Abstract:
An aperture, covering including track-guided interconnectable panels that are compactly stored in a storage area containing weight counterbalancing mechanisms, such as a compressed spring, is described. When the panels are stacked in the storage area and removed one at a time, the first panel is removed from the storage area and enters the track. As the first panel moves through the track, it interlocks with the second panel and forces the second panel out of the storage area and into the track. Interlocking and removal of the panels continues until all of the panels are removed or the first panel reaches the end of the track. Weight counterbalancing can be assisted by track-contained mating mechanisms, cable and ball drive mechanisms, or other counterbalancing methods. The resulting aperture covering requires minimal storage space for the open aperture position, minimizes exposure to potentially hazardous counterbalancing mechanisms, and allows for heavy-weight panel construction.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a divisional of application Ser. No. 09/357,140, filed Jul. 20, 1999, and claims the benefit of Provisional Application Serial No. 60/093,319, filed Jul. 20, 1998. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The following invention relates generally to aperture coverings and specifically to garage doors.  
           [0004]    2. Related Art  
           [0005]    In the interest of brevity, conventional garage doors will first be explained. There are three garage door types that constitute the bulk of those currently used in the United States. The technical names for each type vary, so the generic names will be used.  
           [0006]    The most commonly used door for both commercial and domestic purposes is the sectional door. This door includes horizontal panels which are hinged together along their lengths. These panels may be either solid or may contain windows. The ends of each panel terminate in at least one free turning wheel which travels in a track. A system of counterbalancing is usually employed. One system consists of a cable wound around an overhead drum which is attached to a shaft upon which is a torsion spring. The other end of the cable is attached to the bottom edge of the door. Another system uses extension springs which are fully extended when the door is in the down or closed position with the door down. Parts of these counterbalancing systems can break with explosive force, creating a hazard that could result in severe injury or death. When this door is in the up or open position, it hangs from the track horizontally, overhead and parallel to the garage floor. When it is closed, the track and the drive mechanism remain hanging from the garage ceiling. This precludes the use of this overhead space for storage or recreational purposes.  
           [0007]    The California door is the second most common garage door. When closed, this door can appear like a sectional door. This door can be monolithic, however. Since it can be made in one piece, it can have better weatherproof qualities and can possibly be made less expensively than the sectional door. The California door pivots as a unit from the open to closed position. When open, the California door is suspended overhead and situated parallel to the garage floor, much like the sectional door. This door can be dangerous. Besides the danger of flying spring parts, if the springs fail, the full weight of the door can guillotine down through the doorway, creating a hazard that could result in serious injury or death. As with the sectional door, the brackets, drives and door itself exclude the full use of overhead garage space.  
           [0008]    For commercial use, the roll up door is one of the more popular designs. It wraps around a counterbalancing spring and is stored in a cylindrical canister above the doorway when not in use. Very little usable garage space is taken by the roll up door mechanism. This would be an ideal door except for two factors: 1) the door must be rolled up tightly, and 2) it is difficult to include windows in a roll up door. With regard to the first issue, to achieve a small storage canister diameter, the door must roll up tightly. Consequently, the individual panels have to be very narrow. These slats are approximately 1 to 2″ wide, as opposed to the 12 to 18″ width common in sectional doors. The narrow slats give the door the appearance of a tambour door, like that commonly used on a roll top desk. Many home owners find this look aesthetically unappealing. With regard to the second issue of windows, the narrow slats also make it difficult to include wide windows in the door like those windows preferred by most homeowners.  
           [0009]    While not typically used as a garage door, the prior art teaches a method for covering an aperture with interlocking, track-contained slats that disengage when stored in the aperture open position. The slat design employs minimal counterbalancing mechanisms. This method conserves storage space and eliminates exposure to hazardous counterbalance components, but the minimal use of counterbalancing components does not effectively prevent slat jamming within the track, particularly when heavyweight slats are being moved from the aperture closed to aperture open position.  
