Patent Publication Number: US-2018044977-A1

Title: Rolling door construction for controlling air leakage

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This is a utility application based on provisional application Ser. No. 62/374,329 filed Aug. 12, 2016 entitled “Rolling Door Construction for Controlling Air Leakage for which priority is claimed. 
    
    
     BACKGROUND OF THE INVENTION 
     In a principal aspect the present invention relates to overhead, rolling door constructions which incorporate a seal assembly to control leakage of air flow through the periphery of a door opening when the door opening is closed by the door construction. 
     The International Energy Conservation Code (IECC) is a model building code initiated by the International Code Counsel (ICC) in 2000. Many states and municipal governments in the United States adopted the model code which sets forth minimum building design and construction requirements to promote energy efficiency. The United States Department of Energy has been instrumental in proposing building codes to the ICC designed to achieve the goals of the IECC. 
     A recent publication of IECC code proposals is directed to the requirement of limiting air leakage through openings closed by doors, windows and the like. Various standards are set forth in the proposed code sections based on the type of fenestration or opening which is involved, the type of doors or closure devices that are affected and various other scientific and engineering factors. The standards and goals that are set with respect to IECC code provide builders, manufacturers of products and others with guidance regarding functional parameters that are considered to achieve energy conservation goals. As such, manufacturers, contractors and others have developed techniques designed to meet the code standards. Such techniques include the following representative patents: 
     
       
         
           
               
               
               
             
               
                   
               
             
            
               
                 PATENT NO. 
                 ISSUE DATE 
                 TITLE 
               
               
                   
               
               
                 4,357,978 
                 Nov. 9, 1982 
                 Roller Shade Seal System 
               
               
                 5,201,530 
                 Apr. 13, 1993 
                 Multi-Layered Brush Seal 
               
               
                 5,205,334 
                 Apr. 27, 1993 
                 Double Layer Shade 
               
               
                 5,445,209 
                 Aug. 29, 209 
                 Guide System for Vertically 
               
               
                   
                   
                 Moveable Flexible Door 
               
               
                 6,129,130 
                 Oct.10, 2000 
                 Door Edge Debris Block and 
               
               
                   
                   
                 Air Seal 
               
               
                 6,152,279 
                 Nov. 28, 2000 
                 Strip Barrier Brush Assembly 
               
               
                 6,425,472 
                 Jul. 30, 2002 
                 Strip Barrier Brush Assembly 
               
               
                 6,595,344 
                 Jul. 22, 2003 
                 Strip Barrier Brush Assembly 
               
               
                 7,086,442 
                 Aug. 8, 2006 
                 Garage Screen Door System 
               
               
                 8,505,923 
                 Aug. 13, 2013 
                 Brush Seal with Stress and 
               
               
                   
                   
                 Deflection Accommodating 
               
               
                   
                   
                 Membrane 
               
               
                 8,882,050 
                 Nov. 11, 2014 
                 Railway Track and Switch 
               
               
                   
                   
                 Weather Protection Barrier 
               
               
                   
                   
                 System 
               
               
                 9,068,655 
                 Jun. 30, 2015 
                 Quick Change Brush Seal 
               
               
                   
                   
                 Retaining Arrangement 
               
               
                 9,140,363 
                 Sep. 22, 2015 
                 Brush Seal Cover Assembly 
               
               
                   
               
               
                 PUBLICATION NO. 
                 PUBLICATION DATE 
                 TITLE 
               
               
                   
               
               
                 2003/0096114 
                 May 22, 2003 
                 Method of Fabricating a 
               
               
                   
                   
                 Non-Hollow Fiber Having a 
               
               
                   
                   
                 Regular Polygonal Cross- 
               
               
                   
                   
                 Section 
               
               
                 2008/0309017 
                 Dec. 18, 2008 
                 Environmental Brush Seal 
               
               
                 2010/0083581 
                 Apr. 8, 2010 
                 Environmental Brush Seal 
               
