Abstract:
An improvement in garage door tracks which includes placing an inwardly pressed hem on the distal ends of the sections of track which surround the gap by which wheels from a garage door are placed into a track chamber. The hems on the distal end provide increased strength and a safer smoother edge. The inward hemming also does not interfere with the roller wheels of the garage door. This further solves the problem of track failure and bulge or crimping and causes less stress on the garage door track. A further innovation is to have strengthening ribs at different locations on the garage door track to provide further strength to the garage door track. A further innovation is to provide strengthening ribs at different locations on the garage door track to provide further strength to the garage door track.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to the field of tracks installed in garage openings to accommodate the wheels of garage doors and in particular to enable the garage door to be rolled down in a closed position and to also enable the garage door to be rolled up so that it is generally parallel to the garage floor and the garage is opened to permit entry and exit of vehicles or other items in the garage. 
     2. Description of the Prior Art 
     In general the concept of improving a garage door track has been performed. In conventional garage door tracks, the exterior edges of the track are sharp which can create a risk of a cut to an installer and a home owner. As illustrated in  FIG. 3A , the prior art garage door track  2000  has sharp ends  2100  and  2200  and a reinforcing member  2300  with sharp ends  2400  and  2500 . 
     One improvement is to cause the track edges to be hemmed outwardly. Another variation is to cause the track to be rolled inwardly as described in U.S. Pat. No. 5,954,111. The use is also described in U.S. Pat. No. 6,250,360. In general, the prior art garage door tracks have no stiffening ribs and no mechanism to provide extra support to the track to prevent rollout of the garage door wheels from the track as the garage door is moved upwardly toward the horizontal open position. 
     There is a significant need for an improved garage door track which addresses the deficiencies of the known prior art garage door tracks. 
     SUMMARY OF THE INVENTION 
     In general, the present invention relates to improvements in a track and track support structure for a sectional overhead garage door. 
     In general, the garage door track is an elongated piece of material such as steel, having an outer section with a wall extending at one end to an interior wall section which in turn extends to an inner section having a wall. In general, the outer section is adjacent a wall of a garage door opening, the interior wall section extends generally perpendicularly to the outer section, and the arcuate inner section is farthest from the garage door wall and is rounded and curves toward the outer section. An opening between a distal end of the outer section and the distal end of the inward curve of the inner section enables the wheels of the garage door to enter and be retained in the track area surrounded by the outer section, the interior wall section and the arcuate inner section. 
     In the prior art, the distal end of the outer section and the distal end of the inward curve of the outer section are sharp. Attempts to reduce the sharp ends have been made by hemming the distal ends outwardly from the track interior against an outer wall of the outer section and forming a hemmed edge and extending against an outer wall of the inward curve of the inner section. Other attempts to reduce the sharp ends were to create interior roll formed beads. However, to achieve this the material needs to be very thin which reduced the strength of the track and the garage door wheels would bind on the interior roll formed beads. 
     Hemming is bending in the sharp edges of the track either outwardly so that the edges are bent against adjacent outer walls of the track or bent inwardly so that the edges are bent against adjacent inner walls of the track. It has been discovered, according to the present invention, that if the outermost distal edge portions of the track which include the distal end of the outer section and the distal end of the inward curve of the arcuate inner section are respectively hemmed and bent inwardly against an adjacent inner wall section of the outer section and against an adjacent inner wall of the inwardly curved portion of the arcuate inner section, then hemming the edge of the garage door track inwardly provides increased strength and a safer smooth edge. The inward hemming will also not interfere with the roller wheels of the garage door. The entire track section has a common exterior wall and a common interior wall. 
     It has been discovered, according to the present invention, that hemming the edge of the garage door track inwardly provides increased strength and a safer smoother edge. An inside hemmed edge will provide a means of door roller retention with increased strength of the inward hemmed edge. This solves the problem associated with conventional garage door tracks, including: (a) edge imperfections of a steel edge which can lead to track failure; (b) an edge imperfection could be a bulge, crimp or edge stress concentration; (c) at the blade edge of the steel, edge buckling can lead to failure of the door. 
