AU2015201214A1 - Pressure Resistant Garage Door Assembly - Google Patents

Abstract

A wind resistant closure for an opening including at least two channels, each channel located either side of the opening and at least partially retaining at least one sheet, and at least two substantially L-shaped retainers for locating either side of the opening and for securing relative to the at least one sheet, wherein the at least two substantially L-shaped retainers and the at least one sheet form a sheet assembly, and each channel forms a profile substantially corresponding to an outer profile of the sheet assembly. ____ ___ ____ ___ ___ _ __ ___ ___ ____ ___ ___101 __________100 105 Et ___ _ __ _ 1052_ _ _ _ _ __ _ _ _ _ _ _ 107 ____ _108 _ _ 107 108__ __ ____ 274 44 29 23 280236 278 26 27 24 205 239 204I' 104

Description

PRESSURE RESISTANT GARAGE DOOR ASSEMBLY TECHNICAL FIELD

[0001] The present invention relates to closures for openings in buildings. In particular, pressure resistant closures such as pressure resistant roller garage doors.

BACKGROUND ART

[0002] Traditional garage doors are typically relied upon for security purposes. In particular, garage doors are traditionally used to prevent unauthorized intrusions into a garage.

[0003] In addition, in some areas, garage doors are further relied upon for protection from severe natural climate conditions, for example, airborne debris or high winds.

[0004] Traditional roller garage doors, in particular, comprise a metal sheet, which form a roll at the top of a frame when in an open position, and opposing tracks for guiding the metal sheet from an open to a closed or a closed to an open position. However, in areas where extreme high winds are present, the metal sheet of traditional garage doors may bend, flex, buckle or be forced out of the roller track due to dynamic or static air pressure differentials acting on both sides of the door.

[0005] Further, roller shutters comprise multiple slats that are slid together to assemble a curtain. Each slat pivots relative to adjacent slats. The sides of the curtain are typically partially located within side tracks such that the slats are able to move up and down the side tracks.

[0006] Under the fore-mentioned circumstances, wind pressure acting on the door shortens the width of the sheet causing the sheet to pull out from the side tracks.

[0007] Accordingly, in some regions of Australia, regulations have been introduced which aim to prevent garage or large access doors from dislodging from their mountings during high winds and potentially causing damage to surrounding structures or persons. For example, the National Construction Code (NCC) 2013 - Housing Provisions (Building Code of Australia Volume 2) includes a reference for garage and large access doors in Region C and Region D to comply with AS/NZS 4505 - 2012 ‘Garage doors and other large access doors.’ [0008] Some attempts have been made to overcome the potential damage caused to roller garage doors by high winds. For instance, U.S. Patent No. 6,068,040 discloses roller door assembly comprising an edge retainer and a channel combination.

[0009] Whilst such an assembly assists in preventing the retainer from dislodging from the channel, prolonged pressure on the sheet, and in turn the retainer, may cause the retainer to elongate and dislodge from the channel.

[0010] In light of the foregoing, it would be an advantage to provide a roller garage door assembly having an improved design which resists sheet bending and flexing during high pressure winds.

[0011] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

[0012] Throughout this specification, the term “comprising” and its grammatical equivalents shall be taken to have an inclusive meaning unless the context of use indicates otherwise.

SUMMARY OF INVENTION

[0013] The present invention is directed to a wind resistant closure, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.

[0014] According to one aspect of the present invention, there is provided a wind resistant closure for an opening including: at least two channels, each channel located on respective opposed sides of the opening and for at least partially retaining at least one sheet, and at least two substantially L-shaped retainers for locating either side of the opening and for securing relative to the at least one sheet, wherein at least two L-shaped retainers include one or more wings extending along an edge of the sheet, wherein the at least two substantially L-shaped retainers and the at least one sheet form a sheet assembly, and each channel forms a profile substantially corresponding to an outer profile of the sheet assembly.

[0015] The at least one sheet may be of any suitable size, shape or configuration, and the exact nature of the sheet will be dependent on the dimensions of the opening. The sheet may be fabricated from a relatively strong flexible material. For example, the sheet may be made of corrugated steel. Optionally, the sheet includes one or more slats connected relative to one another. Alternatively, the sheet may be formed of a single piece of sheet metal.

[0016] Each substantially L-shaped retainer may include a member having a first portion for engaging at least one channel when pressure is applied to the at least one sheet and a second portion including an aperture for securing each substantially L-shaped retainer relative to the at least one sheet. Preferably, each L-shaped retainer is secured to the at least one sheet using screws, rivets or any other suitable means.

