US3073382A

US3073382A - Folding door structure

Info

Publication number: US3073382A
Application number: US8777A
Authority: US
Inventors: Hollis P Zimmerman; Bennett W Merrill; Robert J Piros
Original assignee: NEW CASTLE PRODUCTS Inc
Current assignee: NEW CASTLE PRODUCTS Inc
Priority date: 1960-02-15
Filing date: 1960-02-15
Publication date: 1963-01-15
Anticipated expiration: 1980-01-15

Description

Jan. 15, 1963 H. P. ZIMMERMAN ETAL 3,073,382

FOLDING nooR .STRUCTURE Filed Feb. l5, 1960 '7 Sheets-Sheet 1 @M M WW 7 Sheets-Sheet 2 Jan. 15, 1963 H. P. ZIMMERMAN ETAL FOLDING nooR STRUCTURE med Feb, 15, 1960 Jan. I5, 1963 H. P. ZIMMERMAN ETAL FoLnING nooR STRUCTURE 7 Sheets-Sheet 3 Filed Feb. 15, 1960 H. P. ZIMMERMAN Erm. 3,073,382

-FOLDINGIDOOR STRUCTURE I 7 Sheets-Sheet 4 Jan. 15, 1963 Filed Fb. 15, 19Go Jan. l5, 1963 H. P. ZIMMERMAN Erm. 3,073,382

FOLDING DooR STRUCTURE Filed Feb. 15. 1960 7 Sheets-Sheet 5 1NVENToR5 HolgPmfzemzcz/Z. Eem/Zea? WMe/ma,

Jan. 15, 1963 H. P. ZIMMERMAN ETAL 3,073,382

FOLDING DooR STRUCTURE '7 Sheets-Sheet 6 Filed Feb. 15, 1960 Jan. 15, 1963 H. P. ZIMMERMAN ErAL 3,073,382 I FOLDING DOOR STRUCTURE 7 Shee'cs--SheerI 7 Filed` lFeb. l5, 1960 INVENTOR WW/...f

. WMM

@LEM

W fm l Unite States The invention relates to a new and improved folding door structure and certain specific components thereof, the door structure being ofthe type which is subject to folding and unfolding in accordion-like fashion. More specifically, the invention is directed to a new and improved folding door structure composed of a plurality of hingedly interconnected rigid panels arranged for trolley support in an overhead track housing, the panels being foldable relative to one another into stacked relation, the individual special features forming a part of the door structure and the overall combination thereof providing for new and improved folding door structure operation.

It is an object of the present invention to provide a new and improved folding door structure which is capable of economical manufacture as well as eicient and longlife operation.

A further object is to provide a new and improved folding door structure which incorporates therein a number of cooperating features which in combination provide for improved efficiency in manufacture and operation of the door structure and which also may be advantageously used in known types of folding door structures either singly or in combination with one another.

Still a further object is to provide a new and improved folding door structure which includes a plurality of unique rigid panels capable of being efficiently and economically manufactured, a new and improved hinge mounting and retention arrangement, a new and improved trolley support and door movement control arrangement, and a new and improved half panel torsion support arrangement.

Another object is to provide a new and improved folding door panel construction and method of fabrication thereof, the panel being formed from laminated half sections of identical configuration.

Still another object is to provide a new and improved exible hinge construction for use in foldablyr interconnecting rigid panels in a folding door structure, the hinge construction preferably including hinge member retainer means of unique design, these retainer means also constituting a separate part of the present invention.

Another object is to provide a new and improved trolley support and panel movement control arrangement for use in folding door structures, this arrangement including a special hanger member by which a door panel is suspended from a trolley, the arrangement further including hanger member guide means for cooperation with a track housing whereby the extent to which the panel pivots is controlled to provide for eflicient folding door structure operation, the hanger member being further attached to the panel in a unique manner to permit limited pivoting thereof in the plane of the panel to provide for continuous smooth operation of the door structure during folding and unfolding thereof.

Still another object is to provide a new and improvedA torsion spring mounting arrangement which utilizes a unique spring or wire forming a part of the present invention in supporting a panel section as a part of a foldable door structure to maintain the vertical alignment thereof in the door structure while permitting folding movement of the panel section relative to the other panels and sections making up the door structure.

Other objects not specifically set forth will become apparent from the following detailed description of the at@ I 2 present in vention made in conjunction with the accompanying drawings wherein:

FIG. l is a perspective of the door structure of the present invention mounted in closed position within a door frame;

FIG. 2 is a fragmentary, partly sectioned elevation of the door structure having portions thereof broken away to illustrate the combination of important structural features included therein;

FIGS. 3A, 3B and 3C separately illustrate fragmentary portions of the door structure in top plan view, the combination of these iigures in the order set forth providing for a complete top plan view of the door structure in its extended or closed position;

FIG. 4 is a fragmentary, partly sectioned view of the door structure in its folded or open position;

FIGS. 5 and 6 are elevations of the inner faces of half sections used in forming the panels of the door structure, these views illustrating the sections prior to lamination thereof;

FIG. 7 is an enlarged top plan view of a finished door panel following lamination of the half sections of FIGS. 5 and 6 and final shaping thereof;

FIG. 8 is an enlarged perspective of a hanger member forming a part of the door supporting arrangement of the present invention;

FIG. 9 is an enlarged, fragmentary perspective of a section of a hinge strip member used in interconnecting the panels of the door structure;

FIG. 10 is an enlarged, fragmentary top plan view .of one of the hinge connections of the door structure, this view being taken generally along line 10-10 in FIG. 2;

FIG. 11 is an enlarged, partly sectioned, fragmentary perspective of the hinge connection of FIG. 10 better illustrating certain features thereof;

FIG. 12 is a perspective of the hinge retainer forming a part of the present invention;

FIG. 13 is an enlarged, partly sectioned, fragmentary perspective of the trolley supporting arrangement of the present invention taken generally along line 13-13 in FIG. 2;

IFIG. 14 is an enlarged, partly sectioned, fragmentary top plan View of a trolley member of the door structure taken generally along line 14-14 in FIG. 2;

FIG. 15 is a view similar to FIG. 14 taken generally along line 15-15 in FIG. 2 and illustrating a slightly modified trolley member;

FIG. 16 isr an enlarged, fragmentary section of the trolley support arrangement and track housing taken gen# erally along line 16-16 in FIG. 2; y

FIG. 17'is an elevation of one form of trolley member used in the door structure;

FIG. 18 is an elevation of another form of trolley member used in the door structure; and

FIG. 19 is an enlarged perspective of a torsion wire means constituting a part of the present invention.

