Articulating roller arm assembly

An articulating roller arm assembly comprising a single integral piece cantilever beam with a span section and a throw section, with the span section oriented substantially transverse the throw section. A first distal end of the throw section and a distal end of the span section form a bend of the single integral piece cantilever beam. The articulating roller arm assembly further including a first wheel that is coupled with a first distal end of the throw section, and a second wheel that is coupled with a second distal end of the throw section.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to shower doors and, more particularly, to shower door rollers that enable stable articulation and maximum displacement of the shower doors.

2. Description of Related Art

Most conventional corner showers have a generally rounded framed with a set of fixed and sliding panels forming doors that are held in a rail or track at the top and the bottom of the shower, with a handle provided on the door(s) to slide (or move) the sliding panels to one of a closed or open positions to create a passageway to enter the shower area. In general, shower door rollers are typically mounted on the sliding panels and are inserted in the rail or track to enable the sliding panels to roll on the tracks to open and closed positions.

Regrettably, most conventional rollers limit the articulation span of the sliding panels of the shower door and additionally, have no means to reduce or eliminate in-plane and out-of-plane movement of the sliding panels during operations of closing and opening of the sliding doors.

Accordingly, in light of the current state of the art and the drawbacks to current rollers, a need exists for a roller that would not limit the travel distance of the shower doors, and would not reduce their stability during their move.

BRIEF SUMMARY OF THE INVENTION

An optional exemplary aspect of the present invention provides an articulating roller assembly, comprising:a cantilever beam, having:a throw section and a span section;the throw section is oriented substantially transverse the span section;a first distal end of the span section and a distal end of the throw section form a bend of the cantilever beam; anda first wheel that is coupled with a first distal end of the span section, and a second wheel that is coupled with a second distal end of the span section.

Another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the first wheel has a first rotational plane and the second wheel has a second rotational plane, where the first rotational plane is at an angle in relation with the second rotational plane.

Another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the span section is substantially longer than the throw section.

Yet another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the formed bend constitutes an corner-elbow section of the cantilever beam, forming a substantially L-shaped beam with the span section and the throw section as the extremities of the L-shaped beam.

A further optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the formed bend constitutes a rounded corner-elbow section of the cantilever beam, forming a substantially rounded L-shaped beam with the span section and the throw section as the extremities of the rounded L-shaped beam.

Still a further optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the throw section includes a connecting distal end that couples the cantilever beam to a roller support.

Yet a further optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the roller support is comprised of:a channel for mounting the roller support onto a frame of an enclosure;a set of apertures for securely fastening the mounted roller support to the frame of the enclosure.

Another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the roller support houses an adjustment shaft for vertical adjustment of the cantilever beam in relation to the roller support.

Yet another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the channel is inserted within a periphery notch of the frame of the enclosure, positioning the adjustment shaft at an interior side of an enclosed area of the enclosure, which facilitate quick and easy access for adjustment of the adjustment shaft.

Still another optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the connecting distal end of the throw section is pivotally coupled with the adjustment shaft, enabling the throw section to rotate and swing along a reciprocating path within a cavity of the roller support.

A further optional exemplary aspect of the present invention provides an articulating roller assembly, wherein:the adjustment shaft supports the throw section, which rotates about a longitudinal axis of the shaft.

Another optional exemplary aspect of the present invention provides an articulating roller assembly for maximizing travel span and stability of a shower door operation, comprising:a cantilever beam that includes:a throw section having a longitudinal axis that maintains a fixed perpendicular distance between a raceway of a support rail and the shower door;the throw section stabilizes out-of-plane motions of the shower door, and delimits in-plane vertical motions thereof;a span section that supports a set of wheels coupled at a first and second distal ends of the span section with sufficient longitudinal separation between wheels;the span section is oriented substantially transverse the throw section; anda first distal end of the span section and a distal end of the throw section form a bend of the cantilever beam.

Yet another optional exemplary aspect of the present invention provides an articulating roller assembly for maximizing travel span and stability of a shower door operation, wherein:the throw section further includes a connecting distal end that pivotally couples the cantilever beam with an adjustment shaft of a roller support.

Another optional exemplary aspect of the present invention provides a shower enclosure, comprising:

a quadrant shower substrate with curved and straight sections includes a horizontal surface along an exterior periphery that is comprised of a first substantially straight section, an arched mid-section, and a second substantially straight section;

a first vertically oriented inner wall jamb and a second vertically oriented inner wall jamb associated with the shower substrate include a raceway along their respective longitudinal axis, and have a substantially U shaped cross-section, with an outer flat side of the raceway coupled with a surround;

a frame that is configured along a lateral axis substantially commensurate with the exterior periphery of the shower substrate;

the frame is comprised of a header and a sill that have substantially straight portions and a curved mid-portion configured commensurate with the exterior periphery of the shower substrate;

the frame further includes a first outer wall jamb and a second outer wall jamb that are vertically oriented and perpendicular to the header and sill, which couple with a first and a second distal ends of the header and sill by a set of fasteners, the combination of which form a four-sided frame, which is coupled with the first and second inner wall jambs;

