Note: Descriptions are shown in the official language in which they were submitted.
2 ~ ~'~~.0
1 WAY.P.US0017
SUPPORT BRACKET AND TRACK ASSEMBLY FOR SECTIONAL
OVERHEAD DOORS
RELATED APPLICATION
The subject application is a continuation-in-part of U.S. Application
Serial No. 08/056,991 filed on May 3, 1993, now U.S. Pat. No. 5,408,724, in
the
names of Willis Mullet and Thomas B. Bennett 111.
TECHNICAL FIELD
The present invention is directed toward jamb brackets, support .
brackets, and track assemblies for sectional overhead doors and the like. Each
jamb bracket and/or support bracket engages the track member and is in turn
attached to the door jamb or other structural support. The brackets hold the
track in a fixed position relative to the door so that the door may roll
freely in
the track. Such assemblies are typically used in conjunction with overhead
sectional garage doors in both residential and commercial settings.
BACKGROUND AItT
Typically, jamb brackets are manufactured in a single piece from heavy
angle iron or from stamped angles and flat stock, which must be fastened
together with screws or rivets. Heavy material thicknesses are required with
such
brackets to provide the necessary strength. Attachment of the track to the
jamb
bracket has previously been accomplished by flat or round head bolts and nuts.
Such bolts must be adjusted precisely in order to ensure adequate clearance
for
the door rollers in the track.
Generally horizontal angle brackets are provided for overhead door
systems to add stiffness and strength to the track system so that the track
will not
deflect under the load of the door when the door is stored in its open
position.
Typically such brackets are bolted to the track member by means of mechanical
fasteners such as screws if the components are to be assembled in the field,
or
spot welded if the components are pre-assembled. In instances where it is
desired
to assemble track components in the field, it is desired to use versatile
components adapted for use in various arrangements. Known attempts at
imparting a degree of versatility in such component parts include providing
plural
S ,t
Z WAY.P.US0017
holes and/or slots in the components, in the interfacing area to allow some
preassembly and adjustment prior to final securing of the components. The hole
and/or slot arrangement, while flexible, lacks stability during assembly.
Despite the years that jamb brackets, support brackets, and track
assemblies have been employed and the various design variations, assembly and
installation time as well as manufacturing costs can be significant.
Installation
and assembly involving numerous elements and fasteners is tedious and requires
multiple adjustments to ensure smooth operation of the door.
DISCLOSURE OF THE INVENTION
It is therefore an object of the present invention to provide a bracket
whereby a track member can be mounted to a door jamb or other structural
support.
It is another object of the present invention to provide a jamb bracket
and track member which can be manufactured from thin gauge material, yet still
provide adequate strength.
It is yet another object of the present invention to provide jamb
brackets, support brackets, and track members which can be easily connected
and
adjusted without the need for tools or separate fasteners.
It is still another object of the present invention to provide jamb
brackets, support brackets, and track members which can be inexpensively
manufactured using commonly available materials and conventional
manufacturing techniques.
At least one or more of the foregoing objects, together with the
advantages thereof over known brackets and track assemblies, which shall
become apparent from the specification which follows, are accomplished by the
invention as hereinafter described and claimed.
In general, a support bracket and track assembly for the support of
sectional overhead doors comprises track means for supporting the overhead
door
sections, horizontal support bracket means for supporting the track means,
flag
bracket means for mounting the track means and horizontal support bracket
means to a structural support, and tab means for attaching the track means to
the
horizontal support bracket means and the flag bracket means.
CA 02174580 2005-08-29
wAY.P.US0017
The present invention also provides a related fastening system for
joining components of overhead sectional doors comprising first and second
components to be joined, tab means extending from the first component for
engaging the second component, and tab slot means in the second component for
receiving the tab means of the first component.
