DOCK DOOR ASSEMBLY

A dock door assembly and a dock door assembly kit are provided for use in a dock door opening for installation in a warehouse. The dock door assembly comprises a pair of vertical tracks, with each vertical track configured to be attached to a wall along opposing lateral sides of the dock door opening. The dock door assembly also comprises a multiple, horizontal section door characterized by a vertical height when closed and mounted on the pair of vertical tracks. The dock door assembly further comprises a spring shaft assembly and a pair of headplates with each headplate having a U-shaped opening to receive each end of a torsion shaft. Further, the dock door assembly may comprise a pair of door cables and a pair of corner cable attachments connecting each door cable to the spring shaft assembly.

TECHNICAL FIELD

In a principal aspect the present invention relates to a dock door assembly and method of assembly for a multi-section dock door assembly and commercial sectional doors for warehouses and other types of buildings.

BACKGROUND

Various types of buildings, such as warehouses with docks may include openings with doors for ingress and egress comprised of multiple, horizontal sections joined together by hinges and mounted on tracks to guide the articulating door sections between a closed position and an open position.

Warehouses and warehousing storage continue to grow with both new and retrofit requirements. With today’s fast paced shipping world with next day and 2-day deliveries, there is a continued need for more warehouses and more dock doors. Garage door service providers are looking for faster and more cost effective ways to install dock doors. Dock door installation comes at a price, such as time and money. An ideal dock door installation method would include minimal trips to the dock door opening and minimal parts to save installation time and money.

SUMMARY

Briefly, the present invention comprises a unique and novel dock door assembly and method of assembly for a multi-sections dock door assembly and commercial sectional doors for warehouses and other types of buildings.

In a first aspect, a dock door assembly for use in a dock door opening in a warehouse may comprise a pair of tracks; a multiple, horizontal section door; a spring shaft assembly; a pair of headplates; and a pair of door cables and a pair of corner cable attachments. The pair of tracks may include each track configured to be attached to a wall along opposing lateral sides of the dock door opening. Each track may comprise a vertical roller track and a clip angle wall plate to attach each vertical roller track to the wall. The multiple, horizontal section door may be characterized by a vertical height when closed and mounted on the pair of tracks. The door may be moveable on the vertical roller tracks between an open and a substantially vertical closed position. The door may include a plurality of horizontal sections. The spring shaft assembly may be located adjacent and above a top of the door opening at approximately 16 \-½ inches above header height. The spring shaft assembly may include a torsion shaft, a pair of cable drums with each cable drum located near an end of the torsion shaft, at least one counterbalance torsion spring extending along the torsion shaft, and at least one torque bracket. The pair of headplates may include one headplate fastened to each of the clip angle wall plates and vertical track. Each headplate may be located at the opposing lateral sides of the door opening. The headplate may have a U-shaped opening to receive each end of the torsion shaft. The pair of door cables and the pair of corner cable attachments may connect each door cable to each of the cable drums. The door cable may have a first end attached to the cable drum and a second end attached to the corner cable attachment. The corner cable attachment may be located on an interior of the dock door and on a lowermost horizontal section of the dock door.

In other embodiments, the door dock assembly may further include a section cleat that includes a wind lock feature that comprises a wall cleat and a door cleat. The wall cleat and the door cleat may cooperatively engage and secure the dock door for windload resistance. The wall cleat may be attached to the clip angle wall plate and the door cleat may be attached to two of the horizontal sections. The wall cleat may comprise a wall cleat extension arm that extends from a wall cleat support plate attached to the clip angle wall plate. The door cleat may comprise a door cleat extension arm that extends from the door cleat support plate attached to two of the horizontal sections. The wall cleat extension arm and the door cleat extension arm may cooperate and engage with each other to keep the dock door secure for windload resistance.

In other embodiments, the dock door assembly may further include an interior lock that comprises a slide bar attached to one of the horizontal sections. The slide bar may slide between an extended position and a compressed position. When the slide bar is in the compressed position, the slide bar may engage with a strike plate attached to the vertical track and locks the dock door in a closed position. When the slide bar is in the extended position, the slide bar may be disengaged with the strike plate and the dock door is unlocked. The slide bar may be approximately 9 inches long.

