Sectional overhead door and apparatus for making door panels

Abstract: A sectional door (20) having a plurality of panels (21,22,23,24), one of the edges (40) between adjacent panels on a first panel having a substantially concave curvilinear surface (45), the other of the edges (50) having a planar surface (52). The hinges include a first hinge element (66) having a first leaf (67), a cylindrical first knuckle (72) at one edge of the first leaf, a through slot (73) proximate the first knuckle and a second hinge element (80) having a second leaf (85), a cylindrical second knuckle (81) at one edge of the second hinge element extending into the through slot and rotatable about the first knuckle. A panel (22) for sectional door (20) having a foam core (140,240,340), an inner surface (145,245,345) and a recess (150, 250, 350) in the inner surface and the foam core extending the longitudinal length of the foam core. A bracket assembly (110) for the bottom (35) of the door including, an L-shaped plate (111), a sleeve (120) for receiving a shaft (121) mounting one of the rollers (122), fasteners (115) for attaching the L-shaped plate to the lower panel and cut-outs (125) in the cylindrical sleeve positioned substantially above the fasteners whereby the fasteners may be removed only when the shaft is not positioned in the cylindrical sleeve. Conveyor apparatus (400, 500) for the continuous production of foam-cored door panel material (22'), a second conveyor (402,502) having engaging surfaces (451,464;535,540) for engaging spaced skin surfaces (146,146) and an offset skin surface (150).

Description: This is a divisional application based on WO 95/34738. TECHNICAL FIELD The present invention relates generally to a panel for sectional overhead doors. More particularly, the present invention relates to a panel for sectional overhead doors which move between a closed position proximate to a vertical door opening to an open position in substantially horizontal orientation with the door panels articulating through a curved portion of the track system in traversing from the closed to the open position and vice versa. More specifically, the present invention relates to an arrangement for such multi-panel overhead doors having an advantageous door panel configuration. BACKGROUND ART Sectional overhead doors have been commonly employed for many years as garage doors in homes, conunercial and utility building doors, and in similar applications. The panels of conventional sectional doors are commonly joined by hinges positioned on the inner or internal side of the door which form pivot points proximate the juncture between each of the adjacent panels to permit the panels to pivot relative to each other. The hinges at the lateral edges of the panels or separate mounting brackets carry shaft-mounted rollers which inter-engage with track sections that control the path of travel of the doors. These track systems commonly include a generally vertical section positioned proximate a door frame or other opening and a generally horizontal section that extends substantially perpendicular to the vertical section rearwardly into the interior of the building in an overhead position. A curved transition section is normally positioned proximate the header at the top of the door frame and interconnects the vertical section and the horizontal section to provide a continuous track system. The hinges permit the door panels to articulate as the rollers interconnecting the door and the track system traverse from the vertical section through the transition section to the horizontal section of the track and vice versa. In recent years, panels for sectional overhead doors of the type described herein constructed of foam with a skin cover have enjoyed increasing popularity. Refinements in such door panels have come largely in terms of the materials or combinations of materials employed in the skin. While light-gage steel is commonly used for the outer skin exposed to the outdoor environment, less expensive materials, such as treated or metallic-coated paper and non-metallic sheet materials, are increasingly employed as inner skin coverings for selected applications. Efforts have also been made in foam compounding to develop less expensive foams having the required strength and insulation qualities. What has remained constant is the notion that a substantially uniform thickness of foam, whether precut inserts or expanded in place, is necessary to achieve required strength and insulation characteristics of panels having a foam core. In a general sense, various apparatus for the production of conventional sectional overhead door panels has been developed in the industry. In some instances, pre-formed foam slabs have been cut to appropriate sizes and assembled by hand on conveyor lines with an outer skin, an inner skin, stiles, and one or more ribs or struts. In other instances, relatively high-speed, continuous production equipment has been developed to achieve substantially automated production of panels. Existing continuous production equipment has normally been subject to a variety of relatively severe limitations and/or disadvantages. In order to achieve essentially automated production, it is necessary that foam be continuously dispensed within the skins of a moving panel at the time of or before forming the enclosed panels. It is, however, necessary during the expansion of the foam in an oven that the normally relatively thin skins forming the sides of the panel be supported, as by a conveyor surface moving at substantially