[0017] In some embodiments, each substantially L-shaped retainer may include a reinforcing rib. Advantageously, the reinforcing rib strengthens each retainer to prevent each retainer from elongating, cracking, splitting and/or bending, which may result in the retainer being pulled out from at least one channel.

[0018] In some embodiments, each substantially L-shaped retainer includes an overmould made from plastics material, such as nylon. In this embodiment, the plastic overmould contacts the guide track which advantageously acts to reduce noise. The overmould may extend partially over each L-shaped retainer. The overmould may define a face for locating each retainer relative to the at least one sheet.

[0019] In some embodiments, each substantially L-shaped retainer may further include one or more wings, preferably a pair of wings. Advantageously, the one or more wings prevents the at least one sheet from contacting the channel which may result in noise being generated during operation of the sheet (such as by opening or closing a door that incorporates the sheet).

[0020] Each wing may be of similar length. However, preferably, the wings are of different lengths. Preferably, the respective free end of each wing are aligned and located parallel to the second portion of an L-shaped retainer. The length of the wing may be designed to suit the height of the slat to which the L-shaped retainer is attached. The wings prevent the slats from sliding out of alignment with the adjacent slats once the shutter curtain has moved beyond the guide tracks. In this embodiment, the wings act as stop members to prevent transverse movement of the slats.

[0021] Each channel may include an opening for locating the sheet assembly. Each channel may include at least two opposing wall formations. The two opposing wall formations may be connected via a bridge. Each wall formation may include at least one elbow formation.

[0022] Each channel may include a first locating portion for locating the at least one channel relative to a wall opening.

[0023] Each channel may be fabricated using any suitable means and may be of uniform thickness. Preferably, however, each channel is fabricated by forming, such as pressing or roll forming, a relatively strong metal, for example, steel. Alternatively, each channel may be fabricated of multiple sections and butt jointed together. The actual method used to fabricate the channel is not critical to the present invention.

[0024] Commercial embodiments of the present invention will typically have a channel fixed to a building on opposed sides of an opening that is spanned by the garage door when the garage door is closed. Each channel will provide a track or guide for the L-shaped retainers and the side edge of the sheet of the garage door. Each channel will surround the L-shaped retainer and the edge of the sheet of the garage door, it being appreciated that the L-shaped retainer and the edge of the sheet together form the outer profile of the sheet assembly.

[0025] In one embodiment, the wind resistant closure may further include at least one support bar. Preferably, each support bar is rectangular in shape. The length of each support bar may be substantially identical to the width of the at least one sheet. Optionally, a plurality of support bars may be vertically spaced along the height of the at least one sheet using screws, rivets or any other suitable means. Each support bar may comprise a strip or bar that extends across the width of the garage door. Each support bar may be connected to an L-shaped retainer either side of the opening or the L-shaped retainers may be fixed to the sheet on the support bar.

[0026] In another embodiment, the wind resistant closure may further include at least one backing plate. Preferably, each backing plate is rectangular in shape. The length of each backing plate may be shorter than the length of the second member of each retainer. Optionally, a plurality of backing plates may be vertically spaced along the height of the at least one sheet using screws, rivets or any other suitable means. Each backing plate may be fixed to the at least one sheet adjacent a retainer. Each backing plate may be fixed to the at least one sheet betweena retainer and the at least one sheet. In another embodiment, each backing plate may be located on an opposite surface of the sheet to the retainer. Advantageously, each backing plate provides additional strength to the region where each retainer is mounted to the sheet, in particular in relation to more narrow doors which may not require support bars.

[0027] In another embodiment, the sheet of the garage door further includes webbing. The webbing may extend vertically along the edges of the at least one sheet. Preferably, the webbing is fully located within each channel.

[0028] In yet another embodiment, the wind resistant closure further comprises at least one bracket. Each bracket may be used to mount or fix each channel to a building near the opening for the garage door. A plurality of spaced brackets may be used to mount or fix each channel to the building. Each bracket may suitably be located at a position that generally corresponds to a position of an L-shaped retainer when the garage door is in a closed position. This advantageously provides additional strength at the sections where retainers are positioned within each channel when the garage door is closed.

[0029] Optionally, each bracket is substantially L-shaped and may include a first portion and a second portion. Typically, the first portion includes an aperture for fastening each bracket relative to a wall opening using screws, rivets or any other suitable means, and the second portion includes an opening corresponding to the profile of the at least one channel. Alternatively, each bracket is substantially U-shaped and may include a first and second portion as described above, and a third portion. Typically, the third portion is identical to the second portion, and located parallel relative to the second portion with the first portion located in between. The first portion may comprise an intermediate web connecting the second portion to the third portion.

