Patent Abstract:
A draft arrester for an overhead door. An exemplary embodiment may include a flexible draft curtain extending between a ceiling structure and a wound-up portion of the overhead door. The draft arrester may include a follower assembly, which may include one or more rollers arranged to roll against the overhead door. An exemplary embodiment may include a repositionable arm arranged to press the rollers against the wound-up portion of the door.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/069,969, filed Mar. 18, 2008, which is incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    The present disclosure is directed to draft arresters for overhead retractable doors and, more particularly, to non-contact draft arresters for roll-up overhead retractable doors. 
       INTRODUCTION TO THE INVENTION 
       [0003]    Exemplary embodiments include a draft arrester for an overhead door. An exemplary embodiment may include a flexible draft curtain extending between a ceiling structure and a wound-up portion of the overhead door. The draft arrester may include a follower assembly, which may include one or more rollers arranged to roll against the overhead door. An exemplary embodiment may include a repositionable arm arranged to press the rollers against the wound-up portion of the door. 
         [0004]    In an aspect, a draft arrester for a roll-up overhead door may include a draft curtain including a lower end and an upper end; a first pair of spaced-apart rollers operatively coupled to the lower end of the draft curtain, the first pair of spaced-apart rollers biased against a portion of the roll-up overhead door; and a curtain support coupled to the upper end of the draft curtain and adapted to be mounted above the first pair of spaced-apart rollers. 
         [0005]    In a detailed embodiment, the first pair of spaced apart rollers may be mounted approximate a first end of a first repositionable arm, and the first repositionable arm may be pivotable about a pivot located proximate a second end of the first repositionable arm. In a detailed embodiment, a draft arrester may include a spring component arranged to bias the first end of the first repositionable arm towards the portion of the door. In a detailed embodiment, at least one of the rollers may be weighted, and the weighted roller may be arranged to bias the pair of spaced-apart rollers towards the portion of the door. In a detailed embodiment, a draft arrester may include a second pair of spaced-apart rollers operatively coupled to the first end of the draft curtain, the second pair of spaced-apart rollers being biased against the portion of the door. In a detailed embodiment, a draft arrester may include a substantially horizontal rail extending along the lower end of the draft curtain and interposing the first pair of spaced-apart rollers and the second pair of spaced-apart rollers. In a detailed embodiment, the draft curtain may be substantially flexible. 
         [0006]    In an aspect, an overhead door assembly may include a rotatable spool; an overhead door windable onto the rotatable spool, the door being arranged to at least partially cover an opening having a width, a height, and at least one overhead boundary; a first wheeled follower biased against a portion of the overhead door wound around the rotatable spool; and a draft curtain extending vertically between the wheeled follower and the overhead boundary, while at the same time the draft curtain extends horizontally approximately the width of the opening. 
         [0007]    In a detailed embodiment, the overhead boundary may be a ceiling. In a detailed embodiment, the draft curtain may be substantially flexible. In a detailed embodiment, the first wheeled follower may include a first pair of spaced-apart rollers mounted proximate a first end of a first repositionable arm, and a second end of the first repositionable arm may include a pivot. In a detailed embodiment, the first wheeled follower may include a spring component arranged to bias the first pair of spaced-apart rollers against the portion of the overhead door wound around the rotatable spool. In a detailed embodiment, at least one of the rollers may be weighted, and the weighted roller may be arranged to bias the first pair of spaced-apart rollers against the portion of the overhead door wound around the rotatable spool. In a detailed embodiment, an overhead door assembly may include a substantially horizontal rail extending from the first wheeled follower and along the draft curtain. In a detailed embodiment, an overhead door assembly may include a second wheeled follower biased against the portion of the overhead door wound around the rotatable spool, and at least a portion of the substantially horizontal rail may interpose the first wheeled follower and the second wheeled follower. 
