Abstract:
A door jamb for a break-away industrial door including at least one weather strip and methods for making the same. The door jamb may include a guide track which supports one or more pieces of weather stripping. The guide track may be constructed to allow the break-away door to leave the track if the door is deformed to a predetermined extent. The guide track may be formed by an extrusion process.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/919,027, filed Mar. 20, 2007, which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The instant invention is directed to weatherproofing roll-up industrial doors that are adapted to break away from the vertical track of a wall jamb, as well as to vertical wall jambs having tracks that guide roll-up industrial doors. The invention also includes associated methods of fabricating weatherproof vertical wall jambs. 
         [0004]    2. Description of the Related Art 
         [0005]    Conventional roll-up doors often include vertical guide tracks mounted to the sides of the door opening. Break-away doors are designed to deform and disengage from the guide tracks when a predetermined force is applied to the door. 
       INTRODUCTION TO THE INVENTION 
       [0006]    Embodiments of the invention provide a door jamb for a break-away industrial door including at least one weather strip and methods for making the same. The door jamb may include a guide track which supports one or more pieces of weather stripping. The guide track may be constructed to allow the break-away door to leave the track if the door is deformed to a predetermined extent. The guide track may be formed by an extrusion process. 
         [0007]    In a first aspect, a vertical track for an industrial door according to the present invention may include a longitudinal guide track including a first longitudinal wall and a second longitudinal wall, both extending from a first side of a platform, the first longitudinal wall and the second longitudinal wall substantially in parallel to and spaced apart from one another, the first longitudinal wall including a first longitudinal groove facing the second longitudinal wall, and at least two longitudinal legs extending from a second side of the platform, the second side of the platform being opposite the first side of the platform; and a first weather strip operatively coupled to the groove such that the weather strip extends towards the second longitudinal wall. 
         [0008]    In a detailed embodiment of the first aspect, the at least two longitudinal legs may be oriented substantially perpendicular to the second side of the platform. 
         [0009]    In another detailed embodiment of the first aspect, at least one of the first and second longitudinal walls may include two side walls and an upper wall; the two side walls, the upper wall, and at least a portion of the platform substantially defining a longitudinal cavity. At least one of the two side walls and the upper wall may have a convex shape. 
         [0010]    In yet another detailed embodiment of the first aspect, The track may further include a second weather strip, the second longitudinal wall may include a second longitudinal groove facing the first longitudinal wall, and the second weather strip may be operatively coupled to the second groove such that the second weather strip extends towards the first longitudinal wall. 
         [0011]    In yet another detailed embodiment of the first aspect, the first longitudinal wall and the second longitudinal wall may be oriented substantially perpendicular to the first side of the platform. 
         [0012]    In a second aspect, a method of fabricating a vertical guide track for an industrial door according to the present invention may include the steps of extruding a guide track including a platform with a first integral longitudinal arm and a second integral longitudinal arm, the first integral longitudinal arm including a first groove facing the second longitudinal arm. 
         [0013]    In a detailed embodiment of the second aspect, the first and second integral longitudinal arms may extend from a first side of the platform and two integral spaced-apart legs may extend from a second side of the platform, the second side of the platform being opposite the first side of the platform. The two space-apart legs may be oriented substantially perpendicular to the second side of the platform. 
         [0014]    In another detailed embodiment of the second aspect, the method may further include the step of installing a first weather strip onto the guide track by operatively coupling the first weather strip with the first groove so that the first weather strip extends towards the second integral longitudinal arm. The second integral longitudinal arm may include a second groove and the method may further include the step of installing a second weather strip onto the guide track by operatively coupling the second weather strip with the second groove. 
         [0015]    In yet another detailed embodiment of the second aspect, the first integral longitudinal arm and the second integral longitudinal arm may be oriented substantially perpendicular to the platform. 
         [0016]    In yet another detailed embodiment of the second aspect, at least one of the first integral longitudinal arm and the second integral longitudinal arm may include a plurality of walls substantially defining a longitudinal cavity. At least one of the plurality of walls may be convex. 
