Breakaway loading dock door system

A system for allowing a loading dock door to release from a track upon being struck by a fork lift or other sufficiently strong force. The system employs a unique track profile with one or more sidewalls that have an angled sidewall profile to allow a release assembly to move out of the track. The release assembly includes a biasing mechanism that allows the assembly to flex and ride out of the track when the door is impacted.

DETAILED DESCRIPTION

Field of the Disclosure

This disclosure relates generally to the field of dock doors and more specifically to a system for allowing a loading dock door to be mounted and used with the functionality such that, upon being struck by a fork lift or other strong force it releases itself from its tracks.

Background

Warehouse operations generally have several door openings from which truck or rail cargos may be easily loaded and unloaded. These door openings are generally covered when not in use by doors that are specifically designed to be used as loading dock doors. The typical loading dock door has aspects of its design that make it suitable for loading dock operations, such as some ability to be locked and to provide security for the premises, a window through which to see if a truck or train is backed into the loading dock area, a wheel and track system that allows the door to be opened, either by lifting or rolling up in a vertical fashion, so that when opened it is out of the way of any traffic that results from the loading process.

Loading dock doors often sustain damage as large and heavy loads are moved at frequent high speeds by forklift operators through and around the openings on loading docks. A door that has been struck may be damaged and may, in some cases, not be easily or smoothly opened until it has been repaired and/or adjusted to work properly.

To address these issues, most loading dock doors have been designed to withstand a significant amount of abuse. Doors can be built to withstand greater amounts of abuse by using heavier gauge metals and/or braces for reinforcement to withstand greater strikes from forklifts. As these doors are built to be stronger, they also become heavier and more costly.

In some cases, the doors are designed to be able to release themselves from their tracks via a pivot system that has been built into the wheel and axle assemblies. Door systems that are designed to break away from their tracks have involved the creation of designed pivot points on the wheel assemblies or wheel axles. These break-away points allow the door to break away from the tracks and to be remounted with relative ease and a minimum amount of door damage. Unfortunately, the wheel assemblies are complicated, expensive and prone to breakage with continued use.

SUMMARY

Embodiments of the present disclosure may provide one or more of the following advantages: allowing a door to self-release from its tracks when struck by a fork lift or other relatively large force; reducing damage to a door that has been struck; or allowing the door to be quickly and/or easily reset into its tracks for continued use after self-release.

An embodiment of the present disclosure is directed to a dock door system. The dock door system comprises: a track comprising one or more sidewalls that are angled to allow a wheel to move up the sidewall and out of the tracks; and a door comprising a wheel-and-axle assembly. The wheel-and-axle assembly is configured to allow the wheel to move relative to the door. The wheel is biased in a position on the axle by a biasing mechanism so as to ride in the track. The wheel and axle assembly is configured to allow the wheel to ride up the sidewall and out of the track if the door is struck with sufficient force.

Another embodiment of the present disclosure is directed to a dock door hardware system. The dock door hardware system comprises: a track comprising one or more sidewalls that are angled to allow a wheel to move up the sidewall and out of the tracks; and a wheel-and-axle assembly. The wheel-and-axle assembly comprises an axle, an axle bracket attachable to a dock door and having a receptacle for receiving the axle, a wheel positioned on the axle, and a biasing mechanism for applying a force tending to force the wheel away from the axle bracket. The receptacle and axle are configured so as to allow the axle to move back and forth in the receptacle relative to the bracket. The wheel and axle assembly is configured so that the wheel can ride in the track.

Yet another embodiment of the present disclosure is directed to a dock door wheel-and-axle assembly. The wheel-and-axle assembly comprises: an axle; an axle bracket attachable to a dock door and having a receptacle for receiving the axle; a wheel positioned on the axle; and a biasing mechanism for applying a force tending to force the wheel away from the axle bracket. The receptacle and axle are configured so as to allow the axle to move back and forth in the receptacle relative to the bracket.

