NZ563244A - A door opener - Google Patents

Abstract

A narrow door opener having on its flank a waisted region to accommodate a mounting bracket below the axle axis of the door roll to be opened thereby. The flank to flank distance (not counting door roll engagement features) is less than 200mm and preferably less than 100mm.

Description

563244 NEW ZEALAND PATENTS ACT, 1953 Divided out of Application No: 534277 Date: 21 July 2004 COMPLETE SPECIFICATION A DOOR OPENER We, CHAMBERLAIN AUSTRALIA PTY LIMITED, CHAMBERLAIN AUSTRALIA PTY LIMITED, an Australian company (ACN 118 013 362) C/o Level 19, Aurora Place, 88 Phillip Street, Sydney, NSW 2000, Australia, do hereby dcclarc the invention for which patent may be granted to us, and the method by which it is to be performed, ro§ce particularly I r\ described in and by the following statement: | . ^ i 563244 The present invention relates to door openers, door opening arrangements and related assemblies, components and methodologies.

Door openers are manufactured and supplied for use in a number of situations.

Door openers such as those that might be used for curtain, scctional or tilt garage or the like doors frequendy employ a logic controlled DC or an AC motor to drive the movement of the door through a transmission. The transmission may be to a rotating shaft of a curtain door or a tambour type door or to a tracked carriage associated with a sectional or tilt door.

In many existing garage door assemblies the transmission includes a flexible driving element such as a chain or belt. Therefore one of the components of the drive train is usually a sprocket or pulley.

Hitherto drive assemblies utilising a carried electric motor has involved the difficulty of aligning the motor so as to have an output shaft in concert or parallel to that of the sprocket or pulley rotational axis (whether through a reduction gearbox or otherwise) to derive power therefrom or, and this is more usual, requires some transmission capable of allowing the rotational axis of the motor to be disposed at some oblique or right angle to the rotational axis of the sprocket or pulley. See PCT/NZ2003/000211.

There are many instances where a drive system for such door systems requires calibration so as to ensure that the electric motor (or other prime mover) does not continue to drive or drive effectively in its application beyond limits of that application. For example, in the situation with, for example, garage doors, whether of the curtain, tilt or sectional types it is usual (irrespective of whether or not AC or DC motors are being used as the motive force) to provide limits whereby there is a cut-off of the energising power to the motor when the door is either fully open or fully closed.

Frequently such cut-off systems are dependent upon manual inputs by way of screws or the like members that allow the limits to be customised for the particular application.

Our PCT/NZ2003/00212 relates to apparatus and related procedures and the like that has application inter alia in such applications as the limit control of, for example, garage doors but has more widespread application.

The full content of our patent specifications PCT/NZ2003/000211, PCT/NZ2003/000212 and PCT/NZ2003/0013 is herein included, as are all published information on our existing MERLIN1M brand door opener systems particularly to show the background art and also what we hereinafter refer to as control and limit functionalities.

The present invention recognises irrespective of motor rotation axis orientation a desirability for an opener capable of rotating a door element (e.g. such as that of a curtain or 563244 - J - central axis of the roll of the curtain door or the equivalent yet which may need to be installed and/or be serviceable in a small gap between the end of the door roll and some structural member of the building having the door opening to be closed or opened.

It is also an object of the present invention (some instances an alternative to the aforementioned object) to make provision for support of such a door opener from a mount outstanding from the building or other support but extending as an arm or other structure to the door opener in a direction which is in a plane normal to the rotational axis of the door roll and/or the output drive member.

