Abstract:
A sliding door assembly includes a sliding door that is slidingly mounted to a top track via one or more top guide assemblies. The sliding door is also slidingly mounted to a bottom track. Each top guide assembly includes a top guide wheel that rotationally mounts to the top guide assembly and engages the top track to guide the sliding door. The guide wheel rotates relative to the top guide assembly about an axis that extends horizontally in a direction perpendicular to a direction of travel of the sliding door. The guide wheel also movably mounts to the top guide assembly so that the guide wheel moves upwardly and downwardly relative to the top guide assembly and sliding door to correct for any variation in the gap between the top and bottom tracks.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application claims priority to U.S. Provisional Application No. 60/547,424, filed Feb. 26, 2004, the entire contents of which are incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates generally to sliding doors, and more specifically to top guides for guiding sliding doors along top tracks.  
         [0004]     2. Description of Related Art  
         [0005]     Sliding panel doors, such as those used in closets, are constructed from thin panels that gain rigidity from the application of a perimeter frame formed by two side, one top, and one bottom roll formed or extruded metal sections that are mechanically joined at each corner by means of a metal or plastic joining plate. The weight of the panel door is typically supported by a bottom track, and the door is provided with wheels or other slidable elements that can slide or roll within the bottom track. The top portion of the door is often retained and guided in a top “E” section track, which provides downwardly depending leg portions defining vertical surfaces in which the upper portion of the panel door is retained and guided. Particularly, the upper portion of the panel door is typically provided by a top guide assembly that is attached to the metal or plastic frame joining plate at each top corner of the door. The top guide assembly typically includes a pair of top guide wheels (or rollers or other slidable elements) each rotatable about a vertical axis. As the door travels along the bottom and top tracks, the top guide wheels rotate against the inside parallel vertical edges of the E track and keep the sliding door positioned centrally within the track cavity. U.S. Pat. No. 6,449,906 illustrates one such conventional top guide and is incorporated herein by reference in its entirety.  
         [0006]     When the top and bottom tracks are perfectly parallel and the top guide assemblies are properly mounted to the sliding door, the top guide wheel axes are perfectly perpendicular to the direction of travel of the sliding door, and the top guide wheels roll smoothly along the inside parallel vertical edges of the top E track. However, in some installations, the top and bottom tracks are not perfectly parallel to each other (i.e., the top and bottom tracks angle toward each other) due to variations and imperfections in the floor, ceiling, or other substrate onto which the tracks are mounted. These imperfections may occur over time with the settling of the building or structure. When the top and bottom tracks are so skewed, the top guide wheel axes will not be perpendicular to the direction of travel of the sliding door, which follows the bottom track. Such a misalignment of the top guide wheel axis relative to the direction of travel of the sliding door may also result from a misaligned attachment of the top guide assembly to the sliding door. Consequently, the natural rolling path of the top guide wheels will be skewed relative to the actual direction of travel of the sliding door. The skewed path over which the top guide wheels roll causes the top guide wheels to vibrate or jitter as they attempt to follow their natural path, but are forced to follow the actual path of the sliding door. This vibration often generates noise.  
       SUMMARY OF THE INVENTION  
       [0007]     Accordingly, one aspect of one or more embodiments of this invention provides a top guide assembly that operates quietly, smoothly, and effectively, even when the top and bottom tracks are not parallel to each other or the top guide is not perfectly positioned on the sliding door.  
         [0008]     Another aspect of one or more embodiments of the present invention provides a sliding door assembly that includes a sliding door panel and a guide arm movably connected to an upper portion of the sliding door panel. The guide arm is movable relative to the sliding door panel in a vertical direction. The sliding door assembly also includes a top guide wheel pivotally connected to the guide arm at a top guide wheel axis. The guide wheel moves with the guide arm relative to the sliding door panel.  
         [0009]     According to a further aspect of one or more of these embodiments, the movable connection between the guide arm and the sliding door panel is a pivotal connection that defines a guide arm axis. The guide arm axis is spaced from the top guide wheel axis. The top guide wheel axis extends in a lateral, horizontal direction relative to the sliding door panel. The top guide wheel axis and guide arm axis are parallel to each other. An interference between the guide arm and the sliding door panel limits the range of the pivotal movement of the guide arm relative to the sliding door panel.  
         [0010]     The sliding door assembly may further include a top guide base mounted to the upper portion of the sliding door panel. The guide arm pivotally connects to the sliding door panel by way of a pivotal connection between the guide arm and the top guide base.  