FIG. 1 illustrates the folding door structure of the present invention mounted in its operative position within a doorway defined by a doorway jamb fran-le20. The door structure includes a lead p ost 21 at one end thereof and a jamb post 22 at the other end thereof which i-s fixedly attached in overlying parallel relation to a portion of the door jamb structure 20. Intermediate the

post

21 and 22 are a plurality of hingedly interconnected panel 'sections including from right to left, as viewed in FIG. l, a half panel 23,

full panels

24, 25, 26 and 27, and a half panel 28. The door structure as illustrated in its closed condition extends across the doorway with the lead post 21 thereof in sealing abutment with a lead post jamb 30 ofV any suitable type xedly secured to the door frame 20. 'Ihe lead post 21 carries a combination handle and lock assembly 31 of any suitable type.

Asshown in FIG. 2, the lead post jamb' 30 carries a latch strike plate 32 provided with a portion for engagement with a latch element 33 forming a part of the combined handle and latch assembly 31. This assembly extends through the lead post 21and provides on each side thereof a handle 34 and a lock operating element 35. Mounted across the topof the door frame 20 is a track housing 36 of known configuration as best illustrated in FIG. 16, this housing including a pair of spaced track portions 37 which support a plurality of trolleys. The track housing 36 is suitably attached to the door frame V20 by a plurality of fasteners 3S.

The lead post 21 as best illustrated in FIGS. 2, 3C and 4 is supported by a pair of trolleys 40 through L-shaped hanger members 41 which are suitably fixed in grooves ypins 42 shown in FIG. 3C. By the provision of the two spaced trolleys 40 to support the lead post 21, this panel section is held against pivotal movement about its longitudinal axis and thus is maintained in parallel relation with the track `housing 36 during operation of the door structure. The manner in which the lead post 21 is attached to the trolleys 40 is not described in detail for the reason that `any suitable means may be utilized whereby this panel section is supported for nonpivotal movement during operation of the door structure.

The panels identified by the numerals 21 through 28 are interconnected by flexible hinge members 43 which are best shown in FIGS. 3A, 3B, 3C and 4. The special configuration ofthe hinge members 43 and the manner in which these hinge members are received in hinge grooves formed in the side margins of the various panels will -be described below in detail. The hinge members 43 are held in operative panel interconnecting relation against vertical displacement by hinge retainer members 44 as shown in FIG. 2.

As shown in FIGS. 2, 3A, 3B, 3C and 4, the full panels 24 through 27 are supported by a trolley arrangement which in each instance utilizes a hanger member 45 and two different types of

trolleys

46 and 47 which are alternately arranged for nesting in the fully contracted condition of the door structure (FIG. 4). 'Ihe half panel 23 is not supported by a trolley means received in the overhead track housing 36 but is maintained in vertical alignment with the associated panels by means of a torsion member 48 extending between the half panel 23 and the lead post 21 as shown in FIG. 2 and in a manner to be specifically described. Similarly, the half panel 28 is not supported -bya trolley arrangement received in the overhead track housing 36 but is held in vertical alignment with the associated panels of the door structure by a torsion member 48 extending between the same and the fixed jamb post panel 22. The jamb post panel 22 is suitably secured to the door frame 20 by fasteners 50.

The panels 23 through 28 are formed from laminated half panel sections in accordance with the procedure to be described in conjunction with FIGS. -7. FIGS. 5 and 6 illustrate a pair of

half panel sections

51 and 52, respectively. These sections may be formed from any suitable rigid material and, by way of example, they may he formed from hardboard. One surface of each half section is grooved in the manner illustrated in FIGS. 5 and 6 with each

half section

51 and 52 being duplicates insofar as the groove locations and dimensions are concerned -thus providing complete uniformity in half section fabrication. Each

half section

51 and 52 in a direction `extending from its left-hand margin to its right-hand margin, asviewed, is provided with a hinge groove 53 and an adhesive catch groove 54 which is spaced slightly inwardly from the hinge groove 53. The right-hand margin of `each

half section

51 and 52 is provided with an open ended hinge groove 55 while the left-hand edge surface is beveled in a manner to be described. A relatively wide groove 56 is provided in each half section near the top edge thereof with this groove having an arcuate inner end shape and further being of increasing width in a direction toward the top edge of the half section. Accordingly, each groove 56 expands in width in a direction outwardly toward the top edge of the half section with the groove opening outwardly of the top edge of the half section. Near the inner end or base of the groove 56 is a knob-like, round projection 57 which is formed from the material of each half section and which projects into the groove 56 as best illustrated in FIG. 13.

The

half sections

51 and 52 are designed to be xedly laminated in grooved face-to-face relation as shown in FIG. 7. In turning the faces of the

half sections

51 and 52 illustrated in FIGS. 5 and 6, respectively, toward one another, applying any suitable laminating adhesive or glue along one or more of the grooved faces thereof, and tightly pressing the half sections together to laminate the same, results in the forming of a panel for use in the door structure.

