properly suit the application. In another embodiment, the neck portion  60  may comprise a different material from the operator interface, whereas in yet another embodiment, the neck portion  60  may be omitted entirely with the second end of the second leg  50  connecting directly to door panel interface  30 . The choice of the size, shape, length and material of the neck portion  60  is purely a matter of function for any particular application. It is typically determined by the amount of space that is required between the door operator interface  20  and the door panel interface  30  in a particular environment. 
         [0019]    The door panel interface  30 , as shown in  FIG. 1 , has a substantially circular cross-section. In other embodiments, the shape of the door panel interface  30  may be altered to provide a different kind of alignment freedom. Such modifications should be considered as part of the present invention. In the present embodiment, the circular cross-section allows the door panel to swivel about the door hanger about an axis defined through the center of the circular cross-section, such that the final resting position of the door panel can be customized for each application, such resting position being determined by the alignment requirements between the door panel, the door panel operator and the passageway that the door panel is required to cover during operation. 
         [0020]      FIG. 2  is a diagrammatic illustration of an example of the engagement  65  between a door hanger  10  and a portion of a door panel  70 . In the embodied arrangement, a top rail portion  80  of the door panel  70  is slid around the door hanger  10  such that a reciprocating cavity in the top rail portion  80  fits around the door panel interface  30  of the door hanger  10 . In one embodiment, the top rail portion  80  may be an integral part of the door panel  70 . In another embodiment, the top rail portion  80  may be an add-on component to the door panel  70 . In such instances, it is proper to assume that the door panel  70  and the top rail portion  80  may be fastened together using any fastening method known in the art. Such an arrangement proves invaluable for retrofitting operation on a pre-existing door that may not directly engage with the door hanger envisioned by the present invention. 
         [0021]    In the illustrated embodiment of  FIG. 2 , the top rail portion  80  comprises a first lip portion  90  and a second lip portion  100 , the lip portions  90 ,  100  being adapted to wrap around the door panel interface  30  of the door hanger  10  while allowing some relative movement between the door panel  70  and the door hanger  10  prior to being fixed in position. This arrangement allows the door panel  70  to swivel about the door hanger  10  until a desired resting position for the door panel  70  is reached. Such a resting position facilitates the door panel  70  to function, such as open and close operations, properly without any additional wear and/or stress to the door panel  70  and/or to the door operator. Although a substantially circular cross section is illustrated for the door panel interface  30  and the reciprocating cavity of the door panel top rail  80 , any shape capable of allowing the hanger  10  and the door panel  50  to swivel or pivot about one another is contemplated by the invention. 
         [0022]      FIG. 3  is an illustration of another embodiment of the door hanger  10  showing its cross-sectional as well as angular views. In addition to the features already described hereinabove, a plurality of apertures may be present on the door operator interface  20  and the door panel interface  30 . The first plurality of apertures  110  on the first leg of the door operator interface  20  are present to help fasten the door hanger  10  to the door operator. The door operator may comprise any number of assemblies. For example, the door operator interface  30  may engage an overhead track, a drive mechanism, or an automatic actuating mechanism for opening and closing the door panel  70 . The size and shape of the apertures  110  are determined by the choice of fasteners used to secure the door hanger to the door operator. Further, the spacing between the apertures  110  is not required to be constant. When the fastening means is by non-mechanical means, the apertures may be replaced with a plurality of protrusions or cavities with corresponding cavities and protrusions respectively on the door operator to allow for creation of a strong bond between the door hanger and the door operator during application of a suitable chemical or metallurgical bonding techniques such as using adhesives or welding techniques known in the art. 
         [0023]    Similarly, the door panel interface  20  of the door hanger  10  includes a second plurality of apertures  120  to allow fastening of the door panel  70  around the door hanger  10  once the final resting position of the door panel has been determined. 
         [0024]      FIG. 4  is an illustration of an engagement between the door hanger  10  and the door panel  70  that includes the top rail portion  80 . In addition to the apertures  110 ,  120  on the door hanger  10 , the figure also illustrates a pair of third plurality of apertures  130  placed in a pattern that matches and coincides with the pattern of apertures  120  on the door hanger  10 . Each of the pair of apertures  130  is present on the top rail portion  80  such that there is one aperture  130  on each lip portion  90  and  100 . Proper pattern matching of the apertures  120  and  130  along the door hanger  10  and the top rail portion  80  allows proper fixing of the door panel  70  once the desired resting position is reached. In one example, a mechanical fastening means such as a bolt  140  (shown in  FIG. 5 ) is inserted through each of the pairs of apertures  120 , and  130  to secure the door panel in its resting position. In order for the door panel  70  to be pivotable, the bore of each of the aperture  120  is preferably larger than the bore of the corresponding aperture  130 . 