         [0011]     According to a further aspect of one or more embodiments, the sliding door assembly also includes a spring operatively extending between the top guide base or the sliding door panel and the guide arm to bias the guide arm and top guide wheel upwardly away from the sliding door panel.  
         [0012]     The assembly may also include an elongated top track adapted to be mounted to a substrate. The top track has an elongated guide wheel channel. The top guide wheel extends into the channel so that the channel guides the movement of the guide wheel along the top track. The channel has opposing sides that provide lateral support to the sliding door panel by way of the top guide wheel.  
         [0013]     An additional aspect of one or more embodiments of the present invention provides a top guide assembly for mounting a sliding door panel to a top track. The top guide assembly includes a top guide base adapted to be mounted to an upper portion of the sliding door panel. The top guide assembly also includes a guide arm movably connected to the top guide base. The guide arm is movable relative to the top guide base in a vertical direction. The top guide assembly also includes a top guide wheel pivotally connected to the guide arm at a top guide wheel axis. The guide wheel moves with the guide arm relative to the top guide base.  
         [0014]     According to a further aspect of one or more embodiments of this invention, an interference between the guide arm and the top guide base limits the pivotal movement of the guide arm relative to the top guide base.  
         [0015]     According to a further aspect of one or more of these embodiments, the guide arm pivots about a first axis and the top guide wheel axis is spaced from the first axis.  
         [0016]     According to a further aspect of one or more of these embodiments, the movable connection between the guide arm and the sliding door panel allows the guide arm to move in a linear, vertical direction relative to the sliding door panel.  
         [0017]     Additional and/or alternative advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose preferred embodiments of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     Referring now to the drawings which from a part of this original disclosure:  
         [0019]      FIG. 1  is a partial front view of a sliding door assembly according to one embodiment of the present invention;  
         [0020]      FIG. 2  is a cross-sectional view of a top guide assembly in  FIG. 1 , taken along the line  2 - 2  in  FIG. 1 ;  
         [0021]      FIG. 3A  is a top perspective view of a top guide base of the top guide assembly in  FIG. 2 ;  
         [0022]      FIG. 3B  is a bottom view of the top guide base in  FIG. 3A ;  
         [0023]      FIG. 3C  is a side cross-sectional view of the top guide base in  FIG. 3A , taken along the line  3 C- 3 C in  FIG. 3B ;  
         [0024]      FIG. 4A  is an upper perspective view of a guide arm of the top guide assembly in  FIG. 2 ;  
         [0025]      FIG. 4B  is a lower perspective view of the guide arm in  FIG. 4A ;  
         [0026]      FIG. 4C  is a front view of the guide arm in  FIG. 4A ;  
         [0027]      FIG. 4D  is a side cross-sectional view of the guide arm in  FIG. 4A , taken along the line  4 D- 4 D in  FIG. 4C ;  
         [0028]      FIG. 5  is a partial side cut-away view of a top guide assembly according to an alternative embodiment of the present invention; and  
         [0029]      FIG. 6  is a top view of the top guide assembly in  FIG. 5 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0030]      FIG. 1  shows a sliding door assembly  10  according to a preferred embodiment of the present invention. The sliding door assembly  10  includes at least one sliding door or door panel  20 , a top E track  30 , and a top guide assembly  100  that connects the sliding door  20  to the top track  30  to guide the sliding door  20  along the top track  30 . The sliding door assembly  10  may also include a second sliding door  20  (not shown) operatively connected to the top track  30  via a second top guide assembly  100 . One top guide assembly  100  is preferably provided for each end (front and back as shown in  FIG. 1 ) of the sliding door  20 . The sliding door assembly  10  also includes a bottom track (not shown) and at least one bottom guide assembly (not shown) that connects the sliding door  20  to the bottom track. The top track  30  and bottom track are secured to a substrate (e.g., floor, ceiling, house frame, etc.) in a parallel, vertically spaced relationship.  
         [0031]     As shown in  FIGS. 1 and 2 , the top track  30  is an elongated structure. The top track  30  has two elongated, parallel, running channels  50 . The running channels  50  are designed to engage the top guide assembly  100  along the top track  30 . It is contemplated that three or more running channels  50  could be provided, depending on the number of sliding doors  20 . As shown in  FIG. 1 , the top track  30  also includes three downwardly projecting legs  60  that create an “E” shape. The legs  60  hide the top guide assembly  100  from view, discourage foreign objects from interfering with the operation of the top guide  100 , and guide the sliding door  20  if the top guide assembly  100  disengages from the channel  50 .  