The laminated panel structure identified as panel 24 in FIG. 7 has an initial shape which includes the

edge portions

58 and 60 thereof shown in broken lines. Suitable adhesive is applied to the center portions of the

half sections

51 and 52 between the

grooves

54 and 55 thereof and the grooved faces of these half sections are laminated together. The adhesiveupon compression of the half sections together will ow therebetween and the half sections are arranged relative to another upon lamination to place an adhesive clatch groove 54 near each edge of the panel 24 thus formed. In this manner, the ow of adhesive outwardly toward the hinge grooves is trapped by the catch grooves 54 and adhesive will not flow into the hinge grooves to interfere with subsequent hinge installation and operation.

Immediately prior to lamination of the

half sections

51 and 52 to form the panel 24, a hanger member 45 is inserted in one of the grooves 56 thereof. As shown in FIG. 8, each hanger member 45 is of flat plateflike configuration having a relatively'wide body portion provided with a lower end, convex configuration just inwardly of which an aperture 61 is located. The upper .end of the hanger member 45 is provided with an upwardly projecting neck portion 62 which is arranged to be received through a

suitable trolley member

46 and 47 and to be attached thereto by a cotter pin extending through a transversely extending `drilled opening 63 formed in the upper end thereof. The upper end portion of the neck 62 is slightly enlarged and is of rectangular shape to control pivoting of the hanger member 45 in a manner to be described.

Each hanger member 45 is mounted in a panel, such as the panel 24, in the manner best illustrated in FIG. 13. The base aperture 61 has received therethrough the knoblike projection 57 of either one or both of the

half sections

51 and 52. The aperture 61 is of greater diameter than the projection 57 and the hanger member 45 may freely pivot in the plane of the panel 24 about the projection 57. To permit an adequate degree of pivotal action between the hanger member and the panel which it supports, the combined grooves 56 of the

half sections

51 and 52 are of substantially greater width than the width of the hanger member 45. Furthermore, the increasing width of the combined grooves 56 in a direction toward the top edge of the panel 24 permits rather substantial relative movement between the panel and the hanger member. However, the width of the hanger member 45 is adequate to prevent any appreciable relative movement between the panel 24 and the hanger member 45 in a direction about the vertical axis of the hanger member 45. In other words, the atness of the hanger member 45 in its engagement with the panel member within the with the panel 24 about a vertical axis.

Referring again to FIG..7, the face-to-face lamination of the

half sections

51 and 52 results in cooperative alignment of the

grooves

53 and 55 thereof near opposite side margins. The cooperating grooves define hinge grooves and in order to make these grooves accessible for hinge attachement, the laminated half sections are subjected to final shaping whereby the

edge margins

58 and 60 thereof are removed by any suitable trimming operation. Final shaping of the panel 24 along its side margins results in the cutting back of opposite side margins of the

yhalf sections

51 and 52 to an extent that the grooves 5S become exposed to open outwardly along the side margins of the panel 24. The remaining opposite margins of the

half sections

51 and 52 are cut back only to the extent that the portions 58 are removed therefrom to retain these side margins as rib-like projections provided with cooperating

beveled surfaces

64 and 65. The surfaces 64 are preferably formed at an angle of about 45 whereas the surfaces 65 and perferably formed at an angle of about 12. The surfaces 65 define abutment faces which abut with similar faces formed in adjacent panels to prevent movement of the hingedly interconnected panels of the door structure into coplanar relation in the fully extended or unfolded condition of the door structure. This function is illustrated in FIGS. 3A, 3B and 3C.

Each hinge member 43 is in the form of a continuous flexible strip prepared from plastic, rubber or rubber-like material. The special configuration of each hinge strip 43 is best illustrated in FIG. 9 wherein it will be noted that each strip is provided with a generally wide, relatively thin central connecting portion 66 bounded along one face thereof by projecting rib-like marginal portions 67. It will be particularly noted that the ribs 67 project in the same direction solely along one face of the hinge member and are generally rounded to be readily received in the hinge grooves of adjacent panels. FIGS. and 11 particularly illustrate the positioning of a hinge member 43 in adjacent grooves of adjacent panels for foldable interconnection thereof. The ribs 67 of the hinge members 43 may be readily threaded within the hinge grooves of adjacent panels, these hinge grooves being defined by the cooperating

half section grooves

53 and 55. The central connecting portion 66 of each hinge member extends between the interconnected panels through the edge openings of the hinge grooves to completely close off the areas between each of the panels throughout the entire vertical length of the panels.

The particular manner in which each panel is formed from laminated half sections as described in conjunction with FIG. 7 provides for opposite positioning of the hinge grooves along opposite edges of each panel t0 locate the hinge members 43 to obtain accordion-like folding of the door structure as shown in FIG. 4. Also, in referring to FIGS. 3A, 3B and 3C, it will be noted that the rib-like projections extending along the side margins of adjacent panels are alternately positioned to opposite sides of the panels to be brought into cooperating abutment to prevent Y relative movement of the panels into coplanar relation. With thisarrangement the panels are maintained in broken continuity in the expanded condition of the door structure to facilitate accordion folding of these panels merely by movement of the lead post 21 toward the jamb post 22.

In order to hold the hinge members 43 in their operative positions within the hinge grooves and prevent any inadvertent vertical displacement thereof, the hinge retainers 44 may be attached to the ends of the hinge members. Each retainer 44 as shown in FIG. 12 is of generally U-shape having a leg portion 68 provided with a pair of spaced flange portions 70 formed integral theretween a portion of a marginal rib '67 of a hinge strip. The flanges 70 are preferably provided with apertures 71 in which the material of the hinge member protrudes by lreason of the `compressing clamping action of the flanges thereabout to permit adequate gripping of the hinge member by the retainer to prevent displacement therebetween.

