AU2018100770B4

AU2018100770B4 - Overhead rolling door

Info

Publication number: AU2018100770B4
Application number: AU2018100770A
Authority: AU
Inventors: Greg Dengate; Dong Du; Terrence Hardie; Sam Saliba
Original assignee: B&D Australia Pty Ltd
Current assignee: B&D Australia Pty Ltd
Priority date: 2018-06-08
Filing date: 2018-06-08
Publication date: 2019-08-01
Anticipated expiration: 2026-06-08
Also published as: AU2018100770A4; NZ750636A

Abstract

C:\Interwoe\NRPortbI\DCC\KMI\15757043_l.docx-8/062018 Abstract An overhead rolling door is disclosed, including a curtain and a roller. The curtain has an upper edge attached to the roller and two side edges configured to move along vertical guides. The door can move between a closed configuration and an open configuration, where the curtain is rolled about the roller when the door is in the open configuration. The curtain includes a sheet with a plurality of substantially planar sections separated by lateral ridges that run from one side edge to the other side edge, wherein the width of the ridges is less than the width of the planar sections. A spacing device is fitted to at least one of the planar sections at each of the side edges, so that when the door is in the open configuration the planar section to which the spacing devices are fitted does not contact any other overlapping planar section.

Description

[0001] The present invention generally relates to overhead rolling doors and methods of manufacture thereof.

BACKGROUND [0002] Overhead rolling doors are commonly used in residential and industrial settings. They typically have a door curtain made from corrugated sheet metal which is configured to be raised and lowered, the edges being constrained by guides.

[0003] As the curtain is raised towards an open position, it is rolled about a roller located above the door opening. The corrugations in the door curtain run horizontally, so that they provide strength to the door curtain while still allowing a degree of bending only about a horizontal axis to permit the rolling.

[0004] Protective strips are provided along each edge of the curtain to provide smooth travel within the guide. These strips also aid with rolling the curtain so as to avoid wear over time from contact between overlapping portions of the curtain.

[0005] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

SUMMARY [0006] According to one example aspect, there is provided an overhead rolling door, comprising a curtain and a roller, the curtain having an upper edge attached to the roller and two side edges configured to move along vertical guides so that the door can move between a closed configuration and an open configuration, wherein the curtain is rolled

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-2about the roller when the door is in the open configuration, the curtain comprising a sheet with a plurality of substantially planar sections separated by lateral ridges that run from one side edge to the other side edge, wherein the width of the ridges is less than the width of the planar sections, and wherein a spacing device is fitted to at least one of the planar sections at each of the side edges, so that when the door is in the open configuration the planar section to which the spacing devices are fitted does not contact any other overlapping planar section.

[0007] In one form, an edge strip is attached to the sheet proximal to each edge of the curtain and the spacing devices include a groove through which the edge strip is positioned. Preferably, each spacing device comprises a body with two leg portions, the groove being formed between the body and each leg portion.

[0008] In another form, each leg portion comprises a tab projecting from an end opposite the body, such that the spacing device is fitted to the edge of the sheet by inserting the sheet to a space between the tab and the leg portion. In one example form, the body, leg portion and tab together are substantially S-shaped when viewed in a direction parallel to the edge of the curtain, such that the groove has an opening facing in a substantially opposite direction to an opening of the space between the tab and the leg portion.

[0009] In other particular, but non-limiting, example forms: the edge strip is attached to the sheet at a location between the leg portions of at least some of the spacing devices; and the edge strip is attached to the sheet at a location on either side of at least some of the spacing devices.

[0010] In accordance with another optional embodiment, provided by way of example only, an upper portion of the curtain has two spacing devices between each ridge at each edge and a lower portion of the curtain has only one spacing device between each ridge at each edge.

[0011] In other particular, but non-limiting, example forms: the spacing devices are sized so that they are substantially hidden by the guides when the door is in the closed

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-3configuration; the ratio of the width of the ridges to the width of the planar sections is equal to or less than 1:3; the ratio of the width of the ridges to the width of the planar sections is equal to or less than 1:4; the ratio of the width of the ridges to the width of the planar sections is equal to or less than 1:5; and each of the spacing devices is formed as a single piece.

