Note: Descriptions are shown in the official language in which they were submitted.
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LOW HEADROOM CURTAIN RISER FOR A ROLL-UP DOOR,
AND ROLL-UP DOOR USING THE SAME
TECHNICAL FIELD
[0001] The present disclosure relates to the field of door systems.
More specifically, the present disclosure relates to low headroom curtain
riser
for a roll-up door and to a roll-up door having the low headroom curtain
riser.
BACKGROUND
[0002] Roll-up doors offer wide flexibility in terms of sizes and the
capability of undergoing large numbers of fast opening and closing cycles in a
single day. They are used, predominantly in commercial and industrial
applications. These doors usually comprise a large curtain made of a flexible
material, for example rubber, supported by guides on each side of a door
frame.
[0003] US Patent Publication no 2013/0158313 Al, dated June 12
2014, to McTavish et al., discloses a deformable lateral guide for a roll-up
door
having a curtain whose edges are configured for operation with a deformable
lateral guide. An embodiment of the deformable lateral guide is shown on
Figure 1, which is a top cross-sectional view of a vertical side strip of a
door
curtain interacting with a vertical guide. A vertical guide 10 is adapted to
operate with a vertical side strip 12 attached to a side edge of a curtain 14.
The
vertical guide 10 comprises a first vertical guide portion 16 and a second
vertical guide portion 18 having respective series of threaded holes 20 and 22
for attachment to a doorway frame (not shown) using bolts such as 24. In a
particular embodiment, the first vertical guide portion 16 has a thinner cross-
section 26 when compared to a cross-section 28 of the second vertical guide
portion 18.
[0004] The first vertical guide portion 16 is biased against a series of
cylindrical, inner projections 30 of the second vertical guide portion 18 by a
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biasing element, for example a series of springs 32. Each cylindrical
projection
30 is threaded on its internal surface.
[0005] The first vertical guide portion 16 comprises a non-threaded
hole 34 in alignment with the cylindrical projection 30. Each spring 32 is
mounted onto a bolt 36 between an outer surface 38 of the first vertical guide
portion 16 and a head 40 of the bolt 36. The bolt 36 is threaded into the
internally threaded cylindrical projection 30 through the hole 34.
[0006] In normal operation, the springs 32 maintains the first vertical
guide portion 16 in a rest position against the projection 30 of the second
vertical guide portion 18, as shown on Figure 1. While in the rest position,
the
first vertical guide portion 16 forms, with the second vertical guide portion
18, a
longitudinal slot 42 for receiving a link 44 of the vertical side strip 12
between a
U-shaped longitudinal portion 46 attached to the curtain 14 and a generally
trapezoidal longitudinal rib 48.
[0007] Under excessive wind load or impact conditions, the vertical
guide 10 is deformed by moving the first vertical guide portion 16 away from
the second vertical guide portion 18, compressing the springs 32, thereby
widening the longitudinal slot 42 to allow the longitudinal rib 48 first, and
then a
shifted wall section 50, to pass through the longitudinal slot 42 to release
the
vertical side strip 12 from the vertical guide 10. The predetermined threshold
for releasing the vertical side strip 12 under excessive wind load or under
impact may be adjusted by proper selection of material for making the vertical
guide 10, by proper selection of the geometry, thickness and size
configurations of the various elements of the vertical guide 10, and by a
number and a level of resilience of the springs 32.
[0008] Roll-up doors may be at once quite wide and high. When rolled
up and wrapped around a horizontal rod, tube or like elongated structure,
their
curtains form a thick roll that, together with mechanical structures designed
for
holding and rolling up and down the curtains, occupies significant space above
the open door frame, usually underneath a ceiling or underneath some other
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overhead infrastructure. In the particular case illustrated in Figure 1, a
thickness of the roll is to a large extent determined by overlap of the
vertical
side strip 12, especially at the longitudinal rib 48 and at the shifted wall
section
50. The vertical space, called headroom, that is available between the top of
the door frame and the ceiling or other overhead infrastructure is oftentimes
quite limited.
[0009] Therefore, there is a need for a low headroom roll-up door
system.
SUMMARY
[0010] According to the present disclosure, there is provided a roll-up
door. The door includes a curtain, a pair of lateral guides configured to hold
sides of the curtain when lowered, and a horizontal member on which the
curtain can be rolled when raised. A front edge of the horizontal member is
aligned with a path formed by the lateral guides so that a top end of the
curtain
is tangent to the horizontal member when the curtain is fully lowered.
[0011] The present disclosure further relates to a low headroom
curtain riser for a roll-up door having a curtain and a pair of lateral guides
for
the curtain. The curtain riser includes a horizontal member on which the
curtain
can be rolled when raised. A front edge of the horizontal member being aligned
with a path formed by the lateral guides so that a top end of the curtain is
tangent to the horizontal member when the curtain is fully lowered.