The retainer 44 is further provided with an intermediate, at connecting portion 72 which is designed to overlie the top edge surface of a panel in flat engagement therewith. The retainer 44 is also provided with another leg portion 73 which is preferably tapered to -be embedded in a panel at a point spaced inwardly from the hinge groove thereof to fix the retainer in the panel. As shown in FIGS. l0 and l1, the leg portion 73 may be inserted in an adjacent adhesive catch groove 54 to clamp the retainer relative to the panel. If the catch groove 54 is of a size which is inadequate to receive the tapered leg portion 73, a portion of the groove may be enlarged by suitable drilling to accommodate the legvportion. The retainer 43 may be formed from any suitable spring metal material such as stainless steel. Retainers may be used at both the top and bottom edges of each hinge member along sach side thereof or may merely be used in fewer numbers where necessary to perform the desired function.

As previously described, the hanger members 45 are attached to

trolleys

46 and 47 for controlled pivoting about a vertical axis relative to these trolleys and for movement with their respective panels during folding and unfolding of the door structure. The trolley 46 as shown in FIG. 17 include a yoke 74 having a vertically directed central bore 75 extending therethrough. To each side o f the yoke 74 is a xed axle 76 having a wheel 77 rotatably mounted thereon. Each wheel 77 is provided with an integrally formed collar-like spacer 7 S which in combination with an expanded end of each axle 716 maintains the location of the wheels 77 to operate within the track portions 37 of the track housing 36 as shown in FIG. 16. The top surface of the yoke 74 to one side thereof is provided with an integrally formed, upwardly projecting stop means Sti for a purpose to be described. A

The trolley 47 is somewhat similarly constructed being provided with a yoke 31 having a bore 82 extending vertically upwardly therethrough and projecting axles 83 fixed to opposite sides thereof. Wheels 84 are rotatably mounted on the axles 83 and are provided with integrally formed collar-like sleeves 85 which project outwardly therefrom into abutment with enlarged ends of the axle 83. The top surface of the yoke 81 is provided with an upwardly projecting stop means 86 positioned to one side thereof. The arrangement of the

wheels

77 and 84 of' the

trolleys

46 and 47 provided for nesting of the same when the door structure is in its folded or stacked' condition as shown in FIG. 4. With this arrangement, the panels of the door structure are permitted to move into planes which are perpendicular to the direction of operation of the door structure. The

trolleys

46 and 47 are of suflicient width including the wheels to prevent excessive turning thereof in the track housing 36.

As best illustrated in FIG. 13 with regard to a trolley 46, the neck portion 62 of a hanger member 45 is received upwardly through the bore 75 of the trolley member yoke to locate the upper enlarged end thereof slightly above the top surface of the yoke. A hanger member guide means S7 in the form of an arm is provided with a base portion S8 having an aperture therein through which the top end of the neck v62 of the hanger member 45 is received. As shown in FIG. 14, the aperture of the base 88 of the guide means 87 is defined by stop means which are in the form of oppositely positioned, inwardly projecting shoulders 99 arranged to cooperatively limit the degree to which the hanger member 45 can rotate relative to the trolley 46 as well as the track housing 36. As shown in FIG. 13, the hanger member 45 is held against vertical displacement from the trolley 46 -by a cotter pin 7 91 extending through the drilled opening 63 previously described.

The arm portion of the guide means 87 extends toward 'an ,inner surface portion of the track housing 36 and is .provided with an integrally formed, reduced hook-like end portion 92 which retains thereon a bushing 93 formed from relatively soft material for quiet sliding movement -along the track housing in engagement therewith. Any appreciable rotational movement of the guide means 87 relative to the trolly 46 is prevented in one direction by engagement of the bushing 93 thereof with Vthe track housing, and in the opposite direction by engagement of projecting abutment means 94 formed integral with the base 88 with the projecting stop means 80 formed integral with the yoke 74 of the trolley 46.

In explaining the operation of the panel supported by a trolley 46, attention is directed to FIGS. 3B, 3C, 4 and 14. The

panels

24 and 26 shown in FIGS. 3B, 3C and 4 -are supported by trolleys 46 and are arranged in the door Vstructure to pivot relative to the trolleys 46 through an angle of less than 90 and which lies in the iirst or third quadrants. Thus the

panels

24 and 26 upon operation of the door structure from its fully extended condition shown in FIGS. 3B and 3C to the folded or stacked condition shown in FIG. 4 will pivot about their vertical axes in a counterclockwise direction. As previously described, the hanger members 45 of these panels will pivot with -the panels due to the confinement thereof between the panel half sections. These hanger members will each pivot to the position shown in solid lines in FIGS. 4 and 14 from the position shown in broken lines in FIG. 14 land in solid lines in FIGS. 3B and 3C. Further counterclockwise pivoting will be prevented by abutment of the top ends of the neck portions 62 of the hanger member 45 with the inwardly projecting stop means 90 forming a part of the base 88 of each guide means 87 carried by the trolleys 46. Engagement of the bushing 93 with the track housing will prevent counterclockwise pivoting of theguide means 87 relative to the trolley 46 to thus make the stop means 90 effective in preventing further counterclockwise rotation of the hanger member 45.

Upon unfolding of the door structure from its stacked position shown in FIG. 4 to its expanded condition shown in FIGS. 3A, 3B and 3C, the hanger members 45 of the ,

panels

24 and 26 will rotate with the panels in a clockwise direction with the extent of rotation being limited by ultimate abutment of the neck portion 62 of the hanger members 45 with the stop means 90 of the guide means 87 as well as abutment occurring between the beveled surffaces 65 of the projecting ribs of adjacent panels. Any `tendency for the guide means 87 to rotate relative to the trolley 46 in a clockwise direction will be prevented by abutment between theabutment means 94 and stop means 80 previously described.