In a first aspect the present invention consists in a door opener adapted to open and/or close or allow to close a curtain door, the door opener having at least: an at least partial housing assembly, a sun gear carried by the at least partial housing assembly, a drive member or members arranged to rotate as the sun gear rotates and adapted externally of the at least partial housing assembly to engage and to rotate a complementary door curtain assembly, a pinion adapted to rotate the sun gear, the pinion being carried from a rotatable member dependent from the at least partial housing assembly to be rotated with linkages, such rotation allowing a carriage of the pinion into and/or out of mesh with the sun gear; an electric motor, and a transmission from the motor to the pinion selectively by which the pinion rotates responsive to motor movement, wherein the at least partial housing assembly allows for a support thereof to be inset at least in part under part of a rotational axis through the sun gear when the sun gear of the door opener is oriented such that it rotates about a substantially horizontal axis, and wherein the greatest dimensional extent of the opener in a direction parallel to the rotational axis of the sun gear from the exterior of the sun gear (excluding the drive member(s)) to the other side of the opener is less than 150mm, and wherein the at least partial housing assembly provides support for at least the sun gear.

Preferably the greatest extent is from 125 to 85mm.

Preferably the greatest extent is from 110mm to 90mm.

Preferably the greatest extent is about 100mm.

Preferably the drive member or members includes one or more dogs, fingers or the like adapted to engage into a rotatably mounted and/or supported end and/or end member or assembly of a door curtain. 563244 Preferably an axle member (whether a full or stub axle) of a said complementary door curtain assembly is adapted to pass through the sun gear.

Preferably the support of the at least partial housing assembly is a complementary mount, and the assembly allows for the inset of the complementary mount by a waisting of its flank.

In a further aspect the present invention consists in a door opening arrangement including: a curtain door capable of being rotatably unwound and wound about an axis thereby to close and open respectively a door opening of a building, a door opener according to the first aspect of the invention engaging an end of the curtain door and being actuable to rotate the curtain door; and a mount for the door opener from the building, such mount extending substantially to the door opener in a plane or planes substantially normal to the axis.

Preferably the door opener is engaged to said mount in a recessed region thereof on a flank thereof opposite to that flank which has means to functionally engage said curtain door.

In a further aspect the present invention consists in the use of a door opener according to the first aspect of the invention in conjunction with a door roll of a curtain door.

In a further aspect the present invention consists in an assembly of a door opening or closing system which involves the use of a door opener or a door opening arrangement in accordance with the first two aspects of the invention. control and limit functionalities for the motor, the transmission and/or the sun gear/pinion interaction whereby the drive of the sun gear, one way and/or the other in a rotational sense, and also the limiting of rotation thereof in at least one rotational sense, is caused, allowed, and/or controlled by (a) signal inputs alone or (b) a mixture of set up input(s) and signal input(s).

Preferably the transmission is controllable under the action of the functionalities to allow or disallow engagement of the pinion with the internal gearing of the sun gear.

As used herein the term "s" following a noun means the singular and/or plural forms of that noun.

As used herein the term "curtain door" refers to any closure member whether for a window, door, shutter or other closure purpose, whether or not there is edge guiding of the door as it deploys or not, and irrespective of whether or not there is an axle through the door roll or Preferably the door opener further includes: As used herein the term "and/or" means "and" or "or", or both. not. 563244 Preferred forms of the present invention will now be described with reference to the accompanying drawings in which Figure 1 is a perspective view of a preferred door opener in accordance with the present invention looking at that flank of the door opener having a waist for the purpose of engagement with a mounting member, Figure 2 is a side elevation looking at the other flank to that shown in Figure 1, there being seen the rotatable output drive with its dogs or fingers that are to engage into the end member of a door roll of a curtain door le, a roller door, Figure 4 is a side elevational view of a door opener as in Figures 1 to 3 showing the output drive with its dogs to the left and the waisted flank to the right, Figure 5 is a similar view to that of Figure 4 (the base housing being hidden) but showing the section thereof on the line B-B shown in Figure 2, Figure 6 is a similar view to that of Figure 2 but showing the section of the door opener at A-A with respect to Figure 4, Figure 7 in a perspective direction similar to that of Figure 1 shows the door opener in an exploded form, the components of that exploded form being as hereinafter described, Figure 8 is a view of a door opened in a dwelling showing a mount engaging the door opener under the rotational axis of the curtain door roll and the output drive member reliant upon the waisted flank of the narrow door opener, Figure 9 is an enlargement of the mounting arrangement shown in Figure 8, Figure 10 is an elevational view of the arrangement shown in Figure 8, Figure 11 is an enlargement of the door opener and the end of the door curtain roll, and Figure 12 shows an exploded view of a clutched transmission door opener similarly with the waisted flank features previously disclosed.

