Patent Publication Number: US-6698492-B2

Title: Hinge guard for overhead door

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to overhead doors and, more particularly, to guard for the hinge assemblies on an overhead. 
     There are numerous designs of overhead or retractable door assemblies which are commonly used for garage doors, truck doors, warehouse doors or the like. Typically, an overhead door of this type is convertible between an open, overhead or generally horizontal configuration and a closed generally vertically oriented configuration in which the door closes an opening in the building or the like. The overhead door is typically movable along a track assembly mounted proximate the opening and the track assembly commonly includes a generally vertical track section, a generally horizontal track section and a curved transition track section joining the horizontal and vertical sections together. 
     Retractable overhead doors of this type are conventionally constructed of a number of vertically arranged, horizontally oriented panels which can fold along the horizontal divisions between the panels to enable the door to pass along the curved transition section of the track when being opened or closed. The panels are pivotally coupled together with hinges on the interior surface or back face of the door panels. Commonly, gaps appear between the adjacent panels while the panels are traveling toward and/or through the curved transition section of the track. Additionally, the hinges articulate during pivotal movement of the panels and gaps or spaces relative to the hinge assembly change, close and/or constrict. Foreign objects could be inserted into these gaps by accident or due to improper handling of the door which could result in damage to the door and/or the obstructing object. 
     Recently, many different overhead door designs have been suggested which are aimed at addressing this situation. These types of door designs often include complicated structures which cover the gaps between the articulating panels or involved and complicated panel geometries to minimize or inhibit the insertion of a probe or other foreign object between the adjacent articulating panels. One beneficial design to minimize the gaps between adjacent panels is disclosed in U.S. Pat. No. 6,006,817, assigned to the assignee of this invention and hereby incorporated by reference in its entirety. 
     Nevertheless, while the gaps between the adjacent door panels have been addressed by the invention in the above-identified patent, the gaps relative to the hinges and adjacent components may still provide an opportunity for the insertion of foreign objects which could lead to damage to the door, hinge components and/or the obstructing object. 
     Therefore, there is a need in the industry for an improved overhead door and associated panels and hinge assemblies which minimizes the opportunity for the insertion of foreign objects and the resulting damage relative to the hinge assemblies and associated components. 
     SUMMARY OF THE INVENTION 
     Presently preferred embodiments of this invention offer these and other advantages over known overhead door, panel and hinge designs. In one embodiment, this invention includes a number of horizontally oriented panels vertically stacked one upon the other in edge-to-edge relationship. 
     The panels are coupled to a track assembly mounted proximate the garage, warehouse, truck or other opening. The track assembly includes a generally vertical section, a generally horizontal section and a curved transition section joining the horizontal and vertical sections together. Rollers are mounted on the panels and coupled to the track assembly to guide the door between a closed generally vertical configuration with the upper and lower edges of the adjacent panels mated together and an open generally horizontal configuration extending generally parallel to the ceiling of the garage or the like. 
     One aspect of this invention includes a hinge guard which is to be used in conjunction with each of the hinges of a multi-panel or sectional garage door. The hinge guard in one embodiment is constructed of molded polypropylene and can be used as a accessory or add-on feature to the hinge of the door or as original equipment for the door. 
     The hinge guard of this invention includes a base that is screwed, bolted or otherwise secured to a lower one of the door panels or a stile on the lower panel. The hinge guard in one embodiment is secured with a screw or other bolt extending through a central aperture in the base. The base is generally rectangular and has a generally flat or planar lower surface and a smoothly rounded boss is formed on the upper surface. The base is designed and configured to fit between the spaced hinge arms of an upper hinge leaf of the hinge design. 
     The hinge guard also includes a pair of protective side flanges that are each connected by a bridge to a common edge of the base. Each flange extends generally parallel to a respective side of the base and is spaced from the side to provide a gap through which one of the hinge arms of the upper hinge leaf pivots. The protective flanges are positioned on the outboard or external side of the hinge arms to thereby block or inhibit a foreign object from interfering with the movement of the hinge arms during articulation of the hinge. 
     In one embodiment of the hinge guard that is specifically designed for an intermediate hinge on the door, each protective flange has a smoothly continuous contour; whereas, in an alternative embodiment of the hinge guard specifically designed for use with a hinge that incorporates a roller tube, the protective flanges include a step to accommodate positioning of the roller tube mounted on the hinge leaf. 
     The hinge guard design provides principally two features to inhibit interference with the articulation of the hinge. Firstly, the protective outboard flanges inhibit the insertion of a foreign object into the hinge from the side. Secondly, the raised arcuate-molded contour of the boss minimizes the space or clearance between the upper hinge leaf and the lower door panel during articulation of the hinge to thereby inhibit the insertion of foreign matter in this region of the hinge. 
