Door leveling apparatuses and associated methods of manufacture and use

Door leveling apparatuses are disclosed herein. A door leveling apparatus configured in accordance with one embodiment includes a bracket mounted to a door, such as a vertically-opening sectional door. The apparatus further includes a cable assembly having a first end portion coupled to the bracket and a second end portion coupled to a door lifting system, such as a counterbalance assembly. The first end portion includes an adjuster that enables an operator to adjust the operational length of the cable assembly extending between the lifting system and the bracket, thereby enabling the operator to individually adjust the lengths of two such cable assemblies on opposite sides of the door to align the door with a corresponding opening.

TECHNICAL FIELD

The present disclosure relates generally to door leveling apparatuses and, more specifically, to door leveling apparatuses for use with loading dock doors and other doors that move vertically in opposing guide tracks to open and close.

BACKGROUND

Loading docks and other buildings that require relatively large doorways typically utilize sectional doors that retract upwardly to open. Sectional doors typically include a plurality of rectangular panels connected together by hinges along upper and lower edges. The door panels typically carry rollers or other guide members that extend outwardly from the side edges to engage guide channels in door tracks that extend vertically along each side of the door opening. Seals (e.g., bulb seals) are often provided along the side edges of the door panels to seal the gaps between the door and the door tracks. Some door tracks (e.g., tracks for “overhead” doors) extend horizontally into the building above the door so that the door is stored in this position when fully opened. Other door tracks extend vertically, or at least generally vertically, along the wall above the door opening so that the door is stored in a generally vertical position when fully opened.

Many vertically-opening doors are manually opened, while others include powered or automatic door opening systems. Moreover, many vertically-opening door systems include a counterbalance assembly positioned above the door to assist opening. Conventional counterbalance assemblies include two cable drums positioned on opposite ends of a shaft. Each drum carries a cable that is wound around the drum at one end and attached to an upper corner of the door at the other end. The shaft is typically coupled to a one or more torsion springs that bias the drums in a direction that puts tension on the cables to assist raising the door.

Vertically-opening doors should be properly aligned and positioned relative to the door opening. Otherwise, the gaps between the side edges of the door panels and the door tracks may be uneven or excessive. For doors having seals along the side edges, this misalignment can result in gaps between the guide tracks and the seals which may in turn lead to a number of undesirable consequences, including loss of heating or cooling energy, contamination, etc.

Conventional methods for leveling vertically-opening doors typically include enlisting the aid of a specialist to adjust the relative lengths of the two counterbalance assembly cables. This usually involves repositioning one or both of the cable drums on the shaft to take up or let out more cable as necessary to adjust the door angle. This approach has a number of shortcomings, not the least of which is the need to engage a specialist, which can be time-consuming and costly. Moreover, it may be difficult to fine tune cable length by rotating the corresponding cable drum. Accordingly, it would be advantageous to provide a system and method that would enable a door operator to easily and quickly adjust the orientation and/or position of a vertically-opening door without the need for special tools or training.

DETAILED DESCRIPTION

The present disclosure describes various embodiments of door leveling apparatuses for use with loading dock doors and other doors that move vertically to open with the assistance of a counterbalance assembly or similar system. In one embodiment, for example, a door leveling apparatus configured in accordance with the present disclosure can include a pair of brackets mounted to opposite corners of a door panel. Each of the brackets can be coupled to one end of a corresponding cable assembly. The opposite end of each cable assembly is wound around a corresponding drum on a horizontal shaft of a counterbalance assembly positioned above the door. The shaft can be coupled to one or more torsion springs that bias the drums in a direction that pulls on the cables to lift or at least assist lifting the door during opening. In one aspect of this embodiment, each cable is attached to its corresponding door bracket by a threaded end fitting which carries an adjuster, e.g., a threaded adjuster, such as a nut. Turning the adjuster in a first direction can effectively lengthen the corresponding cable, while turning the adjuster in the opposite direction can effectively shorten the cable. Accordingly, one or both of the cable adjusters can be turned as necessary to adjust the relative effective cable lengths and fine tune the vertical alignment of the door.

Certain details are set forth in the following description and inFIGS. 1-8to provide a thorough understanding of various embodiments of the disclosure. Other details describing well-known structures and systems often associated with vertically-opening doors, counterbalance systems, etc. have not been set forth in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the disclosure.

Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions, angles and features without departing from the spirit or scope of the present invention. In addition, those of ordinary skill in the art will appreciate that further embodiments of the invention can be practiced without several of the details described below.

In the Figures, identical reference numbers identify identical, or at least generally similar, elements. To facilitate the discussion of any particular element, the most significant digit or digits of any reference number refers to the Figure in which that element is first introduced. For example, element110is first introduced and discussed with reference toFIG. 1.

FIG. 1is an interior view of a vertically-opening door100(e.g., a loading dock door) operably coupled to a lifting system120by two door leveling apparatuses110configured in accordance with an embodiment of the present disclosure. The door100covers an opening104in a building106. In the illustrated embodiment, the door100includes a plurality of panels108(identified individually as door panels108a-e) pivotally connected together with hinges in a conventional manner. Each side edge of the door panels108can include one or more guide members118(identified individually as guide members118a-l) extending outwardly therefrom. The guide members118can include rollers, plungers and/or other suitable devices for engaging a guide channel in an adjacent door track102(identified individually as a first door track102aand a second door track102b) attached to the wall of the building106along each side of the door opening104.

In one aspect of this embodiment, each of the door leveling apparatuses110includes a cable assembly116having a first end portion operably coupled to a door bracket112. The opposite end portion of each cable assembly116is attached to a corresponding drum122(identified individually as a first drum122aand a second drum122b) mounted to a shaft126of the lifting system120. In one embodiment, the lifting system120can be a conventional counterbalance assembly having one or more biasing members124(e.g., torsion springs) operably coupled to the shaft126to rotationally bias the drums122in a direction that applies tension to the cable assemblies116to assist manual raising of the door100. In other embodiments, the lifting system120can include other types of systems that apply a lifting force to the door100to assist manual opening, as well as other powered systems that automatically lift the door100. In the illustrated embodiment, the door brackets112are attached to the upper corners of the first door panel108a. As described in greater detail below, however, in other embodiments the brackets112can be mounted to the door100in other locations and in other orientations depending on various factors, including the type of door (e.g., overhead verses vertically-storing), space constraints, accessibility, etc.

FIG. 2is a partially exploded side view of the cable assembly116configured in accordance with an embodiment of the disclosure. The cable assembly116includes an elongate cable230extending between a first cable assembly end portion231and a second cable assembly end portion232. In the illustrated embodiment, the cable230can be a steel cable of conventional construction, such as a 7×19 construction galvanized steel cable having a cross-sectional diameter of from about 0.12 inch to about 0.19 inch, or about 0.16 inch. In other embodiments, however, virtually any cable known in the art as having sufficient strength, wear, and other characteristics can be used.

An end fitting238has a collar portion246that is swaged onto the cable230toward the first end portion231. In one aspect of this embodiment, the end fitting238also includes a cable stop portion242positioned between the collar portion246and an engagement or threaded portion244. The cable stop portion242has a shoulder248that is larger in diameter, or is otherwise wider than the collar portion246. The cable stop portion242can also include a plurality of wrench flats to facilitate gripping the end fitting238with a wrench or other suitable tool. The threaded portion244can include conventional external threads (e.g., ¼-20 UNC threads) for engaging complimentary internal threads on an adjuster252(e.g., a hexagonal nut, locknut, wingnut, or other internally threaded member). In one embodiment, the end fitting238can be a stainless steel, threaded stud end fitting, part number 259-5CTRH, as provided by Loos & Co., Inc., Cableware Division, of Naples, Fla. 34104. In other embodiments, however, other suitable end fittings having features similar to those described above can be used.

In another aspect of this embodiment, the cable assembly116further includes a cylindrical pin or lug member240that is slidably disposed over the collar portion246of the end fitting238. As described in greater detail below, the collar portion246extends through an aperture in the lug member240that is smaller than the cable stop portion242. As a result, the lug member240is able to slide back and forth on the collar portion246and the cable230, but the lug member240cannot slide past the cable stop242and off the end fitting238. An annular cable stop234can also be crimped, swaged or otherwise fixed to the opposite end of the cable230toward the second cable assembly end portion232to facilitate attachment of the cable assembly116to the cable drum122. In addition, the cable assembly116can also include an optional floating cable stop236which is free to slide back and forth on the cable230.