         [0025]      FIG. 5  is a diagrammatic illustration of one embodiment of securing the door panel  70  about its door hanger  10  once a final resting position is reached. It is also now apparent that any fastening means, such as a bolt  140  and nut  145  arrangement as shown in  FIG. 5 , will result in closing of the lip portions  90  and  100  around the door hanger  10  such that the door panel  70  is held in the desired position. Furthermore, the  FIG. 5  also illustrates the relative size difference between the apertures in the door hanger  10  and the apertures in the door panel top rail portion  80 . The bore of the apertures in both the door panel interface  30  and the top rail portion  80  may be circular in cross-section, and having a diameter of d 1  and d 2 , respectively. In one embodiment, d 1  may be greater than or at least equal to d 2 . For example, when d 1  is greater than d 2 , the head of bolt  140  and nut  145  may contact only the lip portions  90 ,  100 , thereby squeezing the top rail  80  around the door panel interface  30 , with the bolt extending through the aperture in the door panel interface  30  without contacting the door panel interface  30 . Each of the plurality of apertures  120  on the door panel interface may be of a different dimension, and as long as each corresponding aperture in the top rail portion  80  of the door panel  70  varies in accordance with the preferred difference in dimension. Such variations are contemplated by the present invention as disclosed. 
         [0026]    As shown in  FIG. 6 , the top rail portion  80  of the door panel can be rotated about the door panel interface  30  of the door hanger  10 . The angle of swivel or pivot  150  is defined as a maximum angle by which the door panel  70  can swivel or pivot around the door hanger  10 . Depending on the needs of the particular application and dimensions of the components, the angle of swivel or pivot  150  may vary. For example, in one embodiment, the angle of swivel or pivot is 12 degrees. 
         [0027]      FIG. 7  is a diagrammatic illustration of a door hanger  10  and a partially assembled door panel when seen at an angle. In accordance with one aspect of the present invention, the method of fitting a door panel to a vehicle will first require the operation of fitting the door hanger&#39;s door operator interface  20  to the door operator. Once the door hanger  10  is securely fastened to the door operator, the door panel  70  containing the top rail portion  80  may be slid around the door hanger&#39;s door panel interface  30 . The door panel&#39;s top rail portion  80  is adjusted such that the plurality of apertures in the top rail portion  80  and the plurality of apertures in the door panel interface coincide. Subsequently, fastening means, such as a bolt, is inserted through each of the pairs of apertures such that the bolt clearly exits the aperture at the opposing end of the top rail portion. The position of the top rail portion and thereby the door panel is adjusted until a desired position and/or alignment of the door panel is achieved. The bolt is securely fastened and tightened with a nut until the lip portions  90 ,  100  of the top rail portion  80  tightly grasp the door panel interface such that the door panel&#39;s position remains unaltered thereafter. 
         [0028]    In accordance with another aspect of the present invention, a method of fitting a door panel to a door operator may involve an additional step of fastening the top rail portion  80  to the door panel  70  before any of the steps described in the previous aspect describing a method of fitting the door panel. In accordance with yet another embodiment of the present invention, a method of fitting a door panel to a door hanger may include the step of sliding the door hanger into the top rail portion of the door panel prior to fixing the door hanger to the door operator. In this embodiment, once the door hanger is secured to the door operator, the door panel is adjusted to its desired resting position and fastened into place. 
         [0029]    The choice of materials for preparation of the door hanger and/or the top rail portion may include stainless steel, carbon steel, aluminum, anodized steel, titanium, manganese, copper, nickel, zinc and any known types of plastic polymers including high density polyethylene (HDPE). In some instances, alloys containing portions of one or more of the above specified metals may also be used. The method of producing the top rail portion and/or the door hanger may include an extrusion process utilizing any of the above specified materials. The extrusion process may include linear extrusions, or impact extrusions. In another embodiment, the method of producing the top rail portion and/or the door hanger may be produced by stamping, punching, powder metal compaction, plastic extrusion, milling (including CNC milling) techniques and photochemical machining processes. Using a combination of one or more of the techniques specified above are contemplated by the present invention in creating some or all portions of the door hanger and/or the top rail portion. 
         [0030]    In accordance with one aspect of the present invention, once the door panel is fixed about its final resting position, the position cannot be changed. In other implementations, the position can be changed during maintenance intervals so that optimal performance of the door panels about the vehicle can be attained during regular preventive maintenance periods. 
         [0031]    While several embodiments of an adjustable door hanger and a method of hanging a door have been described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.