NZ577575A - Roller door with linked slats nested against adjacent slats or slat supports in rolled condition - Google Patents

Abstract

A roller door which has a rotatable shaft with one or more slat supports situated along its length. The roller door has a plurality of pivotally linked slats forming a door having a top edge and a bottom edge. The top edge of the door is connected to the or each slat support. The slats of the door are configured such that when in use and the door is rolled onto the slat supports each slat can lie properly nested against the or each slat support or against an adjacent layer of slats. Adjacent slats are pivotally connected with ties, and the ties include flaps which are configured to prevent contact between adjacent slats. The slats have a box section construction for increased strength, and the roller door is intended for use as a rapid acting security door.

Description

Patents Form # 5 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION AFTER PROVISIONAL NO.:577575 PRIORITY DATE : 10 June 2009 TITLE : Improvements relating to Roller Doors We, P60 LIMITED Address: 92 Takanini School Road, Takanini, Papakura, New Zealand, 2105 Nationality: A body corporate organized and existing under the laws of New Zealand do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: 204543NZ_Cap_20100610_ 91 l_PBA.doc FEE CODE 1050 Improvements relating to Roller Doors FIELD OF THE INVENTION This invention relates to roller doors, and in particular, but not exclusively to rapid opening security roller doors.

BACKGROUND Roller doors have been shown to be a convenient style of door for use in wide doorways, for example doorways through which vehicles, or large numbers of people, pass. Since they are suspended from a single roller they tend to operate efficiently without jamming and binding as is common with wider horizontally sliding or pivoted doors. In addition, it 10 is also convenient that sliding doors can open in an up and own direction, without needing to swing out of the door opening.

In many applications, particularly in industrial or commercial applications, there is an increasing need for doors that can open and close rapidly, for example at the entrance or exit of a clean room, a heated workshop, or a cold store. In such cases, a door needs to 15 open quickly, and then close quickly, when a vehicle such as a forklift passes through the door. The rapid movement minimises the likelihood of contaminants migrating through the doorway, or heat being lost, etc.

There are presently a number of rapid opening roller doors in use, however these are primarily light weight doors, and thermally insulated doors, designed to help control 20 building environments, but they are not suitable for security purposes. These light weight doors, which are often constructed using fabrics or plastic sheeting, can be easily cut or damaged by a determined intruder. In addition, they do not provide any significant fire resistance.

Doors that are also suitable for security purposes generally need to be constructed of 25 heavier, stronger and more resistant materials, for example steel or aluminium. And for the door to have a reasonable level of structural integrity the door needs to be relatively thick. 204543NZ_CAP_SpecJunl O.doc/PA A difficulty that is experienced with thicker roller doors is the space required to stow the rolled up door at the top of a doorway. Where this volume is excessive the available door height can be adversely restricted. An example of a door that could exhibit this problem is that described in US patent application number 11/943,393.

Operating noise and friction are also concerns, particularly with rapid opening doors, where the doors are often used frequently during each day. Loud noises are generally undesirable, and friction can cause rapid wear of the door components. Doors having circular or spiral guide tracks to help stow the retracted door, for example those described in US patent application number 11/943,393 and US patent 5,484,007, can exhibit this 10 problem.

Roller doors are sometimes made of a series of horizontal slats which are linked together to create the door. Where the slats are linked together using straps or belts at each end, or at spaced apart intervals, as shown in US patent application number 11/032,952, the slats can tend to sag or gape, particularly with wider span doors.

Doors having complex geometry in the structure of the door guides or rollers, as described in US patent application numbers 11/943,393 and 11/032,952, and in US patent 5,484,007, can also be complex to manufacture and to initially assemble. Mechanical devices that require very accurate construction and assembly to work efficiently, such as these, are more likely to require regular maintenance to assure reliable operation.

Some vertically opening doors use springs or other mechanisms to assist in door opening and/or closing. These can increase the overall footprint of the door and can intrude further into a room. This reduces the available volume within the room and can provide additional obstacles around a doorway where much of the traffic will tend to pass. An example of a door that could exhibit this problem is that described in US patent 25 application number 11/032,952.