               
                 2015/0082704 
                 Mar. 26, 2015 
                 Roll-Up Door Seal 
               
               
                 2015/0197985 
                 Jul. 16, 2015 
                 Overhead Door With Lintel 
               
               
                   
                   
                 Seal Interface System 
               
               
                 EP 1 213 435 A2 
                 Jun. 12, 2001 
                 Roller Shutter Box 
               
               
                 EP 2 290 266 B1 
                 Sep. 19, 2012 
                 Brush Seal with Stress and 
               
               
                   
                   
                 Deflection Accommodating 
               
               
                   
                   
                 Membrane 
               
               
                   
               
            
           
         
       
     
     While such disclosures are considered helpful, there remains the need to provide designs and constructions, particularly of doors used in combination with larger openings that will exhibit improved energy efficiency characteristics and restriction of heat loss through building openings such as doors and windows. 
     SUMMARY OF THE INVENTION 
     Briefly, the present invention is directed to an overhead, rolling door seal construction which restricts air flow, through the periphery of an opening closed by the rolling door. Overhead rolling doors are a type of door wherein a flexible curtain serves as a closure for the door opening. The curtain is designed to be flexible so that it can be wound on a drum or shaft positioned over the top or header of a door opening. Typically the curtain is fabricated from a combination of various materials designed to unfold from an overhead storage drum construction and be guided downward by channels or slots affixed to door jambs on opposite sides of the door opening as the closure curtain is lowered. Leakage through or around the edges of the closure panel or curtain may result in undesirable air and heat flow from or into the structure forming the door opening. 
     The present invention comprises a mechanism wherein the door jambs and a header form a door opening in combination with a base pad or floor. A flexible curtain mounted on an overhead drum or mandrel or shaft is typically fully wound on the drum or shaft or mandrel to open the door and may be unwound from the drum to close the door opening. Features which are included in order to preclude air flow and energy loss through the door opening include elastomeric, elongate blades mounted on rigid plates or brackets positioned around the periphery of the door opening. The blades function as seals that are flexible with an outer end that fits against the surface of the closed door. The blades include an inner end affixed to the assembly of brackets and plates mounted on the door jambs and header that define the door opening. 
     Thus, the elastomeric blades project as cantilever extensions from the brackets with their outer edges aligned, both vertically and horizontally, so that the blades will uniformly and continuously engage the surface of the curtain thereby forming a peripheral seal that provides a flexible coplanar sealing edge positioned against the surface of the closed door curtain which has been lowered into place to cover the opening. By choosing appropriate material to form the cantilever projecting blades in combination with the design and construction of the blade mounting brackets, a coplanar relationship of the outer sealing edges of the blades is maintained for cooperative engagement with a surface of the curtain that is lowered to close the opening. The blades thus comprise a unique shape, dimensional profile, flexibility and hardness to effect sealing of a closed door. 
     Thus, it is an object, aspect and feature of the invention to provide an improved seal construction which precludes air flow through the sides of a rolling curtain door when the door is in the closed position. 
     A further aspect of the invention is to provide an easily installed and maintained sealing system for a rolling door construction of the type wherein the door is maintained on an overhead drum and is positioned to close the door opening upon unwinding from the drum. 
     Yet another object, advantage and feature of the invention is to provide a door seal construction or assembly which can be customized depending upon the size and configuration of a door. 
     Another object, aspect and feature of the invention is to provide a sealing assembly in a kit form to accommodate overhead rolling doors of various sizes and materials. 
     An additional object of the invention is to provide a sealing assembly for an overhead rolling door which is easily installed, repaired, reasonably priced, and durable. 
     These and other objects, advantages and features of the invention are set forth in a detailed description of an embodiment of the invention as follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       In the detailed description which follows, reference will be made to the drawing comprised of the following figures: 
         FIG. 1  is a front elevation view of a rolling overhead door which employs the subject matter of the invention; 
         FIG. 2  is a sectional view of the door of  FIG. 1  taken along the line  2 - 2 ; 
         FIG. 3  is a sectional view of a roller curtain mounted in a drum depicting the manner in which the curtain is positioned within the drum and engaged by a seal; 
         FIG. 4  is a schematic sectional view of the roller curtain of  FIG. 3  depicting a baffle feature; 
         FIG. 5  is a sectional detail view of the slat assembly of the roller curtain; 
         FIG. 6  is an exploded partial perspective view of the rolling door construction depicting the various sealing assembly components; 
         FIG. 7  is a side elevation of a bracket member utilized in combination with a seal for mounting on the header of a door opening; 
         FIG. 8  is a sectional view of a seal used in combination with the bracket of  FIG. 7  to provide a seal along the header of a rolling door; 
         FIG. 9  is a sectional view of the combination of a seal of  FIG. 8  with the bracket of  FIG. 7 ; 
         FIG. 10  is a sectional view of the seals supported by the guides of the door opening; 
         FIG. 11  is a detail sectional view of the brackets and seal of the assembly of  FIG. 10 ; 
         FIG. 12  is a detail sectional view depicting the floor seal assembly for the bottom edge of the rolling door guide assembly with a floor or planar surface; and 
         FIG. 13  is a perspective detail view of an edge seal incorporated along the bottom edge of the rolling door to provide a seal against the floor of the door opening. 
     
