Note: Descriptions are shown in the official language in which they were submitted.
EXPRESS MAIL LABEL NO. ENI302336345US
CA 02167941 2005-O1-25
1
SECTIONAL OVE-R_HFAD DOOR AND APPAR_A_'_I'~JS
FOR MAKING DOOR PANELS
TECI~iNIs,'AL FIELD
The present invention relates generally to a panel and hardware
components for sectional overhead doors and apparatus for making the panels.
More particularly, the present invention relates to a panel and hinge
arrangement
and a bracket for sectional overhead doors which move between a closed
position
proximate to a vertical door opening to an open position ; in substantially
horizontal orientation with the door panels articulating through a curved
portion
of the track system in traversing from the closed to the open position and
vice
versa. More specifically, the present invention relates to an arrangement for
such
multi-panel overhead doors having an advantageous door panel configuration, a
hinge arrangement providing an anti-pinch feature between adjacent panels
during
their relative angular articulation, a bottom bracket with a safety feature,
and
apparatus employed in the manufacture of the panels.
Sectional overhead doors have been commonly employed for many
years as garage doors in homes, commercial and'utility building doors, and in
similar applications. The panels of conventional sectional doors are commonly
joined by hinges positioned on the inner or internal side of the door which
form
pivot points proximate the juncture between each of the adjacent panels to
permit
the panels to pivot relative to each other. The hinges at the lateral edges of
the
panels or separate mounting brackets carry shaft-mounted rollers which inter-
engage with track sections that control the path of travel of the doors. These
track systems commonly include a generally vertical section positioned
proximate
a door frame or other opening and a generally horizontal section that extends
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substantially perpendicular to the vertical section rearwardly into the
interior of
the building in an overhead position. A curved transition section is normally
positioned proximate the header at the top of the door frame and interconnects
the vertical section and the horizontal section to provide a continuous track
system. The hinges permit the door panels to articulate as the rollers
interconnecting the door and the track system traverse from the vertical
section
through the transition section to the horizontal section of the track and vice
versa.
Hinges employed for such sectional overhead doors have remained
of generally consistent design over many years. Most commonly the hinges have
been stamped from relatively lightweight steel, with the formation of gussets
and
sidewalls to obtain the requisite strength. The two hinged leaves with the
formed
contours are normally attached at their knuckle areas by a pivot pin. The
pivot
pins are commonly a rolled pin formed of the same or a comparable light-gauge
steel and flared at the end during assembly for retaining the pin in the
knuckles.
The hinge leaves may be provided with an additional roll pin supported in a
flange and mounting guide rollers which engage the track sections. Hinges of
this
type tend to be relatively crude and are noted for binding and poor operation,
at
least after some operating period if not shortly after installation.
Particularly
troublesome in this respect is the lack of uniformity of the flaring of the
rolled
pivot pins, which is notoriously imprecise. Further, with the rolled pin
configuration, the extreme lateral edges of the hinge material end up serving
as
the bearing surface between the hinges and the rolled pivot pin.
In some instances, sectional doors for certain applications have been
made which employ interfitting cylindrical members at the edges of adjacent
panels. Normally, these cylindrical members have constituted an extension of a
wall or covering for the panels, which extend the entire lateral width of the
panels. Each of the panel extensions are formed into a segment of a cylinder
at
a pivot joint, with one being radially slightly smaller than the other to
interfit
therein. Frequently, a tubular bearing member is inserted within the
interfitting
cylindrical members to serve as a hinge pin and to receive the shaft for a
roller
extending outwardly for engagement with a track positioned proximate to the
~1~'~~4~
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door. Such interfitting cylindrical members, however, in extending the full
length
of the door, require a considerable amount of additional material at
substantial
cost. Additionally, hinges extending the full transverse width of a door
panel,
particularly in sizeable doors, are prone to binding and chafing over large
surface
areas of the cylindrical hinge members due to the inevitable bending or
deflection
which necessarily takes place over the substantial lateral extent or width of
the
cylindrical hinge members.
A recently significant consideration which is involved in the
configuration and operation of the hinges and the interconnected panels is
that
of providing an anti-pinch characteristic. This refers to the provision of
some type
of structure to cover or minimize the gap formed between the panels,
particularly
at their position of maximum angularity when traversing the curved transition
section of the interrelated track, such as to prevent the insertion of a
person's
hands or fingers whereby they could be pinched as the door moves between the
track sections. In this respect, it has been empirically determined that a gap
between the edges of adjacent panels during articulation of the door panels
not
exceeding approximately .2 in. or 5 mm. satisfies these requirements.
To date, various approaches have been taken to incorporate anti-
pinch features to some extent into sectional overhead doors. One approach for
providing an anti-pinch joint between adjacent panels of a sectional overhead
door is to create an external barrier which is designed to preclude the
entrance
of a person's finger or other object into the hinge area. Anti-pinch devices
of this
type may be made of rigid or somewhat flexible materials and are
characteristically attached to the outside of the door panels in proximity to
the
hinge area. For the most part, these barriers are formed or in some manner
biased, as by a spring or otherwise, to maintain the barrier material in
contact
with the exterior surface of adjacent door panels throughout the pivotal
action of
the panels when traversing between the vertical and horizontal track sections.
Such external barriers often require a substantial amount of material, as well
as
precise positioning and operation, to insure that the external barrier is
maintained
during the entirety of the angular movement which takes place between the
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panels. Flexible external barrier devices may be subject to damage or
deterioration caused by weather conditions due to their outward, fully exposed
positioning. As a result of these drawbacks, efforts have been made to provide
anti-pinch devices which take a form other than an external barrier.
$ More recently, efforts have been made to construct what might be
termed an internal barrier to accomplish an anti-pinch function. Doors of this
type endeavor to provide contours on the mating edges of adjacent panels, such
that an overlapping surface or a gap too narrow for the insertion of a
person's
finger is presented at all times during the angular rotation between adjacent
panels from the smallest to the largest angular orientations for a particular
sectional overhead door system.
Numerous problems, however, have been encountered in the
application of an internal barrier configuration to overhead door panels. In
some
instances, intricaxe configurations are employed which may tend to cause very
1$ stringent fabrication requirements or unduly precise installation
procedures. Any
s
deficiencies in these respects normally result in door panels which minimally
interfere or bind to a sufficient extent to cause highly undesirable drag in
the
movement of the door. In some instances, the contoured panel edges may be
configured, such that it is difficult or impossible to effect the attachment
of hinges
at a sufficiently reinforced surface or at locations where the pivot axis of
the
hinges is optimally located. In other instances, the edge configurations make
sealing against water and air filtration extremely difficult, if not
impossible.
Another problem with the use of contoured edges is that in many instances it
is
difficult to achieve a rapid separation of the interfitting surfaces as soon
as an
angularity between the panel commences to preclude the introduction of
undesirable drag forces. To Applicants' knowledge, no internal barner
configuration has fully satisfied all these various competing requirements.
Sectional overhead doors also normally employ brackets rather than
hinges to mount rollers proximate the upper edge of the top panel and
proximate
the lower edge of the bottom panel. The bottom bracket located proximate the
lower edge of the bottom panel also serves the purpose of providing a
connector
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for attachment of the counterbalancing system to the door. In particular, the
bracket has an anchor for attachment of the end of the cable which
interrelates
with the tensioning elements, commonly springs, of the counterbalance system
for
the door. The brackets also normally have an attached cylindrical sleeve for
receiving a shaft mounting a roller that is affixed to a mounting plate of the
bracket, which is normally attached to the door by fasteners. The fasteners
are
normally located spaced from the cylindrical sleeve to permit easy access by
tools
for operating the fasteners.
This common arrangement can produce a significant safety hazard
when installation and repair personnel or owners of buildings having such
sectional overhead doors attempt to effect adjustment or replacement of
damaged
bottom bracket components. The problem from a safety vantage arises when a
person endeavors to loosen or remove the bottom bracket from the door with the
door in the closed, vertical position. Under this condition, the
counterbalance
system is exerting maximum force on the bottom bracket through the connecting
cable. As a result, if the fasteners on the bottom bracket are removed or
nearly
removed, the counterbalance system operating through the connecting cable
forces the entire bottom bracket upwardly at great force and speed causing the
potential for serious injury to a person in close proximity endeavoring to
remove
the bracket. In many instances, persons working on an overhead door do not
perceive the impending danger associated with removal of the bottom bracket in
the closed, vertical position until the above-described dangerous result has
taken
place.
In recent years, panels for sectional overhead doors of the type
described herein constructed of foam with a skin cover have enjoyed increasing
popularity. Refinements in such door panels have come largely in terms of the
materials or combinations of materials employed in the skin. While light-gage
steel is commonly used for the outer skin exposed to the outdoor environment,
less expensive materials, such as treated or metallic-coated paper and non-
metallic sheet materials, are increasingly employed as inner skin coverings
for
selected applications. Efforts have also been made in foam compounding to
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develop less expensive foams having the required strength and insulation
qualities.
What has remained constant is the notion that a substantially uniform
thickness
of foam, whether precut inserts or expanded in place, is necessary to achieve
required strength and insulation characteristics of panels having a foam core.
In a general sense, various apparatus for the production of
conventional sectional overhead door panels has been developed in the
industry.
In some instances, pre-formed foam slabs have been cut to appropriate sizes
and
assembled by hand on conveyor lines with an outer skin, an inner skin, stiles,
and
one or more ribs or struts. In other instances, relatively high-speed,
continuous
production equipment has been developed to achieve substantially automated
production of panels.
Fxisting continuous production equipment has normallybeen subject
to a variety of relatively severe limitations and/or disadvantages. In order
to
achieve essentially automated production, it is necessary that foam be
continuously dispensed within the skins of a moving panel at the time of or
before
forming the enclosed panels. It is, however, necessary during the expansion of
the
foam in an oven that the normally relatively thin skins forming the sides of
the
panel be supported, as by a conveyor surface moving at substantially the same
velocity, to withstand the internal pressure created by the foam until it
becomes
substantially set. Both flat platen or slat conveyors and conventional roller
conveyors may be employed in an oven to meet these requirements.
