Note: Descriptions are shown in the official language in which they were submitted.
CA 02410202 2002-10-30
OVERHEAD BI-FOLD DOOR CONSTRUCTION
FIELD OF THE INVENTION
The present invention relates to construction of an overhead bi-fold
door.
BACKGROUND
Overhead bi-fold doors are known for use in large buildings in which
high clearances, wide spans and simple construction are desirable. Known types
of
overhead bi-fold doors commonly have a large frame including numerous frame
members required for strength. Cladding is typically supported on an outer
side of the
door with insulation accordingly being provided against an inner side of the
door. Due
to the irregular surface of the beams forming the frame of the door along the
inner
side of the door, insulation is typically provided in panels which fit between
the beams
resulting in thermal leakage at the beams thus reducing the insulating value
of the
entire door.
SUMMARY
According to the present invention there is provided an overhead bi-fold
door construction comprising a door member and mounting means for supporting
the
door member on a building, the door member comprising:
a top beam extending along a top end of the door member;
a bottom beam extending along a bottom end of the door member;
two side beams extending along opposing sides of the door member;
a hinged seam extending across the door member partway between the
top and bottom beams of the door member and dividing each side beam into a
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respective upper section and a respective lower section;
the door member being separated by the hinged seam into an upper
panel including the top beam and the upper sections of the side beams and a
lower
panel including the bottom beam and the lower sections of the side beams;
the upper and lower sections of the side beams being foldable relative to
one another at the hinged seam between a closed position of the door member in
which the upper and lower sections lie in a generally common upright plane and
an
open position of the door member in which the bottom beam is raised upwardly
towards the top beam in relation to the closed position;
an upper frame spanning the upper sections of side beams;
a lower frame spanning the lower sections of the side beams;
an outer surface of the upper and lower frames being recessed in
relation to an outer surface of at least one of the top beam, the bottom beam
and the
side beams;
sheeted insulation material being supported on the outer surface of the
upper and lower frame; and
cladding being supported on an outer side of the sheeted insulation
material.
The use of insulation between the frame of the door and the cladding
permits a continuous layer of insulation of substantially constant thickness
to be
provided. This minimizes thermal losses through the door. Furthermore a neater
appearance results while permitting thicker beams to be used for additional
strength
along the top, bottom or sides of the door and optionally along the central
hinged
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seam as well.
The outer surface of the upper frame is also preferably recessed in
relation to an outer surface of both the bottom beam and the top beam, in
addition to
the outer surface of the side members.
In this arrangement, the outer surfaces of the top beam, the bottom
beam and the respective sections of the side beams are preferably all
substantially
flush with one another.
The outer side of the sheeted insulation material may thus be arranged
to lie flush with the outer surfaces of the top beam, the bottom beam and the
side
beams.
The cladding preferably overlaps the outer side of the sheeted insulation
material and the outer surfaces of the top beam, the bottom beam and the side
beams.
Preferably, the sheeted insulation material spans the door member
substantially uninterrupted at a substantially constant thickness between the
side
beams and between the top and bottom beams.
The sheeted insulation material may be divided at the hinged seam in a
manner so as to define a pair of abutting surfaces of the sheeted material in
the
closed position of the door member in which the abutting surfaces are
preferably
capped by a suitable cladding material.
Each of the upper and lower frames may include a cross beam
extending along the hinged seam having an outer surface which is recessed in
relation to the side beams. In this instance, the sheeted material preferably
extends
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between the cross beams and the cladding.
Each of the upper and lower frames may additionally include a layer of
inner sheeted material spanning the side beams between the respective frame
and
the sheeted insulation material.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
Figures 1 and 2 are isometric views of the door member shown
supported on a building in respective closed and open positions.
Figure 3 is an isometric view of a portion of the door member shown
with some of the insulation and cladding removed.
Figure 4 is an enlarged isometric view of one of the top corners of the
door member according to Figure 3.
Figure 5 is an enlarged isometric view of a portion of the side beams at
the hinged seam according to Figure 3.
Figure 6 is a front elevational view of the door member in a closed
position with some of the insulation and cladding shown removed.
Figure 7 is a sectional view along the line 7-7 of Figure 6.
Figure 8 is a sectional view along the line 8-8 of Figure 6.
Figure 9 is sectional view along the line 9-9 of Figure 6.
DETAILED DESCRIPTION
Referring to the accompanying drawings, there is illustrated an
overhead bi-fold door construction generally indicated by reference numeral
10. The
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door construction includes a door member 12 which is arranged to span the door
opening 14 in a building 16 in a closed position of the door member. The door
construction includes a plurality of hinge brackets 18 which are mounted at
spaced
positions along the top of the door member for securement to a header 20 of
the
building extending across a top end of the vertical door opening 14. Plural
brackets
18 are provided at spaced positions along the header.
The door member 12 includes an upper panel 22 and a lower panel 24
which are foldable relative to one another at a hinged seam 26 extending
horizontally
across the door member, centrally located within an inch or two, partway
between the
top and bottom beams. The door member is thus folded between a closed position
of
Figure 1 in which the upper and lower panels (ie in a generally common
vertical plane
spanning the door opening and the open position of Figure 2 in which the
bottom end
of the door member is raised upwardly towards the top end and the panels
project
outwardly from the door opening of the building.
The upper panel includes a top beam 28 which spans the full length of
the top end 30 of the door member. In cross section the top beam 28 is deeper
than it
is tall, being in the order of two inches high but four or five inches deep,
so as to be
generally rectangular in shape. The top beam 28 mounts the hinge brackets 18
thereon so that the top beam and door member suspended therefrom are pivotal
relative to the header 20 of the door opening.
