IE20010751A1

IE20010751A1 - Shutter Door Assembly

Info

Publication number: IE20010751A1
Application number: IE20010751A
Authority: IE
Inventors: Russell Cooper
Original assignee: Hadley Ind Plc
Priority date: 2000-08-17
Filing date: 2001-08-07
Publication date: 2002-04-17
Also published as: GB0020338D0; GB2367851A; GB0118776D0

Abstract

A shutter door assembly including a curtain C made of generally parallel laths L, each pivotally joined to its neighbour by way of a hinge means H1, H2. An elongate drum D is located above the curtain C. A winding means is provided for winding the curtain on to the drum for the purpose of opening the door and for unwinding the curtain from the drum for the purpose of closing the door. A first lath L1 is pivotally connected by way of a hinge means H2 to a bracket (23) mounted on the drum D and which extends in a direction along the length of the drum. The bracket (23) is located at the top dead centre of the drum, and is in the form of an elongate plate (24) secured to the drum. The plate has a longitudinal edge portion shaped to form a hinge means P1 for receiving a complementary shaped hinge means of the said first lath. The Bracket B is shaped and arranged relative to the drum and laths L so as to ensure that when the curtain is wound onto the drum, the laths L are not urged away from the drum.

Description

r t SHUTTER DOOR ASSEMBLY Be lnv^ntioiyrMit’es^fo a skitter door assembly of the type as used in industrial Such a door may include a curtain which travels in vertical side tracks and is made up of a series of horizontal cross members, called laths, each joined to its neighbour along its longitudinal edge. The curtain is wound about a drum or barrel shaped member in the ceiling area, and a mechanism is provided to wind the curtain up for storage when the door is to be opened, and for lowering the curtain when the door is to be shut.

Under recent building regulations it has become necessary for the shutter door to have minimum values of heat and sound insulation. This has caused a redesign of the curtain. Unfortunately prior to the present invention, because of the redesigned laths, it has not been possible to wind the redesigned curtain on to the drum of an existing installation that uses a drum typically of 12.7cm diameter (5 inches), so much of the door assembly has had to be replaced. The capital cost in replacing all of the shutter door system, and not just the curtain, is very high.

It is one object of this invention to provide an improved shutter door. One specific object is to provide a curtain having desirable heat and sound insulation properties and which may be used with traditional roller shutter door equipment.

HUT Cl go& & q//> According to one aspect of the present invention there is provided a shutter door assembly including a curtain made of generally parallel laths each pivotally joined to its neighbour by way of a hinge means, an elongate drum which, in use, is located above the curtain, a winding means for winding the curtain on to the drum for the purpose of opening the door and for unwinding the curtain from the drum for the purpose of closing the door, wherein a first lath is pivotally connected by way of a hinge means to a bracket mounted on the drum, the bracket being shaped and arranged to allow the curtain to be wound on to the drum without urging laths away therefrom.

Preferably the bracket extends in a direction along the length of the drum and is located at the top dead centre of the drum. The bracket comprises an elongate plate secured to the drum, and the plate has a longitudinal edge portion shaped to form a hinge means for receiving a complementary shaped hinge means of the said first lath.

Preferably each lath has a first curled edge along a first longitudinal edge that, in use, defines an inner part of a hinge means, and a second curled edge along a second longitudinal edge that, in use, defines an outer part, and said curled parts of at least one of the laths co-operating with complementary shaped curled edges of an adjacent lath to form a hinge means allowing relative pivotal movement of one lath to another.

Preferably each lath comprises two identical skins, each of which has an elongate main body and first and second longitudinal marginal portions curled to define complementary shaped curls projecting from the same side of the main body of each skin, one of said curled edges being formed with an outwardly curved portion that has a ΙΕΟ 107 bend that forms a flange facing the main body of the skin, and the other curled edge being formed with an outward flange portion and an outwardly curved portion that has a bend that forms a second flange, said skins being assembled back-to-back with each other to form a cavity between the main bodies of the skins, and cause the curls of the curled edges of one skin to nestle inside the curl of the other skin to form a first hinge means along one longitudinal edge of each lath, and a second hinge means along the opposite longitudinal edge of each lath.

It has been found that with a door assembly of the present invention it is possible to wind up the curtain on a standard size drum of only 12.7 cm (5 inches) in diameter, whereas a door assembly not in accordance with the present invention, but using a curtain with identical size of laths as that of the present invention, would require a drum of 15.3cm (6 inches). The unique design of the present invention represents a significant improvement over conventional designs of door assemblies.

To ensure that the door has the necessary sound and heat insulation it is usual to mount brushes in the vertical guides to contact the ends of the laths of the curtain. Conventionally the brushes are discrete items that are kept in place by a sealant. This is awkward to apply, and workers can be careless in applying the seal as a result of which, over time it will detach itself and create undesired air-flow paths. In one embodiment of the present invention it is another object to address this problem.