According to an aspect of the present invention, there is provided a support
bracket and track assembly for the support of sectional overhead doors
including:
track means for supporting the overhead door sections; horizontal support
bracket
means attached to the track means for supporting the track means; flag bracket
means attached to the track means and the horizontal support bracket means for
mounting the track means and the horizontal support bracket means to a
structural
support; and tab means fox attaching the track means to the horizontal support
bracket means and the flag bracket means.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a jamb bracket according to the present
invention;
Fig. 2 is a rear view, partially in section, of the jamb bracket;
Fig. 3 is a top plan view of the jamb bracket, depicting a track member
in phantom; - ,
Fig. 4 is a side elevation of the jamb bracket;
Fig. 5 is a side view of a track member according to the present
invention with an attached jamb bracket;
Fig. 6 is a sectional view of the track member, taken substantially on
line 6-6 of Fig. 5;
Fig. 7 is a perspective view of an alternate embodiment of jamb
bracket according to the present invention;
fig. 8 is a rear view, partially in section, of the jamb bracket of Fig. 7;
fig. 9 is a top plan view of the jamb bracket of Fig. 7, depicting a track
member in phantom;
.....__~_.k . . . .~,~..,~- ",..~... .. __ . .
CA 02174580 2005-08-29
3A
Fig. 10 is a side elevation ,of the jamb bracket of Fig. 7;
Fig. 11 is a side vi~wi of a track member according to the present
25 invention with an attached jamb bracket of Fig. 7;
Fig.12, is a sectional view of the track member, taken substantially on
line 12-12 of Fig. 11;
Fig. 13 is a perspective view of a support bracket and track assembly
according to the invention;
30 Fig. 14 is an elevational view of a section of the assembly of Fig. 13
taken along the line 14-14;
Fig. 15 is an elevational view of the assembly of Fig. 14 taken along
line 15-15;
2174~8Q
4 WAY.P.U50017
Fig. 16 is a cross-sectional view of the assembly of Fig. 14 taken along
the line 16-16.
Fig. 17 is an exploded perspective view of the assembly of Fig. 14; and,
Fig. 18 is an exploded perspective view depicting the assembly of the
track members to the flag bracket.
PREFERRED EMBODIMENT FOR CARRYING OUT THE INVENTION
A representative embodiment of a jamb bracket according to the
concept of the present invention is generally referred to by the numeral 10 in
the
accompanying drawings. The jamb bracket 10 is manufactured from a thin gauge
metal, preferably a galvanized steel in the range of 16 gauge to 20 gauge. The
.
use of such thin gauge material is facilitated by the U-shaped cross section
of
jamb bracket 10. This U-shaped cross section is defined by an inturned flange
12
and a body 14. Flanges 12 are inturned 90 degrees relative to body 14 and are
in the range of 6 to 20 material thicknesses high. Such a configuration
provides
strength and rigidity without the need for thicker, more heavy materials.
With reference to Figs. 1 and 2 it can be seen that jamb bracket 10 is
bent at a right angle thereby defining a first leg 16 and a second leg 18.
First leg
16 and second leg. 18 are each provided with oblong apertures 15 and 17,
respectively, for reasons which will become apparent as the description
continues. First leg 16 is also provided with tab means, indicated generally
by
the numeral 20. Tab means 20 includes an arcuate first arm 21 and an ear 22.
The arcuate first arm 21 extends perpendicularly from the body 14 and ear 22
extends perpendicularly therefrom and parallel to body 14. Tab means 20 also
provides an arcuate second arm 23 and an ear 24. The arcuate second arm 23
extends perpendicularly from the body 14 and ear 24 extends perpendicularly
therefrom and parallel to body 14. For reasons which will become apparent,
ears
22 and 24 are offset from body 14 by a distance approximating the material
thickness of the track member. Tab means 20 is positioned such that the
arcuate
first arms 21 and 23 face one another and form the partial circumference of a
circle.
Tab means 20 is formed in a conventional manner, such as by stamping
the arms 21 and 23 from first leg 16, leaving a pair of apertures 25, and then
,
WAY.P.US0017
bending the ears 22 and 24 away from each other and perpendicular to arms 21
and 23, respectively.