In this specification unless the contrary is expressly stated, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge; 204543NZ_CAP_Spec_Jiml0.doc/PA _4- or known to be relevant to an attempt to solve any problem with which this specification is concerned.

OBJECT It is therefore an object of the present invention to provide a roller door which will at least 5 go some way towards overcoming the above mentioned problems, or at least provide the public with a useful choice.

STATEMENTS OF THE INVENTION Accordingly, in a first aspect, the invention may broadly be said to consist in a roller door having a rotatable shaft, the shaft having one or more slat supports situated along its 10 length, the roller door also having a plurality of pivotally linked slats forming a door having a top edge and a bottom edge, the top edge of the door being connected to the or each slat support, and the slats of the door being configured such that when in use and the door is rolled onto the slat supports each slat can lie properly nested against the or each slat support or against an adjacent layer of slats.

Preferably the width of the slats nearer the top edge of the door is narrower than the width of the slats that are nearer the bottom edge of the door.

Preferably the door is made up of a number of sections of slats, and the width of the slats in each section is different from the width of the slats in an adjacent section.

Preferably the width of the slats in a section nearer the top edge of the door is narrower 20 than the width of the slats in an adjacent and lower section of the door.

Preferably the or each slat support is polygon shaped having a plurality of flat faces.

Preferably an inner face and an outer face of each slat are substantially flat.

Preferably the slats of the door are configured such that when the door is rolled onto the or each slat support, each slat can lie substantially flat against an adjacent slat or against a 25 face of the or each slat support. 204543NZ_CAP_Spec_Junl0.doc/PA Preferably the slats of the section nearest the top edge of the door are configured such that when the door is rolled onto the or each slat support, each slat of the said section can lie substantially flat against a corresponding face of the slat support.

Preferably the slats of each successive section down the door are configured such that 5 when the door is rolled up, each slat of that section can lie substantially flat against a corresponding slat of an upper adjacent section of the door.

Preferably the length of each of the flat faces of the or each polygon shaped slat support, in a circumferential direction, is matched to the width of the corresponding slat that lays against the flat face, when the door is at least partially rolled onto the or each slat support.

Preferably each slat is pivotally linked to each adjacent slat with ties which extend substantially along the length of each slat.

Preferably the ties are shaped to pivotally connect to the edges of adjacent slats.

Preferably the ties have a cross section which includes a slender body section having bulbous ends.

Preferably each tie include flaps which project from the body section of its cross section and which are configured to prevent contact between adjacent slats when the door is in use.

Preferably the slats have sockets running the length of their top and bottom edges which are adapted to receive the ties.

Preferably at least some of the slats have a profile that allows a bottom edge of the slat to at least partially overlie the top edge of an adjacent slat, when the door is at least partly unrolled or is in an at least partly closed configuration.

Preferably the slats are made from metal extrusions.

Preferably the slats each have a hollow cross section.

Preferably the slats are provided with non-metallic spacers adapted to substantially prevent metallic slat to slat contact when the slats are rolled onto the or each slat support. 204543NZ_CAP_Spec_Junl O.doc/PA Preferably the ends of the slats are provided with a low friction material, for example a plastics material, adapted to slide freely within a guide.

Preferably the roller door is a rapid opening roller door.

Preferably the roller door is configured for use as a security door.

In a second aspect, the invention may broadly be said to consist in a roller door having an open configuration and a closed configuration, the roller door having a plurality of substantially rigid slats, each slat being linked to an adjacent slat by a tie member, each tie member having one or more spacer members made of a resilient and flexible material, and the or each spacer member is configured to separate the facing edges of adjacent slats 10 when the door is in the closed configuration.

Preferably the or each spacer member is in the form of a flap or flaps which extends from the tie member.

Preferably the tie member has at least two spacer members, and at least one spacer member extends from each side of the tie member.

Preferably at least one of the spacer members is configured to separate the facing edges of adjacent slats when the door is in the open configuration.

