Patent Publication Number: US-6705378-B1

Title: Retractable garage screen

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a retractable garage screen that can be installed inside a garage at a garage door opening where an existing overhead garage door is already installed without interfering with the operation of the existing garage door. The present invention installs just above an existing overhead garage door and employs some of the same hardware used in installing an overhead garage door. The screen door of the present invention is provided with a center zipper that allows the garage screen door to be retracted around the existing sectional door mechanism and also serves as a door for passing through the screen door when the screen door is in use. 
     2. Description of the Related Art 
     Various types of screens have been proposed for installation at a garage door opening. Some of these screens attach directly to the garage door opening via hook and loop closures or other similar means. These screens have the disadvantage that they must be installed on the outside of the garage door opening so as not to interfere with the operation of an overhead garage door that is installed in the opening. Another disadvantage of these types of screens is that they have to be removed in order for a vehicle to be admitted or removed from the garage. And once they are removed, they must be stored somewhere. 
     To address the removal and storage problems, other screens have been designed to be retractable and are mounted on the outside of the garage opening so that they do not interfere with the operation of the overhead garage door that is mounted on the inside of the opening. These screens are visible from the outside of the building and undesirable esthetically. 
     Other screens that have been proposed are integrated into the same track system as the existing overhead garage door. These screens are difficult and expensive to install since the existing overhead garage door and its tracks must be removed and replaced in order to install these types of screens. 
     The present invention addresses all of these problems by providing an inside mounted retractable screen that quickly installs above an existing overhead garage door without modifying or interfering with the existing overhead garage door. The invention is a retractable screen that automatically rolls up above the existing overhead garage door when the screen is not in use. The invention is provided with a vertical center zipper that allows the garage screen to be retracted around the existing sectional door mechanism when the screen is not in use and also serves as a door for passing through the screen when the screen is in use. 
     Further, the present invention can be installed at a low cost because it employs many of the same standard parts employed to install an overhead garage door. Because installers already have many of the standard parts needed to install the present screen, the screen kit can be shipped to installers without those standard parts, thus greatly reducing the size of the shipping package and the shipping costs. 
     SUMMARY OF THE INVENTION 
     The present invention is a retractable garage screen that installs inside a garage at a garage door opening where an existing overhead garage door is already installed. The present invention installs just above an existing overhead garage door without interfering with the operation of the existing garage door. The screen is installed employing some of the same hardware used in installing an overhead garage door and employing some new items. The screen door of the present invention is provided with a center zipper that allows the garage screen door to be retracted around the existing sectional door mechanism and also serves as a door through which people can pass when the screen is in use. 
     The screen door attaches to a pair of rotatable drums via hook and loop fasteners. Each drum is preferably constructed of a length of 3 inch ID schedule 40 PVC pipe. The drums are provided on a tube so that the drums rotate in conjunction with the tube. The tube is rotatably fastened to either the wall of the garage or to the ceiling of the garage adjacent the garage door opening and just above the existing overhead garage door mechanism. The tube fastens to either the wall or ceiling via two end bearing plates and via a center bearing plate. The tube extends beyond a first end bearing plate and is provided with a pulley attached to the tube so that the tube rotates in conjunction with rotation of the pulley. A chain is provided around the pulley as a means of rotating the pulley. If the pulley is manually operated by a chain, a chain locking bracket is attached to the inside of the wall of the garage to removably receive the chain in order to prevent the pulley and tube from rotating. Optionally, although not illustrated, the pulley can be operated via an electric motor instead of by manually pulling the chain. 
     Each of the drums is attached on one end of the drum to the tube via a first end drum hub. These end drum hubs are each provided with threaded bolt openings extending therethrough. Bolts threadably engage these threaded bolt openings and tighten against the tube as a means of securing the end drum hubs to the tube. The bolt openings are located approximately at right angles to each other so that when the bolts tighten in the threaded bolt openings, the bolts engage the tube and thereby secure the end drum hubs to the tube. The end drum hubs are, in turn, secured to the drums via pop rivets that extend through the drums and engage the end drum hubs. 