According to another aspect of the invention therefore, the door assembly includes a vertical track means comprising a channel section member, having a base and two spaced limbs having mutually confronting surfaces, and a brush means is provided on one of the confronting surfaces. The brush means preferably comprises a cap member located on the free end of a limb, and a brush or wiper is provided on the outer surface of the cap member.

One of the limbs of the channel section member may be provided with studs that frictionally engage in a recess of the cap.

It is usual to place an end cap at the ends of each lath. Present designs require a number of different shapes of end cap and that causes an inventory problem and is generally inconvenient. This invention also seeks to address this problem.

According to another aspect of the invention therefore, there is provided an end cap for the laths used in the assembly as defined, shaped for use at either side of the lath, the cap comprising a body having a cap, the body being shaped to be received in either end of the lath and the cap being shaped to cover one hinge means located between adjacent laths.

Preferably the cap is made of plastics. In an alternative, the cap is made of metal and has a through hole to receive a security bar. In addition the cap may have side wings that, in use, engage the confronting surfaces of the limbs of the channel-shaped member to hold the laths within the channel-shaped member against wind forces. Preferably this cap is made of cast metal.

In order that the invention may be well understood it will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: Figure 1 is a partial exploded view of a roller shutter door assembly constructed in accordance with the present invention; Figure 2 is a perspective view of one shell member of an individual lath of the door assembly of Figure 1; Figure 3 is a partial end view of a curtain of the door assembly of Figure 1 wound about the drum in the ceiling of an industrial building; Figure 4 is a perspective view from underneath, of the bracket secured to the drum of Figure 1; Figure 5 is a partial vertical sectional view of one vertical track of the door assembly of Figure 1; and Figures 6 is a side elevation view of one end cap of one of the laths of the door assembly of Figure 1.

Referring to the drawings, the shutter door assembly comprises a curtain C which travels in vertical guides V at the sides of the curtain C, for the purpose of opening and closing a door opening. Located above the door opening, is a storage mechanism in the IE Ο 1 0 7 5 1 form of a drum, or barrel, D, and a winding means (not shown). The winding means may be a manual or motor driven means (not shown), and is used for winding the curtain on to the drum D, to open the door, or for unwinding it from the drum D to close the door.

The curtain C comprises a set of elongate cross members, or laths, L pivotally joined together at their longer sides by way of hinge means. As shown in Figure 2, each lath is made up of two identical longitudinal shell members SI, S2. Each shell member SI, S2 is made of a length of sheet metal having its longitudinal marginal portions 10, 11 shaped (curled) to define complementary shaped curled edges 12 and 13 projecting from the same side of the metal sheet. One curl 12 is formed with an outwardly curved portion 14 that has a bend 15 to form a straight flange or finger 16 facing the main body 17 of the sheet of metal. The other curl 13 is formed with an outward flange portion 18 and an outwardly curved portion 19 that has a bend 20 to provide a second flange, or finger, 21 extending along the length of the metal sheet.

Two metal sheets SI, S2 are assembled back-to-back with each other to make a lath L that has a cavity 22 between the sheets of metal, as shown in Figure 3. The cavity 22 of each lath is filled with heat insulating material such as, for example, a polyurethane foam F.

The curls 12 and 13 are of each skin are of complementary shape, so that the curl 12 of one skin SI nestles inside the curl 13 of the other skin S2 to form a first hinge part Hl 07 5 1 along one longitudinal edge of each lath, and a second hinge part H2 along the opposite longitudinal edge of each lath.

From Figure 3 it will be seen that the hinge means Hl and H2 of each lath are of complementary shape. A plurality of laths are pivotally joined together as shown in Figure 3 to form a curtain, by locating a hinge part Hl on one lath inside a hinge part H2 of an adjacent lath.

It is necessary to anchor the uppermost lath Ll (that is to say the lath that is closest to the drum) to the drum D. According to the invention an anchor bracket 23 (Figure 4) is mounted on the drum D for that purpose. The bracket 23 comprises a horizontal plate 24 having one long side 25 plain and short, and the other long side 26 fabricated with an upwardly bent portion 27, an arcuate portion 28, reverse bend 29 to provide a short straight flange or limb 30 spaced from the upwardly bent portion 27. The elements 27 to 30 effectively defines a hinge part Pl equivalent to one of the hinge parts Hl of a lath. The bracket 23 extends along the length of the drum at a position on the drum that, in use, will be at the top dead centre of the drum. The bracket 23 is secured to the top of the drum D by a nut and bolt 26 passing through a hole close to the plan side 25 of plate 24. Alternatively the plate 24 may be secured to the drum by welding.