Preferably the spacer members are configured to substantially seal any gap between adjacent slats when the door is in a closed configuration.

Preferably each tie member is shaped to pivotally connect to the edges of adjacent slats.

Preferably the tie members have a cross section which includes a slender body section having bulbous ends.

Preferably the slats have sockets running the length of their top and bottom edges which are adapted to receive the tie members.

In a third aspect, the invention may broadly be said to consist in a roller door having a 25 rotatable shaft, the shaft having one or more slat supports situated along its length, the roller door also having a plurality of pivotally linked slats forming a door having a top 204543NZ_CAP_Spec_Junl0.doc/PA edge and a bottom edge, the top edge of the door being connected to the or each slat support, and the door is configured such that when in use and the door is rolled onto the slat supports in a plurality of layers, each slat of a second or higher layer can lie aligned with, and substantially parallel to, a slat of an adjacent inner layer of slats.

In a fourth aspect, the invention may broadly be said to consist in a door assembly incorporating at least one roller door substantially as specified herein.

Preferably the door assembly further includes shaft supports adapted to support each end of the shaft.

Preferably the door assembly further includes guides adapted to guide and retain the ends 10 of the slats of the door.

Preferably the door assembly further includes a motor and drive system configured to roll the door up or down when operated.

In a fifth aspect, the invention may broadly be said to consist in a kit of parts for forming a roller door substantially as specified herein when assembled, said kit including a 15 rotatable shaft having one or more polygon shaped slat supports along its length, and a plurality of pivotally linkable slats that can be linked to form a door having a top edge and a bottom edge, the top edge of the door being connectable to the or each slat support.

The invention may also broadly be said to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, 20 and any or all combinations of any two or more of the parts, elements or features, and where specific integers are mentioned herein which have known equivalents, such equivalents are incorporated herein as if they were individually set forth.

DESCRIPTION Further aspects of the present invention will become apparent from the following 25 description which is given by way of example only and with reference to the accompanying drawings in which: 204543NZ_CAP_Spec_Junl0.doc/PA FIGURE 1 is a side elevation view of a roller door according to the present invention, FIGURE 2 is an expanded view of a lower section of a door of the roller door, FIGURE 3 is an expanded view of a typical pivoting joint of the door, FIGURES 4 thru 4g are profiles of slats of the roller door, FIGURE 5 is a side elevation view of a slat support of the roller door, FIGURE 6 is a perspective view of a shaft of the roller door, FIGURE 7 is a perspective view of an alternative shaft of the roller door, FIGURE 8 is a front elevation view of the door, FIGURE 9 is a cross sectional plan view of a guide of the roller door, FIGURE 10 is a back plan view of a door assembly shown with the door in a lowered of down position, and FIGURE 11 is a back plan view of the door assembly shown with the door in a raised or up position.

With reference to Figures 1 to 8, a roller door (11) is shown having a rotatable shaft (13) which has a number of polygon shaped slat supports (15) situated along its length. In this example the rotatable shaft (13) is in the form of a drum or tube. A door or door panel (17) of the roller door (11) is made up of a number of pivotally linked slats (19). A top edge (20) of the door (17) is connected to the slat supports (15).

It can be seen that the slats (19) of the door (17) are configured such that when the door (17) is rolled onto the slat supports (15), each slat (19) can lie properly nested against the slat supports (15) or against an adjacent layer of slats (19). And in this example, each of the slats (19) in an upper section of the door (17) lie substantially flat against, a face of the slat supports (15). And the slats (19) in lower sections of the door (17) lie nested and 25 substantially flat against slats (19) of an upper and adjacent section of the door (17). 204543NZ_CAP_Spec_Junl0.doc/PA Received by IPONZ 29 Sep 2011 It can be seen that the width of the slats (19) nearer the top (20) of the door (17) is narrower than the width of the slats (19) that are nearer the bottom (27) of the door. In fact, the door (17) in this example is made up of a number of sections of slats (19). The width of the slats in each section is different from the width of the slats (19) in an adjacent 5 section. The width of the slats (19) in a section nearer the top of the door (17) is narrower than the width of the slats (19) in an adjacent and lower section of the door (17).