     One of the drums is provided with a second end drum hub on its opposite end that attaches that end of the drum to the tube in the same manner as described previously for the first end of the drums. 
     The other drum is provided with a specially designed center end cone and spring assembly via which that second drum is supported by the spring assembly which is secured to the tube and to the center bearing plate, as will be described more fully hereafter. 
     The spring assembly consists of the center end cone, a spring tube, a specially designed fastening cone, a spring, and several washers. 
     The center end cone has an approximately 1 inch diameter bearing on one end of the center end cone and is provided with a flange having bolt openings therethrough on the other end of the center end cone. The flange fastens to the center bearing plate via bolts. A spring opening is provided in the center end cone to allow one end of the spring to be attached to the center end cone. 
     The spring tube is approximately 36 inches long and preferably constructed of 2 inch ID PVC pipe. One end of the spring tube is provided with an approximately 1 inch diameter bearing that mates race to race with the bearing provided in the center end cone. 
     The fastening cone has threaded bolt openings extending therethrough to attach the fastening cone to the tube via bolts that engage the threaded bolt openings. The bolts are tightened so that the threaded end of the bolt contacts the tube and thereby secures the fastening cone to the tube. A spring opening is provided in the fastening cone to allow a second end of the spring to be attached to the fastening cone, and via the fastening cone, to the tube. 
     The spring attaches, as previously described, on one end to the center end cone and on its opposite second end to the fastening cone. Several washers are placed around the abutting bearing of the center end cone and bearing of the spring tube to serve as spacers so that the spring, which encircles the spring tube, will not become entangled between the center end cone and the spring tube and will not interfere with the functioning of the underlying bearings. Approximately four washers are needed for this purpose and they prevent the spring from deforming over time. 
     The spring of the spring assembly is prestretched but not preloaded when the spring assembly is attached to the tube and the associated drum is placed over the spring assembly. Prestretching the spring of the spring assembly is necessary because the spring will lengthen as it is loaded, i.e. twisted to place a torque on the spring. The spring is not loaded until the spring assembly is inserted inside the drum. Therefore, if the spring is not prestretched, it would cause the spring to bind in its coils and not function properly. Instead, by prestretching the spring, the spring remains within the drum and provides a torque force to rotate the attached tube, drums, and screen door. 
     The spring tube holds the center end cone and fastening cone apart a specific distance which is normally approximately 2½ to 3 inches longer than the non-stretched spring. The spring manufacturer dictates the specific distance that a particular type of spring should be stretched. The spring is then inserted over the spring tube and the two ends of the spring are fastened to the center end cone and the fastening cone. In order for the ends of the spring to be fastened to the cones, the spring must be stretched. 
     Once the ends of the spring are fastened to the cones, via the spring openings provided in the cones, the spring is prevented from returning to its pre-stretched length by the spring tube which holds the two cones apart. The spring tube engages the center end cone via their respective bearings and engages the fastening cone by a first shoulder provided on the fastening cone for this specific purpose. A second shoulder is provided on the fastening cone to prevent that end of the spring from being pushed off of the fastening cone. Likewise, the flange on the center end cone prevents the spring opposite end of the spring from being pushed off of the center end cone. 
     Opposite ends of the tube are rotatably supported to the inside wall or ceiling of the garage by end bearing plates having bearings therein through which the tube extends. One of the ends of the tube is attached to a pulley that is provided with a pulley chain or other suitable means for rotating the pulley. 
     Once the spring assembly has been attached to the tube and to the center end cone and the tube has been secured via the end bearing plates to the garage wall or ceiling, the spring is then ready to be loaded. This is done by turning the tube via the attached pulley and pulley chain. In order to properly load the spring, the drum should be rotated by the installer approximately ten to fifteen rotations. Once properly loaded, the spring tends to unwind. It is this tendency to unwind that assists the operator in opening the garage screen door. To ensure that the spring does not unwind until desired, the pulley chain is secured to a wall locking bracket provided for this purpose. 
