Abstract:
An in-floor, adjustable, track assembly for sliding panels with a built-in weep system, the track assembly including: a base having a track extending upward therefrom, wherein the track is configured to engage undercarriage wheels of at least one vertically-oriented panel and support motion of the panel along the track; a conduit coupled to the base and configured to allow moisture that collects on the base to egress from the base; a track support rail configured to be placed underneath the base; and an alignment clamp configured to be coupled to a portion of the base and a portion of the track support rail, wherein the alignment clamp aligns and secures the base and the support rail in a substantially orthogonal direction with respect to one another.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation of U.S. patent application Ser. No. 10/916,562, filed Aug. 11, 2004, which is a continuation of U.S. patent application Ser. No. 10/185,942, filed Jun. 27, 2002, now U.S. Pat. No. 6,792,651. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to the field of sliding door assembly and installation. More particularly, the invention pertains to a novel floor support system for sliding glass or non-glass panels, that act as doors or room dividers, and to a system for supporting them on a floor-level track including means for draining off water that accumulates on the floor or on either side of the door.  
         [0004]     2. Description of the Related Art  
         [0005]     Traditional devices undergo change as our culture matures. The common door, mounted on hinges along one vertical side and arranged to swing through an arc, has given way in part to panels that slide on tracks and disappear into walls, sandwich with other such panels, spread apart to divide a room, or give access from one room to another. In many cases, a plurality of glass panels slides on a single track or on separate, but closely parallel, tracks to form a temporary wall, to divide a room into smaller rooms, or to provide an opening from one room onto a balcony, onto a patio, onto a swimming pool area and the like.  
         [0006]     A significant problem with these types of sliding panels occurs where one side of the panels faces outside the home or building toward the elements. Rain, sleet or snow hitting the glass and panel is drawn downward by gravity so that it puddles at the bottom of the panel and, when in great enough quantities, spills over onto the tracks upon which the panels are mounted for sliding movement. In other situations, the floor on one side of the track is slanted such that rain or melted snow runs toward the track. Once the moisture reaches the tracks, problems develop because of the many directions the moisture may flow. For instance, it sometimes flows under the panel and into a room wetting carpets and rugs that thereafter become stained, crispy, or develop an organic growth that causes bad odors and attracts insects. The moisture sometimes flows outward from the panel and stains concrete or causes deterioration of cement and wood flooring, or corrodes the glue that holds down floor coverings such as linoleum, parquet, and vinyl squares.  
         [0007]     Often the moisture draws dirt, dust, small insects and bits of leaves and flowers toward the track system. Accumulation of this debris causes the wheels mounted on the panels to become harder to rotate and, in severe cases, seize and refuse to turn, making the panel difficult to move in its intended path. Cleaning these tracks is often difficult and all the debris is rarely removable due to the closeness of the tracks. Often, the panels must be removed and this can be a difficult task. In winter seasons, the moisture often freezes thereby anchoring the panel to its present position and eliminating the desirability of having slidable panels in the first place.  
         [0008]     In severe cases, the moisture puddles in the tracks and the subfloor on which the tracks are mounted is weakened. Concrete will crack under freezing and thawing of water and wood beams and wood floors can become weakened by constant exposure to water. Often, the mere beginning of such damage will cause tilting of the tracks and unbalancing of the load of the panels so that they refuse to slide easily along the tracks. Accordingly, it is desirable to provide a system that will capture the moisture and convey it from the track system before such problems begin to develop.  
       SUMMARY OF THE INVENTION  
       [0009]     This invention is an in-floor, adjustable, track assembly for sliding panels with a built-in weep system to collect and thereafter remove the moisture from the track area where, when installation is complete, the exposed surface of the track is minimal resulting in a smooth transition from interior to exterior. It is useful on single or multiple track systems in areas that are divided by the panels into an exterior or outside section and an interior or inside section. This system finds use where the tracks are mounted on a base, are single tracks or are in closely spaced-apart, parallel arrangement and extend upward from the base for engaging the undercarriage of at least two vertically-oriented panels in close arrangement.  
         [0010]     The invention provides for splash guards arranged parallel to and spaced slightly apart from one side of each track, preferably the interior area, and forming, with each track, a channel with the base, for collecting moisture from the floor. At least one collection pan is mounted under each channel, to collect moisture from the channel, and includes a tube or other means to draw off the moisture from the collection pan to a distant location.  
         [0011]     Much of the invention is formed of extruded metal, such as aluminum, so that the cost of construction is minimized. Further, the invention is fully adjustable in vertical, as well as horizontal, directions so that it can be placed in new construction and installed in existing construction as well. Other parts are made of plastic and rubber so that the entire system is generally free from problems of corrosion even in the face of constant exposure to moisture.  