With reference now to Figs. 5 and 6, a representative embodiment of
a track member according to the concept of the present invention is referred
to
5 generally by the numeral 30. Track member 30 is manufactured from any
appropriate material, preferably a galvanized steel in the range of 16 gauge
to 18
gauge in thickness, and is of a conventional C-shaped cross section to
accommodate the conventional door rollers (not shown). The C-shaped cross
section is defined by a main body 26, a flange 28 and a roller race 32. A
number
of tab slots 34 are included in groups, preferably of three or more at various
locations along the length of the main body 26. Tab slots 34 are primarily
circular in shape with the circumference being interrupted by a pair of
rectangular notches 36. The notches 36 are diametrically opposed from one
another and are perpendicular to the length of the track member 30. The
i5 circumference of tab slot 34 is further interrupted by a pair of flared
stops 38.
Flared stops 38 are formed by a stamping process whereby the material is
flared
inwardly at points opposite one another on the circumference of tab slot 34
and
adjacent to respective rectangular notches 36.
Assembly of the present invention is accomplished first by fastening
together the required track members 30. The number of track members 30 which
are required for a particular installation is dictated primarily by the size
of the
door to be installed. )amb bracket 10 may then be mounted to track member 30.
Mounting is accomplished by first aligning ears 22 and 24 of tabs 20 on the
jamb
bracket 10 with the rectangular notches 36 of tab slots 34 on the track member
30. Once such alignment is accomplished, tabs 20 of jamb bracket 10 may be
inserted into tab slots 34 of track member 30. jamb bracket 10 is then rotated
counter-clockwise 90 degrees relative to track member 30 at which point tabs
20
will engage flared stops 38, thereby preventing further clockwise rotation.
Simultaneously, the arcuate surfaces of first arms 21 and 23 of tab means 20
on
the jamb bracket 10 frictionally engage the inner diameter of.the tab slots 34
of
the track member 30.
As discussed previously, ears 22 and 24 of tab means 20 are offset
from the body 14 of jamb bracket 10 by a distance corresponding to the
material
6
217~~80
6 WAY.P.US0017
thickness of track member 30, as such, first and second ears 22 and 24
frictionally engage the inner surface of track member 30. Thus, the jamb
bracket
is held in locking engagement with track member 30 until sufficient torque is
applied in a clockwise direction to overcome the frictional engagement, and
tab
5 means 20 clears tab slots 34.
Once jamb bracket 10 has been assembled to track member 30, the
assembly rnay be mounted to the door jamb. Attachment of the jamb bracket 10
to the door jamb is accomplished by utilizing first oblong aperture 17 which
receives a conventional fastener such as a lag screw. The lag screw is, in
turn,
10 fastened to the door jamb. First oblong aperture 17 allows for adjustment
of the
jamb bracket 10 and track member 30 relative to the door jamb. further
adjustment of the assembly may be accomplished by moving jamb bracket 10
from one tab slot 34 to another horizontally and vertically offset tab slot
34, the
tab slots 34 being provided at numerous locations on track member 30. The
second oblong aperture 15 is provided on the first leg 16 of jamb bracket 10
so
that a track member may be attached to jamb bracket 10 by conventional means
such as flat or round head bolts. The latter is desirable where the jamb
bracket
is to be used with a conventional track member. In such an instance, tabs 20
may be flattened or, removed so as not to interfere with attachment of the
jamb
bracket 10 to the track member.
A representative embodiment of an alternative embodiment of jamb
bracket according to the concept of the present invention is generally
referred to
by the numeral 40 in the accompanying drawings. The jamb bracket 40 is
manufactured from a thin gauge metal, preferably a galvanized steel in the
range
of 16 gauge to 20 gauge. The use of such thin gauge material is facilitated by
the
U-shaped cross section of jamb bracket 40. This U-shaped cross section is
defined by an inturned flange 42 and a body 44. Flanges 42 are inturned 90
degrees relative to body 44 and are in the range of 6 to 20 material
thicknesses
high. Such a configuration provides strength and rigidity without the need for
thicker, more heavy materials.
With reference to Figs. 7 and 8 it can be seen that jamb bracket 40 is
bent at a right angle thereby defining a first leg 46 and a second leg 48.
