OVERHEAD DOOR SYSTEM

TECHNICAL FIELD

The disclosure pertains to the field of overhead door systems. The present invention relates to an overhead door system having a track arrangement with parallel support tracks.

BACKGROUND OF THE INVENTION

Overhead doors systems to provide access for large objects, such as vehicles, to a building due to them being able to seal of relatively large entrances to a comparatively low cost.

Overhead door systems generally comprises a door blade which may comprise a plurality of interconnected door elements/panels or a single solid element/panel. Such overhead door systems may be manually operated or automated by means of a motor arrangment driving the movement of the door blade.

To allow for the vertical movement of the door element the door system is provided with tracks for receiving wheels of a carrier attached to the door element. The tracks has both vertical and horizontal sections connected by a connecting section for guiding the movement of the door element from a vertical position, i.e. a closed position, and a horizontal position, i.e. an opened position.

Due to the movement and vibrations of the door during operation as well as dimension tolerances in the overall overhead door system, the wheels of the carrier has to be able to move in the tracks so as to accommodate play. The achieved play thus safeguard the functionality of the door. In the prior art the required play has been achieved by the track constituting a groove for receiving the wheel of the carrier, the groove being slightly larger than the wheel so as to allow for transversal movement. Further the interfacing surfaces of the wheels and the track may be correspondingly rounded while the shafts connecting the wheels to the part of the carrier attached to the door element are dimensioned so as to allow the wheels and shafts to incline even with the wheel being disposed inside the groove of the track.

However such an arrangement results in a large play being achieved, due to the wheels having a large angular degree of freedom inside the groove. This may lead to the wheels ending up in undesirable positions due to vibrations and movement of the door element which negatively affects both the noise generated by the door system and the function.

SUMMARY

An object of the present disclosure is to provide a method and a device which seek to mitigate, alleviate, or eliminate one or more of the above-identified deficiencies in the art and disadvantages singly or in any combination.

According to an aspect an overhead door system for covering a door opening is provided. The overhead door system comprises a door blade, the door blade being movable between a vertical closed position and a horizontal, opened or overhead position within a side frame comprising a pair of vertical tracks and a pair of horizontal tracks, connected by a pair of connecting track portions.

At least one of the tracks of the pair of tracks, in the form of any one of the pair of vertical tracks, the horizontal tracks and the connecting track portions, comprises an outer track section and an inner track section extending parallel along the track. The overhead door system comprises a guiding arrangement attached to the door blade. The guiding arrangement comprises an outer roller and an inner roller disposed parallel to each other. The outer and inner roller are connected to a shaft of the guiding arrangement. The shaft is arranged to extend outwardly from the door blade in a horizontal direction. The outer track section and the inner track section are arranged to receive the outer roller and the inner roller, respectively.

In one embodiment, the outer track section, the inner track section, the outer roller and the inner roller are arranged to allow inclination of the door blade relative a movement plane extending along the track in an angle of play (b) relative a horizontally extending inclination axis perpendicular to the track. BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particular description of the example embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the example embodiments.

Fig. 1 illustrates an exemplary overhead door system comprising a track arrangement according to one embodiment. Fig. 2a-b depicts a schematic cross-section of a track arrangement as known in the prior art.

Fig. 3a-b depicts a schematic cross-section of a track arrangement of an overhead door system according to one embodiment.

Fig. 4 depicts a schematic door blade and track arrangement according to one embodiment

Fig. 5a-b depicts a schematic cross-section of a track arrangement of an overhead door system according to one embodiment.