fixed panels that are coupled with the substantially straight portions of the header and sill;

the fixed panels are comprised of at least one held-in-place fastener for facilitating installation of the fixed panel onto the frame of the shower enclosure;

the held-in-place fastener is comprised of a fastener holding mechanism with sufficient bulk to enable the holding mechanism to snug fit in between spaces within a channel of a fixed panel frame;

rolling doors having a curved lateral axis that is configured substantially commensurate with the arched mid-portions of the header and the sill, and a vertical length that is parallel along a longitudinal axis of the rolling doors, substantially commensurate with a vertical distance between the header402and the sill406;

the rolling doors and are comprised of a rolling door frame having a top rolling door frame member, a bottom rolling door frame member, and lateral rolling door frame members that enclose a closure, with the frame and the closure constituting the rolling doors;

the top and bottom rolling frame members include notches that house an articulating roller arm assembly that ride along a track of the header and sill of the frame, with the articulating roller arm assembly including:a cantilever beam, having:a throw section and a span section;the throw section is oriented substantially transverse the span section;a first distal end of the span section and a distal end of the throw section form a bend of the cantilever beam; anda first wheel that is coupled with a first distal end of the span section, and a second wheel that is coupled with a second distal end of the span section.

Such stated advantages of the invention are only examples and should not be construed as limiting the present invention. These and other features, aspects, and advantages of the invention will be apparent to those skilled in the art from the following detailed description of preferred non-limiting exemplary embodiments, taken together with the drawings and the claims that follow.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and or utilized.

The present invention provides a new articulating roller arm assembly that greatly increases the overall stability of a curved door that moves along both a curved and straight track system, while enabling maximum articulation (or opening) and maintaining proper door function.FIG. 1is an exemplary illustration of a shower enclosure that uses the articulating roller arm assembly of the present invention. As illustrated inFIG. 1, the present invention provides a shower enclosure100for a quadrant shower pan or substrate (with curved and straight sections) that allows for a wider ingress to and egress from a shower area. The articulating roller arm assembly606of the present invention enables the shower enclosure100rolling doors602and604to roll along to the very distal ends412and414of a reciprocating path of a track806of a header402and a sill406of a frame416of the shower enclosure100, rolling past the fixed panels502and504. This enables the rolling doors602and604to open wider (FIG. 5A) than that of the conventional doors, improving ingress and egress from the shower area and stable articulation.

FIG. 2is an exemplary illustration of the open shower area, including the shower substrate and surround of the shower enclosure ofFIG. 1in accordance with the present invention. As illustrated inFIG. 2, an exemplary shower pan (or substrate)212used by the present invention includes a horizontal surface along its exterior periphery (also known as “curb”)203that is comprised of a first substantially straight (flat) section202, an arched mid-section206, and a second substantially straight (flat) section204. The shower pan212is generally a water basin portion of the shower area that is positioned on top of the shower area flooring. As further illustrated, a surround102is provided that covers the walls to which the shower enclosure is coupled. The surround102can be a plastic wallboard, fiberglass, or the like. The present invention associates the shower pan212and the surround102with a first vertically oriented inner wall jamb208and a second vertically oriented inner wall jamb210. The inner wall jambs208and210include a channel or raceway303along their respective longitudinal axis, and have a substantially U shaped cross-section, with the outer flat side of the raceway coupled with a surround102.

FIGS. 3A to 3Care exemplary illustrations of a frame of the shower enclosure illustrated inFIG. 1in accordance with the present invention. The present invention provides a shower enclosure100that includes a frame416that is configured (along its lateral axis) substantially commensurate with the exterior periphery203of the shower pan212and the surround102, including the position and orientation of the first inner wall jamb208, and that of the second inner wall jamb210. The frame416of the shower enclosure100is comprised of a header402at the top and a sill406at the bottom that have substantially straight portions420and422and an curved mid-portion424configured commensurate with the exterior periphery (or “curb”)203of the shower pan212. The frame416of the shower enclosure100further includes a first outer wall jamb408and a second outer wall jamb410that are vertically oriented and perpendicular to the header402and sill406, which couple with a first412and a second414distal ends of the header402and sill406by a set of fasteners, the combination of which form the four-sided frame416. Upon full assembly of the frame416(FIG. 3A) of the shower enclosure100, the first and the second outer wall jambs408and410are placed over the channel or raceway303of the respective first and second inner wall jambs208and210(FIG. 3C).