         [0008]    In an aspect, a draftless overhead door may include a flexible overhead door; a rotatable spool adapted to have at least a portion of the flexible overhead door wound therearound; a motor operatively coupled to the rotatable spool to wind and unwind the flexible overhead door, where unwinding of the flexible overhead door lowers the flexible overhead door and winding of the flexible overhead door raises the flexible overhead door; a vertical door track arranged to guide movement of the flexible overhead door; a roller biased against a portion of the flexible overhead door wound around the rotatable spool; and a curtain extending vertically between an upper structure and the roller, while at the same time extending horizontally proximate a width of the overhead flexible door. 
         [0009]    In a detailed aspect, an overhead door may include a spring component arranged to bias the roller towards the rotatable spool. In a detailed embodiment, the roller may be mounted to a first end of a repositionable arm, and a second end of the repositionable arm may include a pivot. In a detailed embodiment, the roller may include a pair of spaced-apart rollers. In a detailed embodiment, the door may have a width, and the draft curtain may extend substantially the entire width of the door. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The detailed description refers to the following figures in which: 
           [0011]      FIG. 1  is a cross-sectional view of a repositionable door incorporating an exemplary draft arrester, which may be operative to inhibit drafts between the door roll and the header, where the door is shown in a barrier position; 
           [0012]      FIG. 2  is a cross-sectional view of a repositionable door incorporating the exemplary draft arrester of  FIG. 1 , where the door is shown in an intermediate position; 
           [0013]      FIG. 3  is a cross-sectional view of a repositionable door incorporating the exemplary draft arrester of  FIG. 1 , where the door is shown in a retracted position; 
           [0014]      FIG. 4  is a frontal view, from the exterior, of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester; 
           [0015]      FIG. 5  is an elevated perspective view, from the interior, of one corner of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester; and 
           [0016]      FIG. 6  is an elevated perspective view, from the exterior, of one corner of an exemplary building opening incorporating a repositionable door and an exemplary draft arrester. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Exemplary embodiments described and illustrated herein include apparatus and methods for inhibiting drafts over roll-up retractable doors. It will be apparent to those of ordinary skill in the art that the exemplary embodiments discussed herein are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed herein may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present disclosure as defined by the claims. 
         [0018]    An exemplary door draft arrester  10  is shown in  FIGS. 1-6 . In exemplary form, a door draft arrester  10  may be a component of a repositionable door  12 , which may selectively close off an opening of a building. In exemplary form, the building may be a drive-through car wash, and the opening may be at the end of the car wash path through the building. For purposes of explanation only, the opening may be generally rectangular with a vertical lengthwise dimension  18  and a horizontal widthwise dimension  20 . In an exemplary embodiment, the opening may be defined by generally vertically oriented left and right side walls  22 ,  24  and a generally horizontal header wall  26  which may spans overhead between the side walls  22 ,  24 . The plane of the opening may interpose the interior of the building and its exterior. 
         [0019]    In an exemplary embodiment, a door frame  28  may be inset within the interior of the building proximate the opening. The door frame  28  may include opposing vertical members  30 ,  32  that may be mounted respectively to the left and right side walls  22 ,  24 . Each vertical member  30 ,  32  may include a pair of channel guides  34  that cooperate to define a vertical channel  36  into which lateral ends  38  of a repositionable door  12  may extend. In exemplary form, a channel guide  34  may comprise a vertically oriented angle iron segment  42  having a deflector  44  mounted to its proximal end. An exemplary deflector  44  is adapted to be angled outward away from the channel  36  so that adjacent deflectors  44  cooperate to provide a tapered mouth feeding into the channel  36 . In this fashion, as the door  12  is repositioned from a retracted position toward a barrier position, the free horizontal end of the door may contact one of the deflectors  44 , which may route lateral ends  38  of the door  12  into the channel  36 . The precise dimensions of the angle iron segments  42  and deflectors  44  may be a matter of design choice. Likewise, the angle at which the deflectors  44  are oriented may be a matter of design choice; the greater the angle, the less gradual the taper. 