     It has further been discovered, according to the present invention, that a hemmed edge will provide increased resistance to track bowing. The hemmed edge solves the problem associated with sharp edges. Sharp edges can cut hands or fingers during installation of the garage door into the track or throughout its service life. The stronger design can now be now be produced in a reduced steel thickness without sacrificing the strength and integrity of the track. This also facilitates a reduced cost unit rate and a single thickness for all residential tracks. This reduces inventory for even more reduced costs of manufacturing. 
     It has further been discovered, according to the present invention, that the addition of stiffening ribs into the outer section, interior inner wall, and adjacent the arcuate inner section of the track increases strength rigidity and reduces track bowing and track roll out. Track roll out is used to describe the fallout and failure of the door and door rollers. In the present invention, four stiffening ribs have been incorporated into the garage door tracks. A first stiffening rib is formed on the top sidewall of the outer track section. Two spaced apart stiffening ribs are formed on the interior sidewall section, and a fourth spaced apart stiffening rib is formed in the wall of the curl section which is the portion of the interior sidewall that curves into the arcuate inner section of the track. These roll formed channels or stiffening ribs will provide increased strength to the entire track set. These channels combined with the hemmed inward edge provide increased strength on the entire track set which would take 30-40% thicker steel to achieve the same strength, providing a weight savings of at least 30%. This in turn saves cost per set in the manufacturing. This increased strength will allow the manufacturer to run one gauge (thickness) of steel, thereby eliminating the need for multiple gauges. One gauge can now be used for light duty to heavier duty residential applications by only changing the reinforcing angle. The lower cost to the manufacturer is passed on to the user/dealer and reduced inventory cost. 
     It has been discovered, according to the present invention, that the addition of the top stiffening rib not only increases strength, but also provides a channel and space/area for the door rollers to ride up in. This is while the door is traveling to the raised position. Without the top stiffening rib, roller drag occurs. This is a problem with 10 inch, 12 inch and 15 inch radius track. Carriage house style doors that are 3 sections tall with 28 inch oversize sections and larger 32 inch sections have the same roller drag problem. While the door is rolling up through the radius on the top of the track, the door rollers get forced against the top of the track. This causes roller drag (binding/friction). Roller drag causes extra wear on the hinges, rollers, door sections and garage door operators. The top stiffening rib channel solves this problem. The extra space/area allows the roller to rise/raise into the channel (rib) allowing it to turn freely with no binding and dragging. This provides smooth door action throughout the entire radius transition. It works almost the same way in the down cycle. As the garage operator pushes the door through the radius position, the door is pushed against the front of the track in the vertical position. The stiffening rib channel provides the extra space to move the rollers forward and not bind in the radius. This results in a big improvement in smooth bind free performance, providing extra life for door parts including cost effective performance at no extra cost and extra strength for the life of the door track. 
     Another improvement is a reinforcing angle which matches the ribs on the section of the track which is the top horizontal section of track parallel to the floor. The reinforcing angle provides extra supporting strength to the horizontal track portion by having strengthening ribs which match the strengthening ribs of the track section. A reinforcing angle for the garage door track has been straight cut and has had a sharp edge since it was invented. This sharp edge has a sharp point. This has caused injury to installers and homeowners for years. Having a radius curved edge will eliminate the sharp point and provide a safer edge. There is no added cost and no loss of strength but it provides a substantial improvement over the prior art straight cut tracks for garage doors. 
     It should be noted that the reinforcing angle that have no stiffening ribs [industry standard design] Prior art drawing  FIG. 3A  would have to be 0.075 thick [14 Ga steel] To provide the same strength as the 0.065 [16 Ga steel] reinforcing angle with the present invention. This provides significant savings in the cost of the part. The reduced weight savings in addition to the cost of part savings, would reduce shipping costs. Less weight equals more product per truckload reducing shipping and the final cost of each Track set. Plus radius cut safer edge provides added safety and easy handling of completed track set with no added costs to manufacturing. 
