Guide track assemblies and mounting brackets for upward acting doors

[0002] The present invention pertains to circular radius and elliptical radius configurations of guide track assemblies for upward acting doors and including combined mounting brackets for the guide track assemblies and door counterbalance mechanisms.

[0003] In the art of upward acting single and multi panel garage doors, and the like, there has been a continuing need to develop door guide track assemblies which are easy to install and which can accommodate door installations where low headroom or low ceiling height conditions are encountered. In particular, there has also been a continuing need to develop simplified guide track mounting brackets which reduce the manufacturing cost and installation time associated with the production and installation of upward acting doors. The present invention meets the above mentioned needs and desiderata and overcomes the disadvantages of prior art guide track assemblies and support structure therefor.

[0004] The present invention provides improved guide track assemblies and mounting brackets therefor for use with upward acting garage doors and the like.

[0005] In accordance with one aspect of the present invention, improved guide track assemblies are provided which include two piece track assemblies which make up the entire lengths of the track assemblies including the vertical track section, a transition section and a substantially horizontal track section. In one embodiment of the improved track assemblies, the transition section is substantially of circular radius of curvature and each track section includes a curved section of approximately equal circumferential extent.

[0006] In another embodiment in accordance with the invention, a two piece track assembly is provided which includes a substantially vertical section, a variable radius of curvature transition section and a substantially horizontal section. The track assembly is adapted for low headroom or low ceiling height installations. In a preferred embodiment of the low headroom track assembly, the radius of curvature is elliptical and the two piece track assembly includes a first vertically extending track section having a minor portion of a curved transition section and the second track section comprises the horizontal section and a major portion of the curved transition section. The elliptical track section is preferably provided with major and minor axes having a length ratio of about 2:1.

[0007] In accordance with a further aspect of the present invention, the track assemblies include improved mounting brackets which are also adapted to support counterbalance mechanisms for associated upward acting doors. The mounting brackets preferably comprise formed metal or plastic integral brackets which include elongated slots formed therein to provide for adjusting the positions of the track assemblies with respect to associated support structure including the wall surrounding the door opening. The one piece integral mounting brackets each accommodate selective positioning of the track assemblies with respect to the wall to which the mounting bracket is attached and also eliminate the requirement for a separate, generally horizontally extending bracket part for supporting a track assembly. Moreover, the mounting brackets are advantageously configured to be fabricated of stamped and folded metal plate, for example. Still further, integral mounting tabs or flanges are formed on the mounting brackets to facilitate attachment of the brackets to support structure including the wall surrounding the door opening.

[0008] Those skilled in the art will further appreciate the above mentioned advantages and superior features of the invention together with other important aspects thereof upon reading the detail description which follows in conjunction with the drawings.

[0009] FIG. 1 is a perspective view of one preferred embodiment of an improved guide track assembly and mounting brackets therefor in accordance with the present invention;

[0010] FIG. 2 is a view taken substantially from the line 2—2 of FIG. 1;

[0011] FIG. 3 is a developed plan view of a mounting bracket in accordance with the present invention for use with the door guide track assemblies of FIGS. 1 and 2;

[0012] FIG. 4 is a front elevation of the mounting bracket of FIG. 3 in the final folded configuration;

[0013] FIG. 5 is a side elevation of the mounting bracket shown in FIGS. 3 and 4;

[0014] FIG. 6 is a perspective view of another preferred embodiment of guide track assemblies and mounting brackets therefor in accordance with the present invention;

[0015] FIG. 7 is a view taken generally from the line 7—7 of FIG. 6;

[0016] FIG. 8 is a front elevation of the mounting bracket for the guide track assembly of FIGS. 6 and 7;

[0017] FIG. 9 is a side elevation of the mounting bracket embodiment of FIGS. 6 through 8; and

[0018] FIG. 10 is an end elevation of the bracket shown in FIG. 9.

[0019] In the description which follows, like parts are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures may not be to scale and certain features may be shown in general or somewhat schematic form in the interest of clarity and conciseness.

[0020] Referring to FIG. 1, there is illustrated a sectional upward acting door, generally designated by the numeral 10, which is mounted adjacent a wall 12 for closing a conventional rectangular opening, not shown, in said wall. The door 10 is provided with spaced apart sets of roller type guide members 14, which may be of conventional construction, and are shown mounted on one side edge of sectional door panels 16, respectively. Corresponding guide members 14 are mounted on the opposite side edge of each of the panels 16 in a conventional manner.