The use of flat platens and conventional roller conveyors has, for
the most part, limited panel configurations to essentially rectangular shapes
with
substantially planar surfaces. The use of longitudinal reinforcing struts or
ribs
which are advantageously also interiorly foamed require corresponding recesses
in the platens or rolls. However, it is often necessary, or at least
desirable, to
have different strut dimensions and locations for the three or four different
panel
sizes necessary to provide, for example, the several different standard door
heights. To thus provide different platens or rollers for each panel size and
type
can result in an inordinate number of platens and rollers, considering that
such
conveyors commonly have many dozens of rollers. In addition, many hours of
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production time may be lost in changing the numerous platens or rollers each
time a changeover is made to run a different panel. As a result, sectional
overhead doors have tended to be relatively expensive and/or designed with
significant structural compromises to maintain equipment costs and manual
changeover expenses within permissible bounds.
DISCLOSURE OF THE INVENTION
Therefore, an object of the present invention is to provide a
sectional overhead door having bottom edge profiles and top edge profiles
which
interfit on adjacent panels to provide an anti-pinch function. Another object
of
the invention is to provide such panels which have edge profiles that interfit
during articulation of the panels as the door moves between the closed,
vertical
position and the open, horizontal position, such as to prevent insertion of
hands
or fingers of a person between the panel profiles during articulation of
adjacent
panels. A further object of the present invention is to provide such edge
profiles
that can be adjusted to eliminate the rubbing or abrading of mating profiles,
which would create a drag that would require additional counterbalancing to
overcome.
Another object of the present invention is to provide a sectional
overhead door with panel profiles that can be configured of various types of
material, including lighter gauge steels, wherein the edge profiles can
operate in
close proximity to each other without engaging. Yet another object of the
present
invention is to provide such edge profiles which interfit in a manner to
prevent
air and/or water infiltration between adjacent panels when the door is in the
closed, vertical position. Still a further object of the present invention is
to
provide such edge profiles that are configured to seat a strip of foam or
other
weather-sealing material, which enhances the weather-sealing capability and
may
provide the requisite spacing between adjacent profiles during installation of
a
sectional door.
Another object of the present invention is to provide a sectional
overhead door wherein the panels may be constructed of a variety of materials
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g
or la~.inates of various materials to create panels having varying desired
amounts
of strength. Still a further object of the present invention is to provide
such ,
panels which may have strengthening struts to effect 'increased rigidity to
the
panels and to assist in the attachment of hinges for interconnecting adjacent
panels. Still another object of the present invention is to provide such
panels
which have the various advantageous operational features, while requiring only
relatively small hinges intermittently spaced along the width of a particular
sectional door. Another object of the invention is to provide such panels
wherein
the entire anti-pinch barrier is formed with the surface material of the
panels
without additional components to thereby minimize overall door weight and
cost.
Another object of the present invention is to provide a sectional
overhead door having hinges which are configured to accommodate the edge
profiles of the panels. Still a further object of the present invention is to
provide
such hinges that are constructed of a minimum of pieces consisting of a pair
of
interlocking hinge elements which do not require a hinge pin. Still another
object
of the present invention is to provide such hinges with a cylindrical knuckle
on
one hinge element and a tongue on the other element having an internal
diameter
substantially equal to the external diameter of the cylindrical knuckle with
raised
bearing surfaces on the knuckle or tongue to minimize friction during relative
rotation between the hinge elements.
Still another object of the invention is to provide such a sectional
overhead door having hinges which prevent disassembly of the hinges when the
hinge elements are attached to the door panels in operative position, yet
permit
the detachment of damaged hinge elements from a door and their ready
replacement. Still a further object of the invention is to provide such hinges
which may be variably configured to form roller mounts in selected positions
to
mount rollers positioned at different distances from the back of a door panel
to
achieve appropriate relief of the door from the door frame during operation.
Still
a further object of the invention is to provide such hinges which may have
offset
portions to serve as a backup plate when attaching to relatively thin door
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materials to thereby avoid the necessity of additional components or material
to
effect a hinge back-up function.
Another object of the present invention is to provide a sectional
overhead door having a bottom bracket configuration which, as a safety
feature,
precludes removal of the bottom bracket from a door when the cable
interconnecting the door with the counterbalance system is tension loaded.
Still
a further object of the invention is to provide such a safety bracket wherein
the
fasteners attaching the bracket to the door cannot be removed because the
positioning of the sleeve supporting the roller shaft engaging the tracks
interferes
with removal of the fasteners when the counterbalance cable is tensioned, at
which time the shaft and roller cannot be removed from the sleeve. Another
object of the present invention is to provide such a bottom bracket which may
be
otherwise installed and operates in the manner of a conventional bottom
bracket.
A further object of the present invention is to provide an improved
overhead door panel which can be made of all conventional foams and skin
materials or combinations thereof. Another object of the present invention is
to
provide such an improved door panel which can be adapted to different panel
configurations and to various types of operating hardware to satisfy varying
cost
and climatic parameters. Still another object of the present invention is to
provide such an improved door panel which can substantially maintain strength
and insulation specifications for a foam-filled panel, while employing a
substantially reduced quantity of foam per panel to thus realize significant
cost
savings.
An object of another aspect of the present invention is to provide
curing oven conveyor equipment for the manufacture of door panels for
sectional
overhead doors and other types of door, wall, and panel applications in a
continuous, substantially automated production line. A further object of the
invention is to provide such curing oven conveyor equipment which can produce
a variety of panel configurations having different widths and/or thicknesses.
Yet
another object of the invention is to provide such curing oven conveyor
equipment
which can be quickly and easily adjusted with a minimum of manual labor from
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216'9
a configuration for producing one panel width and thickness to a configuration
for
producing another panel width and thickness.
A further object of the present invention is to provide curing oven
conveyor equipment having a conveyor with panel engaging surfaces for engaging
5 two non-planar skin surfaces on one side of the panel in the configuration
of the
improved overhead door panel of the present invention. Still another object of
the invention is to provide such conveyor equipment having a plurality of
panel
engaging surfaces all moving at substantially the same velocity as the
underlying
panel skin surfaces to thereby eliminate relative motion between the panel
10 engaging surfaces and the panel skin, which could produce pulling and
abrading.
Still a further object of the invention is to provide such conveyor equipment
having at least one panel engaging surface which telescopes within another
panel
engaging surface for varying the width of the panel engaging surfaces to
accommodate panels having different widths. An object of one embodiment of
the conveyor equipment of the present invention is to provide a conveyor
assembly having a driven panel engaging surface of rollers of one diameter and
one or more non-driven panel engaging surfaces of rollers of a different
diameter.
In general, the present invention contemplates a sectional door
having a plurality of panels articulated at the joinder between adjacent
panels for
moving between a closed position and an open position including, a body
portion
of the panels spacing and joining longitudinal edges, one of the edges between
adjacent panels on a first panel having a substantially concave curvilinear
surface
in vertical cross-section in the closed position of the door, the other of the
edges
between adjacent panels on a second panel having a substantially planar
surface
in vertical cross-section in the closed position of the door extending
angularly
from substantially the outer surface of the door, longitudinally-spaced hinges
interconnecting the first and second panels for pivotal movement between
planar
and varying angular orientations when moving between the open position and the
closed position with the concave surface and the planar surface in facing
relation
in the closed position, the planar surface and the concave surface remaining
in
sufficiently close proximity during the entirety of the pivotal movement of
the first
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and second panels so as to preclude the insertion of a person's finger
therebetween while maintaining adequate clearance to avoid interference.
The present invention also contemplates a pivotal connector for a
sectional door having a plurality of panels articulated at the joinder between
l
adjacent panels including, a first hinge element having a first leaf overlying
a
portion of one of the adjacent panels, apertures in the first leaf for
receiving
fasteners to effect attachment of the first leaf to one of the adjacent
panels, a
generally cylindrical first knuckle at one edge of the first leaf, a through
slot in
the first leaf proximate to the first knuckle, a second hinge element having a
second leaf overlying the other of the adjacent panels, bores in the second
leaf
for receiving fasteners to effect attachment of the second hinge element to
the
other of the adjacent panels, and a generally cylindrical second knuckle at
one
edge of the second hinge element extending into the through slot and rotatable
about the first knuckle for controlled relative pivotal motion between the
first
hinge element and the second hinge element.
The present invention further contemplates a bracket assembly for
the bottom of the lower panel of a sectional overhead door operable by rollers
in a track system and counterbalanced by a tensioned cable including, an Lr
shaped plate overlying a portion of the inner surface and side edge of the
lower
~ panel, anchor means for securing the cable to the plate, a generally
cylindrical
sleeve affixed on the plate for receiving a shaft mounting one of the rollers,
fasteners for attaching the Lrshaped plate to the lower panel positioned to
underlie a portion of the cylindrical sleeve and the shaft, and cut-outs in
the
cylindrical sleeve positioned substantially above the fasteners, whereby the
fasteners may be removed only when the shaft is not positioned in the
cylindrical
sleeve.
The present invention additionally contemplates a panel for a
sectional door employing a plurality of such panels articulated at the joinder
between adjacent panels for moving between a closed position and an open
position, including a generally rectangular foam core, an outer surface
extending
the longitudinal length of the foam core, an inner surface extending the
s
. ( ...' f:
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12
longitudinal length of the foam core, an edge profile extending the
longitudinal
length of the foam core and interconnecting the outer surface and the inner
surface, struts on the inner surface extending the longitudinal length of the
foam
core and positioned proximate to the edge profile, and a recess in the inner
surface and the foam core extending the longitudinal length of the foam core.
The present invention further contemplates conveyor apparatus for
the continuous production of foam-cored door panel material for making door
panels of the present invention including, a first conveyor having a first
panel-
engaging surface lying in a plane for engaging the planar skin on one side of
the
panel material, a drive assembly for driving the first conveyor at a selected
speed,
a second conveyor having second and third panel-engaging surfaces for engaging
spaced skin surfaces and an offset skin surface, respectively, on the other
side of
the panel material, and a drive assembly for driving at least one of said
second
and third panel-engaging surfaces of said second conveyor means at
substantially
the selected speed of the first conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of the interior of a sectional overhead
door incorporating hinges and brackets according to the concepts of the
present
20~ invention with the door shown in the vertical, closed position on the
rails.