Still another embodiment of the present disclosure is directed to a dock door system. The dock door system comprises a first track and a second track. The first track comprises (i) a first sidewall comprising a first substantially planar region, (ii) a second sidewall comprising a second substantially planar region and (iii) a third sidewall comprising a third substantially planar region. The third sidewall is positioned between the first sidewall and the second sidewall. The first substantially planar region, the third substantially planar region and the second substantially planar region are consecutive planar regions. A first angle is defined by the first and third substantially planar regions and a second angle being defined by the second and third substantially planar regions. The first angle ranges from about 100° to about 160°. The dock door system also comprises a dock door comprising a first plurality of release assemblies and a second plurality of release assemblies. Each of the first plurality of release assemblies comprise a puck and a biasing mechanism. Each of the pucks is positioned by a respective one of the biasing mechanisms so as to ride in the first track. The first plurality of release assemblies is configured to allow the pucks to move toward the dock door and out of the first track if the door is struck with sufficient force in a direction that pushes the pucks against the first sidewall. Each of the pucks has a first major surface and a second major surface. A beveled edge extends from the first major surface to the second major surface and is configured to be proximate to the first sidewall when the puck is positioned in the first track. A second edge extends from the first major surface to the second major surface and is configured to be proximate to the second sidewall when the puck is positioned in the first track.

Another embodiment of the present disclosure is directed to a dock door hardware system. The system comprises a track comprising (i) a first sidewall comprising a first substantially planar region, (ii) a second sidewall comprising a second substantially planar region and (iii) a third sidewall comprising a third substantially planar region. The third sidewall is positioned between the first sidewall and the second sidewall. The first substantially planar region, the third substantially planar region and the second substantially planar region are consecutive planar regions. A first angle is defined by the first and third substantially planar regions and a second angle is defined by the second and third substantially planar regions. The first angle ranges from about 100° to about 160°. The system further comprises a release assembly comprising an axle, an axle bracket attachable to a dock door and having a receptacle for receiving the axle, a puck positioned on the axle, and a biasing mechanism configured for applying a force tending to force the puck away from the axle bracket and toward the track so as to ride in the track. The receptacle and axle are configured so as to allow the axle to move back and forth in the receptacle relative to the bracket. The release assembly is configured so that the puck can move out of the track if a sufficient force is applied to the release assembly in a direction that pushes the puck against the first sidewall. The puck has a first major surface and a second major surface. A beveled edge extends from the first major surface to the second major surface and is configured to be proximate to the first sidewall when the puck is positioned in the first track. A second edge extends from the first major surface to the second major surface and is configured to be proximate to the second sidewall when the puck is positioned in the first track.

Another embodiment of the present disclosure is directed to a method of installing a breakaway dock door system. The method comprises installing a first track proximate a dock door opening. The first track comprises (i) a first sidewall comprising a first substantially planar region, (ii) a second sidewall comprising a second substantially planar region and (iii) a third sidewall comprising a third substantially planar region. The third sidewall is positioned between the first sidewall and the second sidewall. The first substantially planar region, the third substantially planar region and the second substantially planar region are consecutive planar regions. A first angle is defined by the first and third substantially planar regions and a second angle is defined by the second and third substantially planar regions. The first angle ranges from about 100° to about 160°. The method also comprises installing a first plurality of release assemblies on a side of a dock door. Each of the first plurality of release assemblies comprises a puck and a biasing mechanism. Each of the pucks is positioned by a respective one of the biasing mechanisms so as to ride in the first track. The first plurality of release assemblies is configured to allow the pucks to move toward the dock door and out of the first track if the door is struck with sufficient force in a direction that pushes the pucks against the first sidewall. Each of the pucks has a first major surface and a second major surface. A beveled edge extends from the first major surface to the second major surface and is configured to be proximate to the first sidewall when the puck is positioned in the first track. A second edge extends from the first major surface to the second major surface and is configured to be proximate to the second sidewall when the puck is positioned in the first track.