First leg
46 and second leg 48 are each provided with oblong apertures 45 and 47,
21~~~8~
7 WAY.P.US0017
respectively. First leg 46 is also provided with tab means, indicated
generally by
the numeral 50. Tab means 50 includes a pair of arms 51 and 52 which are
stamped outwardly from the face 53 of first leg 46 and are joined together in
a
saddle 54. Extending outwardly at generally 90 degree angles from arms 51 and
52 and saddle 54 are a pair of ears, 55 and 56, respectively. As is apparent
from
Figs. 7 and 10, the ears 55 and 56 have a north and south orientation while
the
arms 51 and 52 are oriented to the west and east, respectively. Apertures 57
and
58 are formed in first leg 46 when the ears 55 and 56 are stamped. Although
the
ears 55 and 56 appear flat, it is to be understood that they could be further
formed to bend downwardly or upwardly with respect to face 53 and, that they
could also be curved along the north-south axis to provide a concave face
toward
face 53. For reasons which will again become apparent, ears 55 and 56 are
offset from body 44 by a distance approximating the material thickness of the
track member.
With reference now to Figs. 11 and 12, a representative embodiment
of a track member according to the concept of the present invention is
referred
to generally by the numeral 60. Track member 60 is manufactured from any
appropriate material, preferably a galvanized steel in the range of 16 gauge
to 18
gauge in thickness, and is of a conventional C-shaped cross section to
accommodate the conventional door rollers (not shown). The C-shaped cross
section is defined by a main body 66, a flange 68 and a roller race 72. A
number
of tab slots 74 are included in the main body 66. Tab slots 74 are primarily
circular in shape with the circumference being interrupted along the east-west
axis by a pair of semi-circles 76. The semi-circles 76 are diametrically
opposed
from one another and are perpendicular to the length of the track member 60.
The circumference of tab slot 74 is further interrupted by a pair of flared
stops
78, which are formed at the intersection of tab slot circumference and the
semi-
circles 76 by a stamping process whereby the material is flared inwardly at
points
opposite one another on the circumference of tab slot 74.
Assembly of the present invention is accomplished first by fastening
together the required track members 60. The number of track members 60 which
are required for a particular installation is again dictated primarily by the
size of
the door to be installed. lamb bracket 40 may then be mounted to track member
' ' ~ . 2 ~ ~~58~
8 WAY.P.US0017
60. Mounting is accomplished by first aligning ears 55 and 56 of tabs means 50
on the jamb bracket 40 with the semi-circles 76 of tab slots 74 on the track
member 60. Once such alignment is accomplished, the ears 55 and 56 are
inserted into tab slots 74 of track member 60. Jamb bracket 40 is then rotated
counter-clockwise 90 degrees relative to track member 60 at which point ears
55
and 56 will engage flared stops 78, thereby preventing further clockwise
rotation.
Simultaneously, the raised circumferential regions of arms 51 and 52
frictionally
engage the inner diameter of the tab slots 74. As discussed previously, the
ears
55 and 56 of tab means 50 on the jamb bracket 40 are offset from the body 44
of jamb bracket 40 by a distance corresponding to the material thickness of
track
member 60. Thus, the jamb bracket 40 is held in locking engagement with track
member 60 until sufficient torque is applied in a clockwise direction to
overcome
the frictional engagement, and tab means 50 clear tab slots 74.
Once jamb bracket 40 has been assembled to track member 60, the
assembly may be mounted to the door jamb. Attachment of the jamb bracket 40
to the door jamb is accomplished by utilizing oblong aperture 47 which
receives
a conventional fastener such as a lag screw. The lag screw is, in turn,
fastened
to the door jamb. The oblong aperture 47 allows for adjustment of the jamb
bracket 40 and track member 60 relative to the door jamb. Further adjustment
of the assembly may be accomplished by moving jamb bracket 40 from one tab
slot 74 to another, the tab slots 74 being provided at several locations on
track
member 60. The second oblong aperture 45 is provided on the first leg 46 of
jamb bracket 40 so that a track member may be attached to jamb bracket 40 by
conventional means such as flat or round head bolts. The latter is desirable
where the jamb bracket is to be used with a conventional track member. In such
an instance, tab means 50 may be flattened or removed so as not to interfere
with attachment of the jamb bracket 10 to the track member.