Fig. 2 is an enlarged perspective view depicting details of one of the
hinges positioned to the right-hand side of the door of Fig. l and showing the
interrelationship with the door panels which are interconnected by the hinge.
Fig. 3 is a side-elevational view of the sectional overhead door of
Fig. 1 showing a fragmentary portion of the rail and door with the door panels
depicted in a position of substantially maximum angular orientation with the
roller adjacent the hinge positioned substantially medially of the curved
transition
track section between the vertical track and the upper horizontal track.
Fig. 4 is an enlarged fragmentary sectional view taken substantially
along the line 4-4 of Fig. 2 of the hinge of the present invention shown in
relation
to the strut areas of the adjacent panels to which the hinges are mounted,
with
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13
the door panels depicted in the vertical, planar position and shown at a
position
of maximum and intermediate deflection in chain lines.
Fig. 5 is a perspective view depicting the structure of and the
relationship between the two elements of the hinge.
Fig. 6 is a reverse perspective view of the hinge elements of Fig. 5
showing other structural aspects of the hinges and particularly the
interrelationship of the knuckle elements thereof.
Fig. 7A is a perspective view depicting a bottom bracket according
to the concepts of the present invention shown in the process of installation
at the
lower corner of the bottom panel of the door with the roller shaft partially
inserted to permit installation of one of the fasteners through a cutout in
the
roller shaft sleeve.
Fig. 7B is a view similar to Fig. 7A showing the bottom bracket fully
installed with the roller shaft operatively positioned in the sleeve, thereby
precluding removal of the fasteners.
Fig. 8 is a perspective view of a preferred form of panel
construction according to the concepts of the present invention for the
sectional
overhead door herein disclosed.
Fig. 9A is a cross-sectional view of the panel of Fig. 8 taken
substantially along the line 9A 9A of Fig. 8.
Fig. 9B is a cross-sectional view similar to Fig. 9A showing a panel
having a modified form of recess in the inner surface.
Fig. 9C is a cross-sectional view similar to Figs. 9A and 9B showing
another modified form of recess in the inner surface.
Fig. 10 is a fragmentary perspective view of a conveyor system
according to the concepts of the present invention for curing oven equipment
for
making sectional door panels shown in operative relation to an exemplary foam-
cored door panel being fabricated to a configuration according to the present
invention.
'' . ' rcT/US9s/o7s29
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Fig.11 is an end elevational view, with portions in section, depicting
a lower conveyor and an upper conveyor constituting the arrangement of the
conveyor system of Fig. 10, including the drive motors for the conveyor
rollers.
Fig.12 is a fragmentary perspective view of a single upper conveyor .
roller shown in operative relation to derailer tooling for adjusting the
lateral
extent of the rollers of the upper conveyor of the conveyor system of Fig. 10.
Fig. 12A is a fragmentary perspective view similar to Fig. 12
showing the derailer moving in relation to a plurality of upper conveyor
rollers
with some positioned at a lesser lateral extent of the rollers of the upper
conveyor, some positioned at a greater lateral extent of the rollers, and some
in
transition therebetween.
Fig. 13 is an exploded view of an upper conveyor roller of Fig. 10
with portions broken away to depict the structure for maintaining the
positioning
of the sleeves defining the lateral extent thereof.
Fig. 14 is a fully exploded view of the upper conveyor roller of Fig.
13 showing structural details of the individual components thereof.
Fig. 15 is an enlarged cross-sectional view of an upper conveyor
roller as depicted in Figs. 10-15.
Fig. 16 is a fragmentary side-elevational view of an alternate
conveyor system according to the concepts of the present invention for curing
oven equipment for making sectional door panels shown in operative relation to
an exemplary foam-cored door panel being fabricated to a configuration
according
to the present invention.
Fig. 17 is a perspective view of a platen of the upper conveyor
assembly showing particularly the various plate elements for engaging the
inner
skin of panel material positioned in the conveyor system of Fig. 16.
Fig. 18 is a cross-sectional view of the platen of Fig. 17 taken
substantially medially thereof and positioned for engagement with the
laterally
narrowest and thinnest panel material which the platen is adapted to process.
WU 95/34738 PCT/US95107529
Fig.19 is a cross-sectional view similar to Fig. 18 showing the platen
adjusted to engage the laterally widest and thickest panel material which the
platen is adapted to process.
Fig. 20 is a cross-sectional view similar to Figs. 18 and 19 showing
5 the platen adjusted to present a planar panel engaging surface for engaging
a
panel having an inner skin which is entirely or substantially planar.
Fig. 21 is an enlarged fragmentary cross-sectional view of the
portion of the platen of Fig. 18 designated as Fig. 21 and showing details of
the
height-positioning mechanism which maintains the platen in a given adjustment
10 for a particular height.
Fig. 22 is an enlarged fragmentary cross-sectional view of the
portion of the platen of Fig. 18 designated as Fig. 22 and showing details of
the
width-positioning mechanism which maintains the platen in a given adjustment
for
a particular panel width.
15 Fig. 23 is a fragmentary elevational view taken substantially along
the line 23-23 of Fig. 16 showing the height-adjusting mechanisms and the
width-
adjusting mechanisms for the platens of the upper conveyor system.
Fig. 24 is a fragmentary plan view taken substantially along the line
24-24 of Fig. 3 showing details of the width-adjusting mechanism for the
platens
of the upper conveyor assembly.
Fig. 25 is a fragmentary elevational view taken substantially along
the line 25-25 of Fig. 24 and showing particularly details of the height-
adjusting
mechanism for the platens of the upper conveyor assembly.
PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION
A sectional overhead door system embodying the concepts of the
present invention is generally indicated by the numeral 10 in Fig. 1 of the
drawings. The door system 10 includes a pair of spaced track assemblies,
generally indicated by the numerals 11 and 12. As shown, the track assemblies
11 and 12 are symmetrically opposite but otherwise structurally identical. The
track assemblies 11, 12 each have a vertical track section 13 of appropriate
length
R'O 95/34738 . , PCT/US95/07529
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16
to extend substantially the distance from the ground or floor of a garage or
other
structure to a position proximate the header of a door frame in which the door
system 10 is to be mounted. Atop each vertical track section 13, there is a
curved
transition track section 14. The curved transition track sections 14 are
normally
connected to the vertical track sections 13 as by connector plates (not shown)
and
bolts or rivets (not shown) according to common practice in the industry. The
curved transition track sections 14 are in turn attached in an identical
manner to
horizontal track sections 15, which extend preferably substantially
horizontally
inwardly into the building from the door frame a distance comparable to the
length of vertical track sections 13.
The vertical and horizontal track sections 13, 15 are normally
constructed of straight pieces of rail which are cut to length for a
particular door
opening and attached by brackets (not shown) or comparable elements to the
door frame. It is to be appreciated that the track assemblies 11, 12 and their
positioning with respect to a door frame are in accordance with standard
practice
in the industry. In addition, all of the track sections 13, 14, and I5 may
have the
generally J-shaped, cross-sectional configuration which is commonly known and
used in the industry.
As shown, the sectional door, generally indicated by the numeral 20,
of the door system 10 is guided, and in part supported, by the track
assemblies 11,
12. For exemplary purposes, a four-panel sectional door 20 is shown in Fig. 1
of
the drawings. giowever, it will be appreciated by persons skilled in the art
that
five, six, or more panels may be employed in sectional doors of this type,
depending upon the height of the door opening and related considerations.
As shown, the sectional door 20 consists of a top panel 21, an upper
middle panel 22, a lower middle panel 23, and a bottom panel 24. The panels
21,
22, 23, and 24 are interrelated to each other and to the track assemblies 11,
12
in a manner described hereinafter. In conventional fashion, the top panel 21
carries preferably near the top edge 31 thereof a top bracket 30 which mounts
a
roller 32 that is offset from the door 20 a distance to effect closure of the
top
panel 21 when the door 20 is in the vertical, closed position.
WO 95/34738 PCT/US95/07529
17
Referring now to Fig. 3 of the drawings, it is to be understood that
in order to keep the sectional door 20 free from frictional resistance as it
approaches and departs from the fully closed position depicted in Fig. 1 and
thus
permit substantially unobstructed vertical motion, the vertical track section
13 is
S normally located at an angle a of approximately one degree with respect to
the
door frame F. It will thus be appreciated that the vertical track section 13
is
displaced progressively upwardly from the floor an increasing distance from
the
door frame F, which is designed to be a substantially plumb vertical line.
Thus,
the top bracket 30, in being positioned above the top of the vertical track
section
13 and normally in the transition track section 14, must necessarily displace
the
roller 32 a substantial distance from the top panel 21.
The articulation between panels 21 and 22, 22 and 23, and 23 and
24 and the anti-pinch feature of sectional door 20 are effected by the
configurations of the panels and their interconnection as hereinafter
described.
Inasmuch as the configuration of the various panels 21, 22, 23, and 24 may be
identical and the connecting elements identical except as hereinafter noted,
the
structure proximate the joinder of panels 21 and 22 will be detailed
hereinafter
as exemplary.
Referring now to Figs. 1, 2, and 4, it is to be noted that the panels
21 and 22, which are depicted for exemplary purposes, each have a body portion
25, which may be made of any of a wide variety of materials employed for
sectional overhead doors. The body portions 25 may be all or partially of wood
or may be of metallic or non-metallic sheet materials over a rigid foam or
other
laminate combinations. As shown, the panel 21 has an integrally formed,
generally trapezoidal bottom rib or strut 26, and panel 22 has a similarly
configured top rib or strut 27. The struts 26 and 27 serve as reinforcing
members
for effecting increased peripheral rigidity and beam strength and to assist in
interconnecting the panels 21 and 22 in the instances of strut 27. Below the
bottom strut 26 of panel 21, there is a bottom edge profile, generally
indicated by
the numeral 40. The bottom edge profile 40 extends the entire longitudinal
length of the panel 21. Just below the bottom strut 26, the bottom edge
profile
WO 95/34738 PCT/LTS95/07529
2~6'~94~.
18
40 has an inner edge surface 41 and an outer edge surface 42 which are spaced
a distance that may be substantially the same as the thiclrness of body
portion 25
of panel 21.