         [0012]     Accordingly, the main object of this invention is an in-floor, adjustable, track assembly for sliding panels with a built-in weep system that will remove moisture that flows across the floor, and possibly across the track, or that trickles down the sliding panels to puddle at the bottom thereof. Another object of the invention is a fully adjustable track assembly that may be adjusted to compensate for warpage, weakness, and misalignment of walls with floors to allow the panels to slide effortlessly over the track.  
         [0013]     These and other objects of the invention will become more apparent when reading the subsequent Description of the Preferred Embodiment taken together with the drawings appended hereto. The scope of protection desired by the inventor may be gleaned from a fair reading of the claims that conclude this Specification. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]      FIG. 1  is an illustrative view of a single track and weep system according to this invention;  
         [0015]      FIG. 2  is a sectional view taken through the single track and weep system shown in  FIG. 1  depicting the narrow moisture collection channel of this invention;  
         [0016]      FIGS. 2   a  and  2   b  are small sectional views of two materials useful in the narrow moisture collection channel;  
         [0017]      FIG. 3  is an illustrative view of a multiple track and weep system according to this invention;  
         [0018]      FIG. 4  is a cross-sectional view of the rail of this invention showing the moisture collection pan mounted underneath;  
         [0019]      FIG. 5  is an illustrative view of the moisture collection pan of this invention;  
         [0020]      FIG. 6  is a sectional view of the track and rail of this invention taken orthogonally to the view of  FIG. 2 ;  
         [0021]      FIG. 7  is an illustrative view of the side mounting tab formed on the rails of this invention; and,  
         [0022]      FIG. 8  is a perspective view of a moisture trap used in this invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0023]     Turning now to the drawings, wherein elements are identified by numbers and like elements are identified by like numbers throughout the ten figures,  FIG. 1  shows the in-floor, adjustable, single configuration track assembly  1  for a sliding panel with a built-in weep system of this invention to comprise a narrow, elongated track  3  extending upward from a base  5 , slightly above the top surface  7  of finished floor  9  for engaging the undercarriage wheels  13  of a panel  15  (wheels  13  and panel  15  are shown in phantom outline) and supporting panel  15  while it is in motion, such as in rectilinear motion, on track  3 . As shown in  FIGS. 1 and 2 , it is preferred that track  3  is an upright, elongated, narrow-gauge metal plate forming an inverted “T” shape with base  5 . Track  3  includes a shaped top surface with small, lateral undercuts  17  for smooth engagement with wheels  13 , that extend downward from the bottom of panel  15 . Panel  15  has a stout perimeter  19  of metal or wood construction, panel inserts of glass or wood, and generally is quite heavy. It is preferred that track  3  be extruded, such as from aluminum or other extrudable metal, in a single piece with base  5 . Such extrusion further includes flanges  21 , extending outward from both sides of base  5 .  
         [0024]      FIG. 3  shows an in-floor, adjustable, multiple configuration track assembly for a plurality of sliding panels  15  (not shown), each with a built-in weep system of this invention, and shows a plurality of narrow, elongated tracks  3  in closely spaced-apart, parallel arrangement, each track  3  extending upward from a separate base  5 , for engaging and supporting the undercarriage of at least one panel on each track  3  while said panels are in motion, such as recti linear motion, thereon. It is important to this invention that track top surface  17  protrudes or extends slightly above finished floor top surface  7  (see  FIG. 2 ) to form a slight barrier to transverse flow of water or moisture across track  3  from the exterior area to the interior area.  
         [0025]     As shown in  FIGS. 1-4 , an upright splash guard  25  is provided for each of narrow tracks  3 , parallel to and spaced slightly apart therefrom a distance sufficient to capture moisture either dripping or running off panel  15 , shown as drops  27 , or running across finished floor top surface  7  and over the top of track  3  from the exterior area toward the interior area. Splash guard  25  forms, with each track  3  and base  5 , a narrow channel  29  for collecting moisture from the bottom of each panel  15 . When used herein, the term “moisture” means rain, sleet, snow, and water splashed from swimming pools, hoses and the like. Moisture is shown as angled straight lines in the exterior area in  FIG. 2 . As shown in  FIG. 2 , track  3  and splash guard  25  are both upright, elongated, narrow-gauge plates and, together, form an inverted “T” shape with base  5 . In addition, it is preferred that splash guard  25  terminates or “tops” at finished floor top surface  7  so that the entire assembly is at or below top surface  7 , except for a slight upward protrusion of track top surface  17  and thus forms a very smooth, uninterrupted top floor surface. This configuration conforms to the requirements of the Americans with Disabilities Act (42 U.S.C §12100 et sec.). Since splash guard  25  and track  3  together form a substantially inverted “T” with base  5 , it is preferred that they all be extruded together in one monolithic piece from metal such as aluminum. If not possible, it is preferred that track  3  and base  5  be extruded as one piece and splash guard  21  installed, as shown, and soldered or otherwise rigidly mounted in base  5 .  