    
    
     DESCRIPTION OF AN EMBODIMENT OF THE INVENTION 
     Referring to the figures there is depicted an opening  10  in a building construction.  FIGS. 1, 2, 6 and 10  depict the inclusion of a building door opening  10  incorporating a roller door assembly embodiment of the invention. The opening  10  is typically comprised of a frame including a header  12  horizontally extending across the top of the opening  10  connected to or joined to first and second, spaced lateral vertical side jambs  14  and  16 . The jambs  14  and  16  are typically parallel to one another and perpendicular to the header or head  12 . The opening  10  is further bounded by a floor  15  which is typically horizontal and generally parallel to the header  12  at the top of the opening  10 . 
     A rolling door curtain  18  is mounted on a drum  19  in a housing  20 . The housing  20  is mounted on the header  12  above the opening  10 . The drum  19  includes a rotatable mandrel or shaft  22  extending between opposite side walls of the drum  19 . The shaft or mandrel  22  of the drum  19  is typically powered to rotate about an axis  21  and thereby lower or raise the flexible curtain  18 . The drum  19  and curtain  18  exceed the width of the opening  10  and are typically mounted on the inside or outside structure comprising the opening  10 . Thus, the curtain  18  is designed to cover the opening  10  when the curtain  18  is lowered by unwinding the curtain  18  mounted on the shaft  22  in the housing  20 . A flexible hood baffle  11  affixed at one end to a semi-cylindrical curtain restrainer is biased against the curtain  18  wound on drum  19 . 
     Referring to  FIGS. 3 and 5 , the curtain  18  may be comprised of articulating or hinged segments  26  which enable the curtain  18  to be flexed or articulated and wound on the drum  19 . The hinge segments  26  are typically longitudinal panels or elements of narrow width joined together by flexible hinge elements  27 ,  28  so that the segments  26  may articulate one with respect to the other. The elements, e.g.,  27 ,  28  may be formed as tubular with an insulating material core. This configuration and assembly of the curtain  18  enables the top side of the curtain  18  to be affixed to the shaft or mandrel  22  and wound onto that shaft or mandrel  22 . The drum  19  is sized so that it will easily receive the fully wound curtain  18  on the drum  19 . The curtain  18  is thus protected within the drum  19  and may exit through a slot  23  along the bottom edge of the drum  19 . The curtain  18  may include additional aspects or features such as a layer of a flexible sheet or fabric material  29  affixed thereto to facilitate the closure and also facilitate preclusion of air flow through the curtain between the segments  26 . As depicted in  FIGS. 1 and 2  the curtain  18  is sized to be lowered from the drum  19  so that it will cover the entire opening  10  and extend beyond the lateral side edges or jambs  14 ,  16  of the opening  10 . The vertical dimension of the curtain  18  is greater than the vertical height of the opening  10 .  FIG. 10  is a sectional view which depicts vertical curtain assembly of the component parts for guiding the curtain  18  slidably into spaced, first and second vertical slotted track assemblies  31 ,  32  affixed respectively to the spaced jambs  14  and  16 . The vertical guide assemblies  31 ,  32 , mounted on the vertical spaced jambs  14 ,  16 , provide a means to guide the curtain  18  as it is downloaded from the drum  19  so that the curtain  18  will be sealed against and cover the side edges of the opening  10 . 