     Therefore, with this invention, the regions of the mating edges of adjacent panels or hinges in an overhead door which normally would have gaps or spaces providing an opportunity for the insertion of foreign objects therein and potential damage are protected. As a result, the required mating configuration, interrelation and compatibility of the adjacent panels to achieve the design parameters are maintained and opportunities for damage to and/or from foreign objects during opening and closing of the door is minimized. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a perspective view of a pair of adjacent panels of an overhead door with a hinge assembly and hinge guard according to a first embodiment of this invention; 
     FIG. 2 is a top plan view of the hinge guard of FIG. 1; 
     FIG. 3 is a cross-sectional view taken along line  3 — 3  of FIG. 1; 
     FIG. 4 is a view similar to FIG. 3 with the door panels pivoted relative to one another; and 
     FIGS. 5 and 6 are perspective views of a second embodiment of the hinge guard and hinge guard with hinge and roller assembly, respectively. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1, a presently preferred embodiment of a portion of an overhead door  10  according to this invention is shown in a closed generally vertical configuration covering an opening in a wall (not shown) of a garage, warehouse or the like. The door  10  includes a plurality, two of which are shown in FIG. 1, of panels  14 . Each panel  14  includes upper and lower generally horizontally oriented edges  16 ,  18  which are configured to mate with the lower and upper edges  18 ,  16  respectively, of an adjacent panel  14  when the door  10  is in the closed configuration as shown in FIG.  1 . 
     The adjacent panels  14  are pivotally connected together by a number of hinge assemblies  20 . The hinges  20  proximate the lateral side ends of each panel  14  include a roller assembly  12  (FIG. 6) for coupling the door  10  to a track assembly (not shown). The roller assemblies  12  each include a roller  22  mounted for rotation on a shaft  24  contained in a roller tube  26  seated in holes  28  in upright tabs  30  of each hinge  20 . The hinges  20  are mounted on the panels  14  with fasteners such as screws or bolts  31  and the roller assemblies  12  couple to the track assembly to guide the door  10  between the closed and open configurations. 
     Referring to FIGS. 1,  3 , and  4 , the upper and lower edges  16 ,  18  of the panels  14  are each finished with a rail  32  joined to the respective edges  16 ,  18 . The rail  32  includes a back face  36  which is generally parallel to a panel front face  38  and a terminal lip  40  which projects perpendicularly to the back face  36  and toward the front face  38 . The lower edge  18  of each panel  14  according to a presently preferred embodiment of this invention has a generally concave configuration for mating with the upper generally convex-shaped edge  16  of an adjacent panel  14 . 
     A rounded nose  42  is at the junction between the front face  38  of the panel  14  and the lower edge  18 . At the juncture between the front face  38  and the upper edge  16  of the panel  14  is a shoulder  44  providing a landing area for the nose  42  when the door  10  is in the closed configuration as shown in FIG.  1 . In the closed configuration, the nose  42  on the lower edge  18  of the panel  14  normally contacts the shoulder  44  on the upper edge  16  of the adjacent panel  14  at the front faces  38  of the panels  14  thereby providing a first contact location between the mating adjacent panels  14 . 
     A second contact location between the adjacent upper and lower edges  16 ,  18  of the panels  14  according to one embodiment of this invention is proximate the back face  36  of the panels  14  and includes an obliquely angled or, more specifically, a downwardly sloping interface between the upper and lower edges  16 ,  18  when the door  10  is in the closed configuration. A more detailed disclosure of the panel configuration according to one embodiment of this invention is found in U.S. Pat. No. 6,006,817, assigned to the assignee of this invention and hereby incorporated by reference in its entirety. Nevertheless, this invention is readily employed on a panel design of another configuration. 
     Referring particularly to FIGS. 1,  3  and  4 , the hinge assembly  20 , according to a presently preferred embodiment of this invention, includes a first hinge leaf  20   a  which is attached to a stile  46  proximate the lower edge  18  of one panel  14 . The hinge  20  includes a pair of spaced and parallel generally L-shaped arms  34  between which the stile  46  proximate the upper edge  16  of the panel  14  is positioned. A pivot member  48 , such as a pivot pin is inserted through holes  50  in the arms  34  and aligned holes  52  in the stile  46 . The hinge leaf  20   a  is attached to the superjacent panel  14  by bolts, screws or other mechanical fasteners  31 . The fasteners  31  are shown in FIG. 1 as being arranged vertically on the hinge leaf  20   a ; however, preferably the fasteners  31  are arranged horizontally (FIG. 6) and project through holes  54  in the hinge leaf  20   a  to minimize rocking and flexure of the panels  14  during opening and closing of the door  10 . Preferably, upper and lower ends of each of the stiles  46  each include a tab  56  which is juxtaposed to the back face  36  of the panel  14  (FIGS.  3 - 4 ). 