     After the hardware has been thus installed, the garage screen door is then ready to be attached to the drums. Each screen door is provided with two upper portions of the screen door that are preferably constructed of vinyl or other water repellant material. The upper ends of each of the two upper portions of the screen door are provided with a strip of hook and loop fastening tape which mates with a corresponding strip of hook and loop fastening tape provided on each of the drums to thereby removably secure the screen door to the two drums. Hook and loop fastening tape is preferred as a means of securing the screen door to the drums because it allows the screen door to be removed and replaced easily in the event that the screen door becomes damaged and for ease of installation. 
     The remaining lower portions of the screen door are constructed of a woven mesh fabric. One fabric that has been shown suitable for this service is the TEXTILENE® woven polyester fabric available from Unitex or from Twitchell Corporation located at 4031 Ross Clark Circle N.W., Dothan, Ala. 36304. The screen door is provided centrally with a vertically oriented zipper that zips to close the screen door and unzips to allow people to pass through the screen door when the screen door is in use. The zipper also allows the lower portion of the screen door to be unzipped so that the lower portion can be separated in the middle to allow it to pass around a garage door opener bracket that is normally installed centered above the garage door opening. The garage door opener bracket attaches to the garage wall and hardware for a garage door opener mounts to the garage door opener bracket. It is important that the screen door be separated vertically in the middle and that the two halves of the screen door be able to pass around the garage door opener bracket because the tube and drum that support the screen door are installed above the garage door opener bracket within the garage. The various portions of the screen door are secured together with web material and the edges of the screen door are finished by sewing the web material to the screen door. 
     The screen door is provided with a bottom flap to secure the screen door to the garage floor when the screen door is in use. Also, just above the bottom flap, the screen door is provided with a bottom sleeve into which a pipe, tube, or other similar item can be inserted to provide a weight at the bottom of the screen door to further insure that the bottom of the screen door seals to the floor of the garage when the screen door is in use. 
     Optionally, hook and loop fasteners can be attached on the sides of the screen door and to the inside facing of the garage door opening as a means of removably securing the sides of the screen door to the opening when the screen door is in use. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a retractable garage screen constructed in accordance with a preferred embodiment of the present invention, shown installed in a garage along with an overhead garage door. 
     FIG. 2 is a rear view of the retractable garage screen of FIG. 1, shown with the screen in its in use position. 
     FIG. 3 is a rear view of the retractable garage screen of FIG. 2 shown in its retracted position. 
     FIG. 4 is a cross sectional view taken along line  4 — 4  of FIG.  2 . 
     FIG. 5 is a cross sectional view taken along line  5 — 5  of FIG.  3 . 
     FIG. 6 is a detailed cross sectional view of the circled area associated with numeral  6  in FIG.  2 . 
     FIG. 7 is a detailed cross sectional view of the circled area associated with numeral  7  in FIG.  2 . 
     FIG. 8 is a cross sectional view taken along line  8 — 8  of FIG.  7 . 
     FIG. 9 is a side view of the end drum hub illustrated in FIG.  7 . 
     FIG. 10 is an end view of the end drum hub taken along line  10 — 10  of FIG.  9 . 
     FIG. 11 is a side view of the fastening cone illustrated in FIG.  6 . 
     FIG. 12 is an end view of the fastening cone taken along line  12 — 12  of FIG.  11 . 
     FIG. 13 is a side view of the center end cone illustrated in FIG. 6 shown with its associated bearing removed. 
     FIG. 14 is an end view of the center end cone taken along line  14 — 14  of FIG.  13 . 
     FIG. 15 is a cross sectional view taken along line  15 — 15  of FIG.  2 . 
     FIG. 16 is a rear view of the screen door illustrated in FIG. 2 shown detached from the rotatable drums. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT INVENTION 
     Referring now to the drawings and initially to FIGS. 1,  2  and  3 , there is illustrated a retractable garage screen  10  constructed in accordance with a preferred embodiment of the present invention. As illustrated, the retractable garage screen  10  installs inside a garage  12  at a garage door opening  14  where an existing overhead garage door  16  is already installed. The retractable garage screen  10  installs just above an existing overhead garage door  16  without interfering with the operation of the existing garage door  16 . 