FIG. 15 illustrates a similar structural arrangement with regardto the trolleys 47 which support the

panels

25 and 27. These panels as illustrated in FIGS. 3A, 3B and 4 are designed for pivotal movement in directions opposite to the

panels

24 and 26 during folding and unfolding of the door structure. The trolleys 47 supporting the same each .carry a guide means 95 which is identical in structure with .the guide means 87 previously described but which is -nverted in its mounted relation -to the trolley 47. The Aparts ofthe guide means 95 corresponding exactly to those previously described in connection with the guide means 87 are identified by the same reference numerals. However, by reason of its inverted mounting on the trolley 47, the guide means 95 is arranged to engage an opposite guide surface of the track housing 36 and to control pivotal movement of the

panels

25 and 27 in directions which are opposite to the directions of movement of the .

panels

24 and 26. The upwardly projecting stop means 86 of the yoke 81 of the trolley 47 is oppositely positioned relative-,to the stop means 80 of the trolley 46 to provide -smooth operation of the door structure.

for limiting abutment with the abutment means 94 of the guide means 95.

The special trolley suspension arrangement described including the unique hanger member and method of attaching the same to a panel provides for efficient and Each hanger member is conned within the laminated half sections of Ieach panel to prevent relative pivoting therebetween about a vertical axis and in this manner the guide means 87 .and 95 provide for controlled overall pivoting of the panels during folding and unfolding of the door structure. An important aspect of the arrangement resides in the provision of limited pivotal play existing between each hanger member 45 and its respective panel in the plane of each panel. This limited pivotal play is present by reason of the hanger member being of less width than the hanger member groove formed in the panel and further in view of the pivotal attachment of the hanger member to the panel at the base thereof by the knob-like proj- -ection formed integral with the panel. Thus, upon initiating folding or unfolding operation of `the door` structure, the hanger members can pivot within the plane of each panel accompanied by slight pivoting of the

trolleys

46 and 47 and slight verticalrocking of the guide means 87 and 95 within the track housing. This pivotal playprevents wedge-like locking of the door structure in its folded, unfolded or intermediate positions to permit smooth and eicient operation thereof. The amount of play present by reason of the structure defined is not sufficient that the door structure is unstable in any respect and, actually, this play is not readily obvious to the user. The door structure exhibits good operational stability while being provided with built-in play to prevent operational wedging or locking of the relatively movable parts thereof.

FIG. 19 illustrates in detail the torsion wire means 48 used in vertical support of the

half panels

23 and 28. The means 4S is in the form of a wire spring of generally flat Z-shape and includes a straight center section 96 which terminates in oppositely directed hook-

like end portions

97 and 98. It will be noted that the

end portions

97 and 98 are angled slightly toward one another relative to the horizontal to provide a hook-like function in a manner to be described.

Referring to FIG. 2, the mounting of a torsion wire means 48 between the lead post 21 and half panel 23 is illustrated. It will be noted that the end portion 97 is suitably embedded in the lead post 21 and the end portion 98 is suitably embedded in the half panel 23. The center portion 96 extends from the lead post 21 into the half panel 23 and in the installed condition of the torsion wire means 48, this center portion is preferably inclined slightly relative to the vertical. With the arrangement illustrated, the torsion wire means is placed in tension in supporting the half panel 23 by the lead post 21 while the center portion 96 extends across the hinge area existing between these panels to be subject to torsional twisting during folding of the half panel 23 relative to the lead post 21. The torsion wire means 48 may be fixed to or embedded in the

panels

21 and 23 in any suitable manner such as by being placed between half sections during `lamination thereof in forming the

panels

21 and 23.

A similar torsion wire means 48 is used in vertical support of the half panel 28 relative to Ithe jamb post 22. This torsion means is mounted between the panels .in the same manner as described with regard to

panels

21 and 23 with the center portion 96 thereof extending .torsion wire means 48 permits yfolding and unfolding .movement of the half panel 28 relative to the xed jamb `post 22.

As particularly illustrated in FIG. 16 and as partially 9 shown in FIG. l, the track housing 36 may be concealed if desired by the use of molding strips 100 extending across Ithe doorway and spaced outwardly along each side of the track housing. The strips 16) may be formed from hardwood material which matches the panels of the door structure and are suitably 'attached by fasteners 101 to spacer strips 192 which extend yacross the doorway and are attached to the door frame 20 by fasteners 103.

While emphasis has been placed on the forming of the panels 23 through 28 from laminated half sections, it will be understood that the 4lead post 21 and jamb post 22 are also preferably formed in this manner as illustrated in FIGS. 3A, 3C and 4. As particularly shown in FIGS. 3C and 4, the lead post 21 is provided with a nose portion 194 to be received in the lead pos-t jamb 30 (FIG. 2) to seal olf the doorway when the door structure is fully expanded. As previously described, the panels are preferably formed from good quality hardwood with the surfaces thereof being painted and coated for protection. The forming of the panels from laminated sections provides greater panel strength Iand dimensional stability and constitutes an important aspect of the present invention.

Obviously certain modifications land Variations of the invention as hereinbefore set forth may be made without departing from the spirit and scope thereof, and therefore only such limitations should be imposed as are indicated in the appended claims.

We claim:

l. A folding door structure comprising a plurality of rigid panels including full panel sections, half panel sections, a lead post, and a jamb post, said panels being interconnected by hinge members received in side margin hinge grooves formed in said panels for accordion-type folding into and out of stacked relation, said full panel sections and said lead post having trolley support means attached thereto for hanging from an overhead track housing, each of the hinge grooves being partially defined by a projecting rib-like portion located adjacent opposite faces of a panel along opposite side margins thereof, said hinge members each having rib-like side margins received in adjacent hinge grooves o-f adjacent panels, the projecting rib-like portions defining said hinge grooves being arranged for abutment upon complete unfolding of said panels to limit movement thereof into coplanar relation, said full panel sections each carrying a hanger member attached thereto at one end and to a trolley at the other end which `constitutes said trolley support means, said hanger member being arranged to pivot about its longitudinal taxis with said full panel section relative to said trolley during operation of said door structure, and h-anger member guide means carried by said trolley and projecting therefrom for engagement with a portion of a track housing, said guide means including hanger member pivot control means in operative association with said other end of said hanger member.

2. A folding door structure comprising a plurality of rigid panels including full panel sections, half panel sections, a lead post, land -a jamb post, said panels being interconnected by hinge members received in side margin hinge grooves lformed in said panels for accordion-type folding into land out of stacked relation, said full panel sections and said lead post having trolley support means attached thereto for han-ging from lan overhead track housing, each of the hinge grooves 4being partially defined by a projecting rib-like pontion located adjacent .opposite faces of a panel along oppositeside margins end surface portion of the panel, the projecting rib-like portions defining said hinge grooves being arranged for abutment npon complete unfolding of said panels to limit movement 4vthereof into copl-anar relation, said full panel sections each lcarrying a hanger member attached thereto at one end and to a trolley at the other end which constitutes said trol-ley support means, said hanger member being arranged to pivot about its longitudinal axis with said full panel section relative to said trolley during `oper-ation of said door structure, and hanger member guide means carried by said trolley and projecting therefrom for engagement with a portion of a track housing, said guide means including hanger member pivot control means in operative association with said other end of said hanger member.

3. A folding door structure comprising Ia plurality of rigid panels including full panel sections, half panel sections, a lead post, and a jamb post, said panels being interconnected by hinge members received in side margin hinge grooves formed in said panels for accordion-type folding into .and out of stacked relation, said full panel sections and said 4lead post having trolley support means attached thereto yfor hanging from an overhead track housing, said half sections being supported by torsion means extending from an `adjacent panel, each of the hinge grooves being partially defined by a projecting riblike portion located adjacent opposite faces of a panel along opposite side margins thereof, said hinge members each having rib-like side margins received in adjacent hinge grooves of adjacent panels, the projecting rib-like portions defining said hinge grooves being arranged for abutment upon complete unfolding of said panels to limit movement thereof into coplanar relation, said full panel sections each carrying 4a hanger member attached thereto at one end and to a trolley at the other end which constitutes said trolley support means, said hanger member being arranged to -pivot about its longitudinal axis with said Ifull panel section relative to said trolley during opera'- tion `of said door structure, and hanger member guide means carried by said trolley land projecting therefrom for engagement with a portion of a track housing, said guide means including hanger pivot control means in operative Vassociation with said other end of said hanger member. l f

4. A folding door structure comprising a plu-ralityof rigid panels'including full panel sections, half panel sections, a lead post, and a jamb post, 'said panels being interconnected by hinge members for accordion-type folding into and ont of stacked relation, said full panel sectionsA and said =lead post having trolley support means attached Ithereto for hanging from an overhead track housing, at least said full `and .half panel sections each being formed from laminated half sections fixedly secured in face-to-face relation, said half sections being provided lalong inner face side marginal portions thereof with longitudinally directed hinge grooves receiving therein attaching portions ofv said hinge members, adhesive catch 4grooves formed in at least one of said half sections inwardly of said hinge grooves to trap excess adhesive dur- -ing lamination of said half sections and prevent the ow of adhesive'intosaid-hinge grooves, each of the hinge grooves being pa-rtially defined by a projecting rib-like .portion located adjacent opposite faces of a panel along opposite side margins thereof, said hinge members each having rib-like side margins constituting said attaching .portions received in adjacent hinge grooves of adjacent panels, the projecting rib-like portions defining s-aid hinge grooves being -arranged for abutment upon complete unfolding of said panels to limit ymovement thereof into coplanar relation, said full panel sections each carrying a hanger member attached thereto at one end and to a trolley at the other end thereof-which constitute said trolley support means, said hanger member being arrangedgto pivot about its longitudinal axis with said full panel section relative to said trolley during oper-ation of said door structure, and hanger guide means carried by said trolley and projecting therefrom for engagement with a portion of a track housing, said guide means including hanger member pivot control means in operative lassociation with said other end of said hanger member.

5. A folding door structure comprising a plurality of rigid panels including full panel sections, half panel sections, a lead post, and a jamb post, said panels being `interconnected by hinge members for accordion-type folding into and out of stacked relation, said full panel sections -and said lead post having trolley support means attached thereto for hanging rfrom an overhead track housing, said half sections being supported by torsion means extending from an adjacent panel, at least said full and half panel sections each being formed from laminated half sections xedly secured in face-to-face relation, said half sections being provided along inner face side marginal portions thereof with longitudinally directed hinge grooves receiving therein attaching portions of said hinge members, adhesive catch grooves xformed in at least one of said half sections inwardly of said hinge grooves to trap excess adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves, each of the hinge grooves being partially defined by a projecting rib-like portion located adjacent opposite faces of a panel along opposite side margins thereof, said hinge members each having rib-like side margins constituting said attaching portions received in adjacent hinge grooves of adjacent panels, hinge member retainer means of generally U-shape having one leg portion inserted in an open end of a hinge groove and clamping a portion of the rib-like side margin of a hinge member, the other leg portion of said retainer means being embedded in the panel with the intermediate connecting portion thereof overlying an end surface portion of the panel, the projecting rib-like portions defining said hinge grooves being arranged for abutment upon complete unfolding of said panels to limit movement thereof into coplanar relation, said full panel sections each carrying a hanger member attached thereto at one end and to a trolley at the other end which constitutes said trolley support means, said hanger member being arranged to pivot about its longitudinal axis with said full panel section relative to said trolley during operation of said door structure, and hanger member guide means carried by said trolley and pro- -jecting therefrom for engagement with a portion of a track housing, said guide means including hanger member pivot control means in operative association with said other end of said hanger member.

6. A folding door structure comprising a plurality of rigid panels including full panel sections, half panel sections, a lead post, and a jamb post, said panels being interconnected by hinge members for accordion-type fold ing into and out of stacked relation, said full panel sections and said lead post having trolley support means attached thereto for hanging from an overhead track housing, said half sections being supported by torsion means extending from an adjacent panel, at least full and half panel sections each being formed from laminated half sections fixedly secured in face-to-faee relation, said half sections being provided along inner face side marginal portions thereof with longitudinally directed hinge grooves receiving therein attaching portions of said hinge members, ad hesive catch grooves formed in at least one of said half sections inwardly of said hinge grooves to trap excessive adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves, each of the hinge grooves being partially defined by a projecting rib-like portion located adjacent opposite faces of a panel along opposite side margins thereof, said panel members each having rib-like side margins constituting said attach. ing portions received in adjacent hinge grooves of ad jacent panels, and hinge member retainer means of generally U-shape having one leg portion inserted in an open end of a hinge groove and clamping a portion of the rib-like side margin of a hinge member, the other leg portion of said retainer means being embedded in the panel with the intermediate connecting portion thereof overlying an end surface portion of the panel, the projecting rib-like portions defining said hinge grooves being arranged for abutment upon complete unfolding of said panels to limit movement thereof into coplanar relation.

7. A folding door structure panel section, said section comprising a pair of laminated half sections adhesively secured in face-to-face relation, said half sections being `provided along inner face side marginal portions thereof with longitudinally directed hinge `grooves in communication with the adjacent side margin of said panel section and adapted to receive therein attaching portions of flexible hinge members for interconnection of a plurality of panel sections to form a folding door structure, and adhesive catch grooves formed in at least one of said half sections inwardly of said hinge grooves to trap excess adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves.

8. The panel section of claims 7 wherein at least one of said half sections centrally along the inner face thereof is provided with a top edge opening hanger groove which expands in width in a direction toward the top edge, one of said half sections having integrally formed therewith a knob-like projection which projects into said hanger groove near the base thereof, and a hanger mem- -ber of plate-like configuration received in said hanger groove and having a portion projecting outwardly of said hanger groove above the top edge of said panel section for trolley attachment, the base portion of said hanger member being apertured to receive said knob-like projection F therein to support said panel section, said hanger member being of a width which is less than that of said hanger groove to permit limited pivoting of said hanger member and said panel section relative to one another.

9. A folding door structure panel section, said section comprising a pair of laminated half sections adhesively secured in at least substantially co-extensive face-to-face relation, each of said half sections being provided along opposite inner face side marginal portions thereof with cooperating longitudinally directed grooves defining hinge grooves which are in communication with adjacent side margins of said panel section and are adapted to receive therein attaching portions of flexible hinge members for interconnection of a plurality of panel sections to form a folding door structure, and adhesive catch grooves formed in at least one of said half sections just inwardly of said hinge grooves to trap excess adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves.

10. A folding door structure panel section, said seotion comprising a pair of laminated half sections adhesively secured in at least substantially co-extensive faceto-face relation, each of said half sections being provided along inner face side marginal portions thereof with cooperating longitudinally directed grooves defining hinge grooves which are in communication with adjacent side margins of said panel section and are adapted to receive therein attaching portions of flexible hinge members for interconnection of a plurality of panel sections to form a folding door structure, and adhesive catch grooves formed in at least one of said half sections inwardly of said hinge grooves to trap excess adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves, one side margin of one half seetion and the opposite side margin of the other half section projecting outwardly with the outer edge surfaces thereof being beveled for abutment with similar surfaces of adjacent panel sections to prevent coplanar alignment of interconnected panel sections in the extended condition of a folding door structure.

1l. A folding door structure panel section, said section comprising a pair of laminated half sections adhesively secured in at least substantially co-extensive face-to-face relation, each of said half sections being provided along inner face side marginal portions thereof with cooperating longitudinally directed grooves defining hinge grooves which are in communication with adjacent side margins of said panel section and are adapted to receive therein attaching portions of flexible hinge members for interconnection of a plurality of panel sections to form a folding door structure, and adhesive catch grooves formed in at least one of said half sections inwardly of said hinge grooves to trap excess adhesive during lamination of said half sections and prevent the flow of adhesive into said hinge grooves, one side margin of one half section and the opposite side margin of the other half section projecting outwardly with the outer edge surfaces thereof being beveled for abutment With similar surfaces of adjacent panel sections to prevent coplanar alignment of interconnected panel sections in the extended condition of a folding door structure, said hinge grooves opening outwardly of the side margins of said panel section along the inner face of each projecting side margin of the half sections thereof.

12. The panel section of claim 11 wherein at least one of said half'sections centrally along the inner face thereof is provided with a top edge opening hanger groove which expands in width in a direction toward the top edge, one of said half sections having integrally formed therewith a knobelike projection which projects into said hanger groove near the base thereof, and a hanger member of plate-like configuration received in said hanger groove and having a portion projecting outwardly of said hanger groove above the top edge of said panel section for trolley attachment, the base portion of said hanger member being apertured to receive said knob-like projection therein to support said panel section, said hanger member being of a width which is less than that of said hanger groove to permit limited pivoting of said hanger member and said panel section relative to one another.

13. The method of forming a folding door structure panel section, said method comprising grooving a pair of panel half section longitudinally along one face of each thereof inwardly of both side margins to provide for cooperating grooves in which attaching portions of flexible hinge members are received following lamination and final shaping of said half sections, fixedly laminating said half sections in grooved face-to-face relation and removing a side margin of one of said half sections and the opposite side margin of the other half section to an extent that said grooves are exposed to open outwardly of the side margins of said panel section.

14. A folding door structure comprising a plurality of hingedly interconnected rigid panels for accordion-like folding and unfolding, said panels having longitudinal hinge grooves formed therein and opening outwardly along side margins thereof, each of said hinge grooves being partially defined by a projecting rib-like portion located adjacent opposite faces of a panel along opposite side margins thereof, flexible hinge strip members each having rib-like side margins received'in adjacent hinge grooves of adjacent panels to foldably interconnect said panels, hinge strip member retainer means of generally U-shape having one leg portion inserted in an open end of a hinge groove of a panel and clamping a portion of the rib like side margin of the hinge strip member, the other leg portion of said retainer means being embedded in said panel with the intermediate connecting portion of said retainer means overlying an end surface portion of said panel, and trolley means attached to at least some of said panels to support said door structure in an overhead track, the projecting rib-like portions of said panels being arranged for abutment upon complete unfolding of said panels to limit movement thereof into coplanar relation.

15. A hinge retainer for use in a folding door structure wherein a plurality of panels are foldably interconnected by hinge strip members having rib-like longitudinal margins received in hinge grooves formed in the side margins of 'said panels, said retainer being generally U-shaped with one leg portion thereof having a pair of spaced flange portions arranged for clamping a rib-like margin of a hinge strip member therebetween, the other leg portion being tapered for embedding in the material ofa panel when said one leg portion is inserted in the open end of a hinge groove in clamping engagement with a hinge strip member, and the intermediate connecting portion of said retainer being generally flat for overlying engagement with an outer edge portion of the panel to locate said other leg portion in the panel inwardly of the hinge groove.

16. A hinge retainer for use in a folding door structure wherein a plurality of panels are foldably interconnected by hinge strip members having rib-like longitudinal mar gins received in hinge grooves formed in the side margins of said panels, said retainer being generally U-shaped with one leg portion thereof having a pair of spaced flange portions arranged for clamping a rib-like margin of a hinge strip member therebetween, the other leg portion being tapered for embedding in the material of a. panel when said one leg portion is inserted in the open end of a hinge groove in clamping engagement with a hinge strip member, and the intermediate connecting portion of said retainer being generally at for overlying engagement with a outer edge portion of the panel to locate said other leg portion in the panel inwardly of the hinge groove, said flange portions of said one leg portion having apertures therein which are filled by the material of said hinge strip member upon clamping thereof.

17. In a folding door structure wherein a plurality of panels are hingedly interconnected for accordion-folding and unfolding, the provision of an overhead support arrangement including a hanger member attached at one end thereof with one of said panels and at the other end thereof with a trolley, said hanger member being attached to said panel and to said trolley through means providing for pivoting of said hanger member about its longitudinal axis with said panel and relative to said trolley, hanger member guide means carried by said trolley and projecting therefrom for engagement with a portion of a track housing in which said trolley is adapted to be mounted, said guide means including an apertured base through which said other end of said hanger member is received for pivoting relative thereto, first stop means forming a part of said base and defining a portion of the aperture therein for engagement with said other end upon limited pivoting of said hanger member relative to said trolley in opposite rotational directions, and second stop means carried by said trolley for engagement with abutment means forming a part of said guide means to prevent pivoting of said guide means out of engagement with a l track housing during operation of said door structure.

18. The folding door structure of claim 17 wherein the attachment of said hanger member to said panel further includes attachment means providing for controlled relative pivotal movement between said hanger member and said panel in the plane of said panel.

References Cited in the file of this patent

Claims

1. A FOLDING DOOR STRUCTURE COMPRISING A PLURALITY OF RIGID PANELS INCLUDING FULL PANEL SECTIONS, HALF PANEL SECTIONS, A LEAD POST, AND A JAMB POST, SAID PANELS BEING INTERCONNECTED BY HINGE MEMBERS RECEIVED IN SIDE MARGIN HINGE GROOVES FORMED IN SAID PANELS FOR ACCORDION-TYPE FOLDING INTO AND OUT OF STACKED RELATION, SAID FULL PANEL SECTIONS AND SAID LEAD POST HAVING TROLLEY SUPPORT MEANS ATTACHED THERETO FOR HANGING FROM AN OVERHEAD TRACK HOUSING, EACH OF THE HINGE GROOVES BEING PARTIALLY DEFINED BY A PROJECTING RIB-LIKE PORTION LOCATED ADJACENT OPPOSITE FACES OF A PANEL ALONG OPPOSITE SIDE MARGINS THEREOF, SAID HINGE MEMBERS EACH HAVING RIB-LIKE SIDE MARGINS RECEIVED IN ADJACENT HINGE GROOVES OF ADJACENT PANELS, THE PROJECTING RIB-LIKE PORTIONS DEFINING SAID HINGE GROOVES BEING ARRANGED FOR ABUTMENT UPON COMPLETE UNFOLDING OF SAID PANELS TO LIMIT MOVEMENT THEREOF INTO COPLANAR RELATION, SAID FULL PANEL SECTIONS EACH CARRYING A HANGER MEMBER ATTACHED THERETO AT ONE END AND TO A TROLLEY AT THE OTHER END WHICH CONSTITUTES SAID TROLLEY SUPPORT MEANS, SAID HANGER MEMBER BEING ARRANGED TO PIVOT ABOUT ITS LONGITUDINAL AXIS WITH SAID FULL PANEL SECTION RELATIVE TO SAID TROLLEY DURING OPERATION OF SAID DOOR STRUCTURE, AND HANGER MEMBER GUIDE MEANS CARRIED BY SAID TROLLEY AND PROJECTING THEREFROM FOR ENGAGEMENT WITH A PORTION OF A TRACK HOUSING, SAID GUIDE MEANS INCLUDING HANGER MEMBER PIVOT CONTROL MEANS IN OPERATIVE ASSOCIATION WITH SAID OTHER END OF SAID HANGER MEMBER.