In addition to the foregoing components and features, the cable assembly116further includes a spacer250that slides over the threaded portion244and the cable stop portion242to abut the lug member240, and is held in place by the adjuster252. In the illustrated embodiment, the spacer250is a cylindrical member having a central through-hole with an inner diameter that is slightly greater than the cable stop portion242to enable the spacer250to slide over the cable stop portion242. The spacer250, cable stop234, and floating cable stop236can be manufactured from suitable materials known in the art. Such materials can include, for example, stainless steel, galvanized steels, steel alloys, etc.

FIGS. 3A-3Care side, end, and top views, respectively, of the lug member240. Referring toFIGS. 3A-3Ctogether, in the illustrated embodiment, the lug member240is a generally cylindrical pin or member having an outside diameter360of from about 0.25 inch to about 0.75 inch, or about 0.5 inch. In other embodiments, the lug member240can have other cross-sectional shapes and/or other dimensions depending on the particular application. For example, in other embodiments the lug member and/or portions thereof can have a spherical shape, a rectangular shape, and/or a wide variety of other suitable shapes. A through-hole362extends transversely through a mid-portion of the lug member240, and is sized to slidably receive the collar portion246of the end fitting238(FIG. 2). As discussed above with reference toFIG. 2, however, the inner diameter of the through-hole362is smaller than the outer diameter of the shoulder248on the cable stop portion242to prevent the lug member240from sliding off of the end fitting238during use. By way of example, in one embodiment the collar portion246can have an outer diameter of about 0.25 inch, the through-hole362can have an inner diameter of about 0.27 inch, and the shoulder248can have an outer diameter of about 0.30 inch or more. In other embodiments, however, these components and features can have other dimensions as long as the functional relationship between the components remains the same.

The lug member240can further include two additional through-holes364a, bextending transversely through opposite lug member end portions366a, bof the lug member240. As described in greater detail below, the outer through-holes364are configured to receive a locking member, such as a cotter pin, to hold the lug member240in place on the door bracket112. The lug member240can be formed from any number of suitable materials known in the art, including, for example, carbon steels such as AISI 1018 CF carbon steel.

FIGS. 4A and 4Bare front and side views, respectively, of the door bracket112configured in accordance with an embodiment of the disclosure. Referring toFIGS. 4A and 4Btogether, the door bracket112includes a clevis portion or first bracket end portion471formed into an inverted “U” shaped cross-section having a return flange or front panel portion476spaced apart from a mounting or rear panel portion478by a gap480. The first bracket end portion471includes a cutout482. The gap480can be at least approximately equal to the outer diameter360of the lug member240described above with reference toFIGS. 3A-3C. For example, if the outer diameter360is about 0.5 inch, then the gap480can be about 0.5 inch.

The front panel portion476includes a plurality of first apertures484(identified individually as first apertures484a-c) configured to receive one end portion of the lug member240, and the rear panel portion478includes a plurality of corresponding second apertures486(identified individually as second apertures486a-c) configured to receive the opposite end portion of the lug member240. Although the door bracket112of the illustrated embodiment includes three pairs of lug member apertures from which an operator can choose, in other embodiments, the door bracket112and variations thereof can include more or fewer sets of apertures for receiving the lug member240.

In the illustrated embodiment, the first apertures484and the second apertures486have generally oval shapes configured to accommodate installation and retention of the lug member240. For example, if the outer diameter360of the lug member240is about 0.5 inch, then the first aperture484can have a width488of from about 0.505 inch to about 0.53 inch, or about 0.51 inch, and a length490of from about 0.57 inch to about 0.62 inch, or about 0.59 inch. The second apertures486can have the same width488as the first apertures484, but can have a longer length492of from about 1 inch to about 1.5 inch, or about 1.3 inch. As described in greater detail below, elongating the first and second apertures484,486in the foregoing manner can facilitate coupling of the lug member240to the bracket112during assembly of the door leveling apparatus110(FIG. 1). In addition to the foregoing features, the door bracket112can also include a plurality of fastener apertures474located toward a second bracket end portion472for receiving bolts and/or other suitable fasteners for attaching the door bracket112to the door panel108a(FIG. 1). In the illustrated embodiment, the door bracket112can be formed from 11 gauge steel sheet. In other embodiments, however, the door bracket112can be formed or otherwise manufactured from various other suitable materials known in the art having sufficient strength, corrosion and other characteristics.