         [0026]     A filter means  31  is located in said channel  29  for preventing the ingress of debris. As shown in  FIG. 2   a,  filter means  31  may take the form of a strip of highly reticulated plastic foam  33  cut and inserted into channel  29 . As shown in  FIG. 2   b,  a piece of screen  37  may be cut and folded in a shape and slipped into channel  29 . Not only do these means prevent the ingress of debris while also not interfering with the collection of moisture, they also are easily removed so that they can be renewed without significant cost or effort.  
         [0027]     As shown in  FIGS. 4 and 5 , at least one collection pan  39  is mounted under each channel  29  and is accessible through at least one aperture  41  formed in the bottom of channel  29 , preferably at the bottom of channel  29  in base  5 . Collection pan  39  collects moisture that runs down into channel  29 . Collection pan  39  is preferably made from plastic, such as polyvinyl chloride, polyvinylidene chloride, polyethylene, and the like, and can be easily injection molded to reduce the cost of production. As shown in  FIGS. 4 and 5 , collection pan  39  comprises enclosed sidewalls  43 , a closed bottom  45 , and an open top cavity  49  formed therein. Sidewalls  43  are attached through gaskets  51 , along their top surfaces, to the bottom surface  53  of base  5  and cavity  49  is preferably arranged directly below aperture  41  to receive moisture as it drops from the panels into channel  29  and through filter means  31 . An opening  55 , preferably located in or near collection pan bottom  45  is provided and egress means  55 , preferably located in or near collection pan bottom  45  is provided and egress means  57 , such as a hose or tube  61 , is attached thereto to draw off the moisture from the bottom of said panels.  
         [0028]     As shown in the Figures, at least two track support rails  63  are provided, in spaced-apart arrangement, running transversely underneath tracks  3 , splash guards  25 , and bases  5 . As further shown in  FIG. 6 , rails  63  extend outward, in orthogonal arrangement from track bases  5  and each rail  63  includes a rail body  65 , defined by a bottom surface  67  and a top surface  69 . A pair of alignment clamps  73   a  and  73   b  are provided for each track, for assembly with rails  63  to fasten each track to each rail. As shown in  FIG. 1 , the alignment between tracks  3  and rails  63  is orthogonal, i.e., each track is adjusted to be as close as possible to perpendicular from each rail. Each clamp  73   a  and  73   b  includes a bottom clamp surface  75 , a portion  77  of which is shaped for overlapping contact with a curb  79   a  and  79   b  formed on track flanges  21  on both sides of track  3 .  
         [0029]     As shown in  FIG. 6 , a C-shaped groove  81  is formed in track support rail body  63  opening upward through a slot  83  formed in rail body top surface  69 . An aperture  87  is formed in alignment clamps  73   a  and  73   b  for arrangement over upwardly opening C-shaped groove  81 . As shown in  FIGS. 3 and 6 , clamps  73   a  and  73   b  are assembled with track  3  and track support rail  63  such that track  3  is overlaid rail  63  and clamps  73   a  and  73   b  placed on rail  63 , one on each side thereof, with portion  77  of clamp bottom surface  75  overlaying flange  21  with slot  85  aligned with aperture  87 .  
         [0030]     A threaded means  89 , such as a flat headed bolt or machine screw  91 , is inserted down through aperture  87 , through slot  85 , and into a bolt-capturing nut  93  located in C-shaped groove  81 . Nut  93  is wider than slot  85  but smaller than the maximum internal width of C-shaped groove  81  so that it is captured in groove  81  yet is slightly moveable therein. It is preferred that the outside diameter of bolt  91  be made slightly less than the width of slot  85  to allow for some movement between bolt  91 , track  3  and rail  63 . This slight looseness allows track  3  and rail  63  to be adjusted horizontally in the floor on which track  3  will be mounted and further allows track  3  and rail  63  to be brought as close as possible to orthogonal arrangement during assembly. It is preferred that bolt  91  have a flat heat with conical sides, as shown in  FIG. 6 , and aperture  87  in clamps  73   a  and  73   b  have a top chamfer to accept the flat bolt head so that the flat head of bolt  91  will lie flush with the top surface of alignment clamps  73   a  and  73   b.    