FIGS. 4A to 4Eare exemplary illustration of fixed panels of the shower enclosure ofFIG. 1, including the assembly thereof in accordance with the present invention. As illustrated, one or more fixed panels502and504are coupled with the substantially straight portions420and422of the header402and sill406of the frame416. A fixed panel (e.g.,502) is maneuvered (indicated by arrows506ofFIG. 4A) into the shower enclosure area, and coupled with the interior-facing surface of the straight portions420and422of the header402and sill406of the frame416of the shower enclosure100. As best illustrated inFIGS. 4B to 4E, the fixed panels are comprised of at least one held-in-place fastener508for facilitating installation of the fixed panel onto the frame416of the shower enclosure100. The held-in-place fastener508is comprised of a fastener holding mechanism510that holds a fastener512in its place and in a correct orientation for quickly fastening the fixed panel onto the frame416of the shower enclosure100without a user holding the fastener (FIG. 4E). The fastener holding mechanism510frees the users hands from holding the fastener512during installation and assembly, and instead, the users can hold and operate machinery514with one hand and hold the panel502itself with another hand for easy alignment and coupling of the panel onto the frame416of the shower enclosure100. Therefore, there is no longer a need for the users to maintain the fastener512in a certain position and orientation because the holding mechanism510performs that function.

As further illustrated, the fastener holding mechanism510has sufficient bulk to enable it to snug fit in between spaces within voids or channel raceways516of the fixed panel frame518, as illustrated. In other words, the bulk of the fastener holding mechanism510can maintain in place and in a proper position and orientation a fastener512by interference fit or by friction, and continue to allow it to fasten together products during installation. Stated otherwise, the holding mechanism510maintains the fasteners512in the proper position until and during time when the fasteners512are used to mount the fixed panels onto the frame416of the shower enclosure100. The fastener holding mechanism510can be any shape and be configured of any material so long as it holds the fastener and allows the fastener to move within it to mount the fixed panel onto a frame. In this exemplary instance, the holding mechanism510is illustrated as having a soft, cylindrical disc configuration with transparent body and sufficient bulk to fit within the channel or raceway516of fixed panel frame518and hold the fastener512in proper position and orientation. Non-limiting example of materials from which the fastener holding mechanism510can comprise of may include wood, metal, magnetic, plastic, or any others so long as the holding mechanism510allows for movement (or penetration) of the fastener through to mount the panel onto the frame. None limiting examples of a preferred material may be those that are flexible such as a plastic (e.g., Poly Vinyl Chloride (PVC)), thermo plastic elastomer, rubber or anything that is soft. However, rigid material may also work. Transparency of the holding mechanism510(as illustrated) is preferred because the fastener512held within can be viewed as the fastener512is moved through the holding mechanism510to mount the fixed panel onto the frame. As indicated above, the main value of the fastener holder is that one hand is used to hold a machine (such as a drill514) and the other is used to hold the panel in proper orientation in relation to the header and sill of the frame without worrying or having to hold any fastener. The application of the holding mechanism510is not limited to the present invention and may be used on anything that requires a fastener that cannot maintain its position and orientation independently.

FIGS. 5A to 5Care exemplary illustrations of sliding (or rolling) doors of the shower enclosure ofFIG. 1in accordance with the present invention.FIG. 5Ais an exemplary illustration of the shower enclosure ofFIG. 1, with the roller doors in open position in accordance with the present invention.FIG. 5B-1is an exemplary illustration of the top portion of a rolling door, viewed from the exterior side that faces outside of the shower area, with the bottom exterior portion being identical.FIG. 5B-2is an exemplary view of an articulating roller arm assembly in the process of being assembled onto the roller door, shown from the exterior facing side of the top frame member in accordance with the present invention, with the exterior facing side of bottom being identical.FIG. 5B-3is the same as that ofFIG. 5B-2, but viewed from the interior facing side of the top frame member in accordance with the present invention, with the interior facing side bottom being identical.FIG. 5Cis an exemplary illustration of the bottom portion of a roller door, viewed from the interior side that faces the inside of the shower area, with the top interior portion (as partially shown inFIG. 5B-3) being identical.

As illustrated inFIG. 1andFIGS. 5A to 5C, the present invention provides one or more rolling doors602and604, with a rolling door602or604of one or more rolling doors having an arched or curved horizontal or axial width601(FIG. 1) that is configured substantially commensurate with the arched mid-portions424of the header402and the sill406. Further, the rolling doors of the present invention also include a vertical length603that is parallel along a longitudinal axis of the rolling doors that is substantially commensurate with a vertical distance between the header402and the sill406. This arrangement enables the rolling doors402and406to be flush with the header402and sill406for a complete closure of the shower area, making shower enclosure100aesthetically pleasing and practical in terms of blocking and preventing water from splashing outside the enclosed shower area.

As further illustrated inFIGS. 5B-1and5C, the rolling doors602and604are comprised of a sliding panel (or rolling door) frame having a top rolling door frame member605, a bottom rolling door frame member607, and lateral rolling door frame members609that frame a closure611that may comprise of glass, with the frame and the closure constituting a sliding panel or rolling door602and604. Both the top and bottom rolling frame members605and607include notches614(best illustrated inFIGS. 5B-2and5B-3) that house the articulating roller arm assembly606. The notches614(with the exterior facing side of the notch614on the exterior facing surface605A of the top rolling door frame member605show inFIG. 5B-2) are sufficiently separated at a notch distance630to prevent in-plane and out-of-plane movement of the rolling door602and604when doors are articulated (or moved along the track806). As further best illustrated inFIG. 5B-2, the notch614is comprised of periphery edges621that accommodate a channel616of the articulating roller arm assembly606for insertion and mounting of the articulating roller arm assembly606onto the periphery edges621of the notch614of the top and bottom frame member605and607of the rolling door602and604. As best illustrated inFIG. 5B-3, the articulating roller arm assembly606further includes a set of apertures610that are aligned with notch apertures612on the top and bottom rolling door frame members605and607for securely coupling the articulating roller arm assembly606with the frame members605and607using fasteners613(FIG. 5B-1).