           [0010]    What is needed is an aperture covering that eliminates the hazardous conditions created by uncontained, exposed, drive and counterbalance components, while minimizing the amount of overhead space encumbered by the stored covering, allowing for panels large enough to contain aesthetically pleasing windows, and still providing sufficient counterbalancing of the aperture cover such that the aperture covering can be opened without jamming. These and other shortcomings of conventional doors are addressed by the present invention.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention is directed to an aperture covering composed of counterbalanced individual interlocking panels that are disengaged when stored. In an embodiment of the invention, an aperture covering includes at least two interconnectable panels, each panel having a surface that defines more than one notch, a storage area for storing the panels when the covering is in an open position, at least one track positioned along a path within which edges of the panels move when the cover is moved from an open to a closed position, and a toothed belt which is positioned in the track and which mates with the panel notches, where the panels are stacked in the storage area and removed one at a time in such a manner that, upon removal of a first panel from the storage area and into the track, the first panel interlocks with a second panel, forcing the second panel from the storage area and into the track, where interlocking and removal of the panels continues until all of the panels are removed or the first panel reaches the end of the track.  
           [0012]    In another embodiment, a drive mechanism that exerts force upon one or more cables, rather than notched belts, is coupled to the panels.  
           [0013]    In yet another embodiment, weight counterbalancing can be assisted by track-contained toothed belts, cable and ball drive mechanisms, or other counterbalancing methods. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0014]    The present invention will be described with reference to the accompanying drawings, wherein:  
         [0015]    FIGS.  1 A- 1 I are a side elevation of the series of steps for lowering the wall panel system.  
         [0016]    FIGS.  2 A- 2 I are a side elevation of the series of steps for raising the panel wall system.  
         [0017]    [0017]FIG. 3 is a broken-away sectional view of the drive element of the wall panel system.  
         [0018]    [0018]FIG. 4 is a broken-away sectional view of second embodiment of the drive element of the wall panel system.  
         [0019]    [0019]FIG. 5 is a broken-away sectional view of a joint section of the wall panel system.  
         [0020]    [0020]FIG. 6 is a broken-away sectional view of a second embodiment of the joint section of the wall panel system.  
         [0021]    [0021]FIG. 7 is an elevational view of the wall panel system in a raised position.  
         [0022]    [0022]FIG. 8 is a broken-away side elevational view of the wall panel system in a lowered position.  
         [0023]    [0023]FIG. 9 is a front elevational view of the wall panel system in a lowered position.  
         [0024]    [0024]FIG. 10 is a top view of the wall panel system in a closed position.  
         [0025]    [0025]FIG. 11 is a front elevational view of the wall panel system in a closed position.  
         [0026]    [0026]FIG. 12 is a top view of the wall panel system in a partially closed position.  
         [0027]    [0027]FIG. 13 is a front elevational view of the wall panel system in a partially closed position.  
         [0028]    [0028]FIG. 14 is a top view of the wall panel system in an open position .  
         [0029]    [0029]FIG. 15 is a front elevational view of the wall panel system in an open view.  
         [0030]    [0030]FIG. 16 is a broken-away side elevational view of the wall panel system in a closed position.  
         [0031]    [0031]FIG. 17 is a broken-away side elevational view of the wall panel system in a partially open position.  
         [0032]    [0032]FIG. 18 is a broken-away side elevational view of the wall panel system in an open position.  
         [0033]    [0033]FIG. 19 is an exploded view of the joint of the wall panel system.  
         [0034]    [0034]FIG. 20 is a top view of the wall panel system in a partially open position.  
         [0035]    [0035]FIG. 21 is a front elevational view of the wall panel system in a partially open position.  
         [0036]    [0036]FIG. 22 is a top view of the wall panel system in an open position.  
         [0037]    [0037]FIG. 23 is a front elevational view of the wall panel system in an open position. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]    In the following description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof. The description shows by way of illustration specific illustrative embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that logical, mechanical and electrical changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense.  
         [0039]    The invention provides for panels to be stored and retrieved while staying in a plane that is substantially parallel to the plane created by the door when fully deployed. The invention is not limited to parallelism but can include panel counterbalancing mechanisms which allow for panel construction from heavyweight materials. The invention can include other embodiments where other, non-parallel configurations, such as deployment on curved tracks or perpendicular storage of the dissembled sections are advantageous. Additionally, other embodiments of the invention include individual panels that are curved in one or more planes.  