         [0032]     As shown in  FIG. 2 , the top guide assembly  100  includes a top guide base  110 , a guide arm  120 , a guide wheel  130 , a spring pin  140 , and a spring  150 .  
         [0033]     As shown in  FIGS. 1 and 2 , the top guide base  110  mounts to an upper portion of the sliding door  20 . As shown in  FIG. 3B , the top guide base  110  has a channel  200  that is press fit onto an upper corner of the sliding door  20  (see  FIG. 2 ). Alternatively, the top guide base  110  may be secured to the sliding door  20  in any other suitable fashion (e.g., screws, glue, bolts, etc.). Alternatively, the top guide base  110  may be integrally formed with the sliding door  20 .  
         [0034]     As shown in  FIGS. 2, 3B , and  3 C, two guide arm axles  210  are formed on an inside portion of the top guide base  110  and extend into the channel  200 . The guide arm axles  210  define a guide arm axis  220 . Inner axial ends of the guide arm axles  210  abut the sliding door  20  when the top guide base  110  is mounted to the sliding door  20 . The guide arm axis  220  extends laterally (or horizontally) relative to the sliding door  20  in a direction that is perpendicular to a direction of travel of the sliding door  20 .  
         [0035]     As shown in  FIG. 3A , the top guide base  110  includes a mounting slot  230  that is adapted to securely engage an enlarged head  500  of the spring pin  140  (see  FIGS. 1 and 2 ).  
         [0036]     As shown in  FIGS. 2, 4B , and  4 D, the guide arm  120  has a laterally extending bore  300 . As shown in  FIGS. 2 and 4 D, a laterally extending slot  310  extends between the bore  300  and a lower perimeter of the guide arm  120 . The guide arm  120  pivotally connects to the top guide base  110  when the slot  310  and bore  300  are press fit over the axles  210  so that the bore  300  is concentric with the axles  210  (see  FIG. 2 ). The slot  310  is slightly narrower than the outside diameter of the axles  210  so that the slot  310  holds the axles  210  in the bore  300 . The bore  300  has an inside diameter that is slightly larger than the outside diameter of the axles  210  of the top guide base  110  so that the guide arm  120  can freely pivot relative to the top guide base  110  about the guide arm axis  220 .  
         [0037]     As shown in  FIG. 2 , the range of pivotal movement of the guide arm  120  relative to the top guide base  110  and sliding door  20  is limited by lower portions  320 ,  330  of the guide arm  120 , which abut a top edge of the sliding door  20  when the guide arm  120  reaches its extreme pivotal positions. As shown in  FIGS. 2, 3A ,  3 B, and  3 C, two catch plates  340  formed on the inside of the top guide base  110  and a middle portion  360  of the guide arm  120  also limit the range of pivotal movement of the guide arm  120  relative to the top guide base  110 .  
         [0038]     As shown in  FIGS. 2, 4A ,  4 B,  4 C, and  4 D, a through slot  350  is formed in the middle portion  360  of the guide arm  120  and is designed to slide over the spring pin  140 .  
         [0039]     As shown in  FIGS. 2, 4A , and  4 D, a laterally extending guide wheel bore  370  is formed in an upper portion of the guide arm  120 . A laterally extending slot  380  connects the bore  370  to an upper edge of the guide arm  120 .  
         [0040]     As shown in  FIGS. 1 and 2 , the guide wheel  130  has a laterally extending axle  400  that defines a guide wheel axis  410 . The guide arm axis  220  and the guide wheel axis  410  are parallel to and spaced from each other. The guide wheel  130  pivotally connects to the guide arm  120  when the guide wheel axle  400  is press fit into the slot  380  and bore  370  of the guide arm  120  so that the bore  370  is concentric with the axle  400 . The slot  380  is slightly narrower than the outside diameter of the axle  400  so that the slot  380  holds the axle  400  in the bore  370 . The bore  370  has an inside diameter that is slightly larger than the outside diameter of the axle  400  so that the guide wheel  130  can freely rotate relative to the guide arm  120  about the guide wheel axis  410 .  