         [0017]    In a third aspect, a member for a door jamb according to the present invention may include a longitudinal base with a generally rectangular cross section having a first side and a second side; a longitudinal arm extending generally perpendicularly from the first side of the longitudinal base, the longitudinal arm having a first side and a second side, the first side of the longitudinal arm including a longitudinal groove, the longitudinal groove having a substantially uniform cross section; and a longitudinal leg extending generally perpendicularly from the second side of the longitudinal base. The first side of the longitudinal arm may be oriented generally towards a first end of the longitudinal base and the longitudinal leg may extend from the longitudinal base proximate a second end of the longitudinal base, the second end being opposite from the first end. 
         [0018]    In a detailed embodiment of the third aspect, the longitudinal base may include at least one orifice adapted to receive a fastener, the at least one orifice extending through the longitudinal base at a location between the longitudinal arm and the first end of the longitudinal base. 
         [0019]    In another detailed embodiment of the third aspect, the longitudinal arm may include a longitudinal cavity substantially defined by a plurality of walls. The plurality of walls may include two side walls and an end wall. At least one of the two side walls and the end wall may be convex. 
         [0020]    In a fourth aspect, a weatherproof industrial door jamb according to the present invention may include a longitudinal platform having a surface and a first end and a second end, the first end being opposite the second end; a first longitudinal arm extending generally perpendicularly from the surface proximate the first end of the longitudinal platform, the first longitudinal arm including a first longitudinal groove having a substantially uniform cross section facing the second end of the longitudinal platform; and a second longitudinal arm extending generally perpendicularly from the surface proximate the second end of the platform, the second longitudinal arm including a second longitudinal groove having a substantially uniform cross section facing the first end of the longitudinal platform. At least one of the first longitudinal arm and the second longitudinal arm may include a longitudinal cavity defined by two side walls and an end wall. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0021]      FIG. 1  is a cross-section of a first exemplary door jamb for an industrial door; 
           [0022]      FIG. 2  is a cross-section of a first exemplary weatherproof door jamb using the door jamb of  FIG. 1 ; 
           [0023]      FIG. 3  is a cross-section of the first exemplary weatherproof door jamb of  FIG. 2  accommodating an industrial door; 
           [0024]      FIG. 4  is a cross-section of a second exemplary door jamb for an industrial door; 
           [0025]      FIG. 5  is a cross-section of a second exemplary weatherproof door jamb using the door jamb of  FIG. 4 ; 
           [0026]      FIG. 6  is a cross-section of the second exemplary weatherproof door jamb of  FIG. 5  accommodating an industrial door; 
           [0027]      FIGS. 7A-C  are a series of cross sectional views of alternate exemplary grooves adapted to accommodate weatherstripping in accordance with the present invention; and 
           [0028]      FIG. 8  is a cross sectional view of an exemplary two-piece weatherproof door jamb. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    The exemplary embodiments of the present invention are described and illustrated below to encompass methods of fabricating weatherproof door jambs for industrial overhead doors, as well as the associated weatherproof door jambs themselves. Of course, it will be apparent to those of ordinary skill in the art that the embodiments discussed below 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 below 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 invention as defined by the proposed points of novelty. 
         [0030]    Referring to  FIG. 1 , a first exemplary door jamb  10  comprises a longitudinal rail  12  having opposing left and right legs  14 ,  16  connected to one another by a horizontal platform  18 . In this exemplary embodiment, the legs  14 ,  16  are oriented perpendicularly with respect to the platform  18 . A pair of longitudinal guide arms  20 ,  22  upstand from a surface of the platform  18  opposite the left and right legs  14 ,  16 . Each guide arm  20 ,  22  is generally perpendicular to the platform  18  and includes a longitudinal head  24  opposite the platform  18 . 
         [0031]    The head  24  includes a longitudinal groove  26  formed therein having a generally rectangular cross-section that tapers to an hourglass shape partially defined by opposing teeth  28  projecting inward toward one another from the head  24 . In this exemplary embodiment, the groove  26  is adapted to receive a longitudinal section of weatherstripping  30 . As used herein, weatherstripping refers to one or more weather strips. 