     A transverse or horizontal seal assembly comprising a bracket  33  and seal  35  is attached to the header  12  as depicted in  FIG. 4 . The header, transverse, bracket assembly, comprised of flexible seal  35  and retainer bracket  33 , is designed to support the flexible transverse seal member  35  positioned against the face of the curtain  18  and thereby seal the top of the curtain  18  so that air flow may not pass outwardly between the curtain  18  and the opening  10 . The transverse seal  35  attached to the header  12  and the vertical guide assemblies  31 ,  32 , which support laterally projecting seals  38 ,  40  attached respectively thereto, provide a seal arrangement wherein flexible seal members  35 ,  38 ,  40  attached respectively to the transverse bracket  33  and to the first and second vertical guide assemblies  31 ,  32  are positioned to preclude air flow between the closed curtain  18  and the opening  10 . The seals  35 ,  38 ,  40  associated respectively with the transverse bracket  33  and with the vertical guide assemblies  31 ,  32  are comprised of substantially the same seal material such as a vinyl material and are mounted to provide seal engagement along the face of curtain  18  along the entire periphery of the vertical sides of the curtain  18  and the top of the curtain  18 .  FIG. 10  depicts in a sectional view the positioning of the vertical, curtain channel guide slot brackets  31 ,  32  and the associated seal  38 ,  40  constructions. 
     Referring again to  FIG. 4 , the transverse bracket assembly  33  including seal  35  is attached to the header  12 .  FIGS. 7, 8 and 9 , depict the seal  35  in greater detail. Referring to  FIGS. 6 and 10 , the first and second lateral side seal assemblies  31 ,  32  associated with the side jambs  14 ,  16  are depicted in a sectional view. Additionally, a horizontal floor seal assembly  42 , associated with the lower or bottom edge  44  of the curtain or rolling door  18 , is depicted in  FIG. 13 . 
     Referring therefore to  FIGS. 4, 7, 8 and 9 , the transverse header bracket  33  is affixed to the header  12 . The bracket  33  is typically made from a metal extrusion and has a cross section configuration which includes a first generally horizontal section or plate  46  connected at a right angle to a vertical run or plate  48  that, in turn connects at a right angle to a lateral run or plate  50  having a recess opening  52  incorporated at the distal end thereof. The various plates or sections  46 ,  48 ,  50  of the bracket  33  may be adjustable or pre-manufactured to provide for different extensions of the outwardly extending seal  35  support run or cantilever extension  50 . The seal support run  50  is configured to cooperate with seal  35  as depicted in  FIG. 8 . The seal  35  includes an elongate, tapered, flexible elastomeric section  54  coupled to an attachment configured end section  56  designed to cooperate with and be retained by the seal retention slot or opening  52  of bracket  33 . The combination of these two components, bracket  33  and seal  35 , is depicted in  FIG. 9 . 
       FIGS. 7, 8 and 9  are thus illustrative of the construction of a unitary, generally constant cross section header seal bracket assembly. Varied structure design features may be employed with respect to these component parts. For example, the configuration and extent of the various runs or sections of the header bracket  33  may be customized for a particular opening size and construction and header configuration. The configuration of the seal retention pocket  52  may be customized for cooperation with the seal coupling end or section  56 . The seal  35  may have a customized configuration and may be provided in adjustable lengths between an attachment end  57  and the distal outer end  39 . Importantly, the seal  35  is flexible and may vary in length depending upon the width of the header opening  10  that is to be closed. Thus, the header seal assembly employs a constant cross section along the horizontal length thereof extending beyond the width of the door opening  10 . 