         [0040]    In FIGS.  1 A- 1 G, the sequence of figures represents an exemplary cross-section of an aperture covering as viewed from the left side. Hereinafter right and left refer to one&#39;s perspective outside of the garage looking toward the door. FIGS. 1A through 1G progressively show positions of the covering as it moves from an open to closed position. FIG. 1A shows the covering in its full open position. In this position, all of the panels  100   a - e  are stacked one against the other in parallel fashion in the diamond shaped storage box  102  above the aperture  104 . The panels  100   a - e  are completely independent of each other with no hinges, cables or other means of connection. The front most panel  100   a  is partially deployed and held there by the counterbalancing mechanism  108 , which is explained later. As shown in FIG. 7, left rim track  110   a  and right rim track  110   b  capture the last few inches of each end of the panels to guide their deployment and prevent panel disassembly when in use.  
         [0041]    In FIGS.  1 A- 1 G, the covering deployment process is disclosed. There is a compressed spring or other biasing mechanism  108  at the rear of the storage container  102 . A sloping bottom on the storage container  102  gives a gravity assist to deployment of the panels  100   a - e . The compressed spring biasing mechanism  108  is used together or separately with additional biasing mechanisms (see FIG. 3 and FIG. 4), as the application requires. The biasing forces push the panel  100   a - e  faces together within the storage container  102 . As an operator pulls the first panel  100   a  down (see FIG. 1B) the hook-like nose  112  of the first panel  100   a  slides into engagement with the mating groove  114  of the panel  100   b  which it is sliding against (see detailed views  1 H and  1 I), since the first panel  100   a  never leaves the tracks  110   a  and  110   b  (only the left track  110   a  is illustrated), first panel  100   a  guides the second panel  100   b  into the top of the tracks  110   a  and  110   b  (see FIG. 1D), the front bottom edge of the storage container  102  being the terminus of the tracks  110   a  and  110   b . Likewise, once the second panel  100   b  is in the tracks  110   a  and  110   b , track  100   b  will engage (see FIG.  1 D) and guide the third panel  100   c  into the tracks  110   a  and  110   b  (see FIG. 1E), and so on until all of the panels  100   a -e are deployed and the first panel  100   a  contacts the aperture floor  116  (see FIG. 1G).  
         [0042]    FIGS.  2 A- 2 G illustrate an example of aperture covering storage, the reverse of the deployment procedure. An operator lifting on the first panel  100   a  will be aided by the compressed spring counterbalancing system  108  and any additional counterbalancing mechanisms (see FIG. 3 and FIG. 4). This system not only offsets much of the combined weight of the panels  100   a - e , but also prevents the panels  100   a - e  from wedging themselves apart in the tracks  110   a  and  110   b  (only the left track  110   a  is illustrated) and jamming the aperture covering. In FIG. 2A, the panels  100   a - e  are deployed except for a portion of the top panel  100   e . This panel  100   e  is holding the expanded biasing mechanism  108  open. As the top panel  100   e  is pushed up by the panels  100   a -d below it  100   e  and the counterbalancing system  108 , top panel  100   e  has to stop against the top of the storage container  102  (see FIG. 2B). In detailed drawing  2 J, the top panel  100   e  has contacted the top of the storage container  102  and the second panel  100   d  below top panel  100   e  is beginning to force top panel  100   e  out of engagement. In detailed drawing  2 K, the disengagement is concluded. In FIG. 2E, the panel  100   d  has pushed completely past and forced the top panel  100   e  against the biasing mechanism  108 . FIGS. 2F, 2G,  2 H and  21  show the panels  100   a - d  sequentially disassembling and storing themselves  100   a - d  in the overhead container  102 .  
         [0043]    Remaining FIGS. 7 through 19 and FIGS. 20 through 23 show other examples of installed aperture coverings, illustrating that the covering stores completely out of the way, while permitting the use of a panel and window style that homeowners typically prefer. Furthermore, since most or all of the drive and counterbalance parts can be contained in the storage box above the panels, there is little danger of injury due to exposed components.  