In the preferred form of the present invention shown in Figures 1 to 11 the maximum dimension from C to C (see Figure 4) is waisted at D (see Figure 4) for the bracket support.

The maximum distance C-C is less than 200mm and preferably is less than 150mm. An ideal distance to maximise its flexibility of installation is of the order of about 100mm or less.

Figure 3 is a top view of the door opener of Figures 1 and 2, The exploded view shows the preferred components of such a door opener. 563244 Item No.

Description 1 Plastic sun ring retainer clip 2 Nylon sun gear 3 A micro switch 4 Gear cover A plastic gear idler set 6 A gear 7 A gear 8 A PCB 9 A DC transformer Electric motor 11 Micro switch cam of PP plastic 12 Base housing 13 Motor mount plate 14 PP plastic housing cover Pinion (e.g. of aluminium) 16 PP plastic lower cover 17 Motor mount plate lever 18 Motor engage link 19 Motor engage push rod link Diffuser 21 Light base plate cover panel 22 Lightbulb 23 Light terminal 24 Bolt Clamp bracket 26 Motor mount plate As can be seen a mounting 27 can have an arm 28 thereof adapted to engage in the waisted region D (see Figure 4) such that the arm 28 is engaged by appropriate fixing as well as inter-engagements with the region 29 as well as, if desired, to the face 30 (see Figure 1). This intrusion of the arm 28A of the mounting bracket 28 into the overall envelope of the narrow 563244 expansive dimension, thus enabling a butt wall or true wall to be positioned very close to the end of a door curtain roll 31 notwithstanding the need to position the door opener 32 and its mount from the wall 33.

In evolving such a door opener, it is to be seen that the rotational axis of the motor 10 is in a plane normal to the axle 34 of the curtain roll 31 which is to extend through the passageway 35 allowed by the door opener (for alignment and weight bearing purposes) and be supported directly over the mounting arm 28A preferably with its gusseted reinforcement 36.

A feature, as can be seen is that the pivoted motor mounting plate 13 carries the subassembly which includes the motor and items associated therewith in the exploded view of Figure 7 as well as allowing the drive to extend through to the pinion 15. Consequently with the linkages 17 and 18, there is the prospect of the pinion 15 being brought into or out of mesh with the internal gearing of the sun gear 2. Such de-meshing features are known in other door openers but here the arrangement depicted allows such an arrangement in the narrow expanse of the distance C-C and the positioning of the functional features still allows the waisting D for the purpose stated.

The covers shown in the drawings (e.g. 14 and 16) form a rain resistant seal with the base 12. The scal(s) can also at least in part retain, for example, cover(s) 14 and/or 16 to the base 12. Preferably two screws are used to retain both covers and are easily accessible once installed even in tight clearance situations. Diffuser 20 clip fits to cover 16 to undertake the remainder of the assembly.

In the embodiment of the exploded assembly of figure assembly as shown, the pmion 37, when the drive to it is enabled by the clutch mechanism, has the effect of rotating the sun gear 50 with its driving component typified by the extension tubes 39.

A manual input is adapted to clutch the drive by its action on component 40 which, by virtue of its helical engagement with component 41 disengages. Item 41 (clutch collar) is moved in a linear direction away from the pinion gear 37. Item 41 engages a shoulder on shaft dog 38 and disengages it from the pinion gear 37. On releasing the manual input, or any latching thereof e.g. of cord and the tension on clutch lever 40, clutch collar 41 is also free to move back towards the pinion gear 15. The shaft dog 38 with the assistance of spring 43 is able to reengage widi pinion gear 37 at the next rotational alignment. The motor 42 drives sleeve 45 which drives shaft dog 38 and then the pinion gear 37.