         [0041]     While the pivotal connection between the top guide base  110  and guide arm  120  and the rotational connection between the guide arm  120  and the guide wheel  130  comprise axles that are press fit into slotted bores, a variety of other pivotal/rotational connections may alternatively be used. For example, a bolt could be used as an axle and fit through aligned bores in the top guide base and guide arm. A similar bolt axle could be used to pivotally connect the guide arm to the guide wheel. Various other rotational joints that would be known to those of ordinary skill in the art may alternatively be used without deviating from the scope of the present invention.  
         [0042]     As shown in  FIGS. 1 and 2 , the guide wheel  130  includes a central circumferential ridge  450  surrounded by two circumferential shoulders  460 . The circumferential ridge  450  fits into the channel  50  formed in the top track  30 . Opposing inner sides  470  of the channel  50  provide lateral support to the guide wheel  130  to prevent the guide wheel  130  and the sliding door  20  from moving laterally relative to the channel  50 . The circumferential edges of the shoulders  460  abut and roll along the top track  50 . Alternatively, a circumferential edge of the ridge  450  may abut and roll along the top middle of the channel  50 .  
         [0043]     The top guide base  110 , guide arm  120 , and guide wheel  130  are molded and machined parts that preferably comprise a strong light material such as acetal homopolymer, nylon, plastic, etc. The axles  400 ,  210  and bores  300 ,  370  are preferably polished so that the rotational joints facilitate smooth pivotal movement.  
         [0044]     As shown in  FIGS. 1 and 2 , the spring pin  140  has an enlarged head  500  that is secured in the slot  230  formed in the top guide base  110 . Alternatively, the spring pin  140  can have a threaded end that mates with complementary threads on the slot  230 . An opposite end of the spring pin  140  has two radially extending, spaced flanges  510 . The spaced flanges  510  form a stop for the compression spring  150 . The flanges  510  are flexible so that they can be pressed together to reduce their combined outer diameter. The spring pin  140  may be integrally formed with the top guide base  10 .  
         [0045]     Assembly of the top guide assembly  100  is described with reference to  FIG. 2 . The guide arm  120  is pivotally connected to the top guide base  110  by press fitting the bore  300  of the guide arm  120  over the axles  210  of the top guide base  110 .  
         [0046]     The spring  150  is placed on the guide pin  140  and located within a channel formed in the guide arm  120 . The spring  150  contacts the middle portion  360  of the guide arm  120  and the guide pin  140  extends through the slot  350  in the middle portion  360 . The pin  140  is then secured to the slot  230  in the top guide base  110 . As shown in  FIG. 2 , a left end of the spring  140  is supported by the middle portion  360  of the guide arm  120 . The slot  250  in the middle portion  360  of the guide arm  120  is narrower than the diameter of the spring  140  so that the spring  140  does not extend through the slot  350  with the spring pin  140 . Finally, the axle  400  of the guide wheel  130  is press fit into the bore  370  in the guide arm  120 .  
         [0047]     As shown in  FIG. 2 , the entire top guide assembly  100  is then press fit onto an upper corner of the sliding door  20 . The guide arm  120  and guide wheel  130  are then pushed downward relative to the sliding door until the guide wheel aligns with the channel  50  in the upper track  30 , at which point the guide arm  120  and guide wheel  130  are released to allow the guide wheel  130  to engage the channel  50 .  
         [0048]     The operation of the top guide assembly  100  is described with reference to  FIGS. 1 and 2 . As shown by the curved arrows in  FIG. 2 , the guide arm  120  and guide wheel  130  pivot upwardly and downwardly relative to the sliding door  20  and top guide base  110  about the guide arm axis  220 . The compression spring  150  biases the guide arm  120  and guide wheel  130  upwardly (counterclockwise as shown in  FIG. 2 ), which keeps the guide wheel  130  engaged with the channel  50  in the top track  30 . If the top track  30  and bottom track spread away from each other, the guide arm  120  and guide wheel  130  move upwardly so that the guide wheel  130  remains engaged with the channel  50  despite the greater distance between the top track  30  and bottom track. Conversely, if the top track  30  and bottom track converge toward each other over any portion of the sliding door assembly  10 , the guide arm  120  and guide wheel  130  move downwardly and compress the spring  150 . Consequently, the guide wheel  130  remains engaged with the channel  50  and smoothly rolls over the channel  50  regardless of whether or not the top track  30  is perfectly parallel to the bottom track.  