     It has further been discovered, according to the present invention, that a shorter length on the horizontal section of the track rail section will make the track stronger by reducing unsupported span. Most prior art horizontal garage door track sections are 8 feet 6 inches for a 7 foot door; or 9 feet 6 inches for an 8 foot door. Reducing the horizontal track length by 12 inches it moves the point of support (back hang) closer to the top roller of the door. The distance from the back-hang to the top roller is considered unsupported span. Unsupported span tends to let the track twist and bow. This could lead to track roll out or failure. The door roller on the top could fall out of the rack because of the bow/twist. Some prior art involves extra holes in the track. The holes are used to move the back hang forward which looks odd and unsightly. Shortening the horizontal track provides and facilitates the strongest back hang. 
     Sometimes the vertical section of the garage door track is damaged by the owner hitting it with his car. The present invention can be used to replace only the vertical part and inter-fit with the remainder of the existing undamaged track, even if does not have the improvements in the track as described above. 
     The objects of the present invention are to incorporate into a garage door track all of the discoveries and improvements as set forth above. 
     Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated: 
         FIG. 1  is an end view of the present invention garage door track illustrating a first stiffening rib of the top sidewall of the outer track section placed closest to a garage door wall when installed, two spaced apart stiffening ribs on the interior sidewall when installed, and a fourth spaced apart stiffening rib in the wall of the curl section which is the portion of the interior sidewall that curves into the arcuate inner section of the track, the arcuate inner section being farthest away from a garage door wall when installed and having a curved section extending to an inward curving section closest to the outer wall section, leaving a gap into which roller wheels from a garage door are inserted; 
         FIG. 2  is an end view of the present invention garage door track when viewed from a horizontal section of track including a matching reinforcing angle with a section affixed to the interior sidewall of the garage door track and a second portion hanging in the air; 
         FIG. 3A  is a side perspective view of a prior art garage track with a straight wall having no strengthening ribs and a straight reinforcing angle, the track and reinforcing angle having sharp exterior ends to their respective walls; 
         FIG. 3B  is a perspective view of the combination garage door track including a matching reinforcing angle with a section affixed to the interior sidewall of the garage door track and a second portion hanging in the air; 
         FIG. 4  is a front perspective view of the present invention garage door track with backing members used to affix the distal end of the garage door track to a garage ceiling, also illustrating a stop bolt to prevent the garage door wheels from rolling out of the track, also illustrating a rear view of the matching reinforcing angle and illustrating a flag bracket retaining the garage door track at the location where the garage door track extends from a horizontal section to a vertical section and illustrating a return spring member to assist in raising the garage door; 
         FIG. 5  is a rear perspective view of the present invention garage door track illustrated in  FIG. 4 ; and 
         FIG. 6  is a perspective view when standing in a garage with the garage door down, the right side of the garage door wheels inserted into a right vertical right section of track, which vertical right section of track extends onto and is affixed to a portion of the ceiling of the garage. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims. 
     Referring to  FIG. 1 , there is illustrated an end view of the present invention garage door track  10 , illustrating two of the major improvements of the present invention. The garage door track  10  comprises an outer wall section  20  having a distal end  22 , an exterior wall  24  and an interior wall  26 , with one of the innovations being that at the distal end  22 , the garage door track is hemmed inwardly with the inward first hem  28  having a round exterior end  30  and pressed parallel to and against an adjacent section of the interior wall  26 . A second innovation is that the outer section wall  32  bounded by interior wall  26  and exterior wall  24  has a strengthening rib  34  formed into it and centrally disposed along the width “W 1 ” of the outer wall section  20 , the strengthening rib  34  extending outwardly away from an interior chamber  70  to be described. 