         [0032]    Referring to  FIG. 2 , the weatherstripping  30  comprises an integral longitudinal length that is fabricated using extrusion, such as pull extrusion. An exemplary cross-section of the weatherstripping  30  reveals numerous portions that cooperate with the door jamb  10  to form a weatherproof door jamb  32 . For example, the weatherstripping  30  includes a flange  34 , having a rounded end  36 , that extends from a stop  38  that is adapted to abut the teeth  28  of the head  24  when the weatherstripping  30  is installed within the groove  26 . A rectangular-shaped projection  40  of the weatherstripping is connected to the stop  38  by way of a bridge  42  and is received within the groove  26  to retain the weatherstripping  30  in engagement with the door jamb  10 . 
         [0033]    In this exemplary embodiment, the door jamb  10  is fabricated from a mixture of a thermoplastic polymer and fiberglass injected into a die and pull extruded. It is also within the scope of the invention to utilize a thermosetting polymer or other materials to form the door jamb using a molding or extrusion process. Those skilled in the art will be familiar with the advantages imparted by using an extrusion process such as, without limitation, varying the lengths of the door jambs  10  to accommodate varying length walls, without having to fabricate differing molds. 
         [0034]    Referencing  FIG. 3 , the weatherproof door jamb  32  is adapted for use with break-away industrial doors  44  such as those fabricated from flexible frames and covered with a plastic curtain. These exemplary break-away doors  44  are often stored in a rolled up position by using an overhead roller (not shown) that is driven by a motor (not shown). While it is not critical for purposes of the instant invention which type of break-away door  44  is utilized, it is important to understand the operation of typical break-away industrial doors. 
         [0035]    An exemplary industrial break-away door  44  includes a frame  46  that is flexible enough to deform when a force is applied to the door. Generally the applied force comes from a collision with an automobile or other object, but need not, as in the case of a strong wind causing the door  44  to break-away. Initially, just before a force is applied to the door, the ends of the frame  46  are within the track  48 . As an initial force is applied to the door, the frame  46  bows outward in the direction of the force being applied. This outward bowing pulls the ends of the frame toward one another, thereby decreasing the widthwise dimension of the door. At a predetermined point, the widthwise dimension of the door (and or door panel) becomes less then the width between opposing door jamb tracks, which allows the door to become dislodged from between the guide arms  20 ,  22  comprising the track. To account for the bowed movement of the door frame, many tracks are particularly wide to ensure that while the door its is being bowed out it does not become bound up within the track. However, this increase in the width of the track for the sake of allowing the door to flex has come at the expense of sacrificing weatherproofing. 
         [0036]    Referring again to  FIG. 3 , the weatherproof door jamb  32  accommodates for an increased width track, while at the same time ensuring that gaps between the door  44  and guide arms  20 ,  22  are reduced by using weatherstripping  30 , particularly during flexing of the door. As shown in  FIG. 3 , the weatherstripping  30  deforms to accommodate insertion of the door  44  (particularly the frame  46 ) and forms a compliant seal to inhibit substantial travel of gases, liquids, and mists from passing between the door  44  and weatherstripping  30  when the door is positioned within the tracks. Yet the flexibility of the weatherstripping allows the door substantial movement within the track  46 , while maintaining the compliant seal until reaching a point when the door is dislodged from the track. 
         [0037]    Referencing  FIG. 4 , a second exemplary door jamb  50  comprises a horizontal platform  52  having a pair of bubbled projections  54 . Each bubbled projection  54  includes a longitudinal cavity  56  bounded by substantially vertical right and left side walls  58 ,  60 , a substantially horizontal bottom wall comprising the platform  52 , and a convex upper wall  62 . The left side wall  58  of one projection  54  faces the right side wall  60  of the other projection  54  to define a track  64  therebetween. Each interior wall  58 ,  60  includes a longitudinal groove  66  approximate the inception of the convex upper wall  62 . This longitudinal groove  66  includes a generally rectangular cross-section that tapers to an hourglass shape partially defined by opposing teeth  68  projecting inward toward one another. In this exemplary embodiment, the groove  66  is adapted to receive a longitudinal section of weatherstripping  70 . 