         [0049]      FIGS. 5 and 6  illustrate a sliding door assembly  600  according to an alternative embodiment of the present invention. The sliding door assembly  600  includes a sliding door  610 , a top track  630 , and a top guide assembly  620  that operatively connects the top track  30  to the sliding door  610 .  
         [0050]     The top track  630  is identical to the top track  30  and includes a channel  640  like the channel  50  described above.  
         [0051]     A round bore  650  is formed in an upper portion of the sliding door  610  and extends downwardly from a top edge of the sliding door  610 . As shown in  FIG. 5 , a square bore  660  extends downwardly into the sliding door  610  from the lower end of the round bore  650 . The round and square bores  650 ,  660  are axially aligned. A shoulder  655  is defined by the round bore  650  at the intersection between the round bore  650  and the square bore  660 .  
         [0052]     In the illustrated embodiment, the round and square bores  650 ,  660  are formed directly in the sliding door  610 . Alternatively, the round and square bores may be formed in a top guide base that mounts to a top or side of the sliding door.  
         [0053]     As shown in  FIGS. 5 and 6 , the top guide assembly  620  includes a guide arm  680 , a top guide wheel  690 , a compression spring  700 , and a pin  710 .  
         [0054]     The guide wheel  690  rotationally mounts to an upper, U-shaped portion  730  of the guide arm  680  via the pin  710 , which extends through aligned bores in the guide arm  680  and guide wheel  690 . The pin  710  defines a guide wheel axis  720  about which the guide wheel  690  rotates. The guide wheel axis  720  extends in a generally horizontal direction that is perpendicular to a direction of travel of the sliding door  610 . As in the previously described embodiment, the guide wheel  690  engages the channel  640  formed in the top track  630  to guide the sliding door  610  along the top track  630 .  
         [0055]     While the illustrated rotational joint between the guide wheel  690  and the guide arm  680  comprises a pin  720 , the rotational joint may alternatively comprise any other rotational joint. For example, as in the previously described embodiment, an axle formed on the guide wheel  690  could rotationally engage a slotted bore in the guide arm  680 .  
         [0056]     The guide arm  680  includes an upper U-shaped portion  730  and a lower square pin  740  that extends downwardly from the U-shaped portion  730 . The guide wheel  690  extends into the U-shaped portion  730 . A shoulder  735  is defined by the U-shaped portion  730  at the intersection between the U-shaped portion  730  and the square pin  740 .  
         [0057]     The square pin  740  extends downwardly into the round and square bores  650 ,  660  in the sliding door  610 . The square bore  660  is slightly wider that the square pin  740  so that the guide arm  680  can freely slide upwardly and downwardly in the bore  660 , but cannot pivot about a vertical axis relative to the bore  660 . While the illustrated embodiment utilizes a square pin  740  and a square bore  660 , the pin  740  and bore  660  may alternatively comprise a variety of other mating cross-sectional shapes. For example, the pin  740  and bore  660  may have cross-sectional shapes such as rectangles, “+” signs, etc. that allow relative axial movement but prevent relative pivotal movement.  
         [0058]     The compression spring  700  fits over the square pin  740  and has an inner diameter that is slightly larger than a diagonal width of the square pin  740 . The spring  700  extends into the round bore  650  and has an outer diameter that is slightly smaller than the diameter of the round bore  650 . An upper end of the spring  700  engages the shoulder  735  on the guide arm  680 . A lower end of the spring  700  engages the shoulder  655  of the round bore  650 . Consequently, the spring  700  biases the guide arm  680  and guide wheel  690  upwardly (in the direction of the arrow in  FIG. 5 ) to keep the guide wheel  690  engaged with the top track  630 .  
         [0059]     The top guide assembly  620  preferably includes a mechanism that limits the vertical movement of the guide arm  680  to prevent the guide arm  680  from disengaging from the sliding door  610  under the biasing force of the spring  700 . For example, the mechanism may comprise a laterally extending pin that extends through a slot in the side of the sliding door  610  and into the square pin  740 .  
         [0060]     While the round bore  650  advantageously conceals part of the spring  700 , the round bore  650  may be eliminated altogether without deviating from the scope of the present invention. In such an embodiment, the lower end of the spring  700  would abut the top edge of the sliding door  610 .  
         [0061]     The foregoing description is included to illustrate the operation of the preferred embodiments and is not meant to limit the scope of the invention. To the contrary, those skilled in the art should appreciate that varieties may be constructed and employed without departing from the scope of the invention, aspects of which are recited by the claims appended hereto.