It should be noted that some details of the figures have been simplified and are drawn to facilitate understanding of the embodiments rather than to maintain strict structural accuracy, detail, and scale.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to embodiments of the present teachings, examples of which are illustrated in the accompanying drawings. In the drawings, like reference numerals have been used throughout to designate similar elements. In the following description, reference is made to the accompanying drawings that forms a part thereof, and in which is shown by way of illustration a specific exemplary embodiment in which the present teachings may be practiced. The following description is, therefore, merely exemplary.

In accordance with an embodiment of the disclosure, there is disclosed a loading dock door system that is configured so that in the event it is struck by a fork lift or other strong force, it releases itself from its tracks, thereby reducing the risk of substantial damage to the door. The door system comprises a unique track profile with one or more sidewalls that have an angled sidewall profile to allow the wheel assembly to move up the sidewall and out of the tracks. A tensioned or spring loaded wheel assembly biases the door so that it generally stays on the track, while providing enough flex for the door to ride up the sidewall and out of the tracks when struck with sufficient force.

As will be shown in greater detail below, the system comprises a track with an angled sidewall profile combined with wheel assemblies that are spring mounted. The wheel of the wheel assembly can be pushed inward toward the door, allowing the wheel assembly to ride up and out of the track itself, thus releasing the door if it is struck with a force that is large enough to depress the springs in the wheel assembly.

By adjusting the angle of the sidewall in the track and/or the strength of the springs in the assembly, a door can be designed to release easily with relatively modest forces, or to be released only upon relatively large forces striking it. A slight change in the angle of the side wall profile of the track can change the amount of force that is required for a door to be pushed hard enough to be released.

FIG. 1illustrates a dock door system100, according to an embodiment of the present disclosure. A dock door1includes a plurality of wheel assemblies4. A track6is configured to allow wheels of the wheel assemblies4to run in the tracks so that the dock door1can be opened and closed, similar to a traditional overhead door. In addition, the track6and wheel assemblies4are configured so that the wheels can come out of the track6when dock door1is struck with sufficient force, as will now be described in detail.

FIG. 2illustrates an exploded view of a wheel assembly4, according to an embodiment of the present disclosure. Wheel assembly4includes a wheel24, an axle22, an axle bracket21and a biasing mechanism30. Axle22is received by a receptacle in the axle bracket21, so as to allow the axle22to move back and forth in the receptacle relative to the bracket21. Axle22is held in position in track6during operation of the dock door1by any suitable means, such as a pin28and biasing mechanism30. Biasing mechanism30may be, for example, a spring or other tensioning member. In this manner, the wheel24is biased in position so as to ride in the track6, as illustrated inFIG. 3A. The biasing mechanism is configured to also allow the wheel24and axle22to move relative to the bracket21, so that the wheel24can be positioned out of the track6, as shown inFIG. 3B.

Wheel bearings23, washers25and26, bolt27and lock ring29illustrate an example of an inner wheel assembly. Any other suitable inner wheel assembly can be employed.

Referring again toFIG. 1, a plurality of the wheel assemblies4can be attached to one or both sides of dock door1. The wheel assemblies4can be attached to the door using any suitable means, such as brackets2and3.

Track6of dock door system100includes at least one sidewall having angle, θ, relative to a rotational axis32of wheel24, as more clearly shown inFIG. 3A. In an embodiment, the angle θ, can also be taken as relative to a line, L, normal to a side34of the track positioned between the two sidewalls, as shown inFIG. 3B. The one or more sidewalls of track6are angled in a manner that allows wheel24of wheel assembly4to move up the angled sidewall and out of the track6when a sufficient force is exerted on the dock door1to compress the biasing mechanism30. For example, θ can range from about 10° to about 70°, such as about 30° to about 60°, or about 40° to about 50°.

In an embodiment, both sidewalls of track6can have an angle, θ. In an embodiment, an angled track6can be positioned on both sides of dock door1, where one or both of the track sidewalls are angled. The systems of the present disclosure can offer impact protection on one side and not on the other side, both sides, or in differing amounts for each side of the door based on the angle, θ, that is used for each track. In addition, systems are contemplated that provide protection from impacts on either the inside or outside of the door or both, based on which sidewalls of each track are angled. For example,FIG. 1shows an inside view of the dock door1, with the tracks6configured so that the sidewalls closest to the outside are angled to provide protection from impacts occurring from inside the building on which the door is hung.