[0021] Referring further to FIG. 1, the door 10 is also provided with a counterbalance mechanism, generally designated by the numeral 18. The counterbalance mechanism 18 is adapted to suspend spaced apart cables or similar flexible members 20 which depend along opposite sides of the door 10 and are connected to the lowermost panel 16 in a conventional manner for counterbalancing at least part of the weight of the door. One counterbalance mechanism which may be used with the invention is preferably of a type disclosed in co-pending U.S. patent application Ser. No. 09/096,663 filed Jun. 12, 1998 by LeRoy G. Krupke, et al. and assigned to the assignee of the present invention. Improvements in mounting structure for the aforementioned counterbalance mechanism are disclosed and claimed in co-pending patent application Ser. No. 09/313,460 filed May 17, 1999 by Joseph J. Mondragon, et al. and also assigned to the assignee of the present invention. The entire subject matter of the two aforementioned patent applications is incorporated herein by reference.

[0022] The counterbalance mechanism 18 is provided with spaced apart cable drums 22 supported by a shaft 24 which is adapted to be mounted in spaced apart support brackets 26aand 26b,which support brackets also are adapted to support opposed guide member track assemblies 28aand 28bin a unique manner. The support brackets 26aand 26bare substantially identical and are configured as mirror images of each other thereby comprising so called left hand and right hand brackets. In like manner, the track assemblies 28aand 28bare also substantially identical and comprise mirror images of each other. Track assembly 28aincludes a substantially vertically extending section 30aand supported relative to wall 12 by mounting brackets 25, FIG. 1. Track section 30ais also adapted to include a portion of a curved transition section 32a.Track assembly 28aalso includes a substantially horizontal extending track section 34awhich further includes a portion of the transition section 32a.Transition section 32ahas a substantially circular or constant radius of curvature. Track section 34ais preferably supported at a distal end by a conventional support bracket, not shown. In like manner, track assembly 28bincludes a vertically extending track section 30b,a transition section 32bhaving a substantially circular radius of curvature and a generally horizontal track section 34b.The transition sections 32aand 32bare formed as integral parts of the track sections 30aand 34aand 30band 34b,respectively. Track sections 30aand 34aare joined to each other at support bracket 26a.In like manner, track sections 30band 34bare joined to each other at the cooperating support bracket 26band are otherwise supported in a manner similar to track assembly 28a.

[0023] Referring now to FIG. 2, the track assembly 28aand bracket 26aare shown by way of example. Support bracket 26aincludes a mounting flange 38 adapted to mount the bracket 26aon wall 12 by conventional fasteners, not shown. Bracket 26aincludes an integrally formed support plate part 40 which extends normal to the flange 38 and includes an outer distal “flag” portion 42 provided with a plurality of generally elongated slots formed therein, see FIG. 3 also, and designated by numerals 43a,43b,43c,43dand 43e,which slots are generally parallel to each other and are staggered so as to extend along a radius of curvature corresponding substantially to the radius of curvature of the track transition section 32a.As shown in FIG. 2, track sections 30aand 34aare provided with spaced apart fastener receiving openings 44 and 46, respectively, which are alignable with selected ones of the slots 43a,43b,43c,43dand 43e,respectively, as shown. Conventional mechanical fasteners, not shown, may thus be used to join the track sections 30aand 34ato the bracket 26aat the respective fastener receiving openings described on each of the track sections and on the bracket flag portion 42. The slots in bracket 26aare provided such that vertical and horizontal adjustment of the positions of the track sections 30aand 34amay be obtained while at least two fastener receiving openings in each track section are each aligned with a slot in the bracket.

[0024] As shown in FIG. 2, the track sections 30aand 34aeach include an equal portion of the transition section 32aformed thereon and designated by the numerals 33 and 35, respectively. Accordingly, the circumferential extent of the curved, generally circular radiused portions of track sections 30aand 34aare each approximately 45°, angle “y” in FIG. 2, with respect to the axis “g” of the radius of curvature. In this way an additional mounting bracket, such as one of brackets 25 for track section 30a,FIG. 1, or a similar horizontally extending bracket, may be eliminated and the track sections 30aand 34amay also be more easily stacked and packaged for shipment to an installation site. As shown in FIG. 2, the track sections 30aand 34aare adapted to be positioned directly adjacent to each other and suitably connected to the support bracket 26a.The track sections 30band 34bare of identical construction but of the opposite hand and, as previously mentioned, the bracket 26bis substantially a mirror image of the bracket 26a.

[0025] Another advantage of the track assemblies 28aand 28bis that by providing the curved transition section 33 of track section 30a,for example, the uppermost guide member 14, see FIG. 2, resides in the vertical track section 30ain the closed position of the door 10. The uppermost guide member 14 on the opposite side of the uppermost door panel 16 would also reside in the upper curved portion of track section 30b.In this way the track sections 30aand 30bmay be erected and the door 10 assembled and supported in its closed position before erection of the track sections 34aand 34bwould be required. Moreover, the door panel 16 may be moved into position during erection by inserting the guide members 14 into the upper end of the transition section 33 of track section 30aand the corresponding transition section of track section 30bafter these track sections have been erected and supported by the wall 12. Again, this arrangement facilitates assembly of the door.