The slat supports (15) are polygon shaped having a plurality of flat faces. And an inner face, and an outer face, of each slat are substantially flat. This means that when the door (17) is rolled onto the slat supports (15), each slat (19) lies substantially flat against an 10 adjacent slat (19) in an adjacent layer of slats, or against a face of the slat supports (15). It can be seen in figure 1 that when the door (17) is rolled onto the slat supports (15) in a plurality of layers, each slat (19) of a second or higher layer, that is, of the outer layers, can lie aligned with, and substantially parallel to, a slat (19) of an adjacent inner layer of slats.

The door (17) shown in figure 1 has five sections of slats, and when rolled up as shown in the figure, each section makes up a single layer of slats (19) nested on the slat supports (15). In this example, the slats (19) in each section have the same width. Slats (19a), refer to figure 4a, make up an upper section (17a) of the door (17) - see figure 8. And similarly, progressively wider slats (19b thru 19e), refer to figures 4b through 4e, make up 20 successive sections (17b thru 17e) down the door (17) below section (17a).

Figures 4f and 4g show window slats (23a) and (23b) which can be used in place of the slats (19c) and (19d) if it is desired to put windows (25) in the door (17) as shown in figure 8. The window slats (23a) and (23b) have a modified internal profile which is adapted to support glass or plastic window panes (25a).

Figure 4 shows a bottom slat (21), which can be used at a bottom edge (27) of the door (17). The bottom slat (21) has slots (28) which are configured to retain a bumper and/or sensor strip (29) which can be fitted to the bottom of the door (17) to provide a soft contact with a floor, and/or to provide a seal, and or to provide a sensor to indicate when the door (17) is fully down or has contacted something. 204543NZ_Amended_Page9_formal_Sep2011 .doc/PA The slats (19a) of the section (17a) nearest the top (20) of the door (17) have an appropriate width, or are configured, such that when the door (17) is rolled onto the slat supports (15), each slat (19a) can lie substantially flat against a corresponding face (31) of the slat supports (15).

And the slats (19b thru 19e) of each successive section (17b thru 17e) down the door (17) have an appropriate width, or are configured, such that when the door (17) is rolled up, each slat (19b thru 19e) can lie substantially flat against a corresponding slat (19a thru 19d respectively) of an upper adjacent section (17a thru 17d respectively) of the door (17).

With reference to figures 1 and 5, it can be seen that the length of each of the flat faces (31) of each polygon shaped slat support (15), in a circumferential direction, is matched to the width of the slats (19a) that lay against the flat faces (31), when the door (17) is rolled onto the slat supports (15).

With reference to figure 3, it can be seen that each slat (19) is pivotally linked to each 15 adjacent slat (19) with hinge members in the form of ties (33) which extend substantially along the length of each slat (19). The ties (33) are shaped to pivotally connect to the edges (35) of the slats (19). The ties can be made of a resilient material for example a plastics or rubber type of material.

The ties (33) have a cross section which includes a slender body section (37) and bulbous 20 ends (39). Each tie (33) includes spacer members in the form of flaps (41) which in this example project from each side of the body section (37). The spacer members, or flaps (41), are configured to separate the facing edges of adjacent slats (19), to prevent contact between adjacent slats (19) when the door is in use.

The flaps (41) can help to reduce noise when the door is opening or closing. In addition, 25 the flaps can help to provide a weather seal to stop and and/or other contaminants getting into the joint areas between the slats (19). The flaps (41) are ideally made of a resilient and flexible material, for example a plastics material, or rubber. Such a material can be suitable for providing a weather seal, and can be shock absorbing and sound reducing. 204543NZ_CAP_Spec_Junl0.doc/PA In the example shown and described, the flap (41) which extends toward an outer surface of the door (11) separates the facing edges of adjacent slats (19) when the door is in a closed configuration, and the flap (41) which extends toward an inner surface of the door (11) separates the facing edges of adjacent slats (19) when the door is in an open 5 configuration.