DETAILED DESCRIPTION

Present invention relates to an overhead door system comprising a track arrangement allowing for a less noisy operation of the door and a more predictable opening and closing movement. Fig. 1 shows a schematic front view of a first embodiment of an overhead door 10 with the features of the invention in a closed state. The overhead door 10 has a door blade 1 1 for covering a door opening, running in a side frame. In the shown example, the door blade 1 1 covers a door opening surrounded double-sided by a wall 12and by a ceiling above. The side frame has double-sided a vertical track 13, provided as a guiding element on the left and on the right side of the door blade 1 1 , respectively. Further, the side frame has double-sided a horizontal track 14. The horizontal track 14 runs transversely, in this execution example perpendicular to the vertical track 13, extending rearward to the door blade 1 1. A connecting portion 15 with a curved shape connects the vertical track 13 and the horizontal track 14, providing a guideway 16. The horizontal tracks 14 of the side frame are fixed at a rear side under the ceiling. At a front side the horizontal tracks 14 are fixed at the vertical tracks 13 of the side frames, respectively. Accordingly, the overhead door system comprises a pair of vertical tracks 13 and a pair of horizontal tracks 14 connected by a pair of connecting track portions 15. Guiding arrangements 70 are attached to the door blade 1 1 for interfacing with the tracks. In one embodiment, the door blade 1 1 comprises a plurality of panels 17. The shown door blade 1 1 comprises four panels 17, consisting of a rigid material. To provide a better overview, reference signs are only attached to two panels 17. The height of the panels 17 may be between 150 and 1000 millimeters. The height of the panel may for example vary from 400 millimeters from 675 millimeters, making it possible to suit the door’s style to that of the building. As the skilled person recognizes, the panels may be of any size suitable for the application of the overhead door system.

At least one of the panels 17 are connected to a driving member 8 connected to a motor 25 for operating the door blade 1 1 along the tracks.

In one embodiment, one of the topmost panels 17 may be connected to the motor 22 by means of a lifting arm 8. Said lifting arm 8 is arranged to transfer the torque from the motor 25 to one of the panels 17 to pull and push the door blade along the tracks. With reference to Fig. 1 , the lifting arm 8 is connected to the topmost panel 17.

In one embodiment, the driving member may be a driven belt. Accordingly, one belt connects end pieces of the panels 17 on both sides of the panels 17, respectively. Thereby the belt works as a lifting device and as a hinge between the panels 17. The belt runs in vertical direction in a slot 19 on both sides of the vertical track 13 of the side frame, respectively. The belts 20 may be constructed as flexible, flat belts. The motor 25 may be connected to a belt drive for operating the cable. The motor 25 may be connected to a gear box for transferring torque from the motor 25 to the belt drive.

In one embodiment, the driving member may be a cable, preferably in steel. The cable connects to at least one of the panels 17. Thereby the cable works as a lifting device. Further, one cable may connect end pieces of the panels 17 on both sides of the panels 17, respectively. The cable may run in vertical direction in a slot on both sides of the vertical track 13 of the side frame, respectively. The motor 25 may be connected to a cable drum for operating the cable. The motor 25 may be connected to a gear box for transferring torque from the motor 25 to the cable drum.

In one embodiment the belt or cable may only be connected to the bottommost panel of the door blade 1 1. Hence the door blade is lifted by means of the belt or cable working as a lifting device for lifting the bottommost panel of the door blade 1 1 and consequently lifting the entire door blade by means of the lifting force applied to said bottommost panel.

Referencing to Fig. 2 a cross-section view of track arrangement known from the prior art is shown. In this example the cross-section of a track, which may be a horizontal, vertical or connecting track, comprises a guiding groove 1 16. The guiding groove 1 16 receives a guiding roller 162 which is connected to the door leaf via a roller shaft 161 which may be a fixed shaft.

The guiding groove 1 16 has upper and lower phases 1 17, 1 18 extending along the direction of movement of the roller, i.e. along the length of the vertical, horizontal or connecting track. To allow for the play required for the movement of the door leaf the guiding groove 1 16 is provided with an aperture 191 allowing for the shaft 161 and the roller 162 to incline while the roller is disposed in the guiding groove 1 16. As depicted in Fig. 2b the roller 162 and shaft 161 may incline along an angle of play b1 as limited by the groove 1 16 and the aperture 191. Said angle b1 allows for the play necessary for the movement of the door blade. However the angle b1 may become relatively large. A large angle of play is associated with significant movement of the shaft and roller and consequently the door blade, resulting in increased noise as well as unpredictable movement. The angle b1 in such an arrangement may traditionally be up to 7 degrees.

Fig. 3a-b depicts a track arrangement for achieving a more silent and predictably moving overhead door system. In the figure one of the tracks of the pair of vertical tracks 13 is depicted. The track may however be at least one of the tracks of the pair of tracks in the form of any one of the pair of vertical tracks, the horizontal tracks and the connecting track portions. The track 13 comprises an outer track section 97 and an inner track section 98 extending parallel along said track 13.