The lower panel 24 similarly includes a bottom beam 32 having similar
size and shape to that of the top member 28. The top beam 32 spans a full
length of
the bottom end 34 of the door member and mounts a rollers 36 at respective
ends
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thereof for rolling engagement with sides of the opening in the building as
the door is
opened and closed.
Two side beams 38 are provided to extend substantially a full height of
the door member along opposing sides of the door member. The side beams 38 are
each separated at the hinged seam 26 into an upper section 40 forming part of
the
upper panel and a lower section 42 forming a portion of the lower panel. Each
of the
top and bottom beams has a depth which is substantially identical to both of
the side
beams 38 with the beams being mounted so that an inner surface 44 and an outer
surface of the side beams is flush with respective inner and outer surfaces of
the top
and bottom beams on both inner and outer sides of the door. The top beam, the
bottom beam, and both side beams accordingly have respective outer surfaces 46
which lie in a generally common plane.
The upper panel includes an upper frame 50 spanning the upper
sections 40 thereof, while the lower panel includes a lower frame 52 spanning
the
lower sections of the side beams. Each frame includes a cross beam 54 spanning
the
side beams directly adjacent the hinged seam 26 so that the cross beams 54 are
abutted with one another on opposing sides of the hinged seam in a closed
position of
the door. Each frame further includes a plurality of longitudinal supports
which extend
vertically in a closed position of the door between the cross beam 54 and a
respective
one of the top and bottom beams. Lateral supports 58 are also provided which
extend laterally in a horizontal direction between the longitudinal supports
56 and the
respective sections of the side beams 38.
The longitudinal and lateral supports 56 and 58 are similar in dimension,
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having a narrower depth in cross section than either the top, bottom or side
beams.
The supports lie in a generally common plane in a closed position of the door,
being
arranged so that an inner surface of the supports lies generally adjacent with
the inner
surfaces of the top, bottom and side beams so that an outer surface 60 of the
supports is recessed inwardly in relation to the outer surface 46 of the top,
bottom and
side beams.
The cross beams in the illustrated embodiment have a depth which is
greater than that of the lateral supports or longitudinal supports while
having an outer
surface lying in the recessed common plane with the outer surfaces 60 of the
longitudinal and lateral supports. The inner ends 62 projecting from the inner
side of
the door are thus spaced from the inner side of the door so that hinges 64
coupling
the cross beams for pivotal movement at the hinged seam 26 are spaced from the
plane of the upper and lower door panels to increase spacing between the
panels in
the folded and open positions. Increasing the spacing between the panels
permits
greater room for trusses 66 supported on an inner side of the door member to
extend
laterally across the door for additional structural support. The trusses are
arranged to
project generally perpendicularly to the respective panels of the door member
upon
which they are mounted, except for the lowermost truss which is purposely
angled to
extend inwardly at an upward incline to allow clearance between the door and
building.
Arranging the outer surface of the cross beams 54 and the supports 56
and 58 in a generally common recessed plane, permits sheeted insulation
material 68
to be received within the recess to span between the side beams 38 and between
the
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top and bottom beams continuously and substantially uninterrupted at a
constant
thickness throughout. The sheeted insulation material 68 is only interrupted
by the
hinged seam 26 in which a seam is provided in the sheeted insulation material
so that
free ends 70 of the material are abutted with one another when the upper and
lower
panels are in the closed position.
The abutted free ends 70 of the sheeted insulation material 68 include
caps formed of suitable cladding material for weatherproofing which encloses
the
exposed free ends of the sheeted insulation material on either side of the
hinged
seam 26.
The sheeted material 68 spans laterally and longitudinally across the
door member directly adjacent the outer surface of the supports and the cross
beams.
Thickness of the sheeted insulation material 68 is arranged so that an outer
surface
72 of the insulation lies generally flush with the common plane of the outer
surfaces
46 of the top, bottom and side beams. The combined thickness of the supports
and
insulation material is thus approximately equal to a depth of the top, bottom
and side
beams.
Cladding 74 is provided to overlap directly adjacent the outer surface 72
of the sheeted insulation material as well as overlap the outer surfaces 46 of
the
surrounding top, bottom and side beams in an abutted relationship. Threaded
fasteners are provided which extend from the cladding through the sheeted
insulation
material to be tapped into the supports 58 and 56 and the cross beams 54. The
insulation is thus secured between the cladding 74 and the upper and lower
frames of
the upper and lower panels. Fasteners may also be provided to secure the edges
of
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the cladding 74 directly to the top, bottom and side beams. The cladding 74
preferably comprises a conventional type of outdoor weatherproof cladding
possibly
formed of suitably finished metal or plastic.
Other weatherproofing is provided by suitable J-shaped mouldings 71A
and flashing strips 71 B. Along the top edge of the cladding of both the
panels of the
door member, the mouldings 71A are provided for wrapping over the top edge,
while
along the bottom edge of the cladding of both panels of the door member, the
flashing
strips 71 B are provided to project outwardly from the cladding to shed
precipitation
away from the edge of the cladding.
Inner sheeted material 76 is provided in the form of a layer of cladding-
type material which is received directly adjacent an outer side of the
supports 56 and
58 of the frames, between the frames and the sheeted insulation material 68.
The
resulting interior surface of the door member is thus suitably finished with
the
insulation being concealed by the cladding material formed of suitable plastic
or metal
which is waterproof to permit the inner surface of the door to be easily
cleaned.
While one embodiment of the present invention has been described in
the foregoing, it is to be understood that other embodiments are possible
within the
scope of the invention. The invention is to be considered limited solely by
the scope
of the appended claims.
