AU2013101581A4 - Brace for a door guide - Google Patents

Abstract

H: \gl\Intenvoven\NRPortbl\DCC\LGL\5859814_I.doc-3/12/2013 -12 Abstract A brace 1 is provided for use with a door. The door includes door panels 2 coupled to guides 6 using guide wheels 4. The brace 1 is attached to one of the guides 6 and an engaging portion 9 of the brace 1 is located contiguous to the door. In the event of a normal loading condition the engaging portion is not in contact with the door. In the event of deflection of the door during wind or other loading the engaging portion 9 contacts the door and prevents further deformation of the door. [Fig. 14] - 8/9 Fig 17. Fig 18.

Description

H:\Igl\lntenoven\NRPortbl\DCC\LGL\5859814_1.doc-3/12/2013 -1 BRACE FOR A DOOR GUIDE TECHNICAL FIELD [0001] The present invention generally relates to sectional overhead doors and in particular to a brace for a door guide to prevent damage to the door during high wind events. BACKGROUND [0002] Various companies manufacture a range of Sectional Overhead Doors (SOD) for the general market. These "standard" doors are designed to meet the general demands to mechanise the opening and closing of the opening of a typical suburban garage. The construction of a "standard" door is more than adequate to operate under the "normal" loads and environmental conditions associated with this type of installation. In this case, "normal" means conditions that are not covered by the standards for high wind regions, such as AS/NZS 4505:2012. "Standard" refers to a door designed to meet these "normal" conditions. A typical door in this situation would be as shown in Figure 1 (from outside and inside). [0003] In high wind areas around Australia and the world it is well known that considerable property damage can occur from high winds. Accordingly, in many countries there have been standards or guidelines developed and enforced to cover construction in high wind areas. One of the main driving factors for this has been insurance companies aiming to limit the amount of liability they may face when damage occurs. But also, to ensure that people who build property in these areas are safe from injury and damage. [0004] There are various standards in Australia and New Zealand covering wind loading and building practices. One of the first and main aims of these standards is to categorise areas of the country according to the severity of the natural conditions that can occur. For example, classifications within Australia range from A for regions with mild high wind conditions to C or D for cyclone prone regions. Secondly, they cover practices that are compulsory for constructions in any particular high wind area. And thirdly, they H:\gl\nteoven\NRPortbl\DCC\LGL\5859814_1doc-3/12/2O13 -2 cover certification and testing requirements for components that are sold into high wind regions. [0005] As part of the studies carried out for determining measures necessary to prevent damage or injury, it was found that doors, windows and other opening coverings are particularly critical in this regard. The garage door being generally the biggest of these opening coverings is correspondingly often the most critical of these. In short, in a high wind event the garage door can blow-out or blow-in leaving the opening partly or entirely exposed. The opening then becomes a pocket for high pressure which can result in damage to the contents or further blow-out or blow-in of other coverings, such as windows, doors or rooves. Any of these materials may go on to cause further damage or injury, for example by becoming flying debris. Preventing the blow-out or blow-in of the garage door can prevent the initiation of this potentially dangerous chain reaction. [0006] In order to continue supplying doors into all regions, including these high wind regions, it was necessary to test and certify certain doors. One such door was the standard Sectional Overhead Door as shown in Figure 1. Such a door includes panels 2 able to slide along guides 6 mounted to a frame or wall 8 (also see Figure 3). It was soon found that this door was not suitable in standard form for high wind regions. In order to correct this situation, a number of measures were taken to ensure conformance. The measures taken were: " The number of horizontal reinforcing bars 20 increased from one at the top and one at the bottom, to one per panel 2, e.g. in the case shown with four panels 2, there are four horizontal reinforcing bars 20 (see Figure 2); " The addition of doubled structural end components, called double end stiles (see Figure 3). The original end stile 21 remains while a second end stile 22 is added; " The addition of this second end stile 22 also allows the addition of a second hinge 23 between panels 2 at each side of the door left and right (see Figure 3). It also allows a second top bracket on the top panel and a second bottom bracket on the bottom panel on each side (see Figure 3); and H:\gl\Intenvoven\NRPortbl\DCC\LGL\58598141.doc-3/12/2013 -3 * These additional hinges and top and bottom brackets are then used to house a longer guide wheel shaft or axle 5 as shown in Figure 3. This provides greater strength of the guide wheel 4 in the guide 6, thus providing additional resistance to blow-in or blow-out of the door. [0007] Initial testing of the first iteration