[0012] The foregoing and other features will become more apparent
upon reading of the following non-restrictive description of illustrative
embodiments thereof, given by way of example only with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Embodiments of the disclosure will be described by way of
example only with reference to the accompanying drawings, in which:
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[0014] Figure 1 is a top cross-sectional view of a vertical side strip of
a door curtain interacting with a vertical guide;
[0015] Figure 2 is a rear elevation view of a door frame on which a
roll-up door is to be mounted;
[0016] Figure 3 is a rear elevation view of a roll-up door according to
an embodiment;
[0017] Figure 4 is a rear perspective view of the roll-up door of Figure
3;
[0018] Figure 5 is a side elevation view of the roll-up door of Figure 3;
[0019] Figure 6 is a top view of the roll-up door of Figure 3;
[0020] Figure 7 is a cross-sectional, side elevation view of the roll-up
door of Figure 3;
[0021] Figure 8 is a detailed view from Figure 7, showing an
interaction of a roll-up curtain with a horizontal member and
with a curtain deflector;
[0022] Figure 9 is a detailed, cross-sectional view taken along line B-
B of Figure 7, showing an interaction of the roll-up curtain with
a lateral guide; and
[0023] Figure 10 is a detailed view of the bottom of the roll-up door of
Figure 3.
[0024] Like numerals represent like features on the various drawings.
DETAILED DESCRIPTION
[0025] Various aspects of the present disclosure generally address
one or more of the problems related to the low amount of available headroom
for installation of roll-up door systems.
[0026] In conventional roll-up doors, an idler aligns a flexible curtain
of the door in its path as it moves up and down between a pair of lateral
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guides. This idler takes up significant headroom.
[0027] In an embodiment of the present disclosure, the idler is
removed. The curtain is roll-up on a horizontal member positioned lengthwise
above a frame of the door, higher than a top of the opening of the door frame.
A front edge of the horizontal member is generally aligned with a path of the
curtain formed by the lateral guides so that a top end of the curtain is
tangent
to the horizontal member when fully lowered. This configuration allows the
door to operate without any idler, thereby reducing the required headroom
between the top of the door frame and the ceiling or other overhead structure.
When fully raised, the curtain is rolled onto the horizontal member.
Evidently, a
combination of the horizontal member and of the rolled curtain has a larger
diameter than a diameter of the horizontal member. A curtain deflector
positioned at a forward angle from a top of the lateral guides and slightly
lower
than a rolling axis of the horizontal member ensures that the curtain is
directed
toward the lateral guides as it is lowered.
[0028] The curtain may be terminated at its bottom by a horizontal
bottom bar that can be retrieved fully between the horizontal member and the
curtain deflector when the curtain is fully raised. In this way, the
horizontal
bottom bar can be fully hidden as seen from outside of the door, completely
freeing the open space of the door frame when the door is rolled up. This
configuration does not add to the required headroom.
[0029] Referring now to the drawings, Figure 2 is a rear elevation
view of a door frame on which a roll-up door is to be mounted. A door frame 60
is formed of two (2) vertical studs or beams 62 and a top, horizontal stud or
beam 64. As shown, the vertical beams 62 extend beyond a height of an open
area 66 formed within the door frame 60. This height extension of the vertical
beams 62 provide an available headroom 68 where a riser system for the roll-
up door can be installed. Without limitation, the headroom 68 as shown
measures 330.20 mm, or 13 inches. Generally, the construction of the door
frame 60 as well as its measurements, including the shown width (152.40 mm)
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of the vertical beams 62, do not impact the teachings of the present
disclosure.
The beams 62 and 64 may be substituted by edges of a wall. Details of the
door frame 60 are provided for purposes of illustration and do not limit the
present disclosure.
[0030] Figure 3 is a rear elevation view of a roll-up door according to
an embodiment. Figure 4 is a rear perspective view of the roll-up door of
Figure 3. Figure 5 is a side elevation view of the roll-up door of Figure 3.
Figure 6 is a top view of the roll-up door of Figure 3. Referring at once to
Figures 3, 4, 5 and 6, a roll-up door 100 can be mounted on the door frame 60.
In an embodiment, the roll-up door 100 is configured so that the open area 66
of the door frame 60 is fully cleared when the roll-up door 100 is fully
opened.