         [0031]     To aid the location of alignment clamps  73   a  and  73   b  on top surface  69  of track support rail  63 , as shown in  FIG. 6 , it is preferred that a pair of upsets or curbs,  97   a  and  97   b,  be formed in spaced-apart arrangement on track support trail top surface  69  that, together, form a wide, substantially “U”-shaped depression  99  in rail top surface  69 . Alignment clamps  97   a  and  97   b  are preferably made just wide enough to fit into said depression  99  and aligned therein for assembly with track  3  and rail  63  to prevent the clamps from moving about when the assembly is subjected to the movement of panels  15  on tracks  3 .  
         [0032]     As shown in  FIGS. 3 and 7 , a side mounting tab  101  is formed as an extension on the ends of track support rails  63 . An adjustment/mounting slot  103  is formed in rail body  65 , preferably at the center of C-shaped groove  81 , and through the bottom of rail body  65 . As shown in  FIG. 6 , an elongated, slightly V-shaped indentation  105  is formed in the upper surface of the bottom surface of groove  81  and, preferably, along the center-line of rail bottom surface  67  for aiding in aligning a drill bit to drill through the bottom of rail body  65  in order to center the drill bit used in forming adjustment mounting slot  103 .  
         [0033]     As shown in  FIG. 2 , in assembling tracks  3  and rails  63  on the surface wherein the panels are to slide, a first pair of threaded studs  109  is mounted in the cement subfloor  11  or in the wood subfloor or other support surface, in spaced-apart arrangement, a distance equal to the distance between adjusting/mounting slots  103  that are formed at each end of rail  63 , and along an axis orthogonal to the axis of intended travel of the panels. Rail  63  is then set down on studs  109  and is shimmed to level. A first pair of bolt-capturing nuts  113  is then placed in threaded engagement on studs  109  and tightened down against that portion of rail body  65  at the bottom of C-shaped groove  81  and fastened into place to provide rigid support for the entire assembly. Tracks  3  are then placed on top of rails  63  and alignment clamps  73   a  and  73   b  are placed on rail top surface  69 , one on each side of track  3  and partially overlapping onto track flanges  21 . Flatheaded bolts or machine screws  91  are then inserted into clamp aperture  87  and passed down into threaded receipt in bolt-capturing nuts  93  that are first slipped inside C-shaped groove  81 , in rail body  65 . Nuts  93  are then tightened down to rigidify the assembly. It is preferred that tracks  3  be orthogonal or perpendicular to rails  63  when the full assembly is rigidified. As shown in  FIGS. 3 and 4 , collection pans  39 , already mounted under rails  63  are connected to hoses  61  to be passed through holes in the sub-floor, preferably to an outside vent for removing the collected moisture from tracks  3 .  
         [0034]     As shown in  FIGS. 3 and 8 , a trap  115  may be located transversely between at least two adjacent tracks  3  that are in closely spaced-apart, passing arrangement, in order to collect the moisture that impacts the ends of panels  15  and runs down toward the underlying tracks  3 . Panel perimeters  19  often are wide in order to support heavy panel inserts, such as glass panes and wood sheeting. This transverse thickness of the perimeter presents a rather broad surface for moisture to impact and trickle downward. Trap  115  is shown in  FIG. 8  to comprise a pair of closely spaced-apart, parallel walls  117  and  119  and a closed base  123  forms an open top U-shaped duct  125  therebetween. A pair of outwardly directed positioning slots  127   a  and  127   b  are formed in base  123  for sliding over inwardly-facing flanges  21  on the two adjacent track bases  5 . Mounted along the top of wall  117  is a pliable seal  129  for the purpose of contacting panel undercarriage  13  to seal trap  115  against leakage of moisture entering duct  125 . Filter means  31 , as previously disclosed, may also be inserted in duct  125  to prevent the ingress of debris along with the entrance of moisture. At least one collection pan  39  is mounted under each transverse trap  115  and is accessible through an aperture  87 , located at the bottom of duct  125  to pass moisture from duct  129  to an egress means  57 , such as hose  61 , as previously disclosed.  
         [0035]     As shown in  FIG. 2 , sub-floor  111  is thereafter encased, about its sides and underneath, with additional sub-floor  131 , in preparation of the laying of final or finished floor  9  that closes off a view of the invention except for a small upper portion of tracks  3  and the very top of splash guard  25 .  
         [0036]     In some instances, splash guard  25  and narrow channel  29  may be located on the exterior area of the assembly, however, it is preferred that they be located on the interior area of the assembly.  
         [0037]     While the invention has been described with reference to a particular embodiment thereof, those skilled in the art will be able to make various modifications to the described embodiment of the invention without departing from the true spirit and scope thereof. It is intended that all combinations of elements and steps which perform substantially the same function in substantially the way to achieve substantially the same result are within the scope of this invention.