The slats (19) have sockets (42) running the length of their top and bottom edges which are adapted to receive the bulbous ends (39) of the ties (33).

With reference to figures 3 and 4 it can be seen that the slats (19a thru (19e) have a profile that allows a bottom edge (35 a) of the slat to at least partially overlie the top edge (35b) of 10 an adjacent slat (19 or 21), when the door (17) is at least partly unrolled or is in an at least partly closed position. This also helps to provide a weatherproof front face of the door (17) and/or can help to retard the efforts of a person wishing to break through the door (17).

Ideally the slats (19) are made from metal extrusions, for example aluminium extrusions. 15 In this example, the slats (19) have a cross section which is hollow, with reinforcing webs, and which is substantially rectangular. A slat (19) having this cross sectional profile can also be said to have a box section construction. Such a cross sectional shape provides a high level of structural integrity and can also provide a measure of thermal and noise insulation.

With reference to figures 1 and 8, it can be seen that at least some of the slats (19) are provided with non-metallic spacers (43) adapted to substantially prevent or minimise slat to slat contact when the slats (19) are rolled onto the slat supports (15). In this example, the spacers (43) are fitted as end caps on the end of every alternate slat (19) up the door (17). The spacers (43) can be made from a resilient material, for example a plastics 25 material such as urethane, which is capable of absorbing shocks and reducing noise during door operation. The spacers (43) can be made from a low friction material, for example a low friction plastics material, adapted to slide freely within a door guide (45) as shown in figure 9. 204543NZ_CAP_Spec_Junl0.doc/PA The slat supports (15) can also be made from a resilient material, for example a plastics material such as urethane, which is capable of absorbing shocks and reducing noise during door operation.

With reference to Figures 9 to 11, a door assembly (51) incorporating a roller door (11) 5 as described herein is shown. The door assembly (51) further includes shaft supports (53) adapted to support each end of the shaft (13).

The door assembly (51) also includes door guides (45) adapted to guide and retain the ends of the slats (19) of the door (17). The door guides (45) are fitted with plastic strips (55) which contact the slats (19), or in this case the spacers (43) that are fitted to the end 10 of each alternate slat (19). The strips (55) are intended to further reduce friction, noise and wear. Each door guide (45) is attached to a column (57) which can be used to connect the door assembly (51) to a doorway, and/or, which help to keep the door guides (45) straight.

In figure 10 the door (17) is shown fully down, or in a closed configuration, and in figure 15 11 the door (17) is fully, or almost fully up, or in an open configuration, with the majority of the slats (19) rolled onto the shaft (13) at the top of the roller door (11) In use the door assembly (51) will typically include a motor and drive system (not shown) configured to roll the door (17) up or down when operated. Alternatively the door assembly (51) could be hand operated using a continuous chain system for example.

VARIATIONS Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

Figures 5 and 6 show alternative configurations of the shaft (13). Depending on the 25 length of the roller door (11), and the level of support required, more or less slat supports (15) could be used. And in a further variation, one slat support (15) could extend along the length of the shaft (13). 204543NZ_CAP_Spec_Junl0.doc/PA In the above example, the slat supports (15) are polygon shaped, in this case approximating a heptagon shape, however it is envisaged that in an alternative embodiment the slat supports (15) could be a different shape for example a curved or substantially circular shape, with the slats (17) having a corresponding curvature to allow 5 the slats to fully nest as they are rolled onto the slat supports (15).

In the above example, the ties (33) included flaps (41) which are configured to prevent contact between adjacent slats (19) and/or to provide some level of weather sealing. In an alternative configuration plastics or rubber seals could be provided along the top and/or bottom edges of the slats (19) for the same purposes.

Also, in the above example the door (17) is described having ties (33) linking adjacent slats (19). It is envisaged that in an alternative embodiment the slats (19) could be linked with straps in addition to, or as an alternative to, the ties (33).

It is envisaged that the roller door (11) could be sold as a kit of parts for assembly on site. The kit could include a rotatable shaft (13) having one or more polygon shaped slat 15 supports (15) along its length, and a plurality of pivotally linkable slats (19). The slats (19) can be linked to form a door (17) having a top edge and a bottom edge, the top edge of the door (17) being connectable to the or each slat support (15).