the same velocity, to withstand the internal pressure created by the foam until it becomes substantially set. Both flat platen or slat conveyors and conventional roller conveyors may be employed in an oven to meet these requirements. The use of flat platens and conventional roller conveyors has, for the most part, limited panel configurations to essentially rectangular shapes with substantially planar surfaces. The use of longitudinal reinforcing struts or ribs which are advantageously also interiorly foamed require corresponding recesses in the platens or rolls. However, it is often necessary, or at least desirable, to have different strut dimensions and locations for the three or four different panel sizes necessary to provide, for example, the several different standard door heights. To thus provide different platens or rollers for each panel size and type can result in an inordinate number of platens and rollers, considering that such conveyors commonly have many dozens of rollers. In addition, many hours of production time may be lost in changing the numerous platens or rollers each time a changeover is made to run a different panel. As a result, sectional overhead doors have tended to be relatively expensive and/or designed with significant structural compromises to maintain equipment costs and manual changeover expenses within permissible bounds. DISCLOSURE OF THE INVENTION It is desirable to provide a sectional overhead door: with panel profiles that can be configured of various types of material, including lighter gauge steels, wherein the edge profiles can operate in close proximity to each other without engaging. wherein the panels may be constructed of a variety of materials or laminates of various materials to create panels having varying desired amounts of strength; with panels which may have strengthening struts to effect increased rigidity to the panels and to assist in the attachment of hinges for interconnecting adjacent panels; and with panels which have the various advantageous operational features, while requiring only relatively small hinges intermittently spaced along the width of a particular sectional door. It is also desirable to provide an improved overhead door panel which can: be made of all conventional foams and skin materials or combinations thereof; be adapted to different panel configurations and to various types of operating hardware to satisfy varying cost and climatic parameters; and substantially maintain strength and insulation specifications for a foam-filled panel, while employing a substantially reduced quantity of foam per panel to thus realize significant cost savings. US-A-4685266 discloses a panel for an overhead garage door having the features of the preamble of claim 1. The front face of the panel has decorative recesses or embossments. Folded-over marginal hems around the periphery of the panel help to strengthen the construction. US-A-3290845 discloses a pre-fabricated insulated panel system intended for stationary building panels such as wall and roof sections. The panels have outer and inner skins filled with a foam core, and their outer surfaces have recesses so as to present a ribbed profile. A similar building panel is shown in US-A-3479784. US-A-4238544 on which the preamble of claim 1 is based discloses a panel for a garage door having strengthening struts on its rear or inner surface. In general, the present invention provides a panel as defined in claim 1. Preferred features of the invention are described in the subsidiary claims. Embodiments of the invention will not be described with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view of the interior of a sectional overhead door incorporating panels according to the present invention with the door shown in the vertical, closed position on the rails. Fig. 2 is a perspective view of a preferred form of panel construction according to the present invention for the sectional overhead door herein disclosed. Fig. 3 is a cross-sectional view of the panel of Fig. 2 taken substantially along the line 3A-3A of Fig. 2. Fig. 3B is a cross-sectional view similar to Fig. 3A showing a panel having a modified form of recess in the inner surface. Fig. 3C is a cross-sectional view similar to Figs. 3A and 3B showing another modified form of recess in the inner surface. PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION A sectional overhead door system is generally indicated by the numeral 10 in Fig. 1 of the drawings. The door system 10 includes a pair of spaced track assemblies, generally indicated by the numerals 11 and 12. As shown, the track assemblies 11 and 12 are symmetrically opposite but otherwise structurally identical. The track assemblies 11, 12 each have a vertical track section 13 of appropriate length to extend substantially the distance from the ground or floor of a garage or other structure to a position proximate the header of a door frame in which the door system 10 is to be mounted. Atop each vertical track section 13, there is a curved transition track section 14. The curved transition track sections 14 are normally connected to the vertical track sections 13 as by connector plates (not shown) and bolts or rivets (not shown) according to common practice in the industry. The curved transition track sections 14 are in turn attached in an identical manner to horizontal track sections 15, which extend preferably substantially horizontally inwardly into the building from the door frame a distance comparable to the length of vertical track sections 13. The