[0031] The roll-up door 100 comprises a curtain 102, a pair of lateral
guides 104 configured to hold sides of the curtain 102 when lowered, and a
curtain riser 106. The curtain riser 106 includes a standard motorized drive
108
operably connected to a horizontal member 110 on which the curtain 102 can
be rolled when raised. The horizontal member 110 may for example comprise
a hollow tube, a rod, or the like, and generally has a circular cross-section
to
facilitate rolling of the curtain 102. The curtain 102 may terminate on a
lower
horizontal bar 112.
[0032] As best seen on Figure 6, the motorized drive 108 is mounted
to a frame 116 of the curtain riser 106 by use of bolts 118. The horizontal
member 110 is also supported by the frame 116, projections 111 at both ends
of the horizontal member 110 being received in bearings 117 mounted at both
lateral ends of the frame 116. The motorized drive 108 includes a sprocket 120
driving a chain 122 that in turn engages a sprocket 124 mounted to one of the
projections 111 of the horizontal member 110, for rising and lowering the
curtain 102. A further sprocket 126 may be mounted to the motorized drive 108
for mounting thereon a chain (not shown) allowing operation of the roll-up
door
100 in case of a power failure. A controller 128 of the motorized drive 108
controls rising and lowering operations of the curtain 102. One or more
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sensors (not shown), including without a motion sensor or a photocell provide
signals to the controller 128 for safe operation of the roll-up door 100.
[0033] The roll-up door 100 and its components further include
various details such as bolts and other attachments, braces, and the like.
These are believed to be self-explanatory and do not require additional
detailed explanation.
[0034] In an example of realization, the curtain 102 may be a
laminated curtain comprising layers of various materials, for example flexible
recycled rubber material or similar material, and woven or non-woven
fiberglass or nylon fibers, the layers being appropriately adhered to each
other
using a suitable adhesive to form the laminated curtain 102. Suitable
adhesives may comprise, without limitation, silicone, styrene, polyurethane,
isocyanate, organic adhesives, polymers, acrylics, epoxies, hot melts, and the
like. The lateral guides 104, the curtain riser 106 and its frame 116 as well
as
the horizontal member 110 may be manufactured using a variety of materials
including, without limitation steel, for example regular high grade steel such
as
grade W44 steel, aluminum, chromadium, and the like. Distinct materials may
be used for distinct parts of the roll-up door 100.
[0035] Figure 7 is a cross-sectional, side elevation view of the roll-up
door of Figure 3. Figure 8 is a detailed view from Figure 7, showing an
interaction of a roll-up curtain with a horizontal member and with a curtain
deflector. As best seen on Figure 8, a radius 130 of the horizontal member 110
as well as its position within the curtain riser 106 are selected so that a
front
edge 132 of the horizontal member 110 is substantially aligned with a path 134
of the curtain 102 formed by the lateral guides 104. A top end 136 of the
curtain 102 is substantially tangent to the horizontal member 110 when fully
lowered.
[0036] Also shown on Figures 7 and 8, a curtain deflector 138 may be
mounted above an opening of the frame 60, more specifically at or above a
level of a bottom edge 140 of the horizontal beam 64 of Figure 2. The curtain
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deflector 138 is mounted within the curtain riser 106, inclined at a forward
angle in relation to a top end 142 of the lateral guides 104. In the context
of the
present disclosure, the expression 'forward angle' is meant to express that
the
curtain deflector 138 is angled toward the exterior side of the roll-up door
100,
in relation to the top end 142 of the lateral guides 104 extends. At least a
major
part of the curtain deflector 138 is at a position lower than a rolling axis
of the
horizontal member. One function of the curtain deflector 138 is to direct the
curtain 102 as it moves between the lateral guides 104 and an outer diameter
144 formed by partial rolling of the curtain 102 onto the horizontal member
110.
[0037] Space 145 is provided between the horizontal member 110
and the curtain deflector 138 so that the horizontal bar 112 may be retrieved
between the horizontal member 110 and the curtain deflector 138 when the
curtain 102 is fully raised. Otherwise stated, when the outer diameter 144
reaches its maximum because of complete rolling of the curtain 102 on the
horizontal member, there is still sufficient space 145 between the curtain
deflector 138 and this maximum outer diameter 144 for receiving the horizontal
bar 112. In this manner, the horizontal bar 112 rises above the bottom edge
140 of the horizontal beam 64 so that the open area 66 of the door frame 60 is
completely unobstructed.
[0038] Of course, for applications that do not require that the open
area 66 be entirely unobstructed, the curtain riser 106 and the curtain
deflector
138 may be configured differently, for example allowing the horizontal bar 112
to hang at a position lower than the bottom edge 140 of the horizontal beam 64
when the curtain 102 is fully raised.