door showed that the measures listed above were not enough to pass for high wind regions C or D. To further improve the door, the following improvements were added for the second iteration. [0008] In initial testing it was found that the amount of deflection of the door during a simulation of blow-in or blow-out loading from a high wind event was excessive. This deflection caused the guide wheel axles 5 to bend past the elastic limit causing permanent plastic bending (see Figure 12). This in turn caused a lowering of the door load carrying capacity and prevented door opening/closing operation. [0009] Previously shown in Figures 1 and 2, and as shown in Figure 4, for doors of various widths, one or more central columns of stiles 24 are constructed into the door panels 2. These stiles 24 form fixing supports also for hinges 33 between panels 2 and horizontal reinforcing 20. [0010] For high wind region certified doors, it was found that in a severe wind event, typical at times for Regions C and D, it was necessary to further stiffen the one or more central stile column(s) 24. The guidelines in place in the relevant standards allowed that this stiffening could be put into place at the time a severe condition was announced, i.e. not in place all the time but only as required. [0011] The resulting solution for the second iteration was one or more extruded aluminium beams placed vertically about 200mm offset from the inside of the door vertically aligned to the central column (or columns) of stiles 24. Each central beam has to be fitted to a door as per the following description. It is specified that it must be fitted at the time of a severe wind warning or before going away for an extended period of time. A "top anchor bracket" 25 needs to be mounted in a position similar to that shown in Figure H:\g\Inenvoven\NRPortbl\DCC\LGL\5859814_ Ldoc-3/12/2013 -4 5(b). The central beam 26 is a pre-assembled aluminium profile section as shown in Figure 6. [0012] The top of the central beam 26 is fitted with a U-shaped bracket 27 which clamps into place across the aluminium profile as shown in Figure 7. When the beam 26 is fitted, this U-shaped bracket 27 is fitted into the top anchor bracket 25, also as shown in Figure 7. The bottom of the beam 26 is fitted with a lower fitting 28 which has 3 mounting flanges 29. These are aligned to predrilled holes in the garage flooring and fastened into place with 3 mounting screws 30 as shown in Figure 8. This operation fixes the beam 26 into place. [0013] In order for the garage door to be supported by the beam 26, there are a number (corresponding to varying garage door height) of deflection brackets 32 arranged along the length of the central column of stiles 24 to correspond with the positions of the centre panel door hinges 33. Arrangements are shown in Figure 9 and 10. Initially the deflection brackets 32 would hang down, but need to be attached to each panel door hinges 33 as per Figure 9, using a bolt which should be in place in the deflection bracket 32. The deflection brackets 32 have a number of settings holes to allow a range of offsets from the garage door. [0014] The purpose of the description of the previous state of art is to show that it has a number of disadvantages, namely: " The component parts are quite costly in materials; e The installation is more complex, time consuming and costly; e Although it is allowed in relevant standards for conformance, the certified door requires manual intervention, being fitting of a central beam 26 by the garage owner. This may at times, for whatever reason, not happen before the high wind event occurs; e Though the installation of a beam is designed to be as easy as possible for the end user, it requires some time, focus and dexterity; H:\gl\ntemvovenNRPortbl\DCC\LGL\5859814_ .doc-3/12/2013 -5 e Though components of the system have intended storage locations, some parts may for whatever reason, be lost at some time; and e The garage space should be made about 500-800mm deeper to allow the beam to be fitted when a car is parked inside. This space allows the required swing-in action of the beam to be completed without hitting the vehicle or contents, and allowing free movement for persons between the beam and the vehicle or items. [0015] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. BRIEF SUMMARY [0016] The present invention seeks to provide a brace for use with a sectional overhead door that overcomes some of the problems associated with the prior art, including improved probability of successful door performance when subject to high wind loads or other external forces. [0017] According to one example aspect, there is provided a brace for use with a door that is coupled to guides using guide wheels, wherein an engaging portion of the brace is located such that in the event of a normal loading condition the engaging portion is spaced apart from the door and where in the event of deflection of the door during loading the engaging portion contacts the door. [0018] According to another example aspect, the brace can be fitted to an existing guide. [0019] In another particular, but non-limiting, example form, the brace is configured to attach to a door frame and the guide is mounted on the brace. [0020] Preferably, the brace includes a U shaped cross section.