The bottom edge profile 40 terminates in a pair of extending .
members in the form of outer finger 43 and inner finger 44. The outer finger
43
has the outer surface thereof defined by the outer edge surface 42. The inner
surface of the outer finger 43 is a concave curvilinear surface 45 which may
be
circular and have the center of the arc or radius R defining surface 45
positioned
at a point P, which lies a substantial distance inwardly of the body portion
25 of
panels 21, 22. The outer finger 43 has a rounded extremity 46 which connects
the
outer edge surface 42 and the curvilinear surface 45.
The inner finger 44 may have as its inner surface the inner edge
surface 41. The outer surface of finger 43 may be a substantially linear
return
surface 47. Inner finger 44 may also be provided with a rounded extremity 48
which joins the inner edge surface 41 and the return surface 47. The outer
finger
43 and inner finger 44 have the concave surface 45 and the return surface 47
joined by a generally U-shaped receiver 49 constituting the inner boundary of
the
recess between fingers 43 and 44.
As depicted in Fig. 4, panel 22 has a top edge profile, generally
indicated by the numeral S0, which is adapted to operatively pivotally
interfit with
the bottom edge profile 40. The top edge profile 50 includes an elongate
projection 51, which is generally triangular in vertical cross-section. The
projection S1 preferably has an outer planar surface 52, or, if desired,
surface 52
may be slightly curved, such that it is somewhat convex. Outer planar surface
52
may advantageously be directed angularly inwardly and upwardly of body portion
25 of panel 22, such as to approximately constitute a chord of a circle
centered
on point P and passing through the extremities of surface 52. The outer planar
surface 52 may be joined to outer surface 42 of body portion 25 by a short
inset
surface 53 which accommodates the rounded extremity 46 of outer finger 43 of
bottom edge profile 40 in spaced relation when the door 20 is in the closed
position depicted in Fig. 4 of the drawings.
WO 95/34738 PCT/US95/07529
t
19
'~'he projection 51 is bounded interiorly of door 20 by an inner
planar surface 55 which, as shown in Fig. 4, is directed substantially
directly
outwardly of top edge profile 50 of panel 22. Outer planar surface 52 and
inner
planar surface 55 of projection 51 are joined by a rounded extremity 56. The
S rounded extremity 56 moves into and out of proximity to the U-shaped
receiver
49 of the bottom edge profile 40 during articulation of the panels 21 and 22.
It
is to be noted that the entirety of the outer planar surface 52 and the
rounded
extremity 56 of projection 51 lie in close proximity to curvilinear surface
45,
rounded extremity 48, and return surface 47 of bottom edge profile 40 when the
door 20 is in the closed position depicted in Fig. 4 of the drawings.
Interiorly of
the elongate projection 51 of top edge profile 50 is a hinge seating area 58,
which
is for a purpose described hereinafter. The hinge seating area 58 is a curving
area continuing inner planar surface 55 and merging into the strut 27.
Interposed between the elongate projection 51 and the U-shaped
receiver 49 is a sealing member 60. The sealing member 60 may be constructed
of any of a variety of foam or other materials employed for weather sealing
purposes. As shown, the sealing member 60 is an elongate strip which may have
a somewhat semicircular side 61 to assist in its placement and retention in
the U-
shaped receiver 49 of bottom edge profile 40. The sealing member 60, when
compressed by the elongate projection 51 and particularly the rounded
extremity
56 thereof, serves to preclude the undesirable infiltration of water and air
between the bottom edge profile 40 and the top edge profile S0.
The panels 21 and 22 are spaced and joined by a plurality of hinge
assemblies, generally indicated by the numeral 65, as seen in Figs. 1, 2, 4,
5, and
6. As best seen in Fig. 1, hinge assemblies 65 are located at the longitudinal
extremity of the door panels 21, 22 for interaction with the track assemblies
11,
12, as hereinafter described. In addition, one or more similar hinge
assemblies
65 may be intermittently positioned therebetween, depending upon the width of
the door 20, the materials from which the door 20 is constructed, and related
design considerations.
WO 95/34738 PCT/US95107529
21 '~ 41
9
The hinge assemblies 65 each have a first hinge element 66 which
is associated with bottom edge profile 40. The first hinge element 66 has a
first
leaf 67, which is a generally rectangular member having longitudinal ends 68
and
69. The first leaf 67 has a plurality of spaced attachment apertures 70. As
shown
S in Figs. S and 6, there are two apertures 70, with one aperture 70 being
located
proximate each of the ends 68, 69. The apertures 70 are adapted to receive
fasteners 71 (see Fig. 4), which position and attach first hinge elements 66
to a
bottom edge profile 40 and particularly inner edge surface 41 underlying the
bottom strut 26. The fasteners 71 may be screws, bolts, rivets, or other
elements,
10 depending upon the material of the top panel 21, as is well known to
persons
skilled in the art.
'The first leaf 67 of first hinge element 66 has at one longitudinal
edge a first cylindrical knuckle 72. The first cylindrical knuckle 72
preferably
extends the entire length of the first leaf 67 from end 68 to end 69. The
first leaf
15 67 has a through slot 73 positioned proximate to the first cylindrical
knuckle 72.
As shown, the through slot 73 is generally rectangular and is spaced a
distance
from each of the ends 68 and 69 of the first leaf 67. The first cylindrical
knuckle
72 advantageously is provided with a pair of raised cylindrical strips 74 and
75,
which serve as bearing surfaces in a manner described hereinafter. The raised
20 cylindrical strips 74 and 75 are preferably positioned longitudinally of
the first
cylindrical knuckle 72, such as to be spaced at a substantial distance but
inwardly
of the ends 76 and 77 of the through slot 73.
The hinge assemblies 65 also include a second hinge element 80
which is affixed to the upper middle panel 22 and interengages with the first
hinge
element 66 to provide the requisite pivotal connection. The second hinge
element
80 has a second cylindrical knuckle 81 which is preferably of substantially
the
same axial extent as first cylindrical knuckle 72. The second cylindrical
knuckle
81 has an inner diameter 82 which is slightly greater than the outer diameter
76
of the first cylindrical knuckle 72. In this manner, the second cylindrical
knuckle
81 is configured to rotate about the outer diameter 76 of first cylindrical
knuckle
72 to form interlocking hinge elements which do not require a hinge pin. The
WO 95/34738 ~ PCT/US95/07529
21
previously described raised cylindrical strips 74 and 75 are adapted to engage
and
serve as spaced bearing surfaces for the inner diameter 82 of the second
cylindrical knuckle 81. The second cylindrical knuckle ~81 has a tongue 83
over
a portion of its circumferential extent. The tongue 83 is of a longitudinal
extent
slightly less than the longitudinal extent of the through slot 73 in first
leaf 67, such
that the tongue 83 extends into the through slot 73 and overlies a portion of
the
first cylindrical knuckle 72 of the first hinge element 66. The second
cylindrical
knuckle 81 forms lateral support members 84 in the remainder of the second
cylindrical knuckle 81 which is not occupied by the tongue 83. As shown, the
support members 84 extend longitudinally outwardly of the tongue 83 and, as
shown, preferably extend substantially to the same longitudinal dimension as
the
longitudinal extent of first cylindrical knuckle 72. The second cylindrical
knuckle
81 adjacent the support members 84 in the direction opposite the tongue 83
merges into a second leaf 85 consisting of a generally rectangular surface 86,
which is preferably of substantially the same longitudinal extent as second
cylindrical knuckle 81. The surface 86 of second leaf 85 is adapted to seat
against
the top strut 27 proximate the top edge profile S0. The second cylindrical
knuckle
81 of the second hinge element 80 reposes in the hinge seating area 58 of the
top
edge profile 50.
The second hinge element 80 is attached to the upper middle panel
22 to effect the articulation necessary between the panels 21 and 22. In
particular, the second leaf 85 has a flange 88 which is disposed at an angle,
such
as to overlie the inner extremity 27' of top strut 27 of upper middle panel 22
(see
Fig. 4). The flange 88 has a pair of bores 89 for receiving fasteners 90. The
fasteners 90 extend into the top strut 27 and engage a pair of projecting tabs
91
which extend angularly from the extremity of the tongue 83 of the second
cylindrical knuckle 81. The tabs 91 may be provided with bores 92 for
receiving
the fasteners 90 which may have a threaded portion 90' for engagement
therewith.
It will thus be appreciated that the fasteners 90, which may be
screws, bolts, rivets, or other specialty connecting devices, extends through
the
S
rf '
WO 95/34738 PCT/US95/07529
2
~fi7~~~
22
inner extremity 27' and parallels a side of the top strut 27 to provide a
firm,
spaced interconnection with flange 88 and tabs 91 of the second hinge element
80.
The planar surface 86 of the second leaf 85 of second hinge element .
80 are discontinuous to accommodate the formation of a cylindrical sleeve 95.
As best seen in Fig. 2, the cylindrical sleeve 95 supports a shaft 100. In
conventional fashion, shaft 100 mounts a roller 101 which interengages track
assembly 11 as seen in Fig. 2. The cylindrical sleeve 95 may be variously
positioned laterally of the second leaf 85 (Fig. 4), depending upon the
standoff
distance required for a particular hinge assembly 65 due to its positioning on
the
sectional door 20. In particular, the standoff distance between a particular
roller
101 and the adjacent floor panels must provide for closure of the sectional
door
against the door frame F when the sectional door 20 is in the closed, vertical
position. The standoff distance variation is, of course, occasioned by the
angular
15 inclination of the vertical track sections 13 relative to the door frame F.
Thus,
a substantial standoff distance is noted in positioning of the cylindrical
sleeve 95
where a hinge assembly 65 is designed for the juncture between panels 21 and
22.
Progressively lesser standoff distances are necessarily required between the
panels
22 and 23 and panels 23 and 24.
20~ The hinge assembly 65 depicted in Figs. 5 and 6 is exemplary of a
standoff distance positioning as might exist between the panels 22 and 23
wherein
the cylindrical sleeve 95 is positioned in closer proximity to the second
cylindrical
knuckle 81 than that depicted in Figs. 2 and 4. It will be appreciated that
all
hinges assemblies 65 for a sectional door 20 may be identical except for the
positioning of the cylindrical sleeve 95 laterally of second leaf 85,
depending upon
the positioning as between door panels and the particular characteristics of
the
door panels, the door frame F, and the track assemblies 11, 12.