Such a telescopic arrangement as contemplated allows for the maximum flank to flank dimension, ignoring the extension fingers of the final drive (ie, which are usually received within the end of the door roll), to be very thin, thus enabling usage of the opener in confined spaces 563244 It can be seen that the clutch includes: a dog engagement a bias to dog engagement a telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction a manual input to provide the clutched condition.

It is believed therefore, door openers in accordance with the present invention, will find widespread acceptance. 4 FEB 2009 563244

Claims (15)

WHAT WE CLAIM IS:

1. A door opener adapted to open and/or close or allow to close a curtain door, the door opener having at least: an at least partial housing assembly, a sun gear carried by the at least partial housing assembly, a drive member or members arranged to rotate as the sun gear rotates and adapted externally of the at least partial housing assembly to engage and to rotate a complementary door curtain assembly, a pinion adapted to rotate the sun gear, the pinion being carried from a rotatable member dependent from the at least partial housing assembly to be rotated with linkages, such rotation allowing a carriage of the pinion into and/or out of mesh with the sun gear; an electric motor, and a transmission from the motor to the pinion selectively by which the pinion rotates responsive to motor movement, wherein the at least partial housing assembly allows for a support thereof to be inset at least in part under part of a rotational axis through the sun gear when the sun gear of the door opener is oriented such that it rotates about a substantially horizontal axis, and wherein the greatest dimensional extent of the opener in a direction parallel to the rotational axis of the sun gear from the exterior of the sun gear (excluding the drive member(s)) to the other side of the opener is less than 150mm, and wherein the at least partial housing assembly provides support for at least the sun gear.

2. The door opener of claim 1 wherein the greatest extent is from 125 to 85mm.

3. The door opener of claim 1 wherein the greatest extent is from 110mm to 90mm.

4. The door opener of claim 1 wherein the greatest extent is about 100mm.

5. The door opener of any one of the preceding claims wherein the drive member or members includes one or more dogs, fingers or the like adapted to engage into a rotatably mounted and/or supported end and/or end member or assembly of a door curtain.

6. The door opener of any one of the preceding claims wherein an axle member (whether a full or stub axle) of a said complementary door curtain assembly is adapted to pass through the sun gear.

7. The door opener of any of the preceding claims wherein the support of the at least partial housing assembly is a complementary mount, and the assembly allows for the inset of the complementary mount by a waisting of its flank.

8. A door opening arrangement including: 563244 - 10- a curtain door capable of being rotatably unwound and wound about an axis thereby to close and open respectively a door opening of a building, a door opener according to any one of the preceding claims engaging an end of the curtain door and being actuable to rotate the curtain door; and a mount for the door opener from the building, such mount extending substantially to the door opener in a plane or planes substantially normal to the axis.

9. The arrangement of claim 8 wherein the door opener is engaged to said mount in a recessed region thereof on a flank thereof opposite to that flank which has means to functionally engage said curtain door.

10. The use of a door opener of any one of claims 1 to 7 in conjunction with a door roll of a curtain door.

11. Assembly of a door opening or closing system which involves the use of a door opener or a door opening arrangement in accordance with any one of the preceding claims.

12. The door opener according to any of the claims 1 to 7, further having: control and limit functionalities for the motor, the transmission and/or the sun gear/pinion interaction whereby the drive of the sun gear, one way and/or the other in a rotational sense, and also the limiting of rotation thereof in at least one rotational sense, is caused, allowed, and/or controlled by (a) signal inputs alone or (b) a mixture of set up input(s) and signal input(s).

13. The door opener of claim 12, wherein the transmission is controllable under the action of the functionalities to allow or disallow engagement of the pinion with the internal gearing of the sun gear.

14. A door opener substantially as described hereinbefore with reference to Figures 1 to 12 of the accompanying drawings.

15. A door opening arrangement substantially as described hereinbefore with reference to Figures 1 to 12 of the accompanying drawings. DATED THIS h DAY OF AJ PARK 200^ PER AGENTS