The exemplary illustrated wheels708and710(FIG. 5B-1) of the articulating roller arm assembly606ride within a set of horizontally supported rails with tracks, channels or raceways806(shown inFIGS. 7B and 7C) of the header402and sill406of the frame416of the shower enclosure100. The notches614in the top and bottom of the frame members605and607of the roller doors602and604in combination with the channel616of the articulating rolling assembly606allow the wheels708and710of the articulating roller arm assembly606to face “outside” of the shower area (towards the track806,FIG. 5B-1) and yet, allow a vertical adjustment using the adjustment shaft712(described below) to take place from the “inside” (FIG. 5C) of the shower area. That is, the channel616is inserted within the periphery edges621of the notch614of the top and bottom frame members605and607of the rolling doors, positioning the adjustment shaft712at an interior side (FIG. 5C) of the enclosed shower area with first and second wheels710and708positioned at exterior side thereof (FIG. 5B-1). This arrangement facilitates quick and easy access for adjustment of the adjustment shaft by an appropriate adjustment tool and provides for an esthetically pleasing look (it creates a more esthetically pleasing look for the installed shower enclosure when viewed form the outside because as illustrated inFIGS. 1 and 5A, the articulating roller arm assembly606is blocked from view by the header402and sill406). In addition, the adjustment shaft712itself is substantially not visible from outside. The position of the adjustment shaft712on the interior facing surface side605B of the rolling door frame members605and607(FIG. 5C) enables easy access because there is nothing blocking access to the adjustment shafts712on the interior side. On the other hand, the exterior facing surface side (FIG. 5B-1) of the enclosure is closely adjacent to the header402and sill406of the support rail806(best illustrated inFIGS. 7B and 7C). This creates a very limited space that is defined by the short distance between the rolling door602and604and header402and sill406. The axial length of a throw section704of a cantilever beam702defines this distance. This limited space would make access to and adjustment of the adjustment shaft712very difficult, which may accidentally damage the frame and or the header/sill support rail during the operation of adjusting the adjustment shaft712by an appropriate tool such as a screwdriver that may scratch the surface of the frames by accident during adjustment if for example, the screwdriver slips off the adjustment shaft712. Accordingly, the preferred position of the adjustment shaft712is at the interior side of the shower area, as illustrated.

As further illustrated inFIG. 5B-1, the orientation and positioning of the outer distal wheels (or the second wheels)708of the articulating roller arm assemblies606are towards the distal ends751the frame members605and607. These wheel orientations facilitate in preventing in-plane (twisting or rotational) movement of the rolling doors602and604to provide a stable articulation and further, enable the rolling doors602and604to move completely into the straight sections420and422of the shower enclosure100for a wider opening for egress/ingress from the shower area.

FIGS. 6A to 6Gare exemplary illustrations of the various views of a fully assembled articulating roller arm assembly in accordance with the present invention, withFIG. 6Hexemplarily illustrating a disassembled, exploded view of the same with the separated parts to show the relationship and order of assembly of the articulating roller arm assembly in accordance with the present invention. As illustrated, the articulating roller assembly606of the present invention is preferably comprised of a single piece cantilever beam702having a throw section704and a span section706, with the throw section704oriented substantially transverse the span section706, and the span section706having a length714that is substantially longer than the length729(FIG. 6F) of the throw section704. A first distal end of the span section706and a distal end of the throw section define a bend at the general area indicated by reference721. The articulating roller assembly606further includes a first wheel710that is coupled with a first distal end of the span section706(at721), and a second wheel708that is coupled with a second distal end723of the span section706.

The formed bend at721of the single integral piece cantilever beam702constitutes a corner-elbow section, forming a substantially L-shaped beam with the throw section704and the span section706as the extremities of the L-shaped beam. It should be noted that the formed bend at721may also constitute a rounded corner-elbow section, forming a substantially rounded L-shaped beam702with the throw section704and the span section706as the extremities of the rounded L-shaped beam. Therefore, the formed elbow of the beam702at area721does not have to be at a 90-degree angle. Given that the cantilever beam702moves in relation to the roller support608in a reciprocating path indicated by the arrow716, the movement along path716will compensate to a certain degree for the variations in the selected angle or curvature of the elbow.