Referring now to Figs. 3 and 4, it will be appreciated that the panel
edge profiles 40, 50, together with the hinge assemblies 65, provide for
angular
displacement between adjacent panels 21 and 22 when moving from vertical track
sections 13 to horizontal track sections 15 through transition track sections
14
S
WO 95/34738 ~ PCTIUS95/07529
23
through a maximum angle ~ of approximately 70 degrees from the 0 degree angle
existing when adjacent panels are in planar alignment. The position of
essentially
maximum angularity where the angle p is at its maximum 70 degrees is depicted
in Fig. 3 of the drawings. The planar aligned position of adjacent panels 21
and
S 22 where the angle ~ is equal to 0 is depicted in solid lines in Fig. 4,
with top
panel 21 positioned co-planar with upper middle panel 22. During articulation
of the panels, the top panel 21 moves through an intermediate position
depicted
in chain lines as 21 ~ to a position of maximum angularity, with the angle ~
being
equal to approximately 70 degrees as depicted in chain lines at 21~°.
It is significant to note that the configuration of the panel edge
profiles 40, 50 and hinge assemblies 65, together with their placement and
operating interrelationship, serve to provide the anti-pinch feature of the
instant
system. As may be particularly noted from Fig. 4, the rounded extremity 46 of
outer finger 43 of the bottom edge profile 40 remains in close proximity
through
the full extent of angular movement between panels 21 and 22, with the top
edge
profile 50 and particularly either the outer planar surface 52 or rounded
extremity
56 of the elongate projection S1. In a dimensional sense, this proximity may
be
readily controlled to at all times remain within a distance of approximately
.2
inch, such that a person's fingers cannot be inserted between the bottom edge
profile 40 and the top edge profile 50 at any time during operational movement
of sectional door 20.
Referring now to Figs. 1 and 7 of the drawings, the lower corners
of the bottom panel 24 of the sectional door 20 each carry a bracket and
roller
' assembly, generally indicated by the numeral 110. For exemplary purposes,
the
bracket and roller assembly 110 at the lower left-hand corner of the sectional
door 20 depicted in Fig. 1 is shown in detail in Fig. 7A. The bracket and
roller
assembly 110 includes an L-shaped plate 111 which is located near the bottom
edge 35 of the sectional door 20. It will be appreciated by persons skilled in
the
art that the bottom edge 35 may have any of a variety of astragal
configurations
attached to it for purposes of effecting sealing and meeting other operational
requirements.
WO 95/34738 PCTlLTS95/07529
r ._
24
The bottom panel 24 may also have an inner surface 36 and a side
edge 37. The L-shaped plate 111 has a first leg 112 which overlies the inner
surface 36 of the sectional door 20. A second leg 113 of Lrshaped plate 111
overlies the side edge 37 of sectional door 20. As shown, the second leg 113
carries a projecting knob 114 which is adapted to anchor or otherwise secure
the
extremity of a cable C. The cable C interconnects with the counterbalance
system
(not shown) for the sectional door 20. In particular, the cable C is normally
reeved about a pulley (not shown) at the upper corner of the door frame F and
is operatively interrelated with tension members, such as to provide
increasing
counterbalancing forces to the sectional door 20 through the bottom panel 24
as
the sectional door 20 is lowered to the closed, vertical position depicted in
Fig.
1.
As shown, the first leg 112 of the Irshaped plate 111 may be
positioned below bottom strut 26 of the bottom panel 24 in order that all of
the
panels 21, 22, 23, and 24 may be of the same structural configuration, if
desired.
The L-shaped plate 111 is attached to the panel inner surface 36 by a pair of
fasteners 115 that pass through bores 116, which may be threaded strategically
positioned in the first leg 112 and extending into the bottom panel 24. The
fasteners 115 may be screws, bolts, or other appropriate connecting members,
depending upon the material from which a particular sectional door 20 is
constructed. Formed integrally with or attached, as by welds (not shown), to
the
L-shaped plate 111 is a cylindrical sleeve 120, which is adapted to receive a
conventional shaft 121 mounting a roller 122 for engagement with track
assembly
12. The cylindrical sleeve 120 has a pair of cutouts 125 which penetrate the
entire thickness of the cylindrical sleeve 120, such that at least a portion
of the
shaft 121 extends therethrough.
The bores 116 and the sleeve 120 are juxtapositioned on the first
leg 112 of L-shaped plate 111 according to a particular relationship.
Specifically,
the fasteners 115 may be removed by passing through the cutouts 125 in the
sleeve 120 when the shaft 121 is not positioned in the sleeve 120. However,
when
the shaft 121 carrying roller 122 is positioned in sleeve 120, removal of the
WO 95/34738 21 ~ '~ ~ ~ ~ PCTlUS95/07529
fasteners 115 is not possible due to interference with the portions of shaft
121
located in the cutouts 125. This arrangement permits installation of the
bracket
and roller assembly 110 in positions of the sectional door 20 where the cable
C
is not under tension; however, it precludes the possibility for removal of the
S fasteners 115 in the closed, vertical position of the sectional door 20 or
other
locations where the cable C is tensioned because the roller 122 and attached
shaft
121 cannot be removed from the sleeve 120 in those locations. It will be
observed that, as shown, the cutouts 125 are in effect a cylindrical notch
segment
in the sleeve 120, based upon a cut made perpendicular to the first leg 112 of
Lr
10 shaped plate 111, with the notch having a diameter slightly greater than
the heads
of fasteners 115 and positioned substantially concentric therewith.
Additional details of a preferred structure for the panels 21, 22, 23,
and 24 are shown in Figs. 8 and 9A of the drawings. Inasmuch as the hinge
assemblies 65 and other hardware are adapted to fit the basic door panel
15 configuration shown herein, all door panels may be identical, such that
door panel
22 is hereinafter described for exemplary purposes.
The panel 22 has a foam core 140 which is of a generally
rectangular configuration, except for variations that are noted hereinafter.
The
foam core 140 is preferably a low-density, rigid foam of any of a wide variety
of
20 compositions well known in the industry. The foam core 140 is constructed
of an
appropriate synthetic resin, such as polyurethane foam, for purposes of
achieving
both strength and insulating characteristics. The foam core 140 may be in the
nature of a precut, foamed insert or may be foamed in place according to
techniques known in the art. The panel 22 has a front surface, generally
indicated
25 by the numeral 141, which is defined by an outer skin 142. The outer skin
142
is preferably constructed of a light-gauge, high-strength steel, which may be
processed in a manner to resist exposure to the elements in a manner known to
persons skilled in the art.
The outer skin 142 preferably extends the full longitudinal and
lateral extent of front surface 141 of panel 22. In addition, the skin 142
preferably extends about and defines the outer surfaces of top edge profile 50
and
WO 95/34738 ' ' ' PCT/ITS95/07529
216°941
26
bottom edge profile 40. The skin 142 also preferably continues to define the
generally trapezoidal bottom rib or strut 26 and the top rib or strut 27 of
panel
22. The skin 142 preferably terminates laterally inwardly of each of the
struts 26,
27 in spaced flanges 143 and 144. The top and bottom edge profiles 40, SO and
S struts 26, 27 are preferably interiorly filled by the foam core 140.
The door panel 22 has as a portion of an inner surface, generally
indicated by the numeral 145, an inner skin 146, which extends between flanges
143, 144 the longitudinal length of panel 22. The shin 146 preferably has
lateral
extremities 147 and 148 which advantageously overlap and, as shown, underlie
the
flanges 143 and 144, respectively. The inner skin 146 may be made of treated
paper, metallic-coated paper, non-metallic sheet material, or metallic sheet
of
types which are known in the art.
The inner surface 145 has a medial recess, generally indicated by
the numeral 150, which is preferably centered laterally, substantially
medially of
panel 22 in the inner skin 146 and the foam core 140. As shown in Fig. 9A, the
recess 150 extends approximately one-half of the distance from the center of
panel 22 to each edge profile 40, 50. The inner surface 145 has offsets 151
and
152 which transcend from full-thickness sections 140' to a reduced-thickness
section 140" of foam core 140. It has been determined that reduced-thickness
section 140" can be as thin as approximately .25" while maintaining the
desired
stiffness, sound-deadening, and insulating properties of the door panel 22 as
a
whole in an air environment. It will, of course, be appreciated that the
offsets 151
and 152 contribute to increasing the rigidity of the panel 22. It will further
be
appreciated by persons skilled in the art that full-thickness sections 140'
and
reduced-thickness section 140" of foam core 140 may be varied in thickness as
required to meet insulation, sound-deadening, or stiffness requirements for a
particular door design. As seen in Fig. 9A, the offsets 151, 152 may be
relatively
steeply inclined in that they are positioned at an angle of approximately 60
degrees to a line perpendicular to the reduced-thickness surface 153 of recess
150.
With the structural arrangement shown in Fig. 9A., the quantity of foam for
the
foam core 140 can be reduced on the order of 30 to 40 percent of that required
WO 95/34738 4 ,~ PCT/US95/07529
27
for a conventional rectangular foam core without significantly adversely
affecting
the characteristics of the panel 22 as noted hereinabove.
As seen in Fig. 8, the panel 22 may be provided with end caps 155
which overlie the ends of foam core 140 and the longitudinal extremities of
outer
skin 142 and inner skin 146. If desired, spaced stiles or muttons may be
provided
at one or more positions longitudinally of the door panel 22.
A modified door panel 222 is depicted in Fig. 9B of the drawings.
The panel 222 is configured the same as the panel 22 of Fig. 9A, except for
medial recess, generally indicated by the numeral 250, in the inner surface
245.
As shown, the recess 250 extends approximately one-half of the distance from
the
center of panel 22 to each of the edge profiles in a manner comparable to
recess
150. The inner surface 245 has offsets 251 and 252 which transcend from full-
thickness sections 240' to a reduced-thickness section 240" of foam core 240.