vertical and horizontal track sections 13,15 are normally constructed of straight pieces of rail which are cut to length for a particular door opening and attached by brackets (not shown) or comparable elements to the door frame. It is to be appreciated that the track assemblies 11, 12 and their positioning with respect to a door frame are in accordance with standard practice in the industry. In addition, all of the track sections 13, 14, and 15 may have the generally J-shaped, cross-sectional configuration which is commonly known and used in the industry. As shown, the sectional door, generally indicated by the numeral 20, of the door system 10 is guided, and in part supported, by the track assemblies 11, 12. For exemplary purposes, a four-panel sectional door 20 is shown in Fig. 1 of the drawings. However, it will be appreciated by persons skilled in the art that five, six, or more panels may be employed in sectional doors of this type, depending upon the height of the door opening and related considerations. As shown, the sectional door 20 consists of a top panel 21, an upper middle panel 22, a lower middle panel 23, and a bottom panel 24. The panels 21, 22, 23, and 24 are interrelated to each other and to the track assemblies 11, 12 in a manner described hereinafter. In conventional fashion, the top panel 21 carries preferably near the top edge 31 thereof a top bracket 30 which mounts a roller 32 that is offset from the door 20 a distance to effect closure of the top panel 21 when the door 20 is in the vertical, closed position. Additional details of a preferred structure for the panels 21, 22, 23, and 24 are shown in Figs. 2 and 3A of the drawings. Inasmuch as the hinge assemblies 65 and other hardware are adapted to fit the basic door panel configuration shown herein, all door panels may be identical, such that door panel 22 is hereinafter described for exemplary purposes. The panel 22 has a foam core 140 which is of a generally rectangular configuration, except for variations that are noted hereinafter. The foam core 140 is preferably a low-density, rigid foam of any of a wide variety of compositions well known in the industry. The foam core 140 is constructed of an appropriate synthetic resin, such as polyurethane foam, for purposes of achieving both strength and insulating characteristics. The foam core 140 may be in the nature of a precut, foamed insert or may be foamed in place according to techniques known in the art. The panel 22 has a front surface, generally indicated by the numeral 141, which is defined by an outer skin 142. The outer skin 142 is preferably constructed of a light-gauge, high-strength steel, which may be processed in a manner to resist exposure to the elements in a manner known to persons skilled in the art. The outer skin 142 preferably extends the full longitudinal and lateral extent of front surface 141 of panel 22. In addition, the skin 142 preferably extends about and defines the outer surfaces of top edge profile 50 and bottom edge profile 40. The skin 142 also preferably continues to define the generally trapezoidal bottom rib or strut 26 and the top rib or strut 27 of panel 22. The skin 142 preferably terminates laterally inwardly of each of the struts 26, 27 in spaced flanges 143 and 144. The top and bottom edge profiles 40, 50 and struts 26, 27 are preferably interiorly filled by the foam core 140. The door panel 22 has as a portion of an inner surface, generally indicated by the numeral 145, an inner skin 146, which extends between flanges 143, 144 the longitudinal length of panel 22. The skin 146 preferably has lateral extremities 147 and 148 which advantageously overlap and, as shown, underlie the flanges 143 and 144, respectively. The inner skin 146 may be made of treated paper, metallic-coated paper, non-metallic sheet material, or metallic sheet of types which are known in the art. The inner surface 145 has a medial recess, generally indicated by the numeral 150, which is preferably centered laterally, substantially medially of panel 22 in the inner skin 146 and the foam core 140. As shown in Fig. 3A, the recess 150 extends approximately one-half of the distance from the center of panel 22 to each edge profile 40, 50. The inner surface 145 has offsets 151 and 152 which transcend from full-thickness sections 140' to a reduced-thickness section 140" of foam core 140. It has been determined that reduced-thickness section 140" can be as thin as approximately 6.35mm (.25") while maintaining the desired stiffness, sound-deadening, and insulating properties of the door panel 22 as a whole in an air environment. It will, of course, be appreciated that the offsets 151 and 152 contribute to increasing the rigidity of the panel 22. It will further be appreciated by persons skilled in the art that full-thickness sections 140' and reduced-thickness section 140" of foam core 140 may be varied in thickness as required to meet insulation, sound-deadening, or stiffness requirements for a particular door design. As seen in Fig. 3A, the offsets 151, 152 may be relatively steeply inclined in that they are positioned at an angle of approximately 60 degrees to a line perpendicular to the reduced-thickness surface 153 of recess 150. With the structural arrangement shown in Fig. 3A, the quantity of foam for the foam core 140 can be reduced on the order of 30 to 40 percent of that required for a conventional rectangular foam core without significantly adversely affecting the characteristics of the panel 22 as noted hereinabove. As seen in Fig. 2, the panel 22 