[0039] As an example of a particular configuration that does not limit
the present disclosure, a curtain 102 extends to a height of 9 feet and 6
inches
(114 inches). The maximum thickness of the curtain 102 at its edges (see
Figure 1) in on the order of about one (1) inch. The horizontal member 110 is
a
tube having 6 inches in diameter, for a circumference of about 18.8 inches.
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Rolling up the curtain 102 forms six (6) layers on the tube, given its
circumference, adding no more than 7 inches to the diameter of the tube, for a
total outer diameter 144 not exceeding 13 inches. Using a larger tube, with a
diameter of 8 inches, for a circumference of about 25.1 inches, rolling the
full
curtain forms 4.5 layers on the tube, adding no more than 5 inches to the
diameter of the tube, for a total outer diameter 144 not exceeding 13 inches.
In
both cases, a 13-inch headroom is sufficient for installing the curtain riser
106.
A 6-inch tube can accommodate a curtain 102 having a width up to 21 feet
while an 8-inch tube can accommodate a curtain 102 having a width up to 40
feet. Of course, other configurations may be used, for other door dimensions
and for other available headroom values.
[0040] In the above examples, a suitably configured horizontal bar
112 can be hidden in the space 145 between the curtain deflector 138 and the
horizontal member 110.
[0041] Figure 9 is a detailed, cross-sectional view taken along line B-
B of Figure 7, showing an interaction of the roll-up curtain with a lateral
guide.
In a variant of the present disclosure as shown on Figure 9, the lateral
guides
104 may be deformable in a manner as taught in US Patent Publication no
2013/0158313 Al. The lateral guides 104 (one of which is shown) are mounted
on the frame 60, on internal faces of the beams 62 using suitable fasteners
(not shown), for example nails, screws or bolts. Each lateral guide 104
comprises two (2) complementary vertical guide portions 146 and 148,
connected by a series of bolt and nut assemblies 150 and forming an
elongated slot 152. Edges 154 of the curtain 102 are releaseably mounted to
the lateral guides 104 via the elongated slots 152. In this variant, the
curtain
102 may be released from one or both of its lateral guides 104 upon
application thereon of a force exceeding a predetermined threshold. When
compared to the vertical guide 10 of Figure 1, the lateral guides 104 are
simpler. This simplification is facilitated by the fact that the curtain 102
moves
up and down without significant tension, being directed in its path 134 by the
configuration of the curtain riser 106. This configuration of the lateral
guides
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104 in combination with the curtain riser 106 allows operation of the roll-up
door 100 without the use of an idler.
[0042] Figure 10 is a detailed view of the bottom of the roll-up door of
Figure 3. At its center, the lower horizontal bar 112 includes a pair of
horizontal
elongated L-shaped plates 156 terminating a lower end of the curtain 102. The
plates 156 are connected via a hinge 158 and a middle plate 160. Connection
of the middle plate 160 to ends of the plates 156 is made via shear pins 162.
In
case of impact on the curtain 102, the shear pins 162 will break, allowing the
lower horizontal bar 112 to fold at the hinge 158, one of both edges 154 of
the
curtain 102 being released from the lateral guides 104. To reengage the
curtain, an operator simply needs to raise the curtain 102 and reinsert the
lower horizontal bar 112 in place between the horizontal member 110 and the
curtain deflector 138. A deflection 164 at the top of the lateral guides 104
(see
Figures 7 and 8) facilitates reinsertion of the horizontal member 110. The
shear pins 162 should be replaced after lowering of the curtain.
[0043] Those of ordinary skill in the art will realize that the
description
of the door and of the curtain riser are illustrative only and are not
intended to
be in any way limiting. Other embodiments will readily suggest themselves to
such persons with ordinary skill in the art having the benefit of the present
disclosure. Furthermore, the disclosed door and curtain riser may be
customized to offer valuable solutions to existing needs and problems related
to limited available headroom for installation of roll-up door systems.
[0044] In the interest of clarity, not all of the routine features of the
implementations of the door and of the curtain riser are shown and described.
It will, of course, be appreciated that in the development of any such actual
implementation of the door and of the curtain riser, numerous implementation-
specific decisions may need to be made in order to achieve the developer's
specific goals, such as compliance with application-, system-, and business-
related constraints, and that these specific goals will vary from one
implementation to another and from one developer to another. Moreover, it will
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be appreciated that a development effort might be complex and time-
consuming, but would nevertheless be a routine undertaking of engineering for
those of ordinary skill in the field of door systems having the benefit of the
present disclosure.
[0045] The present
disclosure has been described hereinabove by
way of non-restrictive, illustrative embodiments thereof. These embodiments
may be modified at will. The scope of the claims should not be limited by the
embodiments set forth in the examples, but should be given the broadest
interpretation consistent with the description as a whole.
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