         [0020]    In an exemplary embodiment, a horizontal header  46  that spans the complete widthwise dimension of the opening may be mounted on the interior side of the opening. In exemplary form, the header may comprise a Lexan or metal boxed framework that mounts directly to the header wall  26  to provide a partial enclosure for a repositionable curtain assembly  48 . The curtain assembly  48  may be mounted to the framework  46  by way of a generally horizontal molding  50 , which may extend substantially the entire width of the opening, using a plurality of fasteners  52 . A curtain  54  may be mounted to the heater  46  by the molding  50 . The curtain may be fabricated from the same material as the door  12 . Nevertheless, it is to be understood that other materials could be utilized to fabricate the curtain  54  depending upon the end application. The curtain  54 , in exemplary form, may be generally rectangular with its widthwise dimension dominating its lengthwise dimension. Specifically, it is the lengthwise dimension that may span between the molding  50  and a horizontal rail  56  mounted to a pair of opposing arms  58  mounted to corresponding perpendicular plates  60  extending from the upper portions of the left and right side walls  22 ,  24  and adjacent the header wall  26 . Each arm  58  may include a pair of wheels  62 ,  64  that may be interposed by the horizontal rail  56 . Each wheel  62 ,  64  may be adapted to ride upon the exterior of the door  12  as it is rolled up responsive to the arm  58  being forced against the door roll. However, as the diameter of the door roll changes, whether increasing as the door is retracted or decreasing as the door is deployed, the arm  58  may force the wheels  62 ,  64  against the door roll to substantially maintain a constant axial gap between the horizontal rail  56  and door roll. 
         [0021]    In an exemplary embodiment, the door  12  may be repositioned between a retracted position and a barrier position using a motor assembly  66 . In exemplary form, one end of the door  12  may be mounted axially to a horizontal roller which may be turned either clockwise or counterclockwise by the motor assembly. The motor assembly  66  may include an electric motor  70  coupled to an output pulley  72  that repositions a belt  74  engaging a input pulley  76  coupled to the roller  68 . It is too be understood, however, that various drive mechanisms could be utilized, such as using the output shaft of the motor  70  to directly engage the roller  68  or one could easily devise a set of gears to interface between the roller  68  and the motor  70  to accomplish a similar result. In an exemplary embodiment, as the roller  68  is rotated to move the door  12  toward its retracted position, the door  12  may wind around the roller  68  to provide a cylindrical roll (i.e., a “door roll”) that gradually increases in diameter as the door is retracted until a maximum diameter is reached corresponding to substantially the entire door being wound around the roller  68 . It should be noted, however, that it may not be necessary to wind the entire door around the shaft to allow egress of automobiles through the opening as in an exemplary carwash. 
         [0022]    The present disclosure contemplates that a problem experienced with conventional roll-up doors is the occurrence of a draft between the header and the door roll. In some conventional door systems, the gap between the door roll and the header may vary and may be quite substantial to allow air to freely pass therebetween and create a draft that in certain instances is operative to allow liquids and other flowing materials within the interior of the building to escape or conversely to allow external fluids and debris to enter the building even while the door is in its barrier position. Exemplary embodiments described herein, however, may overcome these drawbacks by arresting the draft using the repositionable curtain assembly  48  to substantially decrease fluid flow between the horizontal shaft and header, thereby substantially decreasing any draft. 
         [0023]    In an exemplary embodiment, the repositionable curtain assembly  48  may comprise a fixed length curtain  54  that may be mounted at one end to the molding  50  and may be mounted at an opposite end to the horizontal rail  56 . In exemplary form, the horizontal rail  56  may be substantially in parallel with the door roll and/or roller  68  to maintain a substantially constant spacing between the rail  56  and door roll of approximately two inches. This constant spacing may be accomplished by providing a reactive system that starts with the reactive arms  58 . 