Dock door1can be any suitable type of overhead door. In an embodiment, dock door1is a rigid insulated door that is designed to maintain a substantially planar shape, similar to that shown inFIG. 1, as it is opened and closed. In an alternative embodiment, dock door1can be a roll-up style door. An example of such a door is described in U.S. patent application Ser. No. 13/585,994, filed Aug. 15, 2012, the disclosure of which is hereby incorporated by reference in its entirety.

Dock door1can include one or more optional components. Examples of the one or more optional components include weather stripping7and/or any other type of seal, a lock9, a window10, and a pull-down strap and/or handle12, or other hardware. Any suitable type of automatic or manual door opening system can be employed to open and close the dock door1. Such door opening systems are well known in the art.

In an embodiment of the present disclosure, a plurality of release assemblies4′, each comprising a puck50, as shown inFIGS. 4 and 5, can be employed on a dock door1instead of the wheel-and-axle mechanisms described above. The plurality of release assemblies4′ comprising puck50can be attached to either or both sides of the dock door so as to allow the dock door to open and close on tracks6.

Each release assembly4′ comprises, among other things, a biasing mechanism30for positioning the puck50so as to ride in the track6, as shown inFIG. 6. Release assembly4′ is configured to allow the puck50to move toward the dock door and out of track6, thereby releasing it from the track in the event that the door is struck with sufficient force in a direction that pushes the puck against an angled sidewall of the track. Any suitable release assembly capable of biasing the puck can be employed. For example, release assembly4′ can include a spring loaded bracket21′ and an axle22. Axle22can be attached to puck50in any suitable manner. In an alternative embodiment, the assembly described herein and shown inFIG. 2can also be employed with the puck50in place of the wheel24, where the same or a different inner wheel assembly can be used with the puck50.

In an embodiment as shown inFIG. 6, puck50can have a first major surface or base50A, a second major surface or base50B, and one or more beveled edges50C extending from the first major surface50A to the second major surface50B. The beveled edges50C are configured to be proximate the sidewalls of track6when the puck50is positioned therein. For example, the sidewalls of track6can be ¼ inch or less, such as ⅛ or 1/16 or 1/32 inch or less from the corresponding sidewalls of the track. In an embodiment, the sidewalls of track6directly contact one or both of the sidewalls of the puck when positioned in the track. In an embodiment, the second base50B is parallel with and shorter than the first base50A. A cross section of puck50can have a trapezoidal shape, with a first leg50C-1of the trapezoid extending from the second base at a first leg angle, α1, and a second leg50C2of the trapezoid extending from the second base at a second leg angle, α2.

Angles α1and α2can be the same or different and can be any suitable angle or angles that will provide the desired functionality.FIG. 6illustrates an embodiment in which α1and α2are the same.FIG. 7illustrates another embodiment in which α1and α2are different. Where both α1and α2are obtuse angles, as inFIG. 6, the puck50can function to provide bi-directional releasability, so that the dock door is capable of releasing from the track if struck from either side. Where one of α1and α2has about a 90° angle, such as α2inFIG. 7A, the dock door is capable of uni-directional releasability, so that it is capable of releasing if struck from one side in a direction, for example, that pushes the puck against the beveled sidewall6C-1of track6, but does not release if hit from the opposite side so as to push puck50against the non-beveled sidewall6C-2.

In an embodiment, the shape of puck50allows it to slide up and down the track6, as opposed to rolling down the track as does the wheel24. However, the puck and axle22can be designed so that the puck50can pivot, or rotate, on the axle22, so as to allow the puck to more easily follow the profile of a curved track while it slides up and down. Thus, axle22can have any suitable configuration, and/or puck50can be mounted on axle22using any suitable mechanism or in any suitable manner that will provide the desired movement of puck50as it traverses the track.

In addition to allowing bi-directional or uni-directional release of the puck from a track as discussed above, the chamfered design of puck50can aid in guiding a dock door back into the groove of a track after the door has been struck hard enough to cause it to release from the track. The beveled edge(s) in combination with the biasing mechanism effectively cause the puck to seek the lower energy potential position in the track after it has been knocked out of the track by a large force. With a wheel alone, a door that is knocked out of the track must generally be reset manually by pushing the door into place. With a puck, the door has the capability of resetting itself by simply cycling the door through a complete opening cycle. Thus, the puck shape can specifically act to guide the door back into its proper placement in the tracks after it has been hit with a force strong enough to displace the door from its position in the tracks.

The particular dimensions of the puck will vary depending on factors such as the dimensions of the track. For example, the puck width, “W”, can be set to fit within the track profile, similarly as shown inFIG. 6orFIG. 7A. Puck height, “H”, can vary depending on, for example, the door requirements. In an embodiment, the puck width and height can be approximately the same, so that major surface50A has the approximate shape of a square. In other embodiments, the width is greater than the height. In yet other embodiments, the height is greater than the width. In an embodiment, the thickness, “T”, is less than either the height or the width. Example ratios of T:W and T:H include ranges of from about 1:3 to about 1:8, or 1:4 to about 1:6. Beveled edges are set to fit the track profile and can be angled based on the amount of force that is desired to allow a release of the puck out of the track profile.

In an embodiment where both edges of puck50are beveled, α1and α2can range from about 100° to about 160°, such as about 120° to about 150°, or about 130° to about 140°, or about 135°. In an embodiment where only first leg50C-1is beveled, α1can be any of the angles mentioned above for α1, and α2can be less than 100°, such as about 90°. For example, α2can range from about 90° to about 160°. The puck shape, including the angles α1and α2, can be designed to fit with a particular track profile.

Referring toFIG. 7B, the track can have first angle, φ1, defined by the first and third substantially planar regions, and a second angle, φ2, defined by the second and third substantially planar regions. Angles φ1and φ2can be any of the track angles disclosed herein for track6. In an embodiment, one or both of φ1and φ2can range from about 100° to about 160°, about 120° to about 150°, or about 130° to about 140°, or can be about 135°.

The angles α1and α2for the puck can be the same or different than the corresponding angles φ1and φ2for the track. In an embodiment, α1for the puck is about the same as the corresponding angle, φ1, of the track between sidewall6C-1and a sidewall6B, as shown inFIG. 7B, so that the beveled edge can fit substantially flush against the sidewall6C-1. Similarly, α2for the puck can be about the same as the corresponding angle, φ2, of the track between sidewall6C-2and sidewall6B, so that the non-beveled edge (or beveled edge in the case where both edges are beveled) can fit substantially flush against the sidewall6C-2. In an embodiment, a gap54exists between the puck50and the sidewall6B when the puck is positioned into the first track so that both the legs50C-1and50C-2of puck50are flush against the sidewalls6C-1and6C-2, respectively. In other embodiments, a gap54does not exist.

Puck50can be made of any suitable material, such as metals, polymeric materials, such as plastics or rubbers, and/or composite materials. If desired, the puck can be made or coated with a material that reduces friction between the track and the puck. One example of a suitable polymer that can be used for the puck is high density polyethylene (“HDPE”). HDPE is a relatively dense, self lubricating plastic that is relatively easy to tool to the desired shape. Examples of other suitable materials are well known in the art.

The puck shape can allow for the use of a stop bar56, as shown inFIGS. 6 and 8.FIG. 6illustrates a track6comprising an example stop bar56that extends over a sidewall of track6in a manner that prevents at least one of the pucks50, such as a plurality of pucks50, from moving out of the first track if the door is struck with a force in a direction that pushes the pucks against that sidewall when the door is fully closed.FIG. 8illustrates stop bar56positioned proximate the bottom of the track, according to an embodiment of the disclosure. In this configuration, the dock door can break away from the tracks when the puck closest to the bottom edge of the dock door is positioned above the stop bar56. Stop bar56can be any desired length that will stop at least one puck from coming out of the track6. Examples of suitable stop bar lengths can be 4 or more inches, such as 6 to 24 inches or 8 to 12 inches.