[0012] According to another example aspect, there is provided a method of manufacturing a curtain for an overhead rolling door, comprising the steps of: forming ridges in a sheet of material; fixing an edge strip along two edges of the sheet using staples or other fasteners; and attaching a plurality of spacing devices to each of the edges by inserting a leg of the spacing device between the edge strip and the sheet. Preferably, the curtain is substantially as defined herein.

BRIEF DESCRIPTION OF FIGURES [0013] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but nonlimiting embodiment, described in connection with the accompanying figures, wherein:

[0014] Figure 1 illustrates an isometric view of a curtain for an overhead rolling door according to an embodiment of the invention;

[0015] Figure 2 illustrates a front view of an overhead rolling door according to an embodiment of the invention in a closed condition;

[0016] Figure 3 illustrates a rear view of the curtain from Figure 1;

[0017] Figure 4 illustrates a side view of the curtain from Figure 1;

[0018] Figure 5 illustrates a front view of the curtain from Figure 1;

[0019] Figure 6 illustrates an enlarged portion of Figure 3 as identified by DetailA;

[0020] Figure 7 illustrates an enlarged portion of Figure 3 as identified by DetailB;

[0021] Figure 8 illustrates an enlarged portion of Figure 4 as identified by DetailC;

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2018100770 08 Jun 2018 [0022] Figure 9 illustrates an enlarged portion of Figure 4 as identified by Detail D;

[0023] Figure 10 illustrates an end portion of a sheet that forms part of the curtain, similar to Figure 9 but with a spacing device and edge strip removed;

[0024] Figure 11 illustrates an enlarged portion of Figure 5 as identified by Detail E;

[0025] Figure 12 illustrates an enlarged portion of Figure 5 as identified by Detail F;

[0026] Figure 13 illustrates an inner isometric view of a spacing device that forms part of the curtain from Figure 1;

[0027] Figure 14 illustrates an outer isometric view of the spacing device from Figure 13;

[0028] Figure 15 illustrates an outer side view of the spacing device from Figure 13;

[0029] Figure 16 illustrates a top view of the spacing device from Figure 13;

[0030] Figure 17 illustrates a rear view of the spacing device from Figure 13;

[0031] Figure 18 illustrates an inner side view of the spacing device from Figure 13;

[0032] Figure 19 illustrates a front view of the spacing device from Figure 13;

[0033] Figure 20 illustrates a rear isometric view of an upper portion of an edge of the curtain from Figure 1;

[0034] Figure 21 illustrates a front isometric view of the portion of the curtain from Figure 20;

[0035] Figure 22 illustrates a rear isometric view of a lower portion of the edge of the curtain from Figure 1; and [0036] Figure 23 illustrates a front isometric view of the portion of the curtain from Figure 22.

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-5 DETAILED DESCRIPTION [0037] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

[0038] In the Figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the Figures.

[0039] Referring to Figure 1, a curtain 10 is shown from an overhead rolling door according to an embodiment of the invention. The curtain 10 has an upper edge 12 attached to a roller 13. Two vertical side edges 14 are configured to move along vertical guides so that the door can move between a closed configuration as shown, where a majority of the curtain is substantially flat, and an open configuration. When the curtain 10 is in the open configuration, it is rolled about the roller 13.

[0040] Figure 2 shows the curtain 10 in a closed configuration. Typically, a seal 15 is provided along a lower edge that abuts the ground when the door is in the closed configuration.

[0041] Referring to Figure 3, the curtain 10 is made from a sheet 18 with a plurality of substantially planar sections 20 separated by lateral ridges 21. The ridges 21 run from one side edge 14 to the other side edge 14. A seam 22 may be visible also extending across the curtain 10, however this primarily a visibly line only and does not affect the shape of the curtain 10 to any important extent.

[0042] Figure 10 shows the profile of the sheet 18 in more detail. The ratio of the width 25 of the ridges 21 to the width 26 of the planar sections 20 in the embodiment shown is in the order of 1:4. In alternative embodiments of the invention, the planar sections 20 may be narrower, so that the ratio is only about 1:3, but in yet other embodiments the planar sections 20 may be even wider, so that the ratio is equal to or even less than 1:5.