FIGS. 5A-5Eare a series of views illustrating various stages of a method for coupling the cable assembly116to the door bracket112in accordance with an embodiment of the disclosure. As those with an ordinary skill in the art will appreciate, although the following discussion describes one possible method for installing the cable assembly116, other methods including variations on the steps disclosed can also be used without departing from the present disclosure. Referring first toFIG. 5A, with the lug member240installed on the cable230as described above with reference toFIG. 2, the lug member240is positioned between the front panel portion476and the rear panel portion478of the door bracket112adjacent to a pair of selected apertures484and486(e.g.,484band486b). The particular apertures484,486used can be selected based on the relative position of the corresponding cable drum122(FIG. 1), the desired cable angle, and/or other factors. The second lug member end portion366b(FIG. 3A) of the lug member240is disposed in the second aperture486b, while the first lug member end portion366ais positioned adjacent to the corresponding first aperture484b. As shown inFIG. 58, the operator then rotates the lug member240upwardly about the cable230until the first lug member end portion366aprotrudes through the first aperture484b and the second lug member end portion366bprotrudes through the second aperture486b.

Referring next toFIG. 5C, with the lug member240now fully engaged in the apertures484,486, the cable230and the lug member240are rotated so that the operator can extend the second cable assembly end portion232through the cut-out482in the door bracket112. The operator pulls the second cable assembly end portion232away from the bracket112to draw the cable230and the collar portion246through the lug member240until the cable stop portion242of the end fitting238abuts the lug member240as shown inFIG. 5D. The second cable assembly end portion232of the cable assembly116can now be installed on the corresponding cable drum122(FIG. 1) in a conventional manner.

Referring next toFIG. 5E, the operator installs a lock member or keeper566(e.g., a cotter pin, Rue ring, etc.) through each of the apertures364in both ends of the lug pin240to capture the lug member240on the door bracket112and prevent it from inadvertently falling out of the apertures484,486. In addition, the operator can slide the spacer250over the threaded portion244and the cable stop portion242of the end fitting238until it abuts the lug member240. The operator then threads the adjuster252onto the threaded portion244in a conventional manner to trap the spacer250in place on the end fitting238.

FIG. 6is an enlarged view taken fromFIG. 1showing the attachment of the cable assembly116to the door bracket112in more detail. Referring toFIGS. 1 and 6together, to adjust the effective length of the cable assembly116and thereby adjust the alignment of the door100relative to the tracks102, the operator can grip the collar portion246of the end fitting238with a suitable tool (e.g., a pair of pliers) and turn the adjuster252with another tool (e.g., a wrench) in an appropriate direction to increase or decrease the effective length of the cable assembly116as desired. More specifically, turning the adjuster252in a first direction (e.g., clockwise) so that the adjuster252moves further onto the threaded portion244draws the cable230toward the lug member240, thereby effectively shortening the cable assembly116. Conversely, turning the adjuster252in the opposite direction (e.g., counter-clockwise) to move the adjuster252further aft on the threaded portion244effectively lengthens the cable assembly116. In the event the operator inadvertently turns the adjuster252too close to the end of the threaded portion244and the adjuster252falls off, the end fitting238will only slide through the hole362in the lug member240(FIGS. 3A-3C) until the cable stop portion242(FIG. 2) abuts the lug member240, thereby stopping further movement. This feature prevents the cable assembly116from coming loose and letting the door100drop.

Although the door brackets112described above with reference toFIGS. 1 and 6are positioned at the top of the door100and the corresponding cable assemblies116extend vertically to the corresponding cable drum122, in other embodiments other mounting positions and orientations of the brackets112and/or the cable assemblies116can be used depending on the particular application. For example, in other embodiments the door brackets112can be mounted on the middle or bottom portions of the door100. Moreover, in still further embodiments the door brackets112can be mounted horizontally and the cable assemblies116can be horizontally routed to the brackets112from an overhead counterbalance assembly via a suitable guide member (e.g., an eye bolt, pulley, etc.). In some embodiments involving overhead doors, the brackets112can be mounted near the bottom edge of the door, and the cable assemblies can extend upwardly along the exterior surface of the door to accommodate the upward and horizontal motion of the door during opening. Accordingly, as those of ordinary skill in the art will appreciate, the door leveling apparatuses and associated methods and systems described herein are not limited to use with a particular type of vertically-opening door in a particular manner, but can be used with a wide variety of doors and door systems.