Referring now to Figs. 13-18, a horizontal support bracket according
to the concept of the present invention is referred to generally by the
numeral
80. As shown, horizontal support bracket 80 resembles a conventional angle
bracket, in that it is manufactured from a length of 10-18 gauge steel or
other
appropriate material, bent at a right angle along the entire length thereof to
form
two distinct legs, 82a and 82b. For purposes of discussion, support bracket 80
S
.
9 WAY.P.US0017
will be described with reference to a first end 84 and a second end 86. As can
be seen, support bracket 80 is provided with a plurality (preferably three) of
tab
members 90 in each leg 82 proximate to first end 84 thereof. Tab members 90
are substantially the same as tab means 50 described above with respect to
jamb
bracket 40. Accordingly, each tab member 90 includes a pair of arms 92 and 94
which are stamped outwardly from face 96 of each leg 82 and are joined
together
in a saddle 98. Ears 100 and 102 extend outwardly at generally 90-degree
angles
from arms 92 and 94, respectively. Apertures 104 and 106 are formed in legs 82
when ears 100 and 102 are stamped. For reasons which will become apparent,
ears 100 and 102 are offset from face 96 of legs 82 by a distance equal to or
slightly greater than the material thickness of the horizontal track member
yet to
be described. It should be recognized that ears 100 and 102, while oriented
generally parallel to face 96, may be flat, concave, or otherwise angled with
respect to face 96. In fact, it is preferred, for reasons which will become
apparent, to slightly angle ears 100 and 102.
One or more conventional fastener apertures 108 are provided in each
leg 82 of bracket 80 proximate to second end 86. Apertures 108 may include a
combination of oblong apertures, as well as square or round apertures. The
number, shape, placement, and spacing of apertures 108 rnay vary according to
the application, it being desired only to provide a maximum number for
adaptability to mounting conditions. As is perhaps most apparent in Fig. 13,
tab
members 90 and fastener apertures 108 are located in each leg 82 directly
opposite corresponding tab members 90 or fastener apertures 108 in the other
leg 82. As such, each leg 82 is a mirror image of the other leg 82.
A track assembly adapted for use with the above-described support
bracket 80 is designated generally by the numeral 110. Track assembly 110
includes a horizontal track member 112 and a vertical track member 114. Track
members 112 and 114 are both of a conventional C-shaped cross-section like
that
described with respect to track members 30 and 60 above.
Horizontal track member 112 includes a straight portion 116 and a
curved portion 118. Straight portion 116 is characterized by a plurality of
slotted
tab apertures 120 located proximate to curved portion 118. Each slotted tab
aperture 120 is defined by a north-south oriented oblong portion 122 which is
217~~80
1 O WAY.P.US0017
intersected by an east-west oriented oblong portion 124 to form a generally T-
shaped aperture. The number and location of tab apertures 120 corresponds to
the number and location of tab members 90 on support bracket 80. That is, if
support bracket 80 includes three tab members 90, track member 112 should
include at least three tab apertures 120a, 120b, and 120c. Likewise, the
spacing
of tab apertures 120 should correspond to the spacing of tab members 90 such
that the center spacing of tab members 90 is equal to the center spacing of
north-
south oriented oblong portions 122 of apertures 120. Similarly, the length of
oblong portion 122 should correspond to the distance between the tips of ears
100 and 102 of tab members 90, while the width of oblong portions 124
corresponds to the width of arms 92 and 94 of tab members 90. At the end 126
of track member 112 proximate to curved portion 118, track member 112 is
provided with an additional slotted tab aperture 120d (Fig. 16) and may
further
be provided with one or more conventional fastener apertures 128.
Vertical track member 114 is a generally straight conventional track
section adapted to abut end 126 of horizontal track member 112. A tab aperture
130 similar to tab slots 24 described above with respect to track member 60 is
provided in track member 114 at one end 132 thereof. Tab aperture 130 is
generally circular in shape with the circumference thereof being interrupted
along the east-west axis by a pair of diametrically opposed semi-circles 134.