In
a manner similar to the panel 22, it has been determined that reduced-
thickness
section 240" can be as thin as approximately .25" while maintaining the
desired
stiffness, sound-deadening, and insulating properties of the door panel 222 as
a
whole in an air environment. It will be appreciated that the offsets 251 and
252
contribute, to some measure, to increasing the rigidity of the panel 222,
although
less steeply inclined than the offsets 151, 152. The possibilities of varying
the
thickness of full-thickness sections 240 ° and reduced-thickness
section 240'° of
foam core 240 are, of course, available to satisfy requirements for a
particular
door design. The panel 222 can produce a foam quantity reduction on the order
of 30 to 40 percent without significantly adversely affecting the stiffness,
sound-
deadening, and insulating properties of the panel 222.
Another modified door panel 322 is depicted in Fig. 9C of the
drawings. The panel 322 is configured the same as the panels 22 and 222 of
Figs.
9A and 9B, except for medial recess, generally indicated by the numeral 350,
in
the inner surface 345. In this instance, the recess 350 is in the form of a
gradual
curve, which extends substantially the entire width of the inner surface 345
to
create a concave configuration. Here, the foam core 340 has a minimum-
thickness portion 340" substantially medially of the transverse width of inner
;." ' i~
;.
WO 95/34738 PCTJUS95J07529
2~~'~94~.
28
surface 345 with tapering, progressively thicker sections 340' to either side
thereof. The possibilities of varying the thickness dimensions of foam core
340
and achieving a foam quantity reduction, as discussed in relation to panel 22
and
222 are, are equally applicable.
From the discussion involving panels 22, 222, and 322, it will be
appreciated that innumerable geometric configurations by way of combinations
of curved and linear surfaces could be employed to achieve foam reduction
without substantially compromising specifications by the incorporation of a
recess
or recesses in the inner surface of a door panel.
Exemplary curing oven equipment in the form of a conveyor system
for manufacturing panel material 22 ° for panels 22 according to the
invention is
generally indicated by the numeral 400 in Figs. 10-15 of the drawings. The
conveyor system 400 permits continuous panel production by effecting
pressurized
support of panel material 22' , configured such as panel 22 of Fig. 9A, during
the
expansion and bonding of the internal foam core 140 in an oven, until such
time
as it becomes substantially set in the final configuration prior to the panel
material 22 , being cut to length in a manner well known in the art.
The conveyor system 400 includes a lower conveyor assembly,
generally indicated by the numeral 401, and an upper conveyor assembly,
generally indicated by the numeral 402. The conveyor assemblies 401 and 402
are
selectively adjusted as hereinafter described to permit the passage of panel
material 22' therebetween, as seen in Fig. 11 of the drawings.
Referring particularly to Fig. 11 of the drawings, the lower conveyor
assembly 401 consists of an extended line of identical rollers 405 which have
a
lateral width exceeding the widest panel 22 to be processed in conveyor system
400. Depending upon the speed at which panel material 22 ° is
introduced to the
conveyor system 400, the time required for the foam core 140 to expand and
set,
and related considerations, appropriate lengths of lower conveyor assembly 401
may consist of several dozen lower rollers 405 or more.
Each of the lower rollers 405 is affixed to a shaft 406 mounted in
spaced pillow blocks 407 and 408. The pillow blocks 407, 408 are attached to a
WO 95/34738 PCTIUS95l07529
29
movable frame 409 as by suitable machine screws 410. The movable frame 409
is supported by a plurality of cylinders 412 which are mounted on a iced frame
413. Actuation of the cylinders 412 permits positioning of the lower conveyor
assembly 401, and particularly the lower rollers 405, vertically relative to
the
upper conveyor assembly 402, as seen in Fig. 11, to vary the spacing
therebetween
and thus accommodate panel material 22 ° of differing thickness.
The lower conveyor assembly 401 has the lower rollers 405 powered
by a lower conveyor drive assembly, generally indicated by the numeral 415.
Lower conveyor drive assembly 415 includes a driven sprocket 416 which is non-
rotatably affixed to the shaft 406 of roller 405 as by a set screw 417. A
drive
chain C may be employed to connect the driven sprocket 416 with a drive
sprocket 418 of the lower conveyor drive assembly 415. The drive sprocket 418
is affixed by a set screw 419 to a shaft 420 of a drive motor M, which may be
attached to the fixed frame 413 as by machine screws 421. It will thus be
appreciated that by suitable adjustment of the speed of motor M, the rollers
405
may be driven at any desired speed a.nd preferably at substantially the
velocity of
panel material 22 ° entering the conveyor system 400. As will be
apparent to
persons skilled in the art, all or merely some of the rollers 405 of lower
conveyor
assembly 401 may be driven by a chain drive and sprockets interconnecting the
various shafts 406 (not shown).
The lower conveyor assembly 401, by virtue of rollers 405, provides
a co-planar upper surface which engages the planar outer skin 142 of panel
material 22 ° to resist foaming pressure internally of panel material
22 ° passing
through conveyor system 400 during the manufacturing process. If desired, the
rollers 405 may carry a conveyor belt 425 which has an upper planar surface
426
for directly engaging the outer skin 142 of panel material 22 ° to
assist in the
distribution of forces from the lower conveyor assembly 401 to the panels 22.
The upper conveyor assembly 402 is positioned in operative relation
to the lower conveyor assembly 401 and particularly panel material 22 °
reposing
on the upper surface thereof. As best seen in Figs. 10 and 11, the upper
conveyor
assembly 402 consists of a plurality of spaced but proximate upper rollers,
WO 95/34738 PCT/US95/07529
,,;;,
z~.~'~~4~ 30
generally indicated by the numeral 430. The rollers 430 are each mounted on
shafts 431 having parallel axes A such that the rollers 430 are in close but
spaced
juxtaposition, as schematically depicted in Fig. 10. Referring now to Fig. 11,
each
of the shafts 431 is mounted in spaced pillow blocks 432 and 433. The pillow
blocks 432 and 433 are attached to a portion of the fed frame 413 of conveyor
system 400 as by suitable machine screws 434. The shafts 431 thus remain fixed
in the conveyor system 400 but free to rotate in the pillow blocks 432 and
433.
The upper conveyor assembly 402 includes an upper conveyor drive
assembly, generally indicated by the numeral 435. The upper conveyor drive
assembly 435 includes driven sprockets 436, 436 which are non-rotatably
affixed
to shaft 431 of roller 430 as by set screws 437, 437. A drive chain C' may be
employed to connect the driven sprocket 436 with a drive sprocket 438 of the
upper conveyor drive assembly 435. The drive sprocket 438 is afbxed by a set
screw 439 to a shaft 440 of a drive motor M' , which may also be attached to
the
fixed frame 413 as by machine screws 441. It will thus be appreciated that by
suitable adjustment of the speed of motor M' , the rollers 430 may be driven
at
any desired speed and preferably at substantially the velocity of panel
material
22' entering the conveyor system 400 and at substantially the velocity of the
rollers 405 of lower conveyor assembly 401. In a manner similar to the rollers
405, all or merely some of the rollers 430 of the upper conveyor assembly 402
may be driven by the upper conveyor drive assembly 435, as by conventional
sprockets and an interconnecting chain, generally indicated by the numeral
442.
As can be best seen in Figs. 11 and 13-15, the upper rollers 430 are
specially constructed, as contrasted with the conventional cylindrical
configuration
of the lower conveyor rollers 405, such that rollers 430 engage the inner skin
146
of panel material 22' from a position just inwardly of the struts 26 and 27 of
panels 22 (see Figs. 10 and 11). The upper rollers 430 have a center drum,
generally indicated by the numeral 450, having an outer surface 451 which
engages the medial recess 150 in the inner skin 146 of a door panel 22. The
panels 22 are preferably constructed such that the medial recess 150 is of the
same lateral extent in all panels 22, irrespective of the overall lateral
dimension
w0 95/34738 PCT/US95/07529
31
or thickness of a particular panel 22. The center drum 450 may be fabricated
from a narrow central hub 452 which is press fit on the shaft 431, preferably
medially thereof, and which spaces and joins a pair of elongate annular
elements
453 and 454 as by suitable welds 455. The center drum 450 thus has cylindrical
openings interiorly of the annular elements 453 and 454 extending from the
axial
extremities thereof to the central hub 452, all of which rotate with the shaft
431.
The outside diameter of the drum 450, as defined by outer surface 451, may
conveniently be of substantially the same diameter as the lower conveyor
rollers
405.
The annular center drum 450 of upper rollers 430 has side drums,
generally indicated by the numeral 460, positioned laterally to either side
thereof.
As can be seen particularly in Figs. 11 and 15, the side drums 460 telescope
into
the cylindrical openings formed by the elongate annular elements 453 and 454
of
the center drum 450. The side drums 460 each have an inner sleeve 461 which
is sized to fit over the shaft 431 of the upper conveyor assembly 402, as best
seen
in Fig. 15. On the outer surface of each sleeve 461 at each axial extremity
thereof, there is a bearing race 462 that supports an outer sleeve 463, which
is
thus freely rotatably mounted relative to both the shaft 431 and the inner
sleeve
461. The outer sleeves 463 thus have outer surfaces 464 adapted to engage the
inner skin 146 of panel 22 in the two co-planar areas between each of the
struts
26 and 27 and the medial recess 150 to apply pressure thereto during expansion
of the foam core 140 of panel material 22' . The outer sleeves 463 are freely
rotatable to assume a tangential velocity at the surfaces 464 identical to the
velocity of the inner skin 146 of panel material 22 ~ in engagement therewith
to
thus preclude the scrubbing or pulling which would otherwise occur due to the
differing tangential velocity.
In order to accommodate door panel material 22' of differing
widths, which are necessary to provide sectional doors of differing heights,
the
side drums 460 may be adjustably positioned laterally or axially of center
drum
450. In this manner, all different panel sizes may have the same configuration
laterally outwardly of the struts 26 and 27 and in terms of the width of the
medial
WO 95/34738 '~ PCT/US95/07529
32
recess 150 engaged by the center drum 450, with the differences in panel width
being accounted for exclusively in the lateral extent of the inner skin
surfaces 146
engaged by the side drums 460, as can be appreciated from Fig. 11.
The lateral adjustment of the side drums 460 relative to the center
drum 450 is effected by the outer surfaces 464 of outer sleeves 463
telescoping
differing distances within the annular elements 453 and 454 of center drum
450.