The overhead door system comprises the guiding arrangement 70 which may be attached to the door blade 1 1. To enable the opening and closing motion of the door blade 1 1 , the guiding arrangement 70 comprises an outer roller 62 and an inner roller 63 disposed parallel to each other, the outer roller 62 and the inner roller 63 being connected to a shaft 61 of the guiding arrangement 70. As seen in said figures the outer roller 62 and inner roller 63 are disposed at a distance from each other along the shaft 61.

The shaft 61 is arranged to extend outwardly from the door blade 12 in a horizontal direction. The outer track section 97 and the inner track section 98 are arranged to receive the outer roller 62 and the inner roller 63, respectively. In one embodiment, the guiding arrangement 70 comprises a door mounted portion (not shown) for receiving the shaft 61. In one embodiment, the shaft 61 is fixed. Hence, said door mounted portion is arranged to fixate the shaft 61.

Further referencing Fig. 3a-b the outer track section 97, the inner track section 98, the outer roller 62 and the inner roller 63 are arranged to allow inclination of the door blade 1 1 relative a movement plane extending along the track 13 in an angle of play b relative a horizontally extending inclination axis A perpendicular to the track 13. The angle of play b may be a negative angle extending upwards from the inclination axis A or a positive angle extending downwards from the inclination axis A. The angle of play b may accordingly vary in an interval defined by a minimum negative angle and a maximum positive angle. Preferably the minimum negative angle and the maximum positive angle are of substantially the same size, i.e. have the same absolute value.

The double roller and track section still allows for the play necessary to ensure the movement of the door blade 1 1 , however the angle of play b may be reduced substantially due to the dual rollers abutting to the dual track sections. For example, the angle of play may for example be a maximum of approximately 5 degrees and more preferably 3 degrees. Accordingly, the angle of play b may not exceed 5 degrees and not fall below -5 degrees. More preferably the angle of play b may not exceed 3 degrees and may not fall below -3 degrees.

Compared to a conventional manner to reduce the play in an overhead door system the arrangement according to the invention enables a lower degree of play without requiring complex alteration of the tracks. Such alteration may include implementing complex track geometries or optimization of angles, trajectory etc., which may time-consuming and complex to develop and implement.

In one embodiment, the track 13 is a closed-off track, i.e. a track wherein the inner track section 97 and the outer track section 98 substantially surround the outer roller 62 and the inner roller 63. The track 13 is substantially C-shaped with sections extending so as to form the outer track section 97 and the inner track section 98. The outer track section 97 is formed by the outer track section upper phase 88 and the outer track lower phase 87 extending parallel to each other along said outer track section 97. Correspondingly, the inner track section 97 is formed by an inner track section upper phase 90 and an inner track section lower phase 89 extending parallel to each other along said inner track section 98. To allow for door blade to incline in the angle of play, the outer track section upper and lower phase 88, 87 and the inner track section upper and lower phase 90, 89 are arranged to provide a clearing distance to a peripheral phase of the inner and outer roller 62, 63, respectively.

The clearing distance extends in a direction extending between the upper and lower phases of the outer track section 97 and the inner track section 98. As is recognizable by the skilled person, the distance between the peripheral phases of the rollers and the lower and upper phases of the track section varies during the movement of the door blade. Hence, the clearing distance may be defined as the distance between the phase of the roller and one of the upper or lower phase of the track section when the phase of the roller is in contact with the remaining of one of the phase of the track section.

Notably, the upper and lower phases may extend parallel to each other in a vertical direction, a horizontal direction or in an arc extending from a vertical direction to a horizontal direction depending on if the track is a vertical track, horizontal track or a connecting track portion.

The lower phase 87 and the upper phase 88 of the outer track section 97 extend along said outer track section 97. Similarly the lower phase 89 and the upper phase 90 of the inner track section 98 extend along said inner track section 98. Both the lower phases and upper phases of the track sections are adapted to be in contact with the rollers during the opening and closing movement of the door blade 1 1. Hence the outer roller 62 and the inner roller 63 may alternate between being in rolling contact with the upper and lower phases of the track sections during the opening and closing movement of the door blade 1 1.