[0026] Referring further to FIG. 3, the bracket 26ais shown in a planar developed view in which the flange 38 is coplanar with the support part 40 including its distal flag portion 42. The bracket 26ais shown in FIG. 3 before the bracket is folded along a first fold region 47 defined by three closely spaced dashed lines and before a second flange is formed extending normal to the flange 38 and in the same direction as the support part 40 by folding the bracket 26aalong a second fold region 49 defined by a second set of closely spaced dashed lines, as shown. A second flange 50 formed by folding the metal plate which comprises the bracket 26aalong the fold region 49 has a relieved surface 51 and openings 53 formed therein for receiving portions of the counterbalance mechanism as further described in the above identified patent application to Mondragon, et al.

[0027] As further shown in FIG. 3, the flange 38 is provided with fastener receiving holes 38aand the support part 40 is provided with a cylindrical bore 54 for receiving a bearing assembly for supporting the counterbalance mechanism support shaft 24, neither shown in FIG. 3. Lastly, the bracket 26a,when formed, is provided with two spaced apart bracket mounting tabs 56 and 58 which are formed by a coining or stamping operation by removing metal to form generally rectangular or, as shown, somewhat V shaped slits 56aand 58a,respectively. The base portions of the tabs 56 and 58 extend along the fold region 47 so that when the flange 38 is folded with respect to the support part 40 of bracket 26a,the tabs 56 and 58 remain substantially coplanar with the flange 38, as shown in FIGS. 4 and 5. Mounting tabs 56 and 58 include suitable fastener receiving slots 56aand 58a,respectively. As shown in FIGS. 3 and 4, the flange 38 includes a longitudinally extending portion 38bof approximately less than half the full width of the flange 38 to provide additional rigidity to the bracket support part 40, including the distal flag portion 42. The rigidity of the support part 40, 42 is further enhanced by an elongated rib 55, as shown in FIG. 5. Still further, the bearing bore 54 is also provided with a circumferential flange 54a,FIGS. 4 and 5, as part of the metal displacing operation which forms the bracket 26a.

[0028] Those skilled in the art will recognize that the brackets 26aand 26bmay be formed from the same, so called blank part illustrated in FIG. 3 depending on which direction the folds are accomplished at the fold regions 47 and 49. The rigidity of the support brackets 26aand 26bmay be further enhanced along the fold region 47 by forming respective gussets 59, FIGS. 4 and 5, by a suitable stamping or coining operation.

[0029] A major advantage of the brackets 26aand 26bis that these brackets provide the dual function of supporting a counterbalance mechanism for the door 10 as well as the respective track assemblies 28aand 28bfor the door. Thanks to the provision of the elongated slots 43athrough 43e,the position of track assembly 28a(as well as track assembly 28b) may be easily adjusted with respect to the wall 12 and floor 13, FIG. 1. Accordingly, the brackets 26aand 26breduce the number of parts associated with the support structure for the door 10, are easily fabricated as substantially mirror images of each other and simplify door installation procedures.

[0030] Referring now to FIGS. 6 and 7, another embodiment of guide track assemblies for the door 10 is illustrated including an alternate embodiment of respective counterbalance mechanism and track assembly support brackets. In the embodiment shown in FIGS. 6 and 7, the door 10 is supported for movement between open and closed positions by respective spaced apart track assemblies 70aand 70b.Track assembly 70aincludes a substantially vertically extending track section 72a,a curvilinear transition track section 74aand a generally horizontal extending track section 76a.In like manner, the track assembly 70bincludes a generally vertical extending linear track section 72bcomprising a mirror image of track section 72a,a curvilinear transition section 74band a substantially horizontal extending track section 76b,being mirror images of track sections 74aand 76a,respectively. The curvilinear transition sections 74aand 74bare formed, in part, by the respective vertical and horizontal track sections of each track assembly. Moreover, the curvilinear transition sections 74aand 74bpreferably have a substantially elliptical curvature throughout the transition section length wherein the major axis of the elliptical curvature extends generally horizontally and the minor axis of the elliptical curvature extends generally vertically. In this way, an improved arrangement of a track assembly is provided for low ceiling height or other low “headroom” applications of the door 10.