A plurality of preselected positions of the side drums 460 laterally of the
center
drum 450 are achieved by position retaining assemblies, generally indicated by
the
numeral 470. The position retaining assemblies 470, as best seen in Figs. 13-
15,
each have a detent tab 471 mounted at the lateral end of the inner sleeves
461,
which telescope within the center drum 450. Each detent tab 471 mounts a
spring-loaded detent 472 which projects radially outwardly of the side drums
460
and extends outwardly thereof a sufficient distance to engage the inner
surface of
the elongate annular elements 453 and 454 of the center drum 450. The inner
surfaces of the annular elements 453 and 454 of center drum 450 have a
plurality
of detent receiving bores 475, with three exemplary bores 475, 475' , 475"
being
depicted in Fig. 13. With the detent receiving bores 475, 475' , and
475'°, there
is provision for three different widths of panel 22, depending upon which of
the
bores the spring-loaded detents 472 are engaging. It is to be appreciated that
more or less of the detent receiving bores 475 may be provided, and they can
be
located axially of the annular elements 453, 454 of center drum 450 as
necessary
to operate as hereinabove described with respect to a particular lateral
dimension
of a panel 22.
The position retaining assemblies 470 maintain side drums 460 at
a desired position as long as panels 22 of a given lateral dimension are to be
run
on the conveyor system 400. When it is desired to run panels 22 of a different
lateral dimension or width, each side drum 460 of each of the upper rollers
430
must be adjusted to one of the detent receiving bores 475, 475' , or 475"
appropriate to achieve the correct lateral dimension of the upper rollers 430.
This may be accomplished manually by grasping and physically moving each of
the
WO 95/34738 PCT/US95/07529
. . '.
33
side drums 460 of each of the rollers 430, since the spring-loaded detents 472
retract sufficiently to be moved upon the application of a displacing force.
The adjustment of the side drums 460 can, however, be quickly and
automatically effected by use of a derailer, generally indicated by the
numeral 480
in Figs. 12 and 12A. As best seen in Fig. 12, the derailer 480 consists of a
rectangular block 481 having dimensions generally comparable to a panel 22.
One side of the block 481 has projecting parallel strips 482 and 483 which are
adapted to engage circumferential grooves 485 (see Fig. 15) in the outer
surface
464 of the side drums 460. As best seen in Fig. 12, the upper conveyor roller
430
has grooves 485 engaging strips 482 and 483 in narrowly displaced areas of the
strips 482' and 483', as contrasted with the wider spacing at 482 and 483.
Intermittent these areas, the strips 482, 483 have a non-parallel converging
or
diverging section to transcend between the narrower and wider areas of the
strips
482, 483.
The derailer 480 is shown in operation in Fig. 12A where it is
depicted being fed into the conveyor system 400 between the lower conveyor
assembly 401 and the upper conveyor assembly 402. When the conveyor system
400 is driven in the normal fashion, the derailer 480 moves from left to right
through conveyor system 400, as seen in Fig. 12A. In the illustrated instance,
the
upper rollers 430 are moved from the narrower positioning of the strips 482' ,
483' to the wider position at 482, 483, as the outward displacement of the
groove
485, in passing through the diverging area of strips 482, 483, moves the
spring-
loaded detents 472 from a laterally inner to a laterally outer position, where
a
different detent receiving bore 475 is engaged to thus lock the side drums 460
in
the new position. It will be appreciated that the travel of the derailer 480
through
the entire length of the conveyor system 400 will effect adjustment of all of
the
upper conveyor rollers 430. It will also be understood that with the use of a
plurality of derailers 480 having strategically located and configured strips
482,
483, the automated movement from any width of roller 430 to any other width
can
be accomplished merely by stopping the conveyor system 400, passing an
appropriate derailer 480 through the length of the conveyor system 400, and
then
WO 95/34738 ' ~ PCT/US95/07529
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34
resuming operation of conveyor system 400 in the processing of panels 22 of a
different width.
Exemplary curing oven equipment in the form of an alternate
conveyor system for the manufacture of panels according to the present
invention
is generally indicated by the numeral 500 in Figs. 16-25 of the drawings. The
conveyor system 500, in the manner of conveyor system 400, permits continuous
panel production by effecting pressurized support of a panel, conftgured such
as
panel 22 of Fig. 9A, during the expansion and bonding of the internal foam
core
in an oven, until such time as it becomes substantially set in the final
configuration prior to the panel material 22' being cut to length in a manner
well-known in the art. The conveyor system 500 includes a lower conveyor
assembly, generally indicated by the numeral 501, and an upper conveyor
assembly, generally indicated by the numeral 502. The conveyor assemblies SO1
and 502 are selectively adjusted, as hereinafter described, to permit the
passage
of panel material 22' therebetween, as is generally depicted in Fig. 16 of the
drawings.
The lower conveyor assembly 501, which is depicted schematically
in Fig. 16, is a conventional roller chain conveyor constituting an endless
roller
chain 505 mounting rectangular pressure platens 506 in a manner well known to
persons skilled in the art. The upper run of the lower conveyor assembly 501
thus
presents a substantially flat surface 503 adapted to engage the planar outer
skin
142 of panel material 22' to resist foaming pressure internally of panel
material
22' passing through conveyor system 500 during the manufacturing process. The
roller chain SOS is positioned about spaced end roller sprockets 507 and 508.
The
roller chain 505 may be driven, as indicated in Fig. 16, as by interconnecting
the
sprocket 508 at the trailing end of the conveyor system 500 with a motor
driven
sprocket 509 and drive chain 510. The lower conveyor assembly 501 may be
supported on conventional frame members F. The lower conveyor assembly 501
is thus constituted as a conventional platen or slab conveyor.
The upper conveyor assembly 502, which is similarly depicted
schematically in Fig. 16, is a roller chain conveyor constituting an endless
roller
WO 95/34738 PCT/US95/07529
chain S15 mounting generally rectangular pressure platens 516 in a manner well
known to persons skilled in the art. The lower run of upper conveyor assembly
502 thus presents a generally flat surface, except as hereinafter noted,
adapted to
engage the inner skin 146 and struts 26 and 27 of panel material 22' to resist
5 foaming pressure internally of a panel material 22' passing through conveyor
system 500 during the manufacturing process. The roller chain 515 is
positioned
about spaced end roller sprockets S 17 and 518. The roller chain S 15 may be
driven, as indicated in Fig. 16, as by interconnecting the sprocket 518 at the
trailing end of the conveyor system 500 with a motor driven sprocket 519 and
10 drive chain 520 in the manner employed for lower~conveyor assembly 501. The
upper conveyor assembly 502 may be supported on conventional frame members
F' . Thus, the arrangement of upper conveyor assembly 502 and the drive system
therefor is constituted in the same general manner as lower conveyor assembly
501.
15 In contrast to the conventional rectangular configuration of the
pressure platens 506 of the lower conveyor assembly SO1, the pressure platens
516
of the upper conveyor assembly 502 are specially configured, as depicted in
Figs.
17-22, to accommodate panel material 22' of different widths and thicknesses
(Figs. 18-20). The pressure platens 516 have a base block 525 which is of a
20 generally rectangular configuration and has conventional mounting elements
(not
shown) for connection to roller chain 515 of upper conveyor assembly 502. The
base block 525 is generally in the shape of a shallow U in cross section,
laterally
of upper conveyor assembly 502, with a central recessed portion 526 separating
spaced wings 527 and 528.
25 Referring now particularly to Figs. 17-20, the pressure platen 516
has positioned substantially medially of the lateral extent thereof and
medially of
the recessed portion 526 a center plate 530. The center plate 530 is suspended
from base block 525 as by a plurality of machine screws 531 which may carry
springs 532 that bias the center plate 530 toward base block 525 when
30 compressed. The center plate 530 may be provided with a plurality of bores
533,
there being four such bores shown in Fig. 17, which receive guide pins 534
j n t ~
WO 95/34738 '. ' PCTlUS95/07529
i
36
extending downwardly from base block 525 to maintain the center plate 530
appropriately positioned for direct vertical motion. As can be best seen in
Figs.
18 and 19, center plate 530 has a lower surface 535 with a dimension laterally
of
upper conveyor assembly 502 which is substantially the lateral dimension of
the
medial recess 150 in the inner skin 146 of panel material 22' which, as can be
seen in Figs. 18 and 19, is uniform for all panel sizes.
Positioned laterally of upper conveyor assembly 502 to either side
of center plate 530 are side plates 540 which may be structurally identical.
The
side plates 540 have lower surfaces 541 adapted to engage the inner skin 146
of
panel 22. In order to accommodate door panel material 22' of differing widths,
which is necessary to provide sectional doors of differing heights, the side
plates
540, 540 may be adjustably positioned laterally of upper conveyor assembly 502
by virtue of lateral movement of the side plates 540 to be telescoped within
or
overlapped by the center plate 530 to different lateral extent, as can be
appreciated by comparing the position of the side plates 540, 540 in Figs. 18
and
19. The side plates 540 may be suspended from base block 525 by a plurality of
cap screws 542 which fit in slots 543 in engaging surface 541 to permit the
aforedescribed lateral movement of side plates 540.
Extending laterally outwardly of side plates 540 are platen width
adjustment plates 545 which support side plates 540 in the area of wings 527,
528
of base block 525. In particular, the underside of side wings 527, 528 have
slots
529 which have inward cuts 529' (see Fig. 17) at either side of each of side
wings
527, 528. The upper surfaces of width adjustment plates 545 each have a center
slot 546 which has undercuts 547 that are adapted to matingly engage the
inward
cuts 529' to thus form a dovetail ht between the width adjustment plates 545
and
the wings 527, 528. The base block 525 thus supports the width adjustment
plates
545 for sliding movement relative thereto and to center plates 530.
The side plates 540 are maintained or temporarily locked at one of
a plurality of preselected positions laterally of center plate 530 by virtue
of width
positioning mechanisms, generally indicated by the numeral 550, as seen in
Fig.
22. The width positioning mechanisms 550 are interposed between each of the
WO 9513473 PCT/US95/07529
~16~~~1
37
side plates 540 and the upper side of center plate 530. As shown, the upper
side
of center plates 530 has a projecting spring-loaded detent 551 which lies in
proximity to the lower surface of side plates 540. The~lower sides of side
plates
_ 540 which are overlapped by center plate 530 have an insert 552 having a
plurality
of laterally spaced depressions 553 which are engaged by the mating spring-
loaded
detent SS 1.