         [0038]    Referring to  FIG. 5 , the weatherstripping  70  is extruded to create a longitudinal profile having one end adapted to be received within the groove  66 . This profile includes a flange  72 , having a rounded end  74 , that extends from a stop  76  that is adapted to abut the teeth  68  when the weatherstripping  70  is installed within the groove  66 . A rectangular-shaped projection  78  of the weatherstripping is connected to the stop  76  by way of a bridge  80  positioned to interpose the teeth  68 . Coupling of the weatherstripping  70  to the door jamb  50  creates a weatherproof industrial door jamb  82   
         [0039]    In this exemplary embodiment, the door jamb  50  is fabricated from a mixture of a thermoplastic polymer and fiberglass injected into a die and pull extruded. It is also within the scope of the invention to utilize a thermosetting polymer or other materials to form the door jamb using a molding or extrusion process. Those skilled in the art will be familiar with the advantages imparted by using an extrusion process such as, without limitation, varying the lengths of the door jambs  50  to accommodate varying length walls, without having to fabricate differing molds. 
         [0040]    Referencing  FIG. 6 , the weatherproof door jamb  82  is adapted for use with break-away industrial doors  84  such as those fabricated from flexible frames  86  and covered with a plastic curtain. These exemplary break-away doors  84  are often stored in a rolled up position by using an overhead roller (not shown) that is driven by a motor (not shown). While it is not critical for purposes of the instant invention which type of break-away door  84  is utilized, it is important to understand the operation of typical break-away doors. 
         [0041]    Referring again to  FIG. 6 , the weatherproof door jamb  82  accommodates an increased width track, while at the same time ensuring that gaps between the door  84  and interior walls  58 ,  60  are reduced by using weatherstripping  70 , particularly during flexing of the door. As shown in  FIG. 6 , the weatherstripping  70  deforms to accommodate insertion of the door  84  (particularly the frame  86 ) and forms a compliant seal to inhibit substantial travel of gases, liquids, and mists from passing between the door  84  and weatherstripping  70  when the door is positioned within the tracks. Yet the flexibility of the weatherstripping allows the door substantial movement within the track  64 , while maintaining the compliant seal until reaching a point when the door is no longer within the track. 
         [0042]    Referencing  FIGS. 7A-C , a plurality of alternate groove shapes may be used in lieu of the foregoing exemplary longitudinal groove  66  having a generally rectangular cross-section that tapers to an hourglass shape partially defined by opposing teeth  68  projecting inward toward one another. Those skilled in the art will understand from the foregoing explanation that various shaped grooves may be utilized with the underlying premise of retaining the weather stripping in a weatherproofing position with respect to the industrial door jamb.  FIG. 7A  depicts an H-shaped groove,  FIG. 7B  depicts a circular groove, and  FIG. 7C  depicts a triangular shaped groove. In addition, the groove may simply comprise an indentation of any shape (for example and without limitation, a rectangular groove) in the head, with or without teeth. Certain embodiments may utilize one or more retention devices (such as, but not limited to, one or more fasteners and/or retention strips) and/or an adhesive to retain the weather stripping within the groove. 
         [0043]    Referring to  FIG. 8 , it is also within the scope of the invention to fabricate the industrial door jamb in multiple pieces, such as fabricating the door jamb in halves, where each half  100 ,  102  includes a generally stair stepped cross-section with a joining projection  101 ,  103  on each half  100 ,  102 . This alternate exemplary embodiment is operative to accommodate jambs of various widths. In exemplary form, each half is fabricated so that the joining projections can mount to one another to comprise the jamb. In exemplary form, each joining projection is machined to include horizontal openings  105  at predetermined height intervals that are adapted to receive associated fasteners  104  to lock the overall widthwise dimension of the door jamb. 
         [0044]    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 embodiment of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to this embodiment without departing from the scope of the invention as defined by the claims. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of the invention, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention 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 invention and not expressly described herein.