[0031] Referring primarily to FIG. 7, a portion of the track assembly 70ais shown by way of example. The transition section 74ais made up of a major portion of the transition section formed integral with the track section 76aand generally designated by numeral 77 while a major portion of the curvilinear section 74ais formed as part of the track section 72a.The curvilinear shape of the transition section 74a,including the portions 77 and 79 preferably has a major semiaxis m which is about twice the length of the minor semiaxis n. Preferred dimensions for the major and minor semiaxes are 20.0 inches and 10.0 inches, respectively. Distance p from the inside edge 72a′ of track section 72ais approximately one-fourth of dimension m and angle x, which dictates the extent of the curvilinear track sections 77 and 79, is approximately 40° with respect to the center point c which is located on the major axis of the elliptical radius of curvature at dimension p from the vertical extent of track section 72a.As shown in FIG. 7, the configuration of the track assembly 70aas well as the track assembly 70bis advantageous with respect to applications of the door 10 in low ceiling height structures, as indicated by the ceiling 13 in FIG. 7. Other applications requiring low headroom or height of the guide track assemblies also benefit from the configuration of the track assemblies 70aand 70b.Moreover, track sections 72aand 72bare also operable to support the uppermost guide rollers 14 in the curvilinear transition sections of these track sections in the door closed position of the uppermost door panel 16.

[0032] Referring again to FIG. 6 also, alternate embodiments of combination counterbalance mechanism and track assembly mounting or support brackets are illustrated and generally designated by the numerals 80aand 80b,respectively. The brackets 80aand 80bare mirror images of each other and are formed from metal plate in substantially the same manner that the brackets 26aand 26bare formed. Referring primarily to FIG. 7, the bracket 80ais illustrated and is characterized by a generally planar flange part 82 adapted to be secured to the wall 12 by conventional mechanical fasteners, not shown. Flange part 82 is integral with and extends normal to an elongated support part 84 including a first upper portion 84ahaving a bearing bore 86 formed therein for receiving a support bearing, not shown, for the counterbalance mechanism shaft 24.

[0033] Support part 84 also includes a depending portion 84band a distal, generally horizontally extending track or flag support portion 84c.Bracket flag portion 84cis provided with a plurality of spaced apart, staggered and parallel fastener receiving slots 88a,88b,88cand 88d.The slots 88a,88b,88cand 88dare adapted to be aligned with cooperating fastener receiving bores 90 and 92 formed in the respective track sections 76aand 72aas illustrated in FIG. 7, for receiving mechanical fasteners, not shown, to secure the track sections 72aand 76ato the bracket 80aand in generally abutting relationship to each other. The track assembly 70bis similarly configured for connection to the mounting bracket 80b.

[0034] Referring now primarily to FIGS. 8 through 10, the support bracket 80ais further illustrated as including a second flange part 92 similar to the flange part 50 of bracket 26afor connection to a spring winder support part of the counterbalance mechanism 18 previously described. The configuration of flange part 92 is substantially like that of flange part 50 and extends generally parallel to the support part 84 and spaced therefrom. Support or mounting bracket 80aalso includes a circumferential flange 86adefining the bearing bore 86 and a plurality of spaced apart mounting tabs 98 which are formed by displacing material forming part of the support part 84 during the forming of the bracket 80ain the same manner that the mounting tabs 56 are formed for the bracket 26a.Elongated fastener receiving slots 98aand formed in the tabs 98 and fastener receiving bores 82aare formed in the flange 82. The flange 82 includes an elongated portion 82bof reduced width, FIG. 8, to strengthen and increase the rigidity of support part 84 of the bracket 80a.

[0035] The brackets 80aand 80bare formed in substantially the same manner as the brackets 26aand 26band differ substantially only in their proportions and, for example, the number of mounting tabs 98 which are also coplanar with the flange 82. Accordingly, the brackets 80aand 80benjoy the same advantages for supporting both the counterbalance mechanism and the door guide track assemblies in a manner substantially like that provided for by the brackets 26aand 26b.Moreover, the configuration of the elliptical curved transition sections 74aand 74bis such that the lengths of the distal flag portions of the brackets 80aand 80bare minimized and the rigidity of the brackets and track assemblies connected thereto is improved.

[0036] For residential garage door applications, primarily, the brackets 26a,26b,80aand 80bmay be formed of rolled steel having a thickness of about 0.099 inches and the respective sections of the track assemblies 28a,28b,70aand 70bmay also be formed of roll formed steel having a nominal thickness of about 0.049 inches to 0.099 inches. Fabrication of the track assemblies and support brackets described herein may be carried out using conventional roll forming, stamping or similar metal forming techniques known to those skilled in the art.

[0037] The construction and operation of the embodiments of the door 10 described hereinbefore, including the respective counterbalance mechanism support brackets 26a,26b,80aand 80band the track assemblies 28a,28b,70aand 70b,is believed to be within the purview of one skilled in the art.

[0038] Although preferred embodiments of upward acting door track assemblies and support brackets have been described in detail herein, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.