     The outer wall section  20  extends at its proximal end  36  to an interior side wall section  40  having a wall  42  bounded by an interior wall  44  and an exterior wall  45  with a second strengthening rib  46  formed into wall  42  and extending away from the interior chamber  70 . The interior side wall section  40  has a spaced apart third strengthening rib  48  formed into wall  42  and extending away from the interior chamber  70 . The interior side wall section  40  extends to a curl portion  50  which is still part of wall  42  and bounded by interior wall  44  and exterior wall  45  with a fourth strengthening rib  52  formed into wall  42  and extending away from chamber  70 . Second strengthening rib  46  is spaced apart from third strengthening rib  48 . The length “L 1 ” is from the proximal end of exterior wall section  20  where it joins interior side wall section  40  to adjacent the distal end of fourth strengthening rib  52 . The section distance “L 1 -A” extends from the proximal end  36  to first space  46 A of second strengthening rib  46  and a distance “L 1 -B” extends from a first space  46 A of second strengthening rib  46  to a second space  46 B of second strengthening rib  46 . A length “L 1 -C” extends from a second space  46 B of the second strengthening rib  46  to a first space  48 A of third strengthening rib  48 . The third strengthening rib  48  has a distance “L 1 -D” extending from  48 A to  48 B and the fourth strengthening rib  52  has a distance “L 1 -E”, with distances “L 1 -A”, “L 1 -B”, “L 1 -C”, “L 1 -D” and “L 1 -E” combining to be “L 1 ”. Curl portion  50  extends to arcuate inner section  54  which extends to an inward curved portion  56  terminating in a distal end  58  of arcuate inner section  54  I which is hemmed inwardly with second hem section  60  pressed against interior wall  57  and having a rounded end  62 . A gap “G 1 ” is between first hem section  28  and second hem second  60  leading interior chamber  70  bounded by outer section  20 , interior side wall section  40  and arcuate inner section  54  so that wheels of a garage door can be inserted through the gap “G 1 ” and into chamber  70 . 
     Referring to  FIG. 2 , there is illustrated the present invention garage door track with hemmed distal ends and four strengthening ribs and an additional innovation of a reinforcing angle  100  having a wall  102  with an interior  104  and an exterior  105 . The reinforcing angle  100  has a first section  106  having a first strengthening rib  108  and a spaced apart second strengthening rib  110  which are formed to match second strengthening rib  46  and third strengthening rib  48  of interior side wall section  40  and spaced apart so that the strengthening ribs  46  and  108  are aligned and strengthening ribs  48  and  110  are aligned, with the distal end  112  of the first section of the reinforcing angle  100  terminating adjacent the fourth strengthening rib  52 . As best illustrated in  FIG. 3B , the reinforcing angle  100  is slidably affixed at a location of the rear wall  24  of the interior side wall section  40  of track section  10  by an affixation member  114  which extends through an oval opening  116  in first section  106  of reinforcing angle  100  and a corresponding opening in section  40  of track  10  so that the location of the reinforcing angle  100  can be adjusted. As illustrated in  FIG. 4 , all respective reinforcing ribs run the length of the track and the length of the reinforcing angle. 
     As illustrated in  FIG. 2  and  FIG. 3B , the reinforcing angle  100  has a second section  120  which is generally perpendicular to the first section  106  at its proximal end  103  and extends away freely in the air. The second section  120  of the reinforcing angle  100  also has strengthening ribs  122  and  124  between its proximal end  126  adjacent proximal end  103  and the distal end  128  of the second section  120  of reinforcing angle  100  which further strengthens the track. The edge of the reinforcing angle  100  has a radius to prevent a sharp edge cut to an installer or homeowner. 
     Referring to  FIG. 4 , there is illustrated a front perspective view of a completed track section and supporting members for the section of track  10 A which extends in a horizontal direction to receive the rollers of a garage door when the garage door is rolled up so that it is generally parallel to the garage door floor when the garage is open.  FIG. 5  is a rear perspective view of most of the embodiment illustrated in  FIG. 4 . 
     The rear track section  10 A has the same innovations of the hemmed ends  28  and  60  and supporting ribs  34 ,  46 ,  48  and  52 . Adjacent the distal rear end  8 A of horizontal track section  10 A at a distance beyond the reinforcing angle section  106  of reinforcing angle  100  and affixed to the back of track section  10 A are backing members  200  having a multiplicity of openings  202 ,  210  having a multiplicity of openings  212  and  220  having a multiplicity of openings  222 . The rear track section  10 A is affixed to a ceiling of a garage by affixation members such as one way bolts or one way screws respectively extending through one or more of the multiplicity of openings  202 ,  212  and  222  of the respective backing members  200 ,  210  and  220 . A stop bolt  230  extends through an opening in the back wall  24  of interior side wall section  40  of the track section  10 A adjacent the distal end  8 A and extends into opening  70  to prevent the wheels of the door from moving past the distal end  8 A and off the track  10 A. 