Additionally, in other embodiments, two of the plurality of horizontal sections may be fastened together by a section center plate and two section end cleats using one or more fasteners, such as four fasteners. Further, each of the headplates may extend perpendicular to the wall. The U-shaped opening may be angled upward to ensure the torsion shaft sets into the opening and remains in the opening, thereby allowing the spring shaft assembly to be front loaded and front mounted on the headplate and the pair of tracks and wall. The upward angled U-shaped opening may allow the spring shaft assembly to rest in place while the spring shaft assembly is being bolted to the headplate.

Further, in other embodiments, the dock door assembly may comprise one or more outboard shaft support plates mounted to the wall to support the spring shaft assembly and the torsion shaft. The one or more outboard shaft support plates may include a wall bracket attached to the wall and a support arm extending perpendicularly from the wall bracket to receive and hold one or more of the ends of the torsion shaft. The outboard shaft support plates may limit the deflection of the torsion shaft in the middle of the torsion assembly, with one outboard shaft support plate on each side of the headplate. The outboard shaft support plates may be only required on doors with a weight of the spring shaft assembly and the torsion shaft great enough to cause substantial deflection.

In another aspect, a dock door assembly kit for installation and assembly in a dock door opening of a warehouse, the dock door assembly kit may comprise: a track assembly configured to be attached to a wall; a plurality of pre-assembled door panels; a spring shaft assembly; and a hardware carton comprising components required for final installation of the dock door assembly. The track assembly may include a pair of pre-assembled vertical tracks with each of the pre-assembled vertical tracks comprising a vertical roller track, a clip angle wall plate attached to the vertical roller track with a plurality of track clips, and a headplate. The headplate may have a U-shaped opening and may be attached to the clip angle wall plate and vertical track. Each of the pre-assembled vertical tracks may be configured to attach to opposing lateral sides of a door opening. Each pre-assembled door panel may comprise a plurality of horizontal door sections pre-assembled together with one or more section center plates and one or more section end cleats. The plurality of pre-assembled door panels connected together may define a multiple, horizontal section door characterized by a vertical height when closed and mounted on the track assembly. The door may be configured to be moveable on the track assembly between an open and a substantially vertical closed position. The spring shaft assembly may include a torsion shaft with pre-assembled components defined by a pair of cable drums with each cable drum located at an end of the torsion shaft, at least one counterbalance torsion spring extending along the torsion shaft, and at least one torque bracket adjacent the at least one counterbalance torsion spring. The ends of the torsion shaft may be configured to set in the U-shaped opening of the headplates. The components may include: one or more door cables, an interior lock, a door handle, one or more section center plates, one or more edge hinge assemblies, two corner cable brackets, two top fixtures, a plurality of rollers, a step plate, and a plurality of fasteners for the component installation.

In other embodiments of the dock door assembly kit, the plurality of pre-assembled door panels may include a top door panel and a bottom door panel. The top door panel may be comprised of two or three horizontal sections pre-assembled together with one section center plate and two section end cleats. The bottom door panel may be comprised of two or three horizontal sections pre-assembled together with two section center plates and four section end cleats. In yet a further embodiment of the dock door assembly kit, the hardware carton may include one or more outboard shaft support plates configured to be mounted to the wall to support the spring shaft assembly and the torsion shaft. The one or more outboard shaft support plates may include a wall bracket configured to be attached to the wall and a support arm extending perpendicularly from the wall bracket configured to receive and hold one or more of the ends of the torsion shaft.

The reader is advised that the attached drawings are not necessarily drawn to scale.

DETAILED DESCRIPTION OF EMBODIMENTS

In the following description of various examples of the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures, systems, and steps in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, structures, example devices, systems, and steps may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures. Nothing in this specification should be construed as requiring a specific three-dimensional orientation of structures in order to fall within the scope of this invention.

Dock doors are an important piece to the warehouse and shipping market. Referring toFIG.1, there is depicted a typical warehouse arrangement10with various dock locations and dock doors110. The dock door assembly may be utilized for commercial sectional doors also. The dock door assembly might include minimal parts, such as pre-assembled door panels; pre-assembled clip angle track, headplates, and brackets; pre-assembled spring shaft assembly with counterbalance and drums set on the shaft. The dock doors110may be various sizes known and used in the art, such as 8′-2″, 8′-4″, 9′-2″, or 9′-4″ wide and 8′, 9′, or 10′ high. The dock doors110may be various models and construction, such as 20 gauge steel, 24 gauge steel, 26 gauge steel, 2″ thick sandwich polystyrene, or 2″ thick polyurethane. A dock door assembly may include dock door tracks that may be various sizes, such as for example 2″ and 3″ tracks. The dock door assembly100may include windows, locks, and/or step plates. Other dock door sizes, dock door models and construction, and track sizes may be utilized without departing from this invention.