Stop bar56can reduce the likelihood that the dock door will be knocked out of the tracks when it is in the fully closed position in the event that a sufficiently hard pressure is applied on one side of the dock door to displace it from its tracks. Thus, stop bar56allows the dock door to be a security door and/or to provide a desired level of hurricane proofing when the door is in the fully closed position. Once the door is in a position other than fully closed, the puck50in no longer blocked by the security bar and is now free to be displaced from the tracks if the door is hit while opening or closing. Because doors are often hit by forklifts when opening or closing, a door that acts as a breakaway door when in use, but as a non-breakaway door (e.g., security door) when closed, is a particularly attractive combination. If desired, one or more stop bar56can also be positioned at other positions, such as near the top of the door opening, or at positions between the top and bottom of the door opening, such as half way between the top and bottom, in order to further secure the door.

While only a single track is illustrate inFIG. 8, it is well known in the art that two tracks are employed, one on either side of each dock door. One or both tracks can have a beveled sidewall. In an embodiment, both tracks each have at least one beveled sidewall, such as two beveled sidewalls per track. One or more stop bars56can be positioned on only a single track (such as in the case where only that single track has beveled edges while the other track does not include a beveled edge). In an embodiment, one or more stop bars56can be positioned on both tracks of a dock door. Referring toFIG. 6, in addition to stop bar56a second stop bar (not shown) can be positioned over the other sidewall of the same track6, thereby preventing the dock door from releasing from either side of the track.

Referring again toFIG. 8, track6can include a slot58to allow a dock door hasp (not shown) to secure the door in place. A slot58can be positioned on one or both tracks of a dock door. Examples of suitable dock door hasps are well known in the art.

The present disclosure is also directed to a method of installing a breakaway dock door system. The method can be employed for installing any of the dock door systems of the present disclosure. The method comprises installing a first track proximate a dock door opening. As disclosed herein, the first track comprises (i) a first sidewall comprising a first substantially planar region, (ii) a second sidewall comprising a second substantially planar region and (iii) a third sidewall comprising a third substantially planar region, the third sidewall being positioned between the first sidewall and the second sidewall. The first substantially planar region, the third substantially planar region and the second substantially planar region are consecutive planar regions. A first angle, φ1, is defined by the first and third substantially planar regions and a second angle, φ2, is defined by the second and third substantially planar regions. The first angle ranges from about 100° to about 160°. In an embodiment, a second corresponding track is installed on the dock door opening in addition to the first track.

A first plurality of release assemblies are installed on a side of a dock door. The first plurality of release assemblies are positioned on the door so as to be positionable in a first track. Each of the first plurality of release assemblies comprise a puck and a biasing mechanism, such as illustrated and described herein with respect to any ofFIGS. 3A,5and7A. Each of the first pucks are positioned by a respective one of the biasing mechanisms so as to ride in the first track when the door is installed on the track. The first plurality of release assemblies are configured to allow the first pucks to move toward the dock door and out of the first track if the door is struck with sufficient force in a direction that pushes the pucks against the first sidewall. In an embodiment, a second plurality of release assemblies are installed on a second side of the dock door in a manner similar to that describe above for the first plurality of release assemblies. The second plurality of release assemblies are positioned on the door so as to be positionable in a second track. Installation of the release assemblies and track can occur in any suitable manner using any desired mechanisms for attaching the release assemblies to the dock door and/or attaching the tracks proximate a dock door opening. Suitable attachment mechanisms are well known in the art. For example, release assemblies4can be bolted to the dock door through grooves60of bracket21shown inFIG. 5.

The dock door systems of the present disclosure can be installed on new dock doors and/or on new dock door openings. Alternatively, the systems can be installed on preexisting dock doors and door openings as a replacement of used dock door tracks and the corresponding wheels or other used hardware.