may be provided with end caps 155 which overlie the ends of foam core 140 and the longitudinal extremities of outer skin 142 and inner skin 146. If desired, spaced stiles or muttons may be provided at one or more positions longitudinally of the door panel 22. A modified door panel 222 is depicted in Fig. 3B of the drawings. The panel 222 is configured the same as the panel 22 of Fig. 3A, except for medial recess, generally indicated by the numeral 250, in the inner surface 245. As shown, the recess 250 extends approximately one-half of the distance from the center of panel 22 to each of the edge profiles in a manner comparable to recess 150. The inner surface 245 has offsets 251 and 252 which transcend from full-thickness sections 240' to a reduced-thickness section 240" of foam core 240. In a manner similar to the panel 22, it has been determined that reduced-thickness section 240" can be as thin as approximately 6.35mm (.25") while maintaining the desired stiffness, sound-deadening, and insulating properties of the door panel 222 as a whole in an air environment. It will be appreciated that the offsets 251 and 252 contribute, to some measure, to increasing the rigidity of the panel 222, although less steeply inclined than the offsets 151, 152. The possibilities of varying the thickness of full-thickness sections 240' and reduced-thickness section 240" of foam core 240 are, of course, available to satisfy requirements for a particular door design. The panel 222 can produce a foam quantity reduction on the order of 30 to 40 percent without significantly adversely affecting the stiffness, sound-deadening, and insulating properties of the panel 222. Another modified door panel 322 is depicted in Fig. 3C of the drawings. The panel 322 is configured the same as the panels 22 and 222 of Figs. 3A and 3B, except for medial recess, generally indicated by the numeral 350, in the inner surface 345. In this instance, the recess 350 is in the form of a gradual curve, which extends substantially the entire width of the inner surface 345 to create a concave configuration. Here, the foam core 340 has a minimum-thickness portion 340" substantially medially of the transverse width of inner surface 345 with tapering, progressively thicker sections 340' to either side thereof. The possibilities of varying the thickness dimensions of foam core 340 and achieving a foam quantity reduction, as discussed in relation to panel 22 and 222 are, are equally applicable. From the discussion involving panels 22, 222, and 322, it will be appreciated that innumerable geometric configurations by way of combinations of curved and linear surfaces could be employed to achieve foam reduction without substantially compromising specifications by the incorporation of a recess or recesses in the inner surface of a door panel.

Claims: A panel (22) for a sectional door (20) employing a plurality of such panels joined for articulation between adjacent panels for moving between a closed vertical position and an open horizontal position, said panel comprising a generally rectangular foam core (140) having a longitudinal length and a lateral length, an outer surface (141) extending said longitudinal length and said lateral length of said foam core (140), an inner surface (145) extending said longitudinal length and said lateral length of said foam core (140), edge profiles (40, 50) extending the longitudinal length of said foam core (140) and interconnecting said outer surface (141) and said inner surface (145), an outer skin defining said outer surface and an inner skin defining said inner surface, projecting struts (26, 27) on said inner surface (145) extending the longitudinal length of said foam core (140), one being positioned proximate to each of said edge profiles (40, 50); said foam core (140) extending into said struts (26, 27); said outer surface being generally planar; characterized by said outer skin (142) defining said generally planar outer surface (141), said edge profiles (40, 50) and said struts (26, 27); said inner skin (i46) defining said inner surface (145) between said struts (26, 27) and overlapping said outer skin (142); and a recess (150, 250, 350) in said inner skin (146) and said foam core (140) extending the longitudinal length of said core (140) and laterally centered substantially medially between said struts (26, 27) whereby to reduce the quantity of foam required to fill said foam core (140). A panel for a sectional door according to claim 1, wherein said recess (250) is a notch. A panel for a sectional door according to claim 1, wherein said recess (35) is a concave curvilinear surface. A panel for a sectional door according to claim 3, wherein said recess extends from a position proximate to one strut (26) to a position proximate to the other strut (27). A panel for a sectional door according to any preceding claim, wherein said edge profiles (40, 50) include a top edge profile and a bottom edge profile adapted to interfit with mating profiles of adjacent panels. A panel for a sectional door according to any preceding claim, wherein said outer skin (142) has spaced flanges (143, 144) and said inner skin (146) has lateral extremities which overlap said spaced flanges (143, 144).

Inventors: BENNETT III THOMAS B, MITCHELL ALBERT W, MULLET WILLIS J, WILSON WILLIAM S, BENNETT III, THOMAS B., MITCHELL, ALBERT W., MULLET, WILLIS J., WILSON, WILLIAM S.
Applicants: WAYNE DALTON CORP, WAYNE-DALTON CORP.
Application year: 1995
Main classification: E06B3
IPC codes: B29C31, E06B3, E05D15, E05D1, B29C33, B29C44