[0030] According to another aspect of the present invention, there is provided a channel for guiding a roller sheet including: a pair of opposing walls and two elbow formations, each elbow formation including a first elbow relative to which a first and second portion extend, wherein the second portion includes a second elbow to which one of the opposing walls extends.

[0031] Preferably, the elbow formations are connected via a bridge portion.

[0032] Preferably, the pair of opposing wall formations is longer than the first extending portions.

[0033] Preferably, the channel includes a first locating portion for locating the channel relative to a building structure.

[0034] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

[0035] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

[0036] Various embodiments of the invention will be described with reference to the following drawings, in which: [0037] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: [0038] Figure 1 illustrates a rear view of a roller door assembly according to a preferred embodiment of the present invention; [0039] Figure 2 illustrates a sectional view of the roller door assembly according to a preferred embodiment of the present invention; [0040] Figure 3A illustrates a top view of a L-shaped retainer according to another preferred embodiment of the present invention; [0041] Figure 3B illustrates an isometric view of a L-shaped retainer according to another preferred embodiment of the present invention; [0042] Figure 3C illustrates a back view of a L-shaped retainer according to another preferred embodiment of the present invention; [0043] Figure 3D illustrates a side view of a L-shaped retainer according to another preferred embodiment of the present invention.

[0044] Figure 4A illustrates a top sectional view of the roller door assembly under normal conditions according to another preferred embodiment of the present invention.

[0045] Figure 4B illustrates a top sectional view under high wind conditions according to another preferred embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0046] According to a preferred embodiment of the present invention, there is provided a pressure resistant garage door 100 as best shown in Figure 1. The pressure resistant garage door 100 includes a sheet assembly or curtain assembly 101 for locating within a garage door opening. The curtain assembly 101 includes a sheet 104 to which a plurality of support bars 105 are secured.

[0047] Wind resistant garage door 100 further includes opposing channels 102, 103. Each channel 102 includes a formed body, which may be formed by roll forming or by press forming, for partially locating the curtain assembly 101. It will be appreciated that any other fabrication technique known to the person skilled in the art can be used to fabricate the channel. A detailed description of the channels 102, 103 is provided below.

[0048] Sheet 104 is rectangular in shape. Sheet 104 includes apertures (not shown) for securing support bars 105 relative thereto. Sheet 104 can move from an open to a closed position. When in an open position, sheet 104 is rolled up above the garage door opening. When in a closed position, sheet 104 is unrolled to span the garage door opening.

[0049] Support bars 105 are defined by flat members of length generally corresponding to a width of sheet 104 and are vertically spaced along the height of the sheet 104. Each support bar 105 includes apertures (not shown) for securing the support bar 105 to sheet 104. Preferably, the plurality of support bars 105 are fastened to sheet 104 using screws, rivets or any other suitable means. In Figure 1, only some of the support bars 105 have been numbered.

[0050] Curtain assembly 101 further includes retainers 204. As can be best seen in Figure 2, each retainer 204 is defined by an L-shaped member 215, having a first portion 216 with aperture 206, and a second portion 217 with apertures (not shown). The apertures in second portion 217 enable the second portion 217 to be secured to a support bar 105 and to the sheet 104. Each retainer 204 may be made from a folded or forged strip or rod of metal. Preferably, each retainer 204 is fastened to the sheet 104 using screws, rivets or any other suitable means.

[0051] Each retainer 204 further includes an L-shaped overmould 205, having an end face 218, formed over the end of retainer 204. End face 218 acts as a locator for locating the retainer 204 relative to the sheet 104 and support bar 105. The overmould 205 is suitably made from a strong plastic. The overmould 205 may assist in reducing friction and noise as the garage door is raised and lowered. The overmould 205 also has sides that are closely spaced to the walls of the channel 102, 103. The function of this will be explained in more detail hereunder. During formation of the overmould 205, plastic will flow through aperture 206. Once the plastic has hardened, this secures the overmould 206 to the L-shaped member 217.

[0052] Overmould 205 further includes reinforcing rib 280 that extends across the inner elbow of the overmould. The curtain assembly 101 further includes webbing 211. Once the plurality of support bars 105 and retainers 204 are secured to sheet 104, webbing 211, 212 is secured to form the curtain assembly 101. Webbing 211, 212 extends along the vertical edges of the curtain 104 ensuring that the curtain assembly 101 moves smoothly within the channels 102, 103.