As further illustrated, the throw section704includes a bulkier connecting distal end725(FIG. 6B) with a connecting aperture905(FIG. 6H) that enables the connecting distal end725to pivotally couple within a cavity727of the roller support608with the adjustment shaft712. The pivotal or rotatable coupling of the connecting distal end725of the throw section704with the adjustment shaft712enables the cantilever beam702to rotate and swing along the indicated reciprocating path716(about the longitudinal axis of the shaft712) within the cavity727of the roller support608to enable articulation of the articulating roller arm assembly606along both the curved424and straight420and422portions of the header402and sill406. That is, as the articulating roller arm assembly606moves along the straight/curved sections of track806, the cantilever beam702is forced by the curved/straight track sections to steer or maneuver by pivoting along the reciprocating path716. The roller support608includes inner cavity walls731that delimit the movement of the single piece cantilever beam702in the reciprocating path716. It should be noted that the throw section704does not contact the inner cavity walls731throughout its reciprocating path716along the header/sill railing when fully assembled and installed. In other words, the cavity727has sufficient width733such that the beam702does not contact the sidewalls731of the cavity727when the beam swings along path716during a normal use of an installed door. The travel distance of the reciprocating path716of the beam702is closely associated with the arc, roundness or amount of curvature of the support rail header and sill frame416. That is, sufficient room for travel distance along the path716is provided so that the rolling door602and604does not jamb during opening or closing operations.

Both the throw section704of the articulating roller arm assembly606and the adjustment shaft712are designed to delimit the movement of the rolling doors602and604in relation to the track806of the header/sill402/406of the frame416. The turn or rotation of the adjustment shaft712within a pair of adjustment shaft apertures907(FIG. 6H) of the roller support608enables vertical adjustment of the single piece cantilever beam702along a vertical reciprocating path730in relation to the roller support608. This adjustment, in turn, adjusts the vertical distance between the single piece cantilever beam702coupled with the top frame member605and the single piece cantilever beam702coupled with the bottom frame member607of the rolling door602and604. The adjustment accounts for minor variations from install to install. That is, the adjustability helps tighten the articulating roller arm assemblies606(at the top and the bottom frame members605and607) against the track806of the frame416on which the wheels710and708of the articulating roller arm assembly606ride. Accordingly, the adjustment compensates, amongst others (and without limitations), for material size tolerance variations in the vertical height of the door assemblies and variations in the top and bottom rails806of the header/sill402/406of the frame416. Therefore, after the installation of the articulating roller arm assembly606onto the track806of the frame416, the adjustment shaft712may be turned or rotated to tightened the grip of the rollers onto the track by pulling-in the beam702of the top frame member605towards the beam702of the bottom frame member607to reduce the vertical distance603between the articulating roller arm assembly606of the top and bottom frame members605and607. This adjustment enables a rolling door602and604to fit snuggly onto the tracks806of the frame416for a smooth roll, and help prevent in plane and out of plane movement of the door. Additionally, this adjustment effectively interlocks the rolling doors602/604with the header/sill402/406via the wheels710and708, insuring the rolling doors602/604maintain full connection with header/sill402/406during their respective reciprocating moves.

As indicated above, the articulating roller assembly606that are installed onto the top and bottom frame members605and607of the doors602and604bear the entire weight of the doors. As a result, bending moments and shear stress are incurred in both the throw section704of the roller arm and the adjustment shaft712for each articulating roller assembly606installed. Accordingly, the adjustment shaft712also functions to support608the weight of the door602and604, and is securely interconnected with the roller support by the lock ring911(FIG. 6H). In addition, the connecting distal end725of the throw section704is made bulkier for grater structural integrity in terms of increased structural strength to resist incurred bending moments and shear stresses.

As further illustrated and described above, the roller support608further includes the channel616for insertion and mounting of the roller support608onto the periphery edges621of the notches614of the frames605and607of the rolling door602and604. As further stated above, the set of apertures610on the roller support608are used for securely fastening the mounted roller support608to the frame members605and607of the enclosure611.

The articulating roller arm assembly606further includes the pair of wheels708and710, with the first wheel710of the pair of wheels coupled with the proximal end721of the span section706, with area721defining the general elbow formed from an intersection of the span section706and the throw section704. The articulating roller arm assembly606also includes the second wheel708of the pair of wheels coupled at the second distal end723of the span section706. As illustrated, the first and second wheels710and708are coupled with the respective first and second distal ends721and723by a pair of wheel axels909(FIG. 6H) secured to respective first and second axel holes901and903on the span section706.

FIGS. 6I to 6Kexemplarily illustrate the details of the wheel connections with the span section of the articulating roller arm assembly in accordance with the present invention. As illustrated, the first and second wheels710and708of the articulating roller arm assembly606are not aligned and in fact, the respective rotational planes915and919of the wheels710and708that pass through the body of the wheels are not inline. That is, their rotational planes915and919(the planes within which the wheels rotate) are misaligned at an angle2θ (i.e., θ+θ=2θ) in relation to one another. A non-limiting example of the misalignment angle θ from the perpendicular921is about 2°. As best illustrated inFIG. 6K, which is a sectional view taken from the plane indicated by the broken line6K-6K inFIG. 6J, a first and second axel cavity925and927of the span section706that accommodate the respective wheel axels909have respective central longitudinal axis913and917that are at an angle α in relation to the longitudinal axis714of the span section706, rather than perpendicular therewith (at an angle of 90°) as illustrated by the perpendicularly oriented broken lines921(FIG. 6I), making the total misalignment at a non-limiting exemplary angle α of about 92°. This arrangement misaligns the wheels710and708and situates their respective rotational planes915and919at a non-parallel relationship, perpendicular to the respective central longitudinal axis913and917of the respective first and second axel cavity925and927.

Therefore, the set of wheels710and708of the articulating roller arm assembly606are not perfectly inline, but are misaligned. Typically, the ideal rolling motion along a linear (i.e., straight) path may be defined as one where the rotational plane of a wheel coincides (and is aligned) with its linear translational motion or travel direction of the path. For the two-wheel system of the articulating roller arm assembly606, typically, the ideal rolling motion along a linear (i.e., straight) path may be defined as one where the rotational planes of both wheels coincide (and are aligned) with the linear translational path. That is, to achieve the ideal rolling motion along a linear (i.e., straight) path, the rotational planes915and919of the wheels710and708must coincide (and be aligned) with each other and coincide (and be aligned) with the travel direction of the path on which the wheels travel. Simply stated, to achieve an ideal linear rolling motion, the wheels710and708must be a set of perfectly inline wheels that move along a straight path.

Likewise, typically, the ideal rolling motion along a curved path may be defined as one where the rotational plane of a wheel is aligned to be exactly tangent to the curve on which the wheel travel. In other words, the plane of rotation of the wheel touches the curved path at a point but does not intersect the curve at that point. For a two-wheel system of the articulating roller arm assembly606, typically, the ideal rolling motion along a curved path may be defined as one where the rotational planes of both of the wheels are aligned to be exactly tangent to the curve on which the wheels travel. That is, to achieve the ideal rolling motion along a curved path, the first rotational plane915of the first wheel710must be aligned so that it is exactly tangent to the curve (i.e., the pane915touches the curved path at a point on the curve but does not intersect the curve at that point). In addition, the second rotational plane919of the second wheel708must also be aligned so that it is exactly tangent to the curve (i.e., the second plane919touches the curved path at a point on the curve but does not intersect the curve at that point). Accordingly, both planes915and919of the wheels710and708must be aligned so that each is exactly tangent to the curved path, with both respectively touching the curved path at their respective tangent points but do not intersect the curve at their respective tangent points. Therefore, for a two-wheel system, there would be two separate tangent points (one for each wheel), with a distance between the tangents defined by the distance715between the wheels. Accordingly, for a two-wheel system on a curved path, the rotational planes915and919will be misaligned in relation to one another to achieve the tangential requirements for the ideal rolling motion along a curved path. The amount of misalignment will vary depending on the separation distance715between the wheels and the angle of the curvature of the curved path. It is important to note that the greater the distance (in this exemplary instance, separation distance715) between a set of wheels710and708that travel/roll together on a curve, the greater the angle of misalignment between the wheels in order for the wheels710and708to remain orientated exactly tangent to the curve in which they are traveling so to result in the ideal rolling motion. Accordingly, the alignment of the wheels915and919is closely associated with the travel path, and will vary commensurately with shape (straight or curved) of the path and the distance715between the wheels.

In the event a wheel is not appropriately (or ideally) aligned commensurate with an associated path in which it travels, the wheel will be forced to move in a direction substantially perpendicular to its direction of travel/rolling, causing the wheel to slide (or skid). In general, skidding is an undesirable motion of a wheel because it results in added friction. It is important to note that the greater the amount of angular misalignment of a wheel with the path it is traveling (moving away from the ideal), the greater amount of perpendicular skid experienced by the wheel, thus the greater amount of friction that occurs while moving the misaligned wheel along its path.

For a set of substantially inline wheels that travel/roll in the same direction, any misalignment between the two wheels will cause the wheels to work against each other resulting in the wheels to force each other to move in a direction perpendicular to their respective direction of travel/rolling. In other words, any misalignment between the two wheels causes both wheels to share the collective misalignment of the wheels with the path. It is important to note that the greater the total angle of misalignment between the two wheels, the greater amount of perpendicular skid experienced by both wheels, resulting in a proportional increase in friction.

FIG. 7Ais an exemplary illustration of various potential in-plane and out-of-plane movements of the rolling doors in accordance with the present invention.FIGS. 7B to 7Dare exemplary illustrations of the cooperative relationships between various components of a rolling door (including the wheel misalignments described above) as they are articulated along a track of the frame of the shower enclosure ofFIG. 1for maximum opening for ingress/egress of the shower area and smooth articulation of the doors in accordance with the present invention.

Referring toFIGS. 7B to 7D, the present invention provides a track806on the header/sill402/406that has both a curved section424and straight sections420/422. Accordingly, the set of wheels710and708of the cantilever beam702of the articulating roller arm assembly606P (proximal) and606D (distal) must travel along both the curved and straight sections of track806. Therefore, the wheel710and708cannot have the above ideal rolling motions (curved or straight). Thus, the present invention provides an alignment of the wheels that is a compromise between perfectly inline alignment (for straight sections of the track) and exactly tangent to the curve alignment (for the curved section of the track). This results in minimized friction that is roughly equal in both the straight and curved sections of the track during the operation of the door, while maintaining maximum ingress/egress from the shower enclosure area, and stable door operations.

As illustrated inFIG. 7Awith respect to rolling door602and604, the phrase “in plane” is defined as the plane that passes through the body of the rolling door602and604. That is, as illustrated, in this exemplary instance, the plane passing through the rolling door is the XZ-plane. The in-plane movement may be a rotational movement of the rolling door602and604about the Y-axis in the reciprocating path indicated by arrow703and/or a translational movement along the XZ-plane, which is the move of the door vertically, up or down parallel along the Z-axis or laterally along the X-axis or both, with all movement being within the XZ-plane. The out-of-plane movement is defined as a translational movement along the Y-axis, including rotational movements about the X-axis defined by the arrow707and/or the Z-axis defined by the indicated arrow705. Translational movement may be defined as a straight movement.

Referring back toFIGS. 7B to 7D, in general, the cantilever beam702has associated with it lateral, torsional, and vertical bending modes due to the force of the weight of the doors thereon during operation, which mostly occur at the throw section704of the beam702. The throw section704of the beam702has the longitudinal axis729that maintains a fixed perpendicular distance between the track (or raceway)806of the header/sill402/406of the frame416and the rolling door602and604. In general, the throw section704stabilizes out-of-plane motions of the rolling door602and604due to exerted bending moment (and or shear stress) thereof on the throw section704(in particular at connecting distal end725with the adjustment shaft712), and delimits in-plane motions of the rolling door602and604. Therefore, extending the length of the throw section704would generate a greater moment arm at its connection point725with the adjustment shaft712, placing greater stress thereon the connection point. That is, the entire weight of the door would become more pronounced due to the increased length or distance between the frame416from which the door602and604is hung and the rolling door602and604itself, with the said length or distance defined by the axial length729of the throw section.

The span section706supports the set of wheels710and708that are coupled at respective first and second distal ends721and723that are separated longitudinally along the axial length714of the span section706(with separation distance715). The longitudinal separation715between wheels710and708and the total separation distance630between two articulating roller arm assemblies606P (proximal) and606D (distal), and in particular, separation SD between606P and606D respective second distal wheels708on a rolling door provides for a greater span (or a “wider base”) upon which a weight of the rolling doors602and604is spread or distributed, which facilitates reductions in the in-plane motions of the shower door602and604while the wheels710and708roll within the raceway806of the header/sill402/406of the frame416, resulting in increased stability of motion. In general, the distal end wheels708of both the proximal and distal articulating roller arm assemblies606P and606D mostly facilitate to prevent in-plane rotational movements of the rolling door, and their proximal end wheels710mostly prevent out-of-plane movements of the rolling door. In addition, the extended axial length714of the span section706(from the bend area721) and in particular, the position of the wheel708at distal end723for each unit606enables for maximum reach of the wheels (in particular wheels708) to the very distal ends412and414of the frame416for maximum articulation of the rolling door602and604for an increased ingress/egress from the shower area. Accordingly, the span section706facilitates in stabilizing the rolling door602and604in respect of the in-plane and out-of-plane motions of the doors during their movement, and enables for the maximum reach of the wheels (in particular wheels708) to the very distal ends412and414of the frame416for maximum articulation of the rolling door.

It would be preferred to have the second distal end wheels708of both the proximal and distal articulating roller arms606P and606D positioned as far away as possible from the apex center of the curved doors, with the apex defined at the center width axis759of the rolling doors602and406, which extends lengthwise along the door central longitudinal axis. That is, the closer the distal wheels708of the proximal and distal articulating roller arms606P and606D to the respective distal ends751of the frame members605/607, the greater the stability of the rolling doors due to the greater increase in the separation distance SD between the wheels708of articulating roller arm assemblies606P and606D, which would further reduce in-plane motion. The arrangement would also provide for a greater travel distance for the rolling doors to the very distal ends412and414of the frame416for maximum articulation of the rolling door.

Therefore, the present invention provides the orientation and positioning of the outer distal wheels (or the second wheels)708of the articulating roller arm assemblies606P and606D towards the distal ends751of the frame members605and607, away from the apex759. These wheel orientations facilitate in preventing the in-plane (twisting or rotational) movement of the rolling doors602and604to provide a stable articulation and further, enable the rolling doors602and604to move completely into the straight sections420and422of the shower enclosure100, almost to the very distal ends412and414, for a wider opening for egress/ingress from the shower area. If the wheels are shifted closer to the apex759, then the separation distance SD between respective wheels of both of the installed articulating roller arm assembly606P and606D on the frame members of the doors would reduce, which, in turn, would reduce the articulation and stability of the doors.

It should be noted that increasing the longitudinal axis714of the span section706may increase the distance715between the wheels710and708to place the second distal wheels708further from the apex center759. However, doing so would increase the desired angle of misalignment between the wheels in order for the wheels to remain orientated exactly tangent to the curved section in which they are traveling. Because the alignment of the wheels710and708attached to the cantilever beam702cannot be designed for an “ideal” rolling motion in both straight and curved sections of tracks806of the header/sill402/406, any compromise between perfectly inline orientation with each other and orientated exactly tangent to the curved section of tracks in which they are required to travel would result in an undesirable increase in the incurred friction present while operating the doors of the shower enclosure in both the straight and curved sections of tracks. Simply stated, if the wheel distance715is made longer, then the wheel orientations must be further aligned to compensate for the tangential requirements of the curved track. However, this greater misalignment to enable the rotational planes915and919of the wheels710and708to align tangent to the track curve would mean greater misalignment of the wheels710and708with respect to each other, which would cause greater friction when the wheels710and708travel through the straight sections420/422of the track708.

As further illustrated inFIG. 7D, the support rail or track806includes an installation notch802, which is an area within the track806where portions of the track or rail806of the header402and sill406of the frame416is removed to allow the wheels of the articulating roller arm assembly606to enter the track806. The installation notch802is generally positioned in the center of the header402and the sill406. After insertion of the articulating roller arm assembly606via the installation notch802, a stopper902is installed and secured in the installation notch802area with fasteners904inserted into the illustrated holes804, with the stopper functioning as a stop for the articulating roller arm assembly606in the closed operating position.

FIGS. 8A to 8Care exemplary illustrations of a fully assembled shower enclosure ofFIG. 1, viewed from within the enclosed shower area in accordance with the present invention. As illustrate, after installing both of the rolling doors602and604, the stopper902(FIG. 9C) is installed and secured in the installation notch802area with fasteners904inserted into holes804, which functions as a stop for the rollers. This way, for example, if both doors602and604are at an open position, and a user moves to close only one of the doors (e.g.,602) to its closed position (while the other door604is still at its open position), the stopper902will stop the closing rolling door602at the center of the header/sill, preventing the moving door602to pass center stop. As further illustrated, the second distal end wheels708of the articulating roller arm assemblies606contact the stopper (bumper)902in closed position.

FIGS. 9A to 9Dprogressively illustrate the opening of the rolling doors of the present invention. As illustrated, the wheels710and708of the articulating roller arm assembly606of the rolling doors602and604ride along raceway806of the header402and sill406(both the curved424and straight sections420and422) of the frame416. As the rolling doors progressively move towards the straight sections420and422of the shower enclosure, the wheels positions and orientations, and the movement of the beam along path enable smooth transition for the rolling doors along their reciprocating path within the raceway806. The orientation and positioning of the outer distal wheels708of the distal articulating roller arm assemblies606D are towards the distal ends412and414of the frame416, and the orientation and positioning of the outer wheels708of the proximal articulating roller arm assemblies606P are towards the center of the frame416. These wheel orientations facilitate in preventing the in-plane (twisting or rotational) movement of the rolling doors, enable the rolling doors to move completely into the straight/flat sections420and422, and424of the shower enclosure, which enable wider opening for egress/ingress from the shower enclosure. In particular, the distal end wheels708of the distal articulating roller arm assemblies606D and the distal end wheels708of the proximal articulating roller arm assemblies606P face opposite one another to provide the large separation distance SD that enables the weight of the rolling door to be distributed along a longer or wider span between the distal wheels708of the distal and proximal articulating roller arm assemblies606D and606P, greatly reducing in-plane motion of the doors during operation and thereby improving stability. Additionally, the distal wheels708of the distal articulating roller arm assemblies606D provide a greater reach-span to the very distal ends412and414of the header402and sill406for maximum articulation of the rolling doors602and604to maximize ingress/egress of the shower area.

Although the invention has been described in considerable detail in language specific to structural features and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. For example, silicone is applied on both the inside and outside of the enclosure wherever metal parts meet the pan and the surround. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention.

It should further be noted that throughout the entire disclosure, the labels such as left, right, front, back, top, bottom, forward, reverse, clockwise, counter clockwise, up, down, or other similar terms such as upper, lower, aft, fore, vertical, horizontal, oblique, proximal, distal, parallel, perpendicular, transverse, longitudinal, etc. have been used for convenience purposes only and are not intended to imply any particular fixed direction or orientation. Instead, they are used to reflect relative locations and/or directions/orientations between various portions of an object.

In addition, reference to “first,” “second,” “third,” and etc. members throughout the disclosure (and in particular, claims) is not used to show a serial or numerical limitation but instead is used to distinguish or identify the various members of the group.

In addition, any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. Section 112, Paragraph 6. In particular, the use of “step of,” “act of,” “operation of,” or “operational act of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. 112, Paragraph 6.