     As can be readily seen in FIG. 4, the pivot pin  48  provides a pivot axis for the hinge assembly  20  which is located within the profile of the panel  14  and inwardly of the back face  36  of the panel  14  and between the back face  36  and front face  38  thereof. Advantageously, positioning the pivot pin  48  and pivot axis of the hinge  20  inwardly from the back faces  36  of the panels  14  helps to minimize the spacing between the upper and lower edges  16 ,  18  of the adjacent panels  14  during articulation of the panels  14  while opening and closing the door  10 . 
     Referring to FIGS. 1-4, one embodiment of a hinge guard  60  according to this invention is shown installed on the hinge assembly  20  of an overhead door  10 . The hinge guard  60  includes a generally rectangular base  62  having a generally planar surface. A smoothly continuous arcuate-shaped boss  64  is formed to project upwardly from the base  62 . An aperture  66  is formed through the boss  64  and is adapted to have a mechanical fastener  68  such as a screw, bolt, or the like inserted therethrough to secure the hinge guard  60  to one of the panels  14  and preferably, the stile  46  on a subjacent panel  14  and is shown in FIGS. 1 and 4. 
     The hinge guard  60  also includes a pair of protective flanges  70 , each of which has a generally planar lower surface and a smoothly continuous contoured upper surface. Each flange  70  is spaced from an adjacent side edge of the base  62  to form a gap  72  therebetween. Likewise, each flange  70  is connected to the base  62  by a bridge  74  as clearly shown in FIG.  2 . In one embodiment of this invention, the hinge guard  60  is integrally molded from polypropylene. The base  62  has a generally rectangular configuration and is approximately 1.876″ in length and 1.211″ in width. Each protective flange  70  is approximately 0.94″ wide and has a height of approximately 0.65″. The gap  72  is about 0.1″ wide and is sized and configured to accommodate the movement of the associated hinge arm  34  between the base  62  and protective flange  70  during articulation of the hinge assembly  20  and movement of the door  10  to and between the open and closed positions. 
     Preferably, the size and configuration of the boss  64  is designed to minimize the spacing or gap between the hinge guard  60  and the lower edge of the hinge leaf  20   a  during articulation of the door  10  and adjacent panels  14 . Likewise, the protective flanges  70  shield or block access to openings or gaps produced by the pivotal movement of the panels  14  and articulation of the hinge assembly  20 . As such, foreign objects are inhibited from being inserted into the hinge assembly  20  and potential damage to the foreign objects, the hinge assembly  20  and/or components of door  10  is minimized. 
     Referring to FIGS. 5-6, a second embodiment of the hinge guard  60   a  according to this invention is shown. The second embodiment of the hinge guard  60   a  is particularly designed and adapted for use on a laterally outboard hinge  20  on the panel  14  to which the roller assembly  12  is attached. As such, the protective flanges  70   a  of the hinge guard  60   a  as shown in FIGS. 5 and 6 include a step  76  to accommodate and provide clearance for the roller tube  26  seated within the tabs  30  of the hinge leaf  20   a . Additionally, an anchor plate  78  is provided on the base  62  of the hinge guard  60   a  and a number of holes  80  are included in the anchor plate  78  through which mechanical fasteners (not shown) such as screws, bolts or rivets may be used to mount the hinge guard  60   a  to the back face  36  of the panel  14 . 
     It should be readily appreciated that, although a pivot pin  48  is shown in FIGS. 1,  3  and  4 , alternative pivot members may be included with this invention such as rivets, living hinges or other pivotally coupling members. Moreover, the hinge assembly  20  shown and described herein is a presently preferred embodiment for use with the panel design disclosed in U.S. Pat. No. 6,006,817. However, the hinge guard of this invention can be readily applied to other panel and hinge assembly designs including hinge assemblies having both an upper and lower hinge leaf with a pivot member coupling them together. 
     Advantageously, the hinge guard of this invention can be readily utilized as an accessory or add-on feature to an existing and/or installed overhead door system without disassembly of the overhead door  10 . Alternatively, the hinge guard may be included as original equipment on a newly installed overhead door system. 
     It should be readily appreciated that although certain embodiments and configurations of the invention are shown and described herein, the invention is not so limited. For example, while the hinge guard is shown anchored by fasteners, other attachment mechanisms are readily available within the scope of this invention. Moreover, the hinge guard is shown in a specific configuration for compatibility with the panel design and hinge assembly shown in FIGS. 1,  3  and  4  while other configurations and designs of the invention are envisioned for implementation on panels and/or hinges of different configurations. Likewise, the hinge guard may be utilized or attached proximate to the lower edge  18  of the superjacent panel  14  alone or in combination with attachment to the upper edge  16 . Additionally, the configuration, position, placement and design of the flanges and/or bosses may be modified within the scope of this invention for compatibility with panels and/or hinges which may differ from those shown in FIGS. 1,  3  and  4 . 
     From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.