The hinge part H2 of the uppermost lath Ll is inserted into the hinge part Pl of the bracket B mounted on the drum D. When the door is to be opened the curtain C must be raised and this is done using a winding means (not shown). As the drum D starts to wind, one face of the lath Ll contacts the periphery of the drum D and this actin is ΙΕΟ 1 0 7 5 1 repeated for each subsequent lath L2, L3, L4 and L5. The lath L6 cannot contact the drum D because a wall of lath L7 contacts the hinge part Pl which projects radially beyond the drum, but lath L6 can be as close to the drum as possible because the bracket B has only one hinge part. This condition is shown in Figure 3. If a hinge part Hl or H2 were present at the other longitudinal edge of the bracket 23, the lath L6 would be urged further away from the drum, and laths L7 onwards would be urged even further away from the drum D. The shape of the bracket 23 thus enables the curtain to be used on a relatively smaller diameter drum.

As shown in Figure 5, the vertical track or guide members V located at the vertical sides of the door opening are channel shaped, having a base 31 and two limbs or side-walls 32. Recesses 33 are formed near the free ends of the limbs 32. Cap members 34 on the fee ends of each limb are also channel-shaped, but are smaller to fit onto the limbs. Brushes or wipers 35 are provided on the outer surface of one of the limbs 32 of the cap 34. Studs 36 are present on the inner confronting faces of the limbs 32. The cap members 34 are frictionally engaged on the limbs 32 by engagement of the studs 36 in the recesses 33. The brushes 35 form a draught excluding margin to the laths L that, in use, are engaged between the confronting faces of the limbs 32. The engagement of the cap members 34 on the limbs is secure and there is no need for a sealant.

It is necessary to protect the hinge part Hl and H2 at the ends of adjacent laths and to provide obstructions to draughts. An end cap 37 for each lath is shown in Figure 6. Each end cap is shaped for engagement with the end of one lath L and covers the area of the hinges H1,H2 between the adjacent laths. As shown, the end cap 37 has a top 38 ΙΕΟ 1 07 5 1 which covers the lath and the area to the next lath, and has a foot 39 to be received in the ends of the cavity 22 of the lath. The end cap 37 is shaped so that it can fit either end of the lath. It may be made of a plastics material or metal.

Claims

1. A shutter door assembly including a curtain made of generally parallel laths each pivotally joined to its neighbour by way of a hinge means, an elongate drum which, in use, is located above the curtain, a winding means for winding the curtain on to the drum for the purpose of opening the door and for unwinding the curtain from the drum for the purpose of closing the door, wherein a first lath is pivotally connected by way of a hinge means to a bracket mounted on the drum, the bracket being shaped and arranged to allow the curtain to be wound on to the drum without urging laths away therefrom.

2. An assembly according to Claim 1, wherein the bracket extends in a direction along the length of the drum and is located at the top dead centre of the drum.

3. An assembly according to Claim 1 or 2, wherein the bracket comprises an elongate plate secured to the drum, and the plate has a longitudinal edge portion shaped to form a hinge means for receiving a complementary shaped hinge means of the said first lath.

4. An assembly according to claim 1 or claim 2 wherein each lath has a first curled edge along a first longitudinal edge that, in use, defines an inner part of a hinge means, and a second curled edge along a second longitudinal edge that, in use, defines an outer part, and said curled parts of at least one of the laths co-operating ΙΕΟ 1 07 5 1 with complementary shaped curled edges of an adjacent lath to form a hinge means allowing relative pivotal movement of one lath to another.

5. An assembly according to any one of the preceding claims wherein each lath comprises two identical skins, each of which has an elongate main body and first and second longitudinal marginal portions curled to define complementary shaped curls projecting from the same side of the main body of each skin, one of said curled edges being formed with an outwardly curved portion that has a bend that forms a flange facing the main body of the skin, and the other curled edge being formed with an outward flange portion and an outwardly curved portion that has a bend that forms a second flange, said skins being assembled back-to-back with each other to form a cavity between the main bodies of the skins, and cause the curls of the curled edges of one skin to nestle inside the curl of the other skin to form a first hinge means along one longitudinal edge of each lath, and a second hinge means along the opposite longitudinal edge of each lath.

6. An assembly according to any preceding Claim, wherein the drum measures 12.7 cm in diameter.

7. An assembly according to any one of the preceding claims further comprising a vertical track means comprising a channel section member, having a base and two spaced limbs having mutually confronting surfaces, and a brush means is provided on one of the confronting surfaces. 1E010151

8. An assembly according to claim 7 wherein the brush means comprises a cap member located on the free end of a limb, and a brush or wiper is provided on the outer surface of the cap member.

9. An assembly according to claim 7 wherein one of the limbs is provided with studs that ifictionally engage in a recess of the cap.

10. An assembly according to claim 5 wherein each lath is provided with an end cap shaped for use at either end of each lath, the end cap comprising a body shaped to locate in the cavity of the lath and having a portion that covers the hinge means formed between two adjacent laths.

11. An assembly according to claim 10 wherein the cap has side wings that, in use, engage the confronting surfaces of the limbs of the channel-shaped member to hold the laths within the channel-shaped member against wind forces.