[0043] In contrast, prior art doors are typically manufactured with a relatively equal width of planar sections and ridges, depending on the precise shape of the ridges and how

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-6the width is measured. That is, for prior art doors the width of the ridges is similar to the width of the planar sections, as a result of the planar sections being far narrower. So the embodiment shown in the Figures has planar sections that are at least double the width of typical prior art doors, with similar sized ridges. Described in another way, prior art doors have corrugations where the troughs are similar in size to the raised sections, while the door curtain of the present invention has corrugations where the troughs are much wider than the raised sections.

[0044] While such a change may appear minor, there are a number of practical reasons why doors of such configuration have not been made before. Firstly, a common manufacturing process for making the sheets is “roll forming”. This process involves passing a blank sheet through a series of sequential rollers, which gradually form the blank sheet into the finished configuration. The rollers are shaped according to the desired final profile of the door curtain. In such a process, adjusting the shape and/or spacing of the ridges is not practical, due to the need to change the shape or move the position of the rollers.

[0045] Overhead rolling doors are typically not bulk produced to a particular specification, but rather involve specific production to customer requirements due to the extensive options made available, such as colour, width and material. Most customers will only require single or small numbers of doors, so providing options such as ridge shape or ridge width may require continuously stopping the manufacturing process to adjust the rolls used in the roll forming process.

[0046] By changing the process to a continuous process, whereby a single ridge is stamped at a time, this allows the spacing between ridges to be readily adjusted. This may not appear to be a particular advantage, however by removing the issues described above it makes the process practical in a mass production scenario where the specification for ridge separation distance is changing regularly.

[0047] During development of the present invention, however, it was found that increasing the width of the planar sections too far can introduce problems with the operation of the door. In particular, when the door is rolled on the roller when in the open

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-7position, the greatly increased width of the planar sections can change the way the sheet curves. In particular, the planar sections may not curve sufficiently and/or may deform under the weight of subsequent wraps around the roller. As such, this may result in contact between sections of the sheet that are laying over one another when rolled on the roller. In such a case, protective strips provided along the edges of the curtain may not be enough to prevent such contact.

[0048] This may not immediately cause problems with operation of the door, however after many cycles of opening and closing the door it can result in wear on the sections that touch one another. Initially, this may cause visible signs of wear, such as discolouration, and eventually this wear may increase to a more detrimental failure.

[0049] To ensure the curtain 10 rolls effectively despite being manufactured with wider planar sections 20, spacing devices 30 are fitted to the planar sections 20 at each of the side edges 14. This ensures that when the door is in the open configuration, the planar section 20 to which the spacing devices 30 are fitted does not contact any other overlapping planar section 20.

[0050] Referring to Figures 13 to 19, a spacing device 30 is shown in more detail. The spacing device includes a body 32 with two leg portions 33. Together, the body 32 and leg portions 33 are shaped to form a groove 35 between them, where this groove is in two separate sections.

[0051] Each leg portion 33 also includes a tab 36 projecting from an end opposite the body 32, so that when viewed from the end, as shown in Figure 16, the body 32, legs 33 and tabs 36 together are substantially S-shaped. This means that the groove 35 faces in a substantially opposite direction to a space 37 between the tab 36 and the leg portion 33.

[0052] Preferably, each of the spacing devices 30 is formed as a single piece, such as being moulded from plastic, for example. It will be appreciated, however, that many different methods and/or alternative materials could be used for manufacturing the spacing devices 30.

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-8[0053] Referring to Figure 20, an edge strip 42 is attached to the sheet 18 proximal to the edge 14 of the curtain 10. This edge strip 42 is fixed to the side of the sheet 18 from which the ridges 21 protrude. Two staples 44 in each of the planar sections 20 fixes the edge strip 42 to the sheet 18. Figure 21 shows that another edge strip 45 and metal strip 46 are also attached to the opposite side of the sheet 18.

[0054] When the spacing device 30 is fitted to the edge 14 of the sheet 18, the edge strip 42 is positioned in the groove 35 and the sheet 18 is positioned in the space 37, so that the tabs 36 hook around to the opposite side of the sheet 18.

[0055] The section of the curtain 10 that is shown in Figures 20 and 21 has two spacing devices 30 on a single planar section 20. In this configuration, the edge strip 42 has the staples 44 located between the leg portions 33 of the spacing devices 30.

[0056] Referring to Figures 22 and 23, a section of curtain 10 is shown that has only one spacing device 30 on the planar section 20. In this configuration, the edge strip 42 has the staples 44 located on either side of the spacing device 30.

[0057] Referring to Figure 3, an upper portion of the curtain 10 has two spacing devices 30 between each ridge 21 at each edge 14 and a lower portion of the curtain 10 has only one spacing device 30 between each ridge 21 at each edge 14. When the curtain 10 is rolled, the upper portion is closer to the centre of the roller, and is therefore rolled to a tighter radius.

[0058] In addition, the angle at which the curtain enters the generic door guides is greater when the door is closer to the closed position, due to the smaller roller diameter. This may cause single spacers toward the top of the curtain to “catch” when entering the guides. Using two spacers in the planar sections at the top of the curtain can help to prevent this catching at the end of the guide.

[0059] As such, the extra spacing devices 30 are used to ensure adequate curvature of the planar sections 20 and smoother entry into the door guides. It also means that standard door guides can be used without modification with the door curtain 10 of the present

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-9invention. The lower portion is rolled to a larger radius, however, so a single spacing device 30 per planar section 20 is sufficient.

[0060] The spacing devices 30 are sized so that they are substantially hidden by the guides when the door is in the closed configuration. Therefore, the spacing devices 30 allow the wider planar sections 20 to be successfully used, yet still have the curtain 10 roll in an effective manner, while not creating any negative visual impacts. That is, the spacing devices 30 create adequate curvature and support across the width of the curtain 10 when rolled, without needing to extend across the width of the curtain 10.

[0061] Manufacturing the curtain 10 involves first forming the ridges 21 in the sheet

18. The edge strips 42, 45 are then fixed along the two edges 14 of the sheet 18 using the staples 44 or other suitable fasteners. The spacing devices 30 are then attached to each of the edges 14 by inserting the legs 33 of the spacing device 30 between the edge strip 42 and the sheet 18.

[0062] Once the legs 33 are inserted far enough, the tabs 36 hook over the edge of the sheet 18. The tabs 36 then prevent the legs 33 from being slid back out from under the edge strip 42. At the same time, however, the edge strip 42 sitting in the groove 35 of the spacing device 30 stops it from being moved further past the edge 14 of the sheet 18. In this way, the shape of the spacing device 30 together with the edge strip 42 and the sheet 18 allows the spacing device 30 to be firmly held in place without the need for directly being fastened to the sheet 18 or edge strip 42.

[0063] The spacing devices 30 are advantageous because they allow the curtain 10 to roll effectively and without damage over time, without the need for any component to extend across the curtain 10. This allows the significantly different appearance to be achieved without compromising the lifespan of the curtain 10 to any significant degree.

[0064] Whilst the present invention has been described with reference to particular embodiments, it will be understood that many modifications will be apparent to those skilled in the art. All such variations and modifications should be considered to fall within the scope of the invention as broadly described and as claimed below.

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-10[0065] Throughout this specification and the claims which follow, unless the context requires otherwise, the word comprise, and variations such as comprises or comprising, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Claims

The claims defining the invention are as follows:

1. An overhead rolling door, comprising a curtain and a roller, the curtain having an upper edge attached to the roller and two side edges configured to move along vertical guides so that the door can move between a closed configuration and an open configuration, wherein the curtain is rolled about the roller when the door is in the open configuration, the curtain comprising a sheet with a plurality of substantially planar sections separated by lateral ridges that run from one side edge to the other side edge, wherein the width of the ridges is less than the width of the planar sections, wherein a spacing device is fitted to at least one of the planar sections at each of the side edges, so that when the door is in the open configuration the planar section to which the spacing devices are fitted does not contact any other overlapping planar section, and wherein an upper portion of the curtain has two spacing devices between each ridge at each edge adjacent to one another along the edge, and a lower portion of the curtain has only one spacing device between each ridge at each edge.
2. The overhead rolling door according to claim 1, wherein an edge strip is attached to the sheet proximal to each edge of the curtain.
3. The overhead rolling door according to claim 2, wherein the spacing devices include a groove through which the edge strip is positioned.
4. The overhead rolling door according to claim 3, wherein each spacing device comprises a body with two leg portions, the groove being formed between the body and each leg portion.
5. The overhead rolling door according to claim 4, wherein each leg portion comprises a tab projecting from an end opposite the body, such that the spacing device is fitted to the edge of the sheet by inserting the sheet to a space between the tab and the leg portion.