     The retractable garage screen  10  is installed employing some of the same hardware used in installing an overhead garage door  16  and employing some new items. As illustrated in FIG. 16, the screen door  18  of the present invention is provided with a center zipper  20  that allows the screen door  18  to be retracted around the existing sectional door mechanism  22  and also serves as a door through which people can pass when the retractable garage screen  10  is in use. 
     The screen door  18  attaches to a pair of hollow, rotatable drums  24  via hook and loop fasteners  26 . Each drum  24  is preferably constructed of a length of 3 inch ID schedule 40 PVC pipe. The drums  24  are secured to a tube  28  which extends through the drums  24  so that the drums  24  rotate in conjunction with the tube  28 . The tube  28  is rotatably fastened to either the wall  30  of the garage  12  or to the ceiling  31  of the garage  12  adjacent the garage door opening  14  and just above the existing overhead garage door mechanism  22 . The tube  28  fastens to either the wall  30  or ceiling via two end bearing plates  32  and via a center bearing plate  34 . A first end  36  of the tube  28  extends beyond the first end bearing plate  32 A and is provided with a pulley  38  attached to the tube  28  so that the tube  28  rotates in conjunction with rotation of the pulley  38 . A chain  40  is provided around the pulley  38  as a means of rotating the pulley  38 . If the pulley  38  is manually operated by the chain  40 , a chain locking bracket  42  is attached to the inside of the wall  30  of the garage  12  to removably receive the chain  40  in order to prevent the pulley  38  and tube  28  from rotating. Optionally, although not illustrated, the pulley  38  can be operated via an electric motor instead of by manually pulling the chain  40 . 
     Each of the drums  24  is attached on a first end  44  of the drum  24  to the tube  28  via a hollow end drum hub  46 . The end drum hubs  46  must be hollow because the tube  28  extends through each of the end drum hubs  46 . Details of the end hubs  46  are illustrated in FIGS. 7,  8 ,  9  and  10 . These end drum hubs  46  are each provided with threaded bolt openings  48  extending there through. Bolts  50  threadably engage these threaded bolt openings  48  and tighten against the tube  28  as a means of securing the end drum hubs  46  to the tube  28 . The bolt openings  48  are located approximately at right angles to each other so that when the bolts  50  tighten in the threaded bolt openings  48 , the bolts  50  engage the tube  28  and thereby secure the end drum hubs  46  to the tube  28 . The end drum hubs  46  are, in turn, secured to the drums  24  via pop rivets  52  that extend through the drums  24  and engage the end drum hubs  46 . 
     One of the drums  24  is provided with a second end drum hub  46 A on its opposite second end  54  that attaches that end  54  of the drum  24  to the tube  28  in the same manner as described previously for the first end  44  of the drums  24 . The second end drum hub  46 A is identical to the end drum hubs  46  previously described. 
     The other drum  24  is provided with a specially designed, hollow, center end cone  56  as a part of a spring assembly  58  via which the second end  54  of that second drum  24  is loosely supported. The spring assembly  58  is secured to the tube  28  and to the center bearing plate  34  with the second drum  24  resting on the spring assembly  58 , as illustrated in FIG.  6  and as will be described more fully hereafter. 
     The spring assembly  58  consists of the center end cone  56 , a hollow spring tube  60 , a specially designed hollow fastening cone  62 , a spiral spring  64 , and several washers and  66 . 
     As illustrated in FIG. 6, a first end  68  of the center end cone  56  has an approximately 1 inch diameter bearing  69  attached to the end  68  and an opposite second end  70  that is provided with a flange  72 . As also illustrated in FIGS. 13 and 14, the flange  72  has bolt openings  74  extending there through. The flange  72  fastens to the center bearing plate  34  via bolts  75  which insert through the bolt openings  74  and engage the center bearing plate  34 . A spring opening  76  is provided in the center end cone  56  into which one end  78  of the spring  64  inserts to attach the spring  64  to the center end cone  56 . 