Referring toFIG.2A, there is depicted in an isometric view a new sectional dock door assembly100.FIG.2Bdepicts a front view of the dock door assembly100.FIG.2Cdepicts a top view of the dock door assembly100.FIG.2Ddepicts a side view of the dock door assembly100. The dock door assembly100and dock door assembly kits (as detailed and described in reference toFIGS.10A and10B) may be installed quicker than equivalent prior art versions. For example, prior art dock door installation takes approximately 60-75 minutes using two installers. The dock door assembly100and dock door assembly kit installation of the present invention may take approximately 30 minutes and even as low as 24 minutes using two installers.

The dock door assembly100may include a multiple section, horizontal section dock door110; a track assembly120configured to be attached to a wall; a torsion spring assembly150to raise and lower the dock door110along the track assembly120; and a cable assembly160attached to the spring shaft assembly150with the dock door110.

The dock door110may be made up of a series of horizontal sections111,112,113,114,115. The horizontal sections111,112,113,114,115may be connected by section center plates116and section end cleats118using one or more fasteners. The section center plates116may be a flat plate without a pivoting hinge as utilized in prior art. The section end cleats118may be “L”-shaped plates with holes and fasteners. The section end cleats118may be utilized to allow for both reduced number of edge hinges and the packaging of multiple pre-assembled panels together. The section center plates116and the section end cleats118provide a clean, simple, and less moving parts for installation and operation. The horizontal sections111,112,113,114,115may be of different construction, materials and combinations of materials. For example, the section113depicted inFIGS.2A and2Bincludes a window130. The composition and construction of the various sections thus provide a door construction which may vary in terms of materials, size, and weight.

The composite arrangement of the horizontal sections111,112,113,114,115are depicted from the inside view of the door construction as arranged to provide an access opening upon raising the array of composite sections upwardly guided by first and second multi-sectioned track assemblies120positioned inside of a building such as a warehouse or garage. Each of the track assemblies120may be attached to a wall along opposing lateral sides of the dock door opening. Each of the track assemblies120may include a clip angle wall plate122, a plurality of track clips124, a weather seal125, and a vertical track126which guides wheels or rollers attached to the opposing lateral sides of the horizontal sections111,112,113,114,115on the opposing lateral sides thereof to guide the sections upwardly along the vertical track126.

The dock door110may be raised or lowered by means of a spring shaft assembly150. The spring shaft assembly150may be rotationally mounted above the top horizontal section111on a headplate142attached to the track assembly120. Optionally, one or more outboard shaft support plates144may be mounted to the wall to provide support to the spring shaft assembly150. The spring shaft assembly150may include a torsion shaft152, one or more torque brackets154, one or more cable drums156, one or more bearings, and one or more torsion springs158. The torsion springs158may provide a means to counterbalance the weight of the door construction. The cable drum156may be mounted on opposite ends of the torsion shaft152and be attached to the torsion shaft152to rotate coaxially therewith.

A cable assembly160may be attached to the spring shaft assembly150with the dock door110. The cable assembly160may include a door cable162and a corner cable bracket164connecting the door cable162to the dock door110. Each cable drum156may receive the door cable162which is cooperative respectively with the cable drum156. One end of each door cable162may be attached, respectively, to the cable drum156associated therewith. Each door cable162may wind or unwind from the associated cable drum156upon rotation of the torsion shaft142. The opposite end of each door cable162is attached to the lowest or lower horizontal section115at the corner cable bracket164. Thus, in order to raise the dock door110from the closed position as depicted inFIGS.2A and2B, the torsion shaft152may be rotated appropriately to wind the appropriate door cable162on the appropriate drum156. The winding and unwinding operation may involve rotating the torsion shaft152in the appropriate rotational sense relative to raising and lowering the dock door110. Thus, movement of the dock door110may be affected by manually raising or lifting the spring counterbalanced dock door110. One or more door cables162, such as two door cables162, may be utilized.

The torsion shaft152may be rotationally driven, for example, by an electric motor (not shown). Such opening of the dock door110may thus move the dock door110electronically using the electric motor from the closed position to an open position.

FIGS.3A and3Billustrate a side view of the track assembly120. As illustrated inFIGS.3A and3B, the track assembly120may include a clip angle wall plate122, a plurality of track clips124, a weather seal125, and a vertical track126. The weather seal125may snap onto an edge of the clip angle wall plate122. The clip angle wall plate122may be configured to mount to a wall of the building. The clip angle wall plate122may be defined by an “L” shape. The plurality of track clips124may connect the vertical track126to the clip angle wall plate122using one or more fasteners. As illustrated inFIG.3A, the plurality of track clips124may include approximately eight track clips. Other numbers of track clips124may be utilized to attach the vertical track126to the clip angle wall plate122, which may be based on and vary with the height of the door. As depicted inFIG.3A, the vertical track126may be slightly angled away from the wall using the track clips124. As will be explained and detailed further, the track assembly120may be pre-assembled to create a one-piece track style to save installation time. The track assembly120may also include type “A” track graduation so that the track assembly120may be installed tight to the wall. The track assembly120may be sized for various widths known and used in the art, for example, 2″ tracks and 3″ tracks. Other track sizes/widths may be used without departing from this invention. Additionally, the headplate142may be pre-assembled with the track assembly120.

FIGS.4A and4Billustrate views of and the spring shaft assembly150mounted on the headplate142.FIG.4Aillustrates a spring shaft assembly150without an outboard shaft support plate144.FIG.4Billustrates the spring shaft assembly150with an outboard shaft support plate144mounted to the wall to support the torsion shaft152. The outboard shaft support plate144may be required to reduce deflection of the torsion shaft152if the additional weight of the torsion springs158is over a pre-determined weight.

As illustrated inFIGS.4A and4B, the spring shaft assembly150may include a torsion shaft152, one or more torque brackets154, one or more cable drums156, one or more bearings, and one or more torsion springs158. As illustrated inFIGS.4A and4B, the headplate142may be connected to and/or fastened to the track assembly120and specifically the clip angle wall plate122and the vertical track126using one or more fasteners. The headplate142may extend perpendicular to the wall. The headplate142may include a U-shaped opening143for receiving each end of the torsion shaft152. The U-shaped opening143may be angled upward to ensure that the torsion shaft152sets into the opening143and remains in the opening143. The spring shaft assembly150may be front loaded and front mounted on the headplate142, the track assembly120, and the wall. As will be explained and detailed further, the spring shaft assembly150may be pre-assembled so that the entire spring shaft assembly150can be set into the headplate142and bolted into place to save installation time.

Additionally, as illustrated inFIGS.4A and4B, the spring shaft assembly150may be located approximately 6 inches to 48 inches above the header height above the top horizontal section111of the dock door110. In another embodiment, the spring shaft assembly150may be located approximately 12 inches to 40 inches above the header height above the top horizontal section111of the dock door110. In another embodiment, the spring shaft assembly150may be located approximately \16 \-½ inches above the header height above the top horizontal section111of the dock door110. In other prior art dock door assemblies, the spring shaft assembly is located approximately 8-12 feet above the header height to avoid the interference between the dock door and the traditional A-frame mounting for the torsion spring158and shaft152. Moving the spring shaft assembly150location down to the header height above the top horizontal section111of the dock door110allows for easier installation with safer working conditions by working at approximately twelve feet high instead of approximately 20-24 feet in the air as with prior art dock door assemblies.

FIGS.5A and5Billustrate top views of two exemplary spring shaft assemblies150. The spring shaft assembly150inFIG.5Aincludes one torsion spring158located on one end of the torsion shaft152. The spring shaft assembly150inFIG.5Bincludes two torsion springs158with one torsion spring158located on each of the ends of the torsion shaft152. Various sizes and lengths of springs158may be utilized with the spring shaft assembly150depending on the weight and size of the dock door110.

FIGS.6A-6Dillustrate various views of components of the spring shaft assembly150.FIGS.6A and6Billustrate a front view and a perspective view of the headplate142. As illustrated inFIGS.6A and6B, the headplate142includes a U-shaped opening143. The headplate142may also include various slots and/or holes145for attaching to the clip angle wall plate122and the vertical track126. The headplate142may also include locking holes146at the arms of the opening143to hold the torsion shaft152in place in the U-shaped opening143on the headplate142using one or more fasteners.

FIG.6Cillustrates a perspective view of the torque bracket154. The torque bracket154may include two main holes154A to receive and hold the torsion shaft152next to the torsion spring158.

FIG.6Dillustrates a perspective view of the outboard shaft support plate144. As stated above, the outboard shaft support plate144may be optionally mounted to the wall to support the spring shaft assembly150and the torsion shaft152. The outboard shaft support plate144may be required if the additional weight of the torsion springs158is over a pre-determined weight. The outboard shaft support plate144may include a wall bracket147and a support arm148extending perpendicular to the wall bracket147. The support arm148may include a slot149to receive the ends of the torsion shaft152. The outboard shaft support plate144may include various holes and/or slots to attach to the wall using one or more fasteners. The outboard shaft support plate144may also include various holes and/or slots to hold/lock the torsion shaft152in place within the slot149using one or more fasteners. The spring shaft assembly150may also include one or more bearings with set screws to help support the load, and allow rotational or sliding motion of the spring shaft assembly150.

FIGS.7A and7Billustrate a cable assembly160that may be attached to the spring shaft assembly150with the dock door110.FIG.7Aillustrates a front view of the cable assembly160.FIG.7Billustrates a perspective front view of the cable assembly160fromFIG.2A. The cable assembly160may include a door cable162and a corner cable bracket164connecting the door cable162to the dock door110. The corner cable bracket164may be located at the lowest or lower horizontal section115. The corner cable bracket164may include a door cable pick-up166to connect the door cable162to the corner cable bracket164. The door cable162may be attached to the door cable pick-up166by various methods known and used in the art. The door cable pick-up166may be located at the front of the dock door110. The door cable pick-up166may be repositioned from prior art versions. This repositioning and locating the door cable pick-up166at the front of the door eliminates any cable interference during door operation from the repositioning of the spring shaft assembly150to the front of the dock door110and at approximately 16 \-½ inches above the header above the top horizontal section111of the dock door110. As further illustrated inFIGS.7A and7B, the corner cable bracket164includes a tubular shape167to hold roller shaft169of a roller wheel168in the corner cable bracket164. The roller wheel168may be held in the vertical track126of the track assembly120.

FIGS.8A-8Gillustrate a windload lock (or wind lock)170that may be utilized with the dock door assembly100in accordance with aspects of the invention.FIG.8Aillustrates a perspective front view of the windload lock170installed with the dock door assembly100.FIG.8Billustrates a top view of the windload lock170.FIG.8Cillustrates a perspective view of a wall cleat172as part of the windload lock170.FIG.8Dillustrates a top view of the wall cleat172from the windload lock170.FIG.8Eillustrates a perspective view of a door cleat176as part of the windload lock170.FIG.8Fillustrates a top view of the door cleat176from the windload lock170.FIG.8Gillustrates a side view of the door cleat176from the windload lock170.

The windload lock170may act as a windload cleat that provides seal and security of the dock door110to the door jamb without using the typical number of edge hinges. The windload lock170may keep the door tight to the door jamb for windload resistance. The windload lock170may include a wall cleat172and a door cleat176to cooperatively engage and secure the dock door110for windload resistance and reducing air infiltration. The wall cleat172may be attached to the wall and specifically the clip angle wall plate122. The door cleat176may be attached to the dock door110and one of the horizontal sections111,112,113,114,115in place of the section end cleat118. As illustrated inFIGS.8A and8B, the wall cleat172and the door cleat176may engage with each other to secure the door110against the door jamb.

FIGS.8C and8Ddepicts the wall cleat172of the windload lock170. The wall cleat172may include a wall cleat extension arm173that extends from a wall cleat support plate174. The wall cleat support plate174may attach and/or fasten to the wall and the clip angle wall plate122using one or more holes in the wall cleat support plate174and one or more fasteners.

FIGS.8E,8F, and8Gdepicts the door cleat176of the windload lock170. The door cleat176may include a door cleat extension arm177that extends from a door cleat support plate178. The door cleat support plate178may attach and/or fasten to the dock door110using one or more holes in the door cleat support plate178and one or more fasteners. Additionally, as illustrated inFIG.8G, the door cleat176may include an angled portion179with an angle of A. The angle A may be approximately 2 degrees in an exemplary embodiment. Other angles may be utilized with the angle A without departing from the invention. The angled portion179may provide a lead-in when the wall cleat172and the door cleat176come into contact as the door110moves into the closed position. The angled portion179may also work to pulls the door110tighter against the door jamb and weather seal125to reduce air infiltration. Additionally, the angled portion179may be at a right angle to the body of the door cleat176so that the door cleat176sits at an angle and achieves the same effect.

The wall cleat extension arm173and the door cleat extension arm177may be sized and shaped to ensure engagement with and cooperation with each other when the dock door110moves outwardly from the door jamb. For example, the wall cleat extension arm173may be approximately one inch long and the door cleat extension arm177may be approximately 112 inch long. Other lengths for the wall cleat extension arm173and the door cleat extension arm177may be utilized without departing from this invention.

FIGS.8H and8Iillustrate another wall cleat172B that could be utilized with the windload lock170. The wall cleat172B may include a wall cleat extension arm173B that extends from a wall cleat support plate174B. The wall cleat support plate174B may attach and/or fasten to the wall and the clip angle wall plate122using one or more holes in the wall cleat support plate174B and one or more fasteners.

FIGS.8J and8Killustrate another door cleat176B that could be utilized with the windload lock170and the wall cleat172B. The door cleat176B may include a door cleat extension arm177B that extends from a door cleat support plate178B. The door cleat support plate178B may attach and/or fasten to the dock door110using one or more holes in the door cleat support plate178B and one or more fasteners.

FIGS.9A-9Eillustrate an interior lock180that may be utilized with the dock door assembly100in accordance with aspects of the invention.FIG.9Aillustrates a front view of the interior lock180installed on the dock door110.FIGS.9B-9Dillustrate various views of the interior lock180. The interior lock180may be installed or utilized on the dock door110and one of the horizontal sections111,112,113,114,115.

The interior lock180may include a slide bar181that extends through a lock cover182. The slide bar181may slide within the lock cover182from an open (extended) position or closed/locked (compressed) position. The slide bar181may engage with a strike plate185installed on the vertical track126when the slide bar181is in the closed/locked and compressed position. The slide bar181and lock cover182may be connected by a spring183that provides bias to pull and/or pull the slide bar181from either the open (extended) position or closed/locked (compressed) position. The slide bar181may include a slide bar cover184. The slide bar181may include a longer handle to help keep hands away from the door cable162. The length of the slide bar181may be approximately nine inches long. Other lengths of the slide bar181may be utilized without departing from the invention. The longer handle for the slide bar181allows for a safer lock option where hands will not get in the way of the door cable162.

FIG.9Eillustrates a component and installation view of the interior lock180installed on a dock door110. As illustrated inFIG.9E, the interior lock180may be installed and attached to the dock door110or horizontal door sections111,112,113,114,115using and one or more fasteners. The strike plate185may be attached to or connected to the vertical track126, track assembly120, wall, or door jamb using one or more fasteners.

FIGS.10A and10Billustrate a dock door assembly kit 101 to use minimal parts for assembly and installation, thus providing a fast and easy installation. The dock door assembly100and dock door assembly kits (as detailed and described in reference toFIGS.10A and10B) may be installed quicker than equivalent prior art versions. For example, prior art dock door installation takes approximately 60-75 minutes using two installers. The dock door assembly100and dock door assembly kit installation of the present invention may take approximately 30 minutes and even as low as 24 minutes using two installers. For example,FIGS.10A and10Billustrate the door dock assembly100with pre-assembled door panels102; a pre-assembled track assembly104; a pre-assembled spring shaft assembly106; and a hardware carton108.FIG.10Aillustrates both a front view and a side view of the pre-assembled door panels102of the door dock assembly100. The pre-assembled door panels102, as depicted inFIG.10A, may include two door panels103A,103B with the various horizontal door sections111,112,113,114,115already cleated together. For example, the top door panel may be comprised of two horizontal sections111,112pre-assembled together with one section center plate116and two section end cleats118. The bottom door panel may be comprised of three horizontal sections113,114,115pre-assembled together with two section center plates116and four section end cleats118. The pre-assembled joining of multiple horizontal door sections provides less sub-assembly components/parts (i.e. two pre-assembled panels versus five separate horizontal door sections) for dock door installations. The two door panels103A,103B may be pre-assembled together using the horizontal door sections111,112,113,114,115with the section center plates116and section end cleats118using one or more fasteners. Other combinations of numbers of horizontal door section pre-assembly for the various door panels may be provided without departing from this invention.