         [0024]    In an exemplary embodiment, each arm  58  may include a polyethylene unibody construction having a through hole  78  that receives a bolt extending from a corresponding perpendicular plate  60  toward the door roll. The end of the bolt may also receive a series of washers and/or a lock nut to provide play and freedom of movement rotationally between the bolt and the arm  58 . In other words, this arrangement may allow each arm  58  to freely rotate/pivot around its corresponding bolt. This rotation may be caused by the change in diameter of the door roll as the door is either retracted or deployed. As discussed previously, each arm  58  may include a pair of wheels  62 ,  64  adapted to ride upon the exterior of the door as it is rolled up and/or down. In order to maintain the wheels against the exterior of the door roll, the arm  58  itself may be biased towards the door roll. This biasing may be accomplished by using weighted wheels that gravity directs against the door roll or alternatively using a spring biasing structure (not shown) circumscribing the bolt to apply a spring force resisting rotation of each arm  58 . However, those skilled in the art will understand that other mechanisms may be used to maintain the wheels  62 ,  64  against the door roll in accordance with the present disclosure. 
         [0025]    As mentioned previously, an exemplary door draft arrester  10  may find application in a carwash facility. By way of illustration, and not limitation, an exemplary draft arrester may be installed at the exit of a carwash. In exemplary form, an electric motor  70  may be electrically controlled by an automated control system (not shown) and at least one position sensor for sensing the presence of an automobile in proximity to the exit. Those skilled in the art are quite familiar with automated controls and a discussion of such a system in detail, with sensors, has been omitted for purposes of brevity. In exemplary operation, the door  12  may be selectively repositioned from a barrier position to a retracted position to allow egress of automobiles through the exit. Specifically, in a carwash, the door&#39;s default position may be the barrier position and movement of the door to the retracted position may only occur when the automated system senses an automobile in proximity to the exit or opening  14 . At this time, the automated system may engage the electric motor  70  to rotate the roller  68  in the appropriate direction to retract the door from its barrier position (see  FIG. 1 ) through an intermediary position (see  FIG. 2 ) to a retracted position (see  FIG. 3 ). As can be seen from the foregoing figures, repositioning of the door  12  does not compromise the draft arresting capabilities of the exemplary draft arrester. 
         [0026]    In an exemplary embodiment, the curtain  54  may operate to substantially shut off the widthwise opening between the door roll and the header  46 . As can be seen by the change in position of the arms  58 , the wheels  62 ,  64  may continue to ride upon the exterior of the door roll and correspondingly pivot each arm  58  as the diameter of the door roll decreases (as the door is deployed) or increases (as the door is retracted). Correspondingly, the horizontal rail  56  mounted to each arm  58  at the rail&#39;s axial ends may maintain a substantially constant spacing from the door roll, regardless of the diameter of the door roll. To accommodate the changing door roll diameter, the curtain  54  may floats and/or deform. In an exemplary embodiment, at no time, however, does the deformation of the curtain  54  result in the absence of a barrier arresting drafts between the door roll and the header  46 . 
         [0027]    The material composition of the components of the instant invention may be a matter of design choice and may be selected from composites, metals, alloys, ceramics, plastics, or other materials. Those skilled in the art will recognize that different applications for an exemplary draft arrester may require selection of differing materials. By way of example, and not limitation, an exemplary repositionable door  12  may be fabricated from any weatherproof material and may include a series embedded horizontal ribs  80  to generally maintain the door in a planar orientation. The door material, by its nature may be flexible and able to be deformed, and may include weights (not shown) attached proximate to the exposed horizontal end of the door nearest the floor. One of the advantages of using a flexible door is that collisions with automobiles cause less damage to the door itself and the automobile. 
         [0028]    Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatus herein described constitute an exemplary embodiments, the disclosure contained herein is not limited to these precise embodiments and that changes may be made without departing from the scope of the disclosure as defined by the claims (for example, and without limitation, it is within the scope of the invention that the base plate and cover plate take different forms, such as a box and a lid that are separate from each other or even connected by a hinge). Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects disclosed herein in order to fall within the scope of any claim, since the invention is defined by the claims and since inherent and/or unforeseen advantages may exist even though they may not have been explicitly discussed herein. Finally, it will be apparent that additional claims may be inherent in the disclosure and may not be expressly described herein.

Technology Classification (CPC): 4