     Referring again to FIG. 6, the spring tube  60  is approximately thirty six (36) inches long and preferably constructed of 2 inch ID PVC pipe. One end  80  of the spring tube  60  is provided with an approximately 1 inch diameter bearing  82  that mates race to race with the bearing  69  provided in the first end  68  of the center end cone  56  and an opposite second end  83  of the spring tube  60  attaches to the fastening cone  62  via friction. 
     As also illustrated in FIGS. 11 and 12, the fastening cone  62  has threaded bolt openings  84  extending there through to attach the fastening cone  62  to the tube  28  via bolts  86  that engage the threaded bolt openings  84 . Each of the bolts  86  is tightened so that a threaded end  88  of the bolt  86  contacts the tube  28  and thereby secures the fastening cone  62  to the tube  28 . A spring opening  90  is provided in the fastening cone  62  to allow a second end  92  of the spring  64  to be attached to the fastening cone  62 , and via the fastening cone  62 , to the tube  28 . 
     The spring  64  attaches, as previously described, on one end  78  to the center end cone  56  and on its opposite second end  92  to the fastening cone  62 . Several washers  66  are placed around the abutting bearings  69  and  82  of the center end cone  56  and the spring tube  60  to serve as spacers so that the spring  64 , which encircles the spring tube  60 , will not become entangled between the center end cone  56  and the spring tube  60  and will not interfere with the functioning of the underlying bearings  69  and  82 . Approximately four washers  66  are needed for this purpose and they prevent the spring  64  from deforming over time. 
     The spring  64  of the spring assembly  58  is pre-stretched but not preloaded when the spring assembly  58  is attached to the tube  28  and the associated drum  24  is placed over the spring assembly  58 . Pre-stretching the spring  64  of the spring assembly  58  is necessary because the spring  64  will lengthen as it is loaded, i.e. twisted to place a torque on the spring  64 . The spring  64  is not loaded until the spring assembly  58  is inserted inside the drum  24 . Therefore, if the spring  64  is not pre-stretched, it would caus the spring to bind in its coils and not function properly. Instead, by pre-stretching the spring  64 , the spring  64  functions properly to provide a torque force to rotate the attached tube  28 , drums  24 , and screen door  18 . 
     The spring tube  60  holds the center end cone  56  and fastening cone  62  apart a specific distance which is normally approximately 2½ to 3 inches longer than the length of the spring  64  prior to the spring  64  being stretched. The spring manufacturer dictates the specific distance that a particular type of spring  64  should be stretched. The spring  64  is then inserted over the spring tube  60  and the two ends  78  and  92  of the spring  64  are fastened respectively to the center end cone  56  and the fastening cone  62 . In order for the ends  78  and  92  of the spring  64  to be fastened to the cones  56  and  62 , the spring  64  must be stretched. 
     Once the ends  78  and  92  of the spring  64  are fastened to the cones  56  and  62  via the spring openings  76  and  90  provided respectively in the cones  56  and  62 , the spring  64  is prevented from returning to its pre-stretched length by the spring tube  60  which holds the two cones  56  and  62  apart. The first end  80  of the spring tube  60  engages the center end cone  56  via their respective bearings  69  and  82  and a second end  83  of the spring tube  60  engages an end of the fastening cone  62  so that the second end  83  abuts a first shoulder  96  provided on the fastening cone  62  for this specific purpose. A second shoulder  98  that is larger in diameter than the first shoulder  96  is provided on the fastening cone  62  adjacent to the first shoulder  96 . The second end  92  of the spring  64  rests against the second shoulder  98 , and the spring  64  is stretched between the two cones  62  and  56 . 
     Opposite ends  36  and  36 A of the tube are rotatably supported to the inside wall  30  or ceiling of the garage  12  by a pair of end bearing plates  32  and  32 A having bearings  100  and  100 A therein through which the tube  28  extends. The first end  36  of the tube  28  is attached to the pulley  38  that is provided with the pulley chain  40  or other suitable means (not illustrated) such as for example a motor, for rotating the pulley  38 . 