In one embodiment, the inner roller 63 and the outer roller 62 are arranged to be in relation to the shaft 61 , whereby it is possible for the rollers to interface with opposite phases of the track sections at the same time. Hence, the inner roller 63 and the outer roller 62 may be connected to the shaft 61 by means of bearings. In one embodiment, the peripheral phase of outer roller 62 is substantially rounded. The outer track section upper phase 88 and outer track lower phase 87 are substantially rounded and arranged to interface with the outer roller 62. Similarly the peripheral phase of the inner roller 63 is substantially rounded as well. Hence the inner track section upper phase 90 and the inner track lower phase 89 are substantially rounded and arranged to interface with the inner roller 63.

With the curvatures the inclination of the door blade 1 1 in the angle of play b is guided in a smoother manner which enables a more silent overhead door system. Further it allows for an overhead door system which is less susceptible to wear due to lower friction between the rollers and the track sections during the inclination of the door blade 1 1 . Consequently, the curvatures of the track sections and the rollers are adapted to delimit the angle of play b by means of the rollers being arranged to slide along the curvatures of upper and lower phases of the track section.

In one embodiment, the track 13 comprises an elongated groove 91 extending along the length of the track 13 for receiving the shaft 61 of the guiding arrangement 70 and allowing said shaft 61 to move along the track 13. The elongated groove 91 defines a pair of opposing phases 92 and 93. Each of opposing phases 92 and 93 protrudes from the inner track section upper phase 90 and the inner track section lower phase 89, respectively. Said pair of opposing phases 92 and 93 are arranged so as to protrude between the inner roller 63 and the door blade 1 1 in a horizontal direction.

The opposing phases 92 and 93, i.e. the first opposing phase 92 and the second opposing phase 93 are accordingly arranged at a distance from each other in a direction extending between the inner track section upper phase 90 and the inner track section lower phase 89. Said first opposing phase 92 and second opposing phase 93 are arranged to delimit movement of the door blade 1 1 in the angle of play b by means of abutting to the inner roller 63. In one embodiment, the first track portion 97 and second track portion 98 are separated by an elongated intermediate groove 51 extending along the at least one track 13. The elongated intermediate groove 51 is for receiving the shaft 61 of the guiding arrangement 70 and allowing said shaft 61 to move along the at least one track 13. The elongated intermediate groove 51 defines a pair of intermediate opposing phases 50, 51 of the track 13. The intermediate opposing phase extends substantially perpendicularly from the outer and inner track section upper phases 88, 90 and the outer and inner track section lower phases 87, 89, respectively. Said pair of intermediate opposing phases 50, 51 are arranged to extend between the outer track section 97 and the inner track section 98 in a horizontal direction. The intermediate opposing phases 50 and 51 , i.e. the first intermediate opposing phase 50 and the second intermediate opposing phase 51 are accordingly arranged at a distance from each other in a direction extending between the inner track section upper phase 90 and the inner track section lower phase 89 and the inner roller 63 and outer roller 62. Said first intermediate opposing phase 50 and second intermediate opposing phase 51 are arranged to delimit movement of the door blade 1 1 in the angle of play b by means of abutting to the inner roller 63 and outer roller 62. Again referencing Fig. 3a-b, the first track section 97 comprises an outer end wall 86 extending along the at least one track 13. Said outer end wall 86 is disposed outwardly of the outer roller 62 in a horizontal direction extending outwardly from the door blade 1 1 towards the track 13. Hence the outer end wall 86 may be arranged to delimit movement of the door blade 1 1 in the angle of play b by means of abutting to the outer roller 62.

In one embodiment, the inner roller 63 and the outer roller 62 has substantially the same diameter.

In one embodiment, the inner roller 63 and the outer roller 62 has different diameters, i.e. the inner roller may substantially have a larger or smaller diameter than the outer roller.