While three spaced depressions 553 are shown for exemplary
purposes in Fig. 22, it will be appreciated that more or less depressions may
be
provided, depending upon the number of different widths of panel material 22
° ,
to be processed in the conveyor system 500. It will be noted that the
depression
553 shown engaged in Fig. 22 produces the narrowest width of panel material
22' ,
as depicted in Fig. 18. In Fig. 19, the widest panel material 22' is depicted
in
which the spring-loaded detent 551 would repose in the depression 553 at the
lateral inner extremity of side plates 540, as seen in Fig. 22. Fig 20 depicts
a
lateral positioning of the side plates 540, such that the center plate 530 is
retracted by springs 532 on machine screws 531, whereby the lower surfaces 541
of side plates 540 and lower surface 535 of center plate 530 are co-planar. In
such instance, the conveyor system 500 is adapted to process panel material 22
° ,
as seen in Fig. 20, which is of uniform thickness between the struts 26 and 27
or
over the entire width, as shown. It will thus be appreciated that the width
positioning mechanism 550 maintains the side plates 540 at any of the selected
positions laterally of center plate 530 until a width adjustment is made in a
manner hereinafter described.
' Positioned laterally outwardly of the lower surfaces 541 of each of
side plates 540 is a height adjustment block 560. The height adjustment blocks
560, as seen particularly in Figs. 17-20, have substantially L-shaped lower
and
laterally inner surfaces 561 adapted to engage the laterally outer portions of
the
struts 26, 27 and any inner surface configuration of the panel material 22'
located
laterally outwardly thereof. In order to accommodate door panel material 22'
of differing thicknesses, which is desirable to provide sectional doors of
differing
insulation values, the height adjustment blocks 560, 560 are mounted for
WO 95/34738 PCT/US95/07529
2 ~ 6''19 '~~'~~ r ..
38
movement substantially perpendicular to the lower surfaces 541 of the side
plates
540. The path of the height adjustment blocks 560 and the suspension relative
to
side plates 540, 540 is accomplished by height adjustment Bibs 562 attached to
the
side plates 540 laterally outwardly of and above the lower surfaces 541 of
side
plates 540, 540.
The height adjustment gibs 562, 562 have inward cuts 563 at the
extremities thereof (see Fig. 7). The laterally inner surface of the height
adjustment blocks 560 has vertical center slots 565 which have undercuts 566
that
are adapted to matingly engage the inward cuts 563 of height adjustment gibs
562
to thus form a dovetail fit between the height adjustment blocks 560 and the
height adjustment gibs 562. The side plates 540 thus support the height
adjustment blocks 560 for sliding vertical movement relative thereto.
The height adjustment blocks 560, 560 are maintained at one of a
plurality of preselected positions vertically of or perpendicular to side
plates 540
by virtue of height positioning mechanism, generally indicated by the numeral
570,
as seen particularly in Fig. 21. The height positioning mechanisms 570 are
interposed between each of the height adjustment blocks 560 and the height
adjustment gibs 562. As shown, the laterally outer surface of height
adjustment
gibs 562 has a projecting spring-loaded detent 571 which lies in proximity to
the
center slots 565 in the height adjustment blocks 560. The center slots 565 of
height adjustment blocks 560 have a plurality of spaced depressions 573 which
are
engaged by the mating spring-loaded detent 571. While three spaced depressions
573 are shown for exemplary purposes in Fig. 21, it will be appreciated that
more
or less depressions may be provided, depending upon the number of different
thicknesses of panel material 22 ° to be processed in the conveyor
system 500. It
will be noted that the depression 573 shown engaged in Fig. 21 produces the
thinnest panel material 22 ° , as depicted in Fig. 18. In Fig. 19, the
thickest panel
material 22 ° is depicted in which the spring-loaded detent 571 would
repose in
the depression 573 closest to the upper vertical extremity of the height
adjustment
block 560, as seen in Fig. 21. It will thus be appreciated that the height
positioning mechanism 570 maintains the height adjustment blocks 560, 560 at
any
WO 95/34738 PCT/US95/07529
~~s~~4~
39
of the selected positions vertically of the side plates 540, 540 until a
height
adjustment is made in a manner hereinafter described.
The side plates 540, 540 are moved between the plurality of
preselected positions laterally of center plate 530 established by width
positioning
S mechanism S50 by a width adjusting mechanism, generally indicated by the
numeral 580 in Figs. 16, 23, and 24. As best seen in Fig. 16, the width
adjusting
mechanism 580 is positioned on the upper run of the upper conveyor assembly
502. As seen in Fig. 23, a width adjusting mechanism 580 is positioned to
either
side of upper conveyor assembly 502 in operative relationship to the width
adjustment plates 545, 545 of the platens 516. Each width adjusting mechanism
580 has a fixed mounting plate 581 which may be mounted to a portion of the
frame F of the conveyor assembly 500, preferably at a pair of spaced
locations,
as seen in Fig. 24. Each fixed mounting plate 581 carries a width adjusting
plate
582 which is mounted for movement laterally of the upper conveyor assembly
502.
Width adjusting plate 582 is supported for movement relative to fixed mounting
plate 58I by a plurality of spaced guide rods 583. The guide rods 583 are each
supported by a pair of spaced rod hangers 584 attached to the fixed mounting
plate 581. The guide rods 583 also pass through and are supported by bearing
blocks 585 attached to the width adjusting plate 582.
~ The width adjusting plate 582 is moved relative to the fixed
mounting plate 581 on guide rods 583 by means of a width adjusting screw 586
which is supported on the fixed mounting plate 581 by a screw block 587 and on
the width adjusting plate 582 by a screw support block 588. It will be
appreciated
that actuation of the screw 586 will effect lateral movement of the width
adjusting
plate 582 relative to the fixed mounting plate 581, as controlled by the guide
rods
583. The width adjusting plate 582 has a cam track 589 which has a converging
portion 589' and a parallel portion 589". The width adjusting plates 582
carry,
preferably proximate the lateral extremities thereof, cam rollers 549 which
each
engage cam track 589.
When the upper conveyor assembly 502 is operating at a preselected
position of the width positioning mechanism 550, the cam rollers 549 engage
only
WO 95/34738 PCT/US95/07529
21~'~941 ' '~' v
the parallel portion 589" of the cam track 589. When it is desired to run a
different width of panel material 22 ° , the upper conveyor assembly
502 is
stopped, and the width adjusting screw 586 is actuated to move the width
adjusting plate 582 and thus cam track 589 laterally inwardly or outwardly to
the
5 desired preselected position of width positioning mechanism 550. Upon
actuation
of the upper conveyor assembly 502, the cam rollers 549 on the platens 516 are
guided to the new lateral position established by the parallel portions 589"
of cam
track 589 by the converging portions 589' of cam track 589. It will be
appreciated that operation of the upper conveyor assembly 502 through one
10 complete revolution will adjust the side plates 540 of all platens 516 to a
new
lateral width which will be maintained by the width positioning mechanism 550
until such time as it is desired to convert to a different width of panel
material
22' .
The height adjustment blocks 560, 560 are moved between the
15 plurality of preselected positions vertically of the side plates 540, 540
established
by height positioning mechanism 570 by a height adjustment mechanism,
generally
indicated by the numeral 590 in Figs. 16, 23, and 25. As best seen in Fig. 16,
the
height adjustment mechanism 590 is positioned on the upper run of upper
conveyor assembly 502 at a location which may be proximate to the width
20 adjusting mechanism 580. As seen in Fig. 23, a height adjustment mechanism
590
is positioned to either side of upper conveyor assembly 502 in operative
relationship to height adjustment blocks 560, 560 of the platens 516. Each
height
adjustment mechanism 590 has a fixed mounting plate 591 which may be mounted
' to a portion of the frame of the conveyor assembly 500. Each fixed mounting
25 plate 591 carries a height adjusting plate 592 which is mounted for
movement
vertically of the upper conveyor assembly 502. Height adjusting plate 592 is
supported for movement relative to fixed mounting plate 591 by a plurality of
spaced guide rods 593. The guide rods 593 are each supported by a rod mounting
block 594 attached to the height adjusting plate 592. The guide rods 593 also
30 pass through and are supported by bearing blocks 595 attached to the fixed
mounting plate 591.
s
WO 95/34738 , PCT/US95/07529
:.
41
The height adjusting plate 592 is moved relative to the fixed
mounting plate 591 on the guide rods 593 by means of a height adjusting screw
596 which is supported on the fixed mounting plate 591 ~by a screw block 597
and
. on the height adjusting plate 592 by a screw support block 598. It will be
S appreciated that actuation of the height adjusting screw 596 will effect
movement
vertically of upper conveyor assembly 502 of the height adjusting plate 592
relative to the fixed mounting plate 591, as controlled by the guide rods 593.
When the upper conveyor assembly 502 is operating at a preselected
position of the height positioning mechanism 570, 570, the cam followers 569
engage only parallel portion 599°' of cam track 599. When it is desired
to run a
different width of panel material 22 ° , the upper conveyor assembly
502 is
stopped, and the height adjusting screw 596 is actuated to move the height
adjusting plate 592 and thus 'cam track 599 vertically upwardly or downwardly
to
the desired preselected position of height adjustment blocks 560, 560. Upon
actuation of the upper conveyor assembly 502, cam followers 569, and thus the
height adjustment blocks 560 are guided to the new vertical position or height
established by the parallel portions 599" of cam track 599 by converging
portions
599' of cam track 599. It will be appreciated that operation of the upper
conveyor assembly 502 through one complete revolution will adjust the height
adjustment blocks 560, 560 to a new vertical height which will be maintained
by
the height positioning mechanisms 570, 570 until such time as it is desired to
convert to a different height of panel material 22 ° .
Thus, it should be evident that the sectional overhead door and
manufacturing apparatus disclosed herein carries out various of the objects of
the
present invention set forth above and otherwise constitutes an advantageous
contribution to the art. As will be apparent to persons skilled in the art,
modifications can be made to the preferred embodiments disclosed herein
without
departing from the spirit of the invention, the scope of the invention being
limited solely by the scope of the attached claims.