     Once the spring assembly  58  has been attached to the tube  28  and to the center end cone  56 , the tube  28  has been secured via the end bearing plates  32  and  32 A to the garage wall  30  or ceiling, and the drums  24  have been secured to the tube  28 , the spring  64  is then ready to be loaded. This is done by turning the tube  28  via the attached pulley  38  and pulley chain  40 . In order to properly load the spring  64 , the chain  40  should be pulled by the user or installer casusing the drum to rotate approximately 10 to 15 revolutions. Once properly loaded, the spring  64  tends to want to unwind. It is this tendency to unwind that assists the operator in opening the screen door  18 . To ensure that the spring  64  does not unwind until desired, the pulley chain  40  is secured to the wall locking bracket  42  provided attached to the wall  30  of the garage  12  for this purpose. 
     After the hardware has been thus installed, the screen door  18  is then ready to be attached to the drums  24 . Each screen door  18  is provided with two upper portions  104  of the screen door  18  that are preferably constructed of vinyl or other water repellant material. As illustrated in FIG. 15, upper ends  106  of each of the two upper portions  104  of the screen door  18  are provided with a strip of hook and loop fastening tape  26 A which mates with a corresponding strip of hook and loop fastening tape  26 B provided on each of the drums  24  to thereby removably secure the screen door  18  to the two drums  24 . Hook and loop fastening tape  26  comprised of the two mating portions  26 A and  26 B is preferred as a means of securing the screen door  18  to the drums  24  because it allows the screen door  18  to be removed and replaced easily in the event that the screen door  18  becomes damaged. 
     The remaining two lower portions  108  of the screen door  18  are constructed of a woven mesh fabric. One fabric that has been shown suitable for this service is the TEXTILENE® woven polyester fabric available from Unitex or from various suppliers. The lower portions  108  of the screen door  18  are separated by the zipper  20  that is centrally located and vertically oriented. The zipper  20  zips to close the two lower portions  108  and unzips to allow people to pass through the screen door  18  when the screen door  18  is in use. The in use position  110  of the retractable garage screen  10  is illustrated in FIGS. 1,  2  and  4  where the screen door  18  is extended to the floor  112  of the garage  12 . The zipper  20  also allows the lower portions  108  of the screen door  18  to be unzipped so that the lower portions  108  can be moved to its retracted position  113  when the screen door  18  is not in use, as illustrated in FIGS. 3 and 5. The zipper  20  unzips to separate the lower portions in the middle, thereby allowing the lower portions  108  of the screen door  18  to pass around a sectional door mechanism  22  and a garage door opener bracket  114  that are normally installed centered above the garage door opening  14 . The sectional door mechanism  22  and the garage door opener bracket  114  each attaches to the garage wall  30 . Hardware for a garage door opener mounts to the garage door opener bracket  114 . It is important that the lower portions  108  of the screen door  18  be separated vertically in the middle and that the two halves of the screen door  18  be able to pass around the sectional door mechanism  22  and the garage door opener bracket  114  because the tube  28  and drums  24  that support the screen door  18  are installed above both the sectional door mechanism  22  and the garage door opener bracket  114  within the garage  12 . The various portions  106  and  108  of the screen door  18  are secured together with web material  116  and the side edges  118  of the screen door  18  are also finished by sewing web material  116  to the side edges  118 . 
     The screen door  18  is provided with a bottom flap  120  to seal the screen door  18  to the garage floor  112  when the screen door  18  is in use. Also, just above the bottom flap  120 , the screen door  18  is provided with a bottom sleeve  122  into which a pipe, tube, or other similar item  124  can be inserted to provide weight at the bottom flap  120  to further insure that the screen door  18  seals against the floor  112  of the garage  12  when the retractable garage screen  10  is in its in use position  110 . 
     Optionally, although not illustrated, additional hook and loop fasteners can be attached on the side edges  118  of the screen door  18  and to the inside facing of the garage door opening  14  as a means of removably securing the side edges  118  of the screen door  18  to the opening  14  when the retractable garage screen  10  is in its in use position  110 . 
     While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for the purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.