Various embodiments of the door leveling apparatuses described herein can provide advantages over conventional door leveling systems and methods. For example, the threaded end fitting238will not pull through the lug member240if the adjuster252inadvertently comes off of the end fitting during adjustment. Moreover, in some embodiments the first cable assembly end portion231of the cable assembly116can be easily attached to the bracket112with the second cable assembly end portion232of the cable assembly116already installed on the cable drum122. This permits the cable assembly116to be easily replaced in the field. In addition, the cylindrical nature of the lug member240enables the cable230to rotate about both its longitudinal axis and the lug member axis, thereby reducing stress on the cable230and prolonging cable life.FIGS. 7A-7Care side, end, and top views, respectively, of a door bracket712for use with a leveling apparatus configured in accordance with another embodiment of the disclosure. Referring toFIGS. 7A-7Ctogether, the door bracket712includes a generally flat and elongate mounting portion778having fastener apertures774(identified individually as a first fastener aperture774aand a second fastener aperture774b) in opposing end portions thereof for receiving fasteners to secure the bracket712to a door panel. For example, in one embodiment one bracket712can be mounted to each of the upper corners of the first door panel108a, as shown inFIG. 1for the door bracket112. The door bracket712also includes two parallel and upstanding clevis flanges776(identified individually as a first flange776aand a second flange776b) extending outwardly from the mounting portion778. The opposing flanges776each include a corresponding pin bore784which are axially aligned with each other. In the illustrated embodiment, the door bracket712can be manufactured from any suitable metal known in the art, such as 11-gauge galvanized steel. In other embodiments, the bracket712can be manufactured from other suitable materials that are bent, machined, welded, or otherwise formed to shape.

FIG. 8is an enlarged side view of a door leveling apparatus810that includes the door bracket712described above with reference toFIGS. 7A-7C. In the illustrated embodiment, a lug member, such as the lug member240, is operably received in the opposing pin bores784of the door bracket712. More specifically, in this embodiment the opposing end portions366of the lug member240are rotatably received in the corresponding pin bores784. A keeper, such as a cotter pin866, Rue ring, etc. can be installed through each of the through-holes364in the end portions of the lug member240to retain the lug member240on the door bracket712. In one aspect of this embodiment, however, the through-holes364in the lug member240can extend parallel to the central through-hole362(see, e.g.,FIG. 3C) to facilitate installation of the keepers866in the lug member240.

In the illustrated embodiment, the cable assembly116is operably coupled to the bracket712by means of the lug member240in substantially the same manner as described above with reference toFIGS. 5A-5E. More specifically, the cable230and collar portion246of the end fitting238are extended through the through-hole362in the mid-portion of the lug member240until the stop portion242on the end fitting238abuts the lug member240. The adjuster252can then be installed on the threaded portion244of the end fitting238to retain the spacer250and adjust the effective length of the cable assembly116as necessary to level the corresponding door.

Various modifications can be made to both the door leveling apparatus810and the door leveling apparatus110described above with reference toFIGS. 1-6without departing from the spirit or scope of the present disclosure. For example, in one embodiment the cable stop portion242on the end fitting238can be omitted such that the end fitting238would normally be able to pass entirely through the through-hole362(FIG. 3C) in the lug member240. To prevent this from happening, however, a cable stop890, such as a nut, collar, pin/through-hole combination, and/or other similar features can be welded or otherwise secured to the distal end portion of the end fitting238after the spacer250and the adjuster252have been installed. The cable stop890provides a fail-safe feature that prevents the cable assembly116from pulling all the way through the lug member240after installation. Accordingly, various modifications can be made to aspects of some of the embodiments disclosed herein without departing from the scope of the present disclosure.

From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the various embodiments of the invention. Further, while various advantages associated with certain embodiments of the invention have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited, except as by the appended claims.