Fig. 4 schematically depicts the movement trajectory of the door blade 1 1 of the overhead door system. As described above, the outer track section, the inner track section, the outer roller and the inner roller are arranged to allow inclination of the door blade 1 1 relative a movement plane extending along the at least one track 13, 14, 15 in the angle of play b relative a horizontally extending inclination axis (A) perpendicular to the at least one track 13, 14, 15. Referencing said Fig. 4, the movement plane may extend vertically as defined by the vertical track 13, horizontally as defined by the horizontal track 14 or along a curvature as defined by the connecting track portion 15. The movement plane may thus be defined as a plane extending between the first and second track of the pair of horizontal, vertical and connecting track portion. Accordingly the angle of play b may be defined as an offset angle of the door blade 1 1 relative said movement plane.

Expressed differently the angle of play b may be defined by pivoting of the door blade 1 1 about an axis defined along the length of the tracks 13, 14, 15 relative the horizontally extending inclination axis A.

Referencing Fig. 4, one of the tracks 13, 14, 15 of the pair vertical tracks 13, horizontal tracks 14 and connecting track portions 15 may comprise the outer track section 97 and the inner track section 98. The play may thus be reduced throughout the entire opening and closing movement of the door blade 1 1 further reducing the noise generated by the overhead door system. Thus the inner and outer track section may extend continuously through the vertical track, the connecting track portion and the horizontal track.

Although not required for the implementation of the invention, each of the tracks of the pair of tracks 13, 14, 15 comprises the outer track section 97 and the inner track section 98. However to achieve a more predictable movement behaviour of the door blade 1 1 and a more silent overhead door system it may be preferable that each of the pair of tracks 13, 14, 15 comprises the outer track section 97 and the inner track section 98.

Hence, the guiding arrangement 70 comprises an additional outer roller 62 and an additional inner roller 63 disposed parallel to each other. The additional outer roller 62 and the additional inner roller 63 are connected to an additional shaft 61 of the guiding arrangement 70. The additional shaft 61 is arranged to extend outwardly from the door blade 12 in a horizontal direction opposite to the shaft.

The outer track section 97 and the inner track section 98 are arranged to receive the outer additional roller 62 and the additional inner roller 63, respectively. The outer track section 97, the inner track section 98, the additional outer roller 62 and the additional inner roller 63 are arranged to allow inclination of the door blade 1 1 relative the movement plane extending along the at least one track 13, 14, 15 in the angle of play b relative the horizontally extending inclination axis A perpendicular to the at least one track 13, 14, 15.

With reference to Fig. 4, guiding arrangements may be connected to each of the panels 17 as depicted by the inclination axes A. Preferably, the guiding arrangements are connected to the panels at positions proximal to the horizontal end phases of the panels 17. Thereby, the door blade 1 1 is allowed to move in a more smooth and predictable manner which more closely follows the trajectory of the tracks. In one embodiment, guiding arrangements are connected to the panels proximal to each horizontal end phase of the panels 17.

Turning to Fig. 5a-b, the outer track section 97 and the inner track section 98 may be disposed offset to each other. As depicted, a centrum axis C1 of the outer track section extends along said outer track section (and parallel to the inner track section). A similar centrum axis C2 of the inner track section 98 extends along said inner track section (and parallel to the outer track section).

Said centrum axes C1 and C2 defines the center of the cross-section of each of the inner and outer track section 98 and 97, i.e. the sections of the track which is arranged to receive the corresponding inner and outer rollers 63 and 62.

The centrum axis C1 of the outer track section 97 is disposed at an offset distance d perpendicular to the at least one track 13 and a horizontal direction in relation to a centrum axis C2 of the inner track section 98. In one embodiment, the offset distance d may be between 0,1 and 30 millimeters, more preferably between 0,25 and 5 millimeters, and even more preferably between 0,5 and 2 millimeters.

As shown in Fig. 5b the offset relation between the inner and outer track sections further limits the potential maximum angle of play b due to the phases of the track sections which at least partially surrounds the rollers coming into contact with said rollers at a lower degree of inclination compared to the embodiment depicted in Fig. 4a-b.

Thereby a significantly more silent overhead door system is achieved in a simple and non-complex manner compared to conventional measures for reducing the noise, i.e. by costly material alterations, seals or complex track and driving arrangements. In the drawings and specification, there have been disclosed exemplary embodiments. However, many variations and modifications can be made to these embodiments. Accordingly, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the embodiments being defined by the following claims.