         [0044]    [0044]FIG. 3 illustrates an exemplary view of an aperture covering from the left side. Track  110   a  prevents panels  100   b  and  100   c  from moving in any direction other than up or down. The panels  100   b  and  100   c  also cannot disengage because they cannot move forward or backward far enough to do so. There is a toothed belt  302  at the front of the track  110   a  that engages notches in the end caps  304   a  or in the faces  304   b  of the covering panels  100   b  and  100   c . This belt  302  can be permanently attached to the bottom panel of the door on one end. In one unillustrated embodiment, one end is coiled in spiral fashion around a flanged drum attached to a horizontal shaft which rotates in bearings within a compartment above the panel storage box. The shaft can have a torsion spring wound around it in such a way as to offset all or a portion of the weight of the covering panels. In FIG. 3, both ends of the panels  100   b  and  100   c  are confined in the front, back, and sides by the tracks  110   a  and  110   b  (only  110   a  is illustrated) and toothed belts  302  engaging them  100   b  and  100   c  on both ends. These belts  302  are biased to offset the panel  100   b  and  100   c  weight by wrapping the belts  302  around drums attached to a common shaft. Both panel  100   b  and  100   c  ends will move in synchronous fashion up and down within the track  110   a . The panels  100   b  and  100   c  are prevented from moving up or down relative to each other within the tracks  110   a  and  110   b  because they are engaged in the notches  306  of a common belt  302 . This prevents panels  100   b  and  100   c  from wedging apart and possibly jamming within the track  110   a.    
         [0045]    In FIG. 4 a simplified exemplary cable  402  and ball  404  drive is shown as another mechanism for counterbalancing the panels  100   b  and  100   c . Many different drive types can be used. In some applications, a drive or counterbalancing system is not needed or desired.  
         [0046]    Many of the motorized drive systems in use today can be adapted to automate the invention, as embodied in FIG. 4. In one unillustrated embodiment, a motorized drive system is situated in a compartment within or above the storage container where the mechanism would turn the counterbalance shaft in one direction to lower the door and in the other to raise it. In another unillustrated embodiment, commonly used remote controls and security locks are integrated into the design.  
         [0047]    [0047]FIGS. 7 through 9 illustrate an exemplary vertical up-and-down embodiment of the present invention.  
         [0048]    [0048]FIGS. 10 through 15 and FIGS. 20 through 23 illustrate an exemplary vertical side-to-side embodiment of the present invention, which is, in a particular embodiment, used as a closet door. In FIG. 21, two vertical shafts  2102  are attached to the top edge of each panel  2104   a  and  2104   b . Two wheels  2106  are attached to each shaft  2102 . The wheels  2106  ride on opposite ledges (one per wheel) within the “C” shaped track  2108  attached above the aperture  104 . When stored in the storage container  102  (see FIG. 22), the back panel  2104   b  is biased toward the front panel  2104   a  (see FIG. 22). When removed from the storage container  102  (see FIG. 20), the back panel  2104   b  wheels  2106  are guided by a curved track section  2108  which aids in engaging the back panel  2104   b  with the front panel  2104   a  as it slides past.  
         [0049]    FIGS.  16 - 18  illustrate an exemplary horizontal embodiment of the present invention. One or more storage containers  102  are located above or below ground level. A toothed belt or other drive mechanism can be located under the panels  100  on one or both sides of the aperture  104 . A SERAPID (meaning “chains that push”) brand or another powered drive can be used to push/pull the lead panel or to drive the toothed belt or other drive mechanism. Above ground storage containers  102  may be disguised as benches, equipment storage boxes, or planters for flowers.  
         [0050]    Other exemplary embodiments of the claimed invention (not illustrated) include: security doors, aircraft hanger doors, shutters, automobile doors, flat roofs, sloped roofs, arched roofs, domed roofs, automotive roofs, dance floors, ice skating rinks, machine way covers, auditorium walls, gymnasium walls, arena walls, convention hall walls, cylindrical buildings, dome buildings, green houses, mobile buildings, bridges, and missile silo doors.  
         [0051]    The panels can be constructed of a variety of conventional building materials such as, e.g., metal, glass, wood, plastic, or fiberglass.  
         [0052]    While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the relevant art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.