A flag bracket according to the concept of the invention is designated
generally by the numeral 140. Flag bracket 140 is substantially similar to
conventional flag brackets used for mounting a track assembly to a structural
support. As such, flag bracket 140 is bent at a right angle along the length
thereof to form a structural mounting flange 142 and a track supporting flange
144. Flange 142 is provided with a plurality of fastener apertures 146 which
may
be round, square, or of an oblong shape, as shown. Track supporting flange 144
is defined by a horizontal bracket mounting portion 148 and a track member
mounting portion 150. Horizontal bracket mounting portion 148 includes one
or more conventional fastener apertures 152, proximate to a first end 154 of
flag
bracket 140. Track member mounting portion 150 is characterized by a pair of
tab members 90d and 90e which extend outwardly from face 156 thereof,
proximate to a second end 158 of bracket 140. As is best shown in Fig. 18, tab
WAY.P.US0017
member 90d has its ears 100 and 102 oriented east and west, respectively. Tab
member 90e is spaced directly below tab member 90d but is rotated 90 degrees
relative thereto so that its ears 100 and 102 are oriented north and south,
respectively.
Assembly of horizontal support bracket 80, track assembly 110, and
flag bracket 140 is accomplished by first aligning tab member 90e with tab
aperture 130 of vertical track member 114, as shown in Fig. 18. Accordingly,
semi-circles 134 of tab aperture 130 are aligned to receive ears 100 and 102
of
tab member 90e. Track member 114 may then be rotated counterclockwise 90
degrees to the position shown in Fig. 13. Slotted tab apertures 120d of track
member 112 may then be aligned with tab member 90d of flag bracket 140, as
shown in Fig. 18. As such, ears 100 and 102 of tab member 90d may be passed
through the oblong portion 122 of aperture 120d. Track member 112 may then
be slid downward relative to flag bracket 140 to seat against track member
114,
as shown in Fig. 13. Tab members 90a, 90b, and 90c of horizontal support
bracket 80 may be similarly aligned with slotted tab apertures 120a, 120b, and
120c, respectively, of track member 112, as shown in Fig. 17. Support bracket
80 may then be slid toward the flag bracket 140 so that tab members 90 are
seated in apertures 120, as shown in Figs. 14 and 15. Support bracket~80 may
then be affixed to flag bracket 140 by way of a conventional fastener 160
which
engages apertures 108 and 152 of support bracket 80 and flag bracket 140,
respectively. The entire assembly may then be mounted to a structural support
by affixing flag bracket i 40 to the support using conventional fasteners.
It should now be apparent to those skilled in the art that the brackets
and track assembly of the invention allow the component parts to be assembled
quickly and sturdily in the field prior to final adjustment. It should further
be
recognized that tab members 90, tab apertures 130, and slotted tab apertures i
20
may be provided at other locations and on other components. For example, a
jamb bracket such as that described above could be adapted to engage a track
member and hanger means to support the track member from overhead. Further,
the provision of conventional fastener apertures 128, 146, and 152 allows the
component parts to be utilized in a conventional manner.
~~7~~80
WAY.P.U50017
Thus it should be clear, to those skilled in the art, the manner in which
the jamb bracket and track assembly described herein is constructed, assembled
and used. It should also be clear that the jamb brackets 10 and 40 are novel
and
may be utilized with the track member 30 and 60, respectively, of this
invention
as well as existing track members.
Based upon the foregoing disclosure, it should now be apparent that
the use of the assembly described herein will carry out the objects set forth
hereinabove. It should also be apparent to those skilled in the art that the
jamb
bracket and track assembly can be utilized in conjunction with various types
of
overhead sectional doors.
Although approximate thicknesses have been disclosed for the
materials, none of the ranges should be interpreted as limiting. It is
believed that
those skilled in the art can determine the materials and sizes that will be
most
useable from the total specification disclosure provided herein.
'S It is, therefore, to be understood that any variations evident fall within
the scope of the claimed invention and thus, the selection of specific
component
elements can be determined without departing from the spirit of the invention
herein disclosed and described. Moreover, the scope of the invention shall
include al! modifications and variations that may fall within the scope of the
attached claims.