DEFINITIONS Throughout this specification the word "comprise" and variations of that word, such as 20 "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps.

ADVANTAGES Thus it can be seen that at least the preferred form of the invention provides a roller door which can be used as a rapid opening roller door, which can also be suitable for use as a 25 security door. The compact nested slats occupy minimal space, and because they can be rolled up without the use of spiral shaped guides they can roll up with minimal friction, noise or wear. The careful nesting of the adjacent layers of slats also helps to minimise 204543NZ_CAP_Spec_Junl O.doc/PA slat to slat rubbing and movement which is associated with other slat doors which do not nest together neatly when rolling up.

The door is strong and the slats are well linked together along their entire lengths which can eliminate the possibility of individual slats sagging, and means that each slat can 5 support adjacent slats improving the overall durability of the door.

The slender guides occupy minimal space around busy doorways. Such a door is suitable for a number of applications including industrial, commercial, and even residential applications. 204543NZ_CAP_Spec_Junl0.doc/PA Received by IPONZ 29 Sep 2011

Claims (16)

1. A roller door having a rotatable shaft, the shaft having one or more slat supports situated along its length, the roller door also having a plurality of pivotally linked slats forming a door having a top edge and a bottom edge, the top edge of the door being connected to the or each slat support, and the slats of the door being configured such that when in use and the door is rolled onto the slat supports each slat can lie properly nested against the or each slat support or against an adjacent layer of slats.

2. A roller door as claimed in claim 1, wherein the door is made up of a number of sections of slats, the width of the slats within each section is substantially the same, and the width of the slats in each section is different from the width of the slats in an adjacent section.

3. A roller door as claimed in claim 2, wherein the width of the slats in a section of slats nearer the top edge of the door is narrower than the width of the slats in a section of slats that is nearer the bottom edge of the door.

4. A roller door as claimed in any one of the preceding claims, wherein the or each slat support is polygon shaped having a plurality of flat faces.

5. A roller door as claimed in any one of the preceding claims, wherein an inner face and an outer face of each slat are substantially flat.

6. A roller door as claimed in any one of the preceding claims, wherein the slats of the door are configured such that when the door is rolled onto the or each slat support, each slat can lie substantially flat against an adjacent slat or against a face of the or each slat support.

7. A roller door as claimed in any one of the preceding claims, wherein each slat is pivotally linked to each adjacent slat with ties which extend substantially along the length of each slat.

8. A roller door as claimed in claim 7, wherein the ties are shaped to pivotally connect to the edges of adjacent slats. 204543NZ_Rvsd_Clms_formal_Sep2011 .doc/PA -16-

9. A roller door as claimed in any one of claims 7 or 8, wherein the ties have a cross section which includes a slender body section having bulbous ends.

10. A roller door as claimed in any one of claims 7 to 9, wherein each tie include flaps which project from the body section of its cross section and which are configured 5 to prevent contact between adjacent slats when the door is in use.

11. A roller door as claimed in any one of claims 7 to 10, wherein the slats have sockets running the length of their top and bottom edges which are adapted to receive the ties.

12. A roller door as claimed in any one of the preceding claims, wherein at least some 10 of the slats have a profile that allows a bottom edge of the slat to at least partially overlie the top edge of an adjacent slat, when the door is at least partly unrolled or is in an at least partly closed configuration.

13. A roller door as claimed in any one of the preceding claims, wherein the slats are made from metal extrusions. 15

14. A roller door as claimed in any one of the preceding claims, wherein the slats each have a hollow cross section.

15. A roller door as claimed in any one of the preceding claims, wherein the slats are provided with non-metallic spacers adapted to substantially prevent metallic slat to slat contact when the slats are rolled onto the or each slat support. 20

16. A roller door substantially as herein described with reference to any one of the accompanying drawings 25 PIPERS Attorneys for: P60 Limited 204543NZ_CAP_Spec_Junl0.doc/PA