FIG.10Billustrates the pre-assembled track assembly104, the pre-assembled spring shaft assembly106, and the hardware carton108. The pre-assembled track assembly104may include the clip angle track, headplates, weather seal, and brackets all pre-assembled. The pre-assembled track assembly104may be configured to be attached to a wall. The pre-assembled track assembly104may include a pair of pre-assembled vertical tracks with each of the pre-assembled vertical tracks comprising a vertical roller track, a clip angle wall plate attached to the vertical roller track with a plurality of track clips, and a headplate having a U-shaped opening and attached to the clip angle wall plate and the vertical track. Each of the pre-assembled vertical tracks may be attached to opposing lateral sides of a door opening. The pre-assembled spring shaft assembly106may include the torsion shaft with the counterbalance torsion springs, torsion brackets, bearings, and drums set on the torsion shaft all pre-assembled. The hardware carton108may include the various other contents required for final installation of the door assembly100. For example, the hardware carton108may include one or more of the following: the door cable162, the interior lock180, a door handle134, one center plate116, two edge hinge135, two upper top fixtures136, two corner cable brackets164, six roller wheels168, and various fasteners required to complete the installation. The hardware carton108may be pre-assembled and/or loaded on a pallet with each of the components attached to the pallet.

Additionally, as illustrated inFIGS.11A,11B, and12, the pre-assembled door panels102, the pre-assembled track assembly104, the pre-assembled spring shaft assembly106, and the hardware carton108may all be provided on specific racking to ship the pre-assembled portions of the door assembly100of the present invention. These racking are designed to protect the assemblies during shipment, maximize the amount of product on a truck, provide an easy method for unloading the truck with a forklift rather than by hand, and getting the parts easily to the door openings.

FIGS.11A and11Billustrate a racking200to ship a plurality of pre-assembled spring shaft assemblies106.FIGS.11A and11Billustrate the racking200both empty and with the plurality of pre-assembled spring shaft assemblies106stacked within the racking200. Various stacking configurations may be utilized for the plurality of pre-assembled spring shaft assemblies106within the racking200.

FIG.12illustrates a racking300to ship the pre-assembled door panels102. The racking300may hold any of the pre-assembled door panels102, such as door panels103A,103B with the various horizontal door sections111,112,113,114,115already cleated together. The pre-assembled joining, packing, and shipping of multiple horizontal door sections provides less sub-assembly components/parts (i.e. two pre-assembled panels versus five separate horizontal door sections) for dock door installations.FIG.12illustrates the racking300both empty and with the pre-assembled door panels102stacked within the racking300. Various stacking configurations may be utilized for the pre-assembled door panels102within the racking300. The racking300may utilized perforated angles fastened to keep the pre-assembled door panels102upright. Additionally, the racking300may include spaces between the pre-assembled door panels102filled with bubble wrap or possibly cardboard. The racking300may include two perforated angle pieces per pre-assembled door panels stack that may be required to ensure the pre-assembled door panels102do not slant in a “zigzag” pattern. In a given method of installation of the dock door assembly kit, a dock door installation method may be defined various steps. In a first step, a left or right track assembly104may be installed on the wall and lateral side of the dock door opening. In a second step, the other of the left or right track assembly104may be installed on the opposing side of the wall and lateral side of the dock door opening. In a third step, the lower door panel103B may be installed and stacked within the track assembly104. The bottom half of the two edge hinges135may be attached to the top of the lower door panel103B using one or more fasteners and two rollers137may be installed. The two corner cable brackets164may be attached at the bottom of the lower door panel103B using one or more fasteners and two rollers137may be installed. In a fourth step, the upper door panel103A may be installed and stacked above the lower door panel103B within the track assembly104using a center plate116. The top half of the two edge hinges135may be attached to the bottom of the upper door panel103B using one or more fasteners. The top fixture136may be attached to the top of the upper door panel103B using one or more fasteners and two rollers137may be installed. In a fifth step, the pre-assembled spring shaft assembly106may be installed adjacent and above a top of the door opening at approximately 16 \-½ inches above header height. In a sixth step, the other various components may be installed, such as: the door cable162and the two corner cable brackets164, the door cleat176of the windload lock170, the interior lock180, a door handle134, two edge hinges135, two upper top fixtures136, and the six roller wheels168. The order of steps detailed above may be varied, and/or one or more steps may be omitted, and/or one or more steps may be added.

While there has been set forth a preferred embodiment of the invention, it is to be understood that the invention is limited only by the following claims and equivalents thereof.