       FIG. 4  illustrates in detail the manner in which the bracket and seal assembly  33 ,  35 , attached to the header  12 , interacts with the curtain  18 . That is, the seal  35  projects from the pocket  52  of the support bracket  33  and extends outwardly so that the flexible end  57  of the seal  35  may be engaged by the curtain  18  as the curtain descends from the drum  19  through the slot  23  as it is discharged from the drum  19 . Because of the choice of the length of the seal  35  and the fact that it is positioned above the opening  10  at the entry of the curtain  18  in opposition to the opening  10 , the seal  35  will flex in a manner which augments the effect of the seal  35 . That is, the seal  35  is thus biased or compressed against the curtain  18  surface to enhance the ability of the seal  35  to preclude undesired air flow through the opening  10  between the curtain  18  and the header  12 . 
       FIGS. 6, and 10-12  depict the design of the vertical seal assemblies comprised of brackets and channel members  31 ,  32  with attached lateral side seals  38 ,  40  that engage the outside face of the curtain  18 . The vertical seal and bracket assemblies comprise generally mirror images of one another positioned on opposite lateral sides of the opening  10 . Specifically, in the embodiment depicted, each vertical guide seal bracket  31 ,  32  is comprised of three L-shaped cross section members  59 ,  60 ,  62 . The first bracket member  59  and the second bracket member  60  each include a leg section  63 ,  64  respectively which fit one against the other to provide a space  70  for receipt of the sliding curtain  18 . The first and second section members  59 ,  60  thus are designed to extend from the floor  15  to above the top of the opening  10  in opposition to a jamb  14  or  16 . The section members flare outwardly and diverge to end  23  to receive the curtain  18 . A third attachment bracket member  62  is also L-shaped and has one leg  63  thereof fixed to a jamb  14  or  16  and a second leg  64  coupled with the bracket, channel members  59 ,  60  comprising the curtain channel  70 . Importantly, the members  59 ,  60  defining the channel  70  are uninterrupted and extend from the floor  15  to the region above the opening  10 . The support bracket  62  is fastened to the other bracket assembly members  59 ,  60  joined by a fastener  75 . But support bracket or brackets  62  need not extend the entire distance or space between the floor  15  to the header  12 , however, the channel bracket does extend the full height of the opening and appropriately above the opening height so that seals  38 ,  40  will seal against header seal  35  when the door is closed. 
     The bracket member  60  of the vertical bracket assembly include respectively the seal members  38 ,  40  attached thereto and projecting to engage the sliding door curtain  18 . It is to be noted that outer edge  78  of the seal members  38 ,  40  associated with the vertical brackets as well as the seal member  35  supported by the header bracket  33  lie in a single plane to provide a complete peripheral seal against the door  18  when closed. 
     As an additional feature of the invention, a floor seal  42  depicted in  FIG. 13  is provided along the bottom edge  44  of the curtain  18 . Typically the floor seal  42  is a flexible elastomeric material such as a neoprene tubular material retained in position by first and second, back-to-back facing L-shaped brackets  82 ,  84  which facilitate squeezing on the floor seal  42  when the door or curtain  18  is lowered. 
     Variations include positioning the rolling door on the inside or outside of the frame. Multiple seals may be arrayed in parallel on the header and jambs along the periphery thereof for engagement with the rolling door in the closed position. Multiple flexible seal materials may be utilized. The seals may incorporate multiple outer end or tip constructions to enhance the sealing function. 
     While an embodiment of the invention is set forth herein, the invention is limited only by the following claims and equivalents thereof.