[0053] Channel 102 is shown in Figure 2. The channel 103 located on the opposed side of the garage door opening is essentially a mirror image of channel 102. The channels are mounted to the building in the vicinity of the garage door opening.

[0054] Channel 102 has an opening 220. The opening 220 is defined between a first sidewall 222 and a second sidewall 224. First sidewall 222 has a first elbow 226. Elbow 226 is positioned between a first portion 227 and a second portion 228 of the first sidewall 222. A second elbow 229 extends from the second portion 228 to a third wall portion 230.

[0055] The second sidewall 224 has a first elbow 232 positioned between a first portion 234 in the second portion 236. A second elbow 238 is located between the wall portion 236 and a third wall portion 239. A connecting wall portion 240 bridges the opposed wall portions 230 and 238. Elbows 242, 244 are located between wall portions 230 and 240, and between wall portions 239 and 240, respectively.

[0056] As can be seen from Figure 2, the opening 220 has an outer wall portion (in the context of the specification, the terms "outer" and "inner", when describing the channel, are used to describe the relative location of the wall portions relative to the building to which the channel is secured) in which wall portion 228 forms a shoulder. Wall portion 236 also forms a shoulder on an inner wall portion. Wall portions 230, 239, 240 form a closed end of the channel.

[0057] During assembly, the side edge 130 of sheet 104 is positioned in the opening 220 of the channel 102. The side edge 130 is closely spaced from the shoulder formed by wall portion 228. Similarly, the webbing 112 and the outer surface 250 of the metal sheet 104 are closely spaced from wall portion 222. The webbing 211 and the inner surface 252 of the metal sheet 104 are closely spaced from wall portion 224.

[0058] Each channel includes two opposing walls and two elbow formations. Each elbow formation includes a first elbow from which extends a first and a second portion. The second portion includes a second elbow from which one of the opposing walls extends. The elbow formations are interconnected by a bridging portion. The channel is of uniform thickness.

[0059] As can be seen in Figure 2, side wall 224 further includes an elbow 254 positioned between first wall portion 234 and a fourth wall portion 256. A further elbow 258 extends from the fourth wall portion 256 to a fifth wall portion 260. This acts to space the opening 220 from the edge of the garage door opening by the desired distance.

[0060] Side wall 222 further includes wall portion 262 extending from first portion 227. Wall portion 262 forms a flared outer end to the opening220 in the channel 102.

[0061] Pressure resistant garage door 100 further includes brackets 107, 108 for reinforcing the channel 102, 103. In Figure 1, only some of the brackets 107, 108 have been numbered. A detailed description of the brackets is provided below.

[0062] Bracket 107 is shown in Figure 2. Bracket 108 located on the opposed side of the garage door opening is essentially a mirror image of bracket 107. Alternatively, bracket 107 can be turned upside down and used on the opposite side of the garage door opening. The brackets are mounted to the building in the vicinity of the garage door opening.

[0063] Bracket 107 includes an L-shaped member 270 including a first portion 272 with aperture 274 and a second portion 276 with opening 278. The opening in second portion 276 is of a corresponding shape to opening 222. The first portion 272 is positioned in abutment with a wall of a building 290 and is secured to the building 290 near the edge of the garage door opening. Preferably, the brackets are fastened to the building 290 using screws, rivets or any other suitable means.

[0064] As can be seen in Figure 1, the brackets are secured to the building structure at intervals corresponding to the location of each support bar 105 when the garage door is in the closed position.

[0065] In another embodiment, the overmould further includes a pair of wings 302, 304 which extend either side of the second portion of the L-shaped member 217. As best shown in Figure 3B, the pair of wings extends outwardly angled away from the second portion 217 of the L-shaped member 215 and in a direction away from the first potion 216 of L-shaped member 215. As best shown in Figures 4A and 4B, the height of the pair of wings substantially corresponds to the width of the metal slat 308.

[0066] As best shown in Figures 3C, the distance between the ends of the pair of wings substantially corresponds to the height of the metal slat 308. Wings 302, 304 extend relatively along the vertical edges of the curtain to prevent the support bar from contacting the wall of the channels 102, 103 and to ensure that the curtain assembly 101 moves smoothly within the channels 102, 103.

[0067] The pressure resistant garage door will now be described under specific conditions: [0068] Under normal conditions, the edge of curtain assembly 101 rests within the at least one channel 102 as best shown in Figures 2 and 4A.