     The angle support  100  is only on the horizontal portion of the track  10 A and supports only a portion of the track section  10 A. A flag bracket  300  is mounted to the garage wall. The flag bracket  300  has a first section  320  with mounting members  330  affixed to an extended portion of the reinforcing angle  100  with a coiling spring member  340  having a coil  342  to help raise the garage door. The flag bracket  300  has a multiplicity of slotted openings  350 ,  360 ,  370  and  380  to adjustably mount the distal end  102  of the reinforcing angle  100  to one or more affixation members  390  such as mounting bolts which extend through the proximal section  400 . 
     The track section  10 A extends from its horizontal position around a curved section before it is joined to a vertical section  10 B of track  10 . A flag  410  located at a distal end  420  of the flag bracket  300  has mounting members  430  which affix the flag  410  to the distal end  10 A-D of track section  10 A. The flag  410  also has mounting members  440  which affix the flag  410  at an upper or distal end  10 B-D of vertical track section  10 B. In this way, the track sections  10 A and  10 B of track  10  are supported. 
     Another innovation of the present invention is to reduce the distance from the distal end  8 A to distal end  10 A-D of horizontal track section  10 A by 12 inches. This section is known as unsupported span covering the distance from the back hangers  200 ,  210  and  220  to distal end  10 A-D. In the prior art, the span of 8 feet 6 inches or more enables the track section  10 A to twist and bow leading to track roll out. The reduction of span length to 7 feet 6 inches for a 7 foot tall door (or reduction to 8 feet 6 inches for a eight foot tall door) provides for a much stronger unsupported span reducing the track twisting and bowing and reducing the incidence of rack roll out. 
     Referring to  FIG. 6 , there is illustrated a view standing inside a garage with the garage door viewed from a rear view in the down condition with the right side of the garage door wheels inside the right vertical section of track and the horizontal section of track extending around a curve and mounted to the ceiling of the garage on the right side of the garage door track structure. The rear track section  10 A which is horizontal is adjacent the ceiling  500  of garage  600  with the backing members  200 ,  210  and  220  with their respective affixation members extending through respective openings  202 ,  212 , into the ceiling  500  with the backing members illustrated adjacent the distal end  8 A of the horizontal track section  10 A of track  10 . The flag bracket  300  is mounted to the upper interior garage wall  550  with its first section  320  affixed to an extended portion of the enforcing angle  100  with the coil spring member  340  having a coil  342  affixed to the bottom  710  of the garage door  700  to help raise the garage door  700 . The enforcing angle  100  is only against the horizontal section  10 A of the track  10 . The back  24  of the lowermost portion of the vertical track section  10 B of track  10  is affixed to flag bracket  430  which is affixed to the back  720  of the garage door  700 . Mounting brackets  800 ,  810  and  820  further affix the vertical track section  10 B to respective locations along the vertical distance of the back of the garage door  720 . Garage door wheels  760 ,  770 ,  780  and  790  are illustrated inserted into chamber  70  along respective locations along respective vertical locations of the vertical track section. The wheels  760 ,  770 ,  780  and  790  are affixed to a side of the garage door  700 . It will be appreciated that the left track  10  and its vertical and horizontal track sections are a mirror image of the right track section illustrated in  FIG. 6  with wheels affixed onto the left side of the garage door inserted into a corresponding chamber in a left track section. 
     The wheels of the garage door ride on the vertical track sections until they arrive at the horizontal track sections so that the garage door is horizontal adjacent the ceiling  700  and generally parallel to the floor  900 . The garage door  700  is rolled down the vertical track sections to close the garage. 
     Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated.