GB2512932A

GB2512932A - A support member for a bi-fold door

Info

Publication number: GB2512932A
Application number: GB201306682A
Authority: GB
Inventors: Neal Desorgher
Original assignee: Caldwell Hardware UK Ltd
Current assignee: Caldwell Hardware UK Ltd
Priority date: 2013-04-12
Filing date: 2013-04-12
Publication date: 2014-10-15
Also published as: GB201306682D0

Abstract

A support member 180 for a bi-fold door is composed of thermally insulating material. The support has side portions 184 spaced apart from one another and defining a guide channel 168 between them, for receiving a guide member (1200, fig 3) of the door. At least one of the side portions has a holding formation 1100 for holding a support rail 140, 160 for the door. The support may be made of plastics material and may form a thermal break between two frame members (120, 122, fig 2) which altogether form a track assembly (110, fig 2).

Description

Title: A support member for a bi-fold door.

Descrirtion of Invention This invention relates to a support member for supporting and guiding a wheel assembly at the bottom of a panel of a bi-fold door.

Multi-panel folding doors have been popular for a number of years. They enable a large door opening to be provided in an exterior or interior wall of a building.

A typical multi-panel door comprises at least two, and possibly a plurality of, hinged panels which run along tracks at both floor and overhead level. For the purpose of describing the invention we make reference to a bi-fold door comprising (at least) two such panels. A first panel is hinged to a vertical member at one edge of a door opening. A second adjacent panel is hinged to the first panel and is supported on a track at floor level, extending lengthwise of the door opening (each subsequent panel is hinged to the preceding panel in the same way), the second panel having a wheel assembly which has at least one wheel and runs along the track. The track has at least one rail, but more typically two spaced parallel rails for spaced wheels to move on. The bi-fold door forms a flat wall when closed and opens by folding, in a concertina fashion, to one side of the opening. This allows the opening space to be maximised, as the panels are then largely parallel to one another, and perpendicular to the door frame. The track at floor level both supports the doors wheels on the support rails and guides the door in a guide channel between the support rails.

It is advantageous to reduce heat transmission from the inside of the door (i.e. in the house) to the outside, and increase the efficiency of a dwelling. Heat dissipation through the metal track at the bottom of the door can be reduced by adding a thermal break" between the two sets of rails. This is achieved by adding a thermally insulating member across the bottom of the guide channel, rather than using a metal one.

One problem with this solution is that the support rail(s) have to be a set distance apart to provide support for the two sets of door wheels; this dictates how wide the thermal break can be.

Another problem is that, because the support rail(s) are usually made of metal and carried by a metal frame, when the door is opened, it can generate excessive noise from the wheels moving over the support rail(s), causing the support rail to vibrate within its metal frame. This results in sound waves resonating through the entire lower track.

According to an aspect of the invention we provide a support member for a bi-fold door, of thermally insulating material and comprising side portions spaced apart from one another and defining a guide channel between them, for receiving a guide member of the door, and at least one of the side portions having a holding formation for holding a support rail for the door.

The side portions may provide the side walls of the guide channel.

The side portions may have respective holding formations for holding respective support rails.

The, or each, holding formation may comprise two spaced grooves.

The grooves may be mirror images of one another.

The support member may be of a plastics material.

According to another aspect of the invention we provide a support member for a bi-fold door, of thermally insulating material and comprising side portions spaced apart from one another and defining a guide channel between them, for receiving a guide member of the door, at least one of the side portions having a holding formation for holding a support rail for the door, and at least one support rail held in the holding formation.

The base portion of the support member may have a wave-shaped portion.

The support member may hold respective support rails in respective holding formations.

The, or each, support rail may be substantially of an inverted-U shape.

The, or each, support rail may have outwardly extending feet.

The, or each, support rail may be stainless steel.

The, or each, support rail held in the holding formation(s) may be supported at more than one position in the, or each, holding formation.

The frame assembly may comprise two frame members and a connecting member.

The support member may be carried by the frame assembly to creat a track assembly.

The support member may be disposed within a receiving formation of the frame assembly.

The support member may be a snap fit with the frame assembly.

The support member may create a thermal break between one side of the frame assembly and the other.

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, wherein; Figure 1 is a perspective view of a known support track for a bi-fold door; Figure 2 is a perspective view of a support member for a bi-fold door, in accordance with the invention, in co-operation with a standard metal frame; Figure 3 is a cross-sectional view of the support member, in accordance with the invention, shown in co-operation with a standard frame and a wheel assembly of a bi-fold door; Figure 4 is a cross-sectional view of the support member, in accordance with the invention; Figure 5 is a perspective view of the support member, in accordance with the invention, in co-operation with a low threshold frame; Figure 6 is a cross-sectional view of a support member, in accordance with the invention, in co-operation with a low threshold frame.

Figure 1 shows a known bi-fold door support track. A track assembly 10 comprises a left frame member 20 and a right frame member 22, both of which are, typically, extrusions of an aluminium alloy In the following description, the support member is described as supporting the door from below. It should be understood that additionally, or as an alternative, a support member and support rail(s) may be provided above, or at the top of, a door. References to "uppermost" or "lowermost", "top" and "bottom", or "upper" and lower" should therefore be construed accordingly, such that when the support member is located above the door, parts described as "uppermost" should be read as "lowermost", etc..

The left frame member 20 has a base wall 24, two spaced upstanding side walls (inner 28 and outer 26), and a top wall 30 which define within them an interior space 32 of generally square cross-sectional shape. The top wall 30 extends outwards beyond the outer side wall 26; followed by an upwardly extending wall portion 34. Adjacent the uppermost edge of the upwardly extending wall portion 34 two lips 36 extend inwardly defining an undercut groove between them, for holding a door seal.

On the inner edge of the top wall 30 there are two upright wall portions 38a, 38b, spaced parallel to one another, these allow a support rail 40 to be inserted into the space between them. The support rail 40 is a generally inverted U-shape, and typically made of stainless steel.

The right frame member 22 comprises a base wall 44, two spaced upstanding side walls (inner 46 and outer 48), and a top wall 50. The right frame member 22 is generally a mirror image of the left frame member 20. There is no upwardly extending wall portion 34 on the outer edge of the top wall 50. A second steel rail 60 can be inserted between the two spaced upright wall portions 54a, 54b.

The left frame member 20 and the right frame member 22 are spaced parallel to one another. The distance between them is dictated by the lateral spacing of wheels of a wheel assembly of the door (see figure 3, 1240) and the rails 40, 60 they run along. There are two connecting members (upper 64 and lower 62), they are spaced vertically apart and connect the left and right frame members 20, 22. The gap between the connecting members 62, 64 creates an interior space 66.

Each of the connecting members 62, 64 has a dovetail-shaped formation 63 on both edges. The dovetail formations 63 cooperate with respective undercut grooves 61 defined between projections extending from the inner walls 28, 46 of the left and right frame members 20, 22. The track assembly 10 is assembled by sliding the connecting members 62, 64 into the undercut grooves 61 from the end of the track assembly 10. The formations defining the undercut grooves 61 are then bent (e.g. by rollers through which the track assembly is passed lengthwise), towards the dovetail formations 63 to grip the connecting members 62, 64 in place.

The connecting members 62, 64 are typically manufactured of a thermally insulating material (e.g. polyamide) and are approximately 20mm wide. The interior space 66 and the thermally insulating connecting members 62, 64 create a thermal break between the respective frame members 20, 22 to reduce the heat being conducted away from the interior of the house.

The inner walls 28, 46 of the left and right frame members 20, 22 and the upper connecting member 64 define a guide channel 68. Each set of wheels 1220 of the wheel assembly 1240 runs along each of the support rails 40, 60 and a guide member 1200 can move along the guide channel 68 to stop the door from veering off the support rails 40, 60.

Figures 2 and 3 show a support member in accordance with the invention, in co-operation with a frame. Where aspects of this embodiment are the same and/or perform the same function as in the prior art (figure 1) the same reference numerals are used, prefixed by 1.

A track assembly 110 is shown, comprising a support member 180 and frame assembly 111. The frame assembly 111 comprises a left frame member 120 and a right frame member 122.

The left frame member 120 has a base wall 124, two spaced side walls (inner 126 and outer 128), and a top wall 130. The outer side wall 126 extends above the top wall 130 and ends in a lip formation 136 defining an undercut groove for a door seal. The inner side wall 128 extends above the top portion 130 and ends in an overturned portion 172.

The right frame member 122 comprises a base wall 144, two spaced upright side walls (inner 146 and outer 148) and a top wall 150. The inner and outer side walls 146, 148 both extend above the level of the top wall 150, and form respective inwardly facing lip formations 174.

The left and right frame members 120, 122 are connected by upper and lower connecting members 164, 162. The lower connecting member 162 has a substantially horizontal central portion 163, at each edge there are upwardly angled portions 165, extending into a V-shape edge portion 167. The upper connecting member 164, has a substantially horizontal central portion 169, at each edge there is a downwardly angled portion 171, extending into a V-shaped edge portion 173. The V-shaped edge portions 167, 173 on each of the connecting members 162, 164 engages with complementary undercut formations 175a, 175b defined between projections extending from the inner side walls 128, 146 of each frame member 120, 122. Both connecting members 164, 162 are, typically, of a thermally insulating material (e.g. Polyamide), and in this embodiment are about 38mm wide. Each connecting member is slid into the correct position, within the undercut formations 175a, 1 75b, from the end of the frame assembly 111, and the undercut formations 175a, 175b are bent (e.g. by rollers as described above) to grip the connecting members 162, 164.

A support member 180 sits above the upper connecting member 164. The support member is typically manufactured of a plastics material, so as to be thermally insulating.

Figure 4 illustrates the support member 180; ii comprises a base portion 182 and two side portions 184, one at each side of the base portion 182. The base portion 182 is substantially horizontal in the central region 186, and at each side there is a wave-shaped portion 188. The corners 190 of the base portion are rounded upwards and extend into the outer side walls 192 which are substantially vertical. The corners 190 of the support member sit on the edge of the undercut formations 175a, 175b of the respective frame members 120, 122, whereas the base portion 182 sits on the upper connecting member 164.

In this embodiment the base portion 182 is typically 4mm deep.

The outer side walls 192 each have a recess 194, which allows the support member to be fitted into the track assembly with a snap fit. Corresponding tapered projections 196 are found on the inside of the inner side walls 126, 146 of the respective left and right frame members 120, 122.

Each side portion 184 has an outer top surface 198 and an inner top surface 199. In between these two top surfaces 198, 199 there are holding formations 1100. Each holding formation 1100 comprises two respective shaped grooves 11 02a, 11 02b, the grooves being mirror images of each other. They are adapted to hold the support rails 140, 160 in place. The support rails 140, 160 are substantially of inverted U-shape, including substantially vertical legs 1110 ending in outwardly turned feet 1112. Each shaped groove 11 02a has an inner surface 1104 with a ridge 1106, which abuts the support rail leg 1110, and a recess 1108, which is adapted to receive the support rail foot 1112.

Additionally, the centres of the support rails 140, 160 are supported on upwardly extending formations 1107, which have a curved top surface 1109 adapted to support the internal surface of the U-shape of the rails 140, 160.

The side portions 184 have respective inner walls 1114, which define a guide channel 168 between them. Each inner wall 1114 has a small recessed portion 1116 towards the bottom. The wheels 1220 of the wheel assembly 1240 can run along the support rails 140, 160 of the support member 182 and the guide member 1200 of the door assembly can move along the guide channel 168.

Figures 5 and 6 show the support member as already described in a second embodiment of frame assembly. This frame assembly provides a lower height threshold to that of the frame assembly of figure 3 and 4. Where aspects of this embodiment are the same and/or perform the same function as in the already described embodiment the same reference numerals are used, prefixed by2.

A track assembly 210 comprises left and right frame members 220, 222, and support member 280. The right frame member 222 is a mirror image of the left frame member 220. Each frame member 220, 222 comprises; a base portion 224, 244 and an inner wall portion 228, 246 and a top wall portion 230, 250.

The top wall portions 230, 250 extend outwardly horizontally and then are inclined downwardly 231, 251 to meet the base portions 224, 244. These walls define an interior space 232, 252. On the inside of the inner wall portions 228, 246 there are ridge formations 275a, 275b, which are adapted to hold a connecting member 262 and provide a flange 276 adapted for holding the support member 280 in place using a snap fit. A lower ridge formation 277 can be bent upwards when the connecting member 262 is in position, to hold it in place.

In this embodiment there is a single connecting member 262, extending between the respective frame members 220, 222, of the same general shape as the lower connecting member 162 already described. The support member 280 engages the connecting member 262, which in turn lies directly on the ground surface. The connecting member 262 is again typically made of a thermally insulating material. This arrangement provides a lower threshold option compared to that described in figures 1 to 3 while still creating a thermal break between the interior of the house and the outside.

When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

CLAIMS: 1. A support member for a bi-fold door, of thermally insulating material and comprising side portions spaced apart from one another and defining a guide channel between them, for receiving a guide member of the door, and at least one of the side portions having a holding formation for holding a support rail for the door.
2. A support member according to claim 1, wherein the side portions provide the side walls of the guide channel.
3. A support member according to claim 1 or claim 2, wherein the side portions have respective holding formations for holding respective support rails.
4. A support member according to any one of the preceding claims, wherein the, or each, holding formation comprises two spaced grooves.
5. A support member according to claim 4, wherein the grooves are mirror images of one another.
6. A support member for a bi-fold door according to any of the preceding claims, wherein the support member is of a plastics material.
7. A support member for a bi-fold door, of thermally insulating material and comprising side portions spaced apart from one another and defining a guide channel between them, for receiving a guide member of the door, at least one of the side portions having a holding formation for holding a support rail for the door, and at least one support rail held in the holding formation.
8. A support member according to any of the preceding claims, wherein the base portion of the support member has a wave-shaped portion.
9. A support member according to claim 7, wherein the support member holds respective support rails in respective holding formations.
10. A support member according to any one of claims 7 to 9, wherein the, or each, support rail is substantially of an inverted-U shape.
11. A support member according to claim 10, wherein the, or each, support rail has outwardly extending feet.
12. A support member according to any one of claims 7 to 11, wherein the, or each, support rail is stainless steel.
13. A support member according to any one of claims 7 to 12, wherein the, or each, support rail held in the holding formation is supported at more than one position in the, or each, holding formation.
14. A track assembly comprising a frame assembly and a support member according to any one of the preceding claims, wherein the frame assembly comprises two frame members and a connecting member.
15. A track assembly according to claim 14, wherein the support member is carried by the frame assembly to create a track assembly.
16. A track assembly according to claim 15, wherein the support member is disposed within a receiving formation of the frame assembly.
17. A track assembly according to claim 15 or 16, wherein the support member is a snap fit with the frame assembly.
18. A track assembly according to any one of claims 14 to 16, wherein the support member creates a thermal break between one side of the frame assembly and the other.
19. A support member according to any one of claims 1 to 13, or a track assembly according to any one of claims 14 to 18 therefore, substantially as described herein with reference to and/or as shown in the accompanying drawings.
20. A door assembly including a support member, or a track assembly according to any one of the preceding claims.
21. A support member substantially as described herein and/or as shown in Figures 2 to 6 of the accompanying drawings.
22. A track assembly substantially as described herein and/or as shown in Figures 2 to 6 of the accompanying drawings.
23. Any novel feature or novel combination of features disclosed herein.