[0069] Under high wind conditions, in particular when positive external pressure A acts on the curtain assembly 101, the curtain assembly width shortens and retainers 204 slant inwards engaging channels 102, 103. Specifically, retainer 104 engages second portion 236, shoulder 232, and elbow 229 which impedes withdrawal of the curtain assembly 101 from channels 102, 103. Thus, there is more than one point of contact between the outer profile of the curtain assembly and the channel, thereby providing for increased resistance to removal of the retainer from the channel.

[0070] Conversely, when negative external pressure B acts on the curtain assembly 101, the curtain assembly width shortens, however, retainers 204 slant outwardly, engaging channels 102, 103 as shown in Figure 4B. The retainers 204 engage second portion 236, shoulder 232, and third portion 230, which impedes withdrawal of the curtain assembly 101 from channels 102, 103. Thus, there is more than one point of contact between the outer profile of the curtain assembly and the channel, thereby providing for increased resistance to removal of the retainer from the channel.

[0071] The brackets 107, 108 provide additional strength or reinforcement to the channels, thereby minimising the likelihood that the channels will deform under the pressure applied by high winds or cyclonic winds impacting on the sheet 104.

[0072] The brackets 107, 108 are also used to mount or fix the channels 102, 103 to the building 290. Brackets 107, 108 also act to transfer the reaction forces of the positive and negative pressures on the curtain assembly 101 to the walls of the building.

[0073] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0074] Reference throughout this specification to ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification are not necessarily all referring to the same embodiment.

Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0075] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims (23)

1. A wind resistant closure for an opening including: at least two channels, each channel located on respective opposed sides of the opening and for at least partially retaining at least one sheet, and at least two substantially L-shaped retainers for locating either side of the opening and for securing relative to the at least one sheet, wherein at least two L-shaped retainers include one or more wings extending along an edge of the sheet, wherein the at least two substantially L-shaped retainers and the at least one sheet form a sheet assembly, and each channel forms a profile substantially corresponding to an outer profile of the sheet assembly.

2. A wind resistant closure for an opening as claimed in claim 1, wherein the at least one sheet is formed of at least two or more slats.

3. A wind resistant closure for an opening as claimed in claim 1 or claim 2, further including at least one support.

4. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein the at least one support extends across a width of the at least one sheet.

5. A wind resistant closure for an opening as claimed in claim 3 or claim 4, wherein a plurality of supports are vertically spaced along a height of the at least one sheet.

6. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein each substantially L-shaped retainer includes a first portion and a second portion.

7. A wind resistant closure for an opening as claimed in claim 6, wherein each substantially L-shaped retainer includes a pair of wings extending from the second portion of the L-shaped retainer.

8. A wind resistant closure for an opening as claimed in claim 7 wherein a first wing is shorter in length than the second wing.

9. A wind resistant closure for an opening as claimed in claim 7 or 8 wherein each wing includes a free end, and wherein the free end of the first wing and the free end of the second wing are aligned and located parallel to the second portion of the L-shaped retainer.

10. A wind resistant closure for an opening as claimed in any one of the preceding claims wherein the one or more wings extend beyond the width of the at least one sheet.

11. A wind resistant closure for an opening as claimed in claim 3 wherein the one or more wings extends beyond the combined width of the at least one sheet and the at least one support.

12. A wind resistant closure for an opening as claimed in claim 6, wherein the second portion includes apertures for securing each substantially L-shaped retainer relative to the at least one sheet.

13. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein each substantially L-shaped retainer includes a reinforcing rib.

14. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein each substantially L-shaped retainer includes an overmould.

15. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein the wind resistant closure further comprises at least one bracket.

16. A wind resistant closure for an opening as claimed in claim 15, wherein the bracket is substantially L-shaped.

17. A wind resistant closure for an opening as claimed in any one of claim 16, wherein the bracket includes a first portion and a second portion.

18. A wind resistant closure for an opening as claimed in claim 17, wherein the bracket is substantially U-shaped.

19. A wind resistant closure for an opening as claimed in claim 18, wherein the bracket includes a first portion, a second portion and a third portion, wherein the third portion is substantially identical to the first portion.

20. A wind resistant closure for an opening as claimed in claims 17 or 19, wherein the first portion includes an aperture corresponding to a profile of each channel.

21. A wind resistant closure for an opening as claimed in any one of the preceding claims, wherein each channel includes a first locating portion for locating each channel relative to a building structure.

22. An L-shaped retainer for securing at least one sheet within an opening, the retainer including: one or more wings extending along an edge of the at least one sheet, wherein one or more retainers and one sheet form a sheet assembly.

23. An L-shaped retainer as claimed in claim 22, wherein the at least one sheet is formed of at least two or more slats.