H:\Ig\Intenvoven\NRPortbI\DCC\LGLX5859814_I.doc-3/12/2013 -6 [0021] In accordance with other optional embodiments, provided by way of example only, there is provided an overhead sectional door and frame including a brace as described herein. BRIEF DESCRIPTION OF FIGURES [0022] Example embodiments should become apparent from the following description, which is given by way of example only, of at least one preferred but non limiting embodiment, described in connection with the accompanying figures. [0023] Figure 1 (prior art) illustrates (a) a typical standard sectional overhead door from outside and (b) a typical standard sectional overhead door from inside the garage; [0024] Figure 2 (prior art) illustrates (a) a typical standard sectional overhead door with horizontal reinforcing bars at the top and bottom only and (b) a door with horizontal reinforcing bars on every panel; [0025] Figure 3 (prior art) illustrates (a) the bottom of a typical standard sectional overhead door, (b) the top of a typical standard sectional overhead door, (c) the bottom of a sectional overhead door with second end stiles and second hinges, and (d) the top of a sectional overhead door with second end stiles and second hinges; [0026] Figure 4 (prior art) illustrates a door with a centre stile; [0027] Figure 5 (prior art) illustrates (a) a standard door with no central beam and (b) a door with a central beam fitted; [0028] Figure 6 (prior art) illustrates a central beam; [0029] Figure 7 (prior art) illustrates a central beam fitted to a top anchor bracket; [0030] Figure 8 (prior art) illustrates a central beam lower fitting; [0031] Figure 9 (prior art) illustrates fitting of deflection brackets to door hinges; [0032] Figure 10 (prior art) illustrates various prior art beams and brackets; H:\lgl\lnteoven\NRPortbl\DCCGL\5859814_l.doc-3/12/2013 -7 [0033] Figure 11 (prior art) illustrates the coupling between a door and a guide; [0034] Figure 12 (prior art) illustrates (a) a guide wheel dislodged from a guide and (b) lower loading where a guide wheel has deformed but is still in the guide; [0035] Figure 13 (prior art) illustrates (a) a guide mounted to a garage opening frame and (b) slots in the guide mounting brackets allow the guide to be angled; [0036] Figure 14 illustrates a sectional view with a brace installed; [0037] Figure 15 illustrates a 3D view with a brace installed; [0038] Figure 16 illustrates a guide with brace with simulation loading; [0039] Figure 17 illustrates a side view of guide positioning, where the guide is angled to the wall; [0040] Figure 18 illustrates a perspective view of a full version of a brace; [0041] Figure 19 illustrates a perspective view of an adapter version of a brace; and [0042] Figure 20 illustrates installing an adapter brace to an existing door. PREFERRED EMBODIMENTS [0043] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments. [0044] In the figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the figures. [0045] Referring to Figure 14, a preferred embodiment of the brace 1 is shown. A panel 2 of a sectional overhead door has a bracket 3 attached that supports a guide wheel 4 using an axle 5. The guide wheel 4 runs in the guide 6 as the door is moved between a lowered and a raised position. The guide 6 is connected by a support bracket 7 to the door frame or wall 8.

H:\Igl\Intevoven\NRPortbl\DCC\LGL\5859814_1 doc-3/12/2013 -8 [0046] An engaging portion 9 of the brace 1 is located such that there is a gap 10 to the axle 5. This gap 10 is shown to illustrate that during a normal loading condition of the door 2, no part of the bracket 3, axle 5 or door 2 contact the brace 1. This allows the door 2 to be raised and lowered without any additional restriction. In the event of a high wind loading, however, a small amount of elastic deformation of the guide wheel 4 or axle 5 results in the door 2 or axle 5 contacting the engaging portion 9 of the brace 1, preventing any further deformation and thereby preventing permanent plastic deformation of the axle 5 or other components. This thereby prevents the detachment of components from the door frame. [0047] The brace 1 is connected to the wall 8 by bolts 11 through holes 12 (see Figure 18). The holes 13 are used to connect the guide 6 using bolts 14. In cases where standard doors are already fitted, the brace 1 can be supplied as a separate component as shown in Figure 19. In this embodiment the brace 1 can be connected to an existing door and guide setup using the existing guide mounting bolts 14 through bracket holes 15. An exploded version of this embodiment is also shown in Figure 20. [0048] Without the abovementioned central beams 26 in place, the guide wheels 4 in the guide 6 were found to be the weak link. The high wind standard requires that for a door to be high wind rated for a particular region, it needs to be tested with loads simulating a high wind blow-in or blow-out event, which also includes cyclic loading. [0049] After this testing, for a door to pass the requirements, there shall be: 9 no dislodgement of door components; and 9 no damage to any of the connections between the frame and the supporting structure, or between the door and the guide which would allow the door to become unlocked or open. [0050] A summary of garage door construction is that there is a guide 6 fixed to the garage door frame 8. A guide wheel 4 runs in this guide 6 and is coupled to the door 2. This allows the door 2 to be raised along the guide 6 to open or close the garage opening (see Figure 11).

H:\lInteroven\NRPortl\DCC\LGL\5859814 _.do-3/12/2013 -9 [0051] During testing of a simulated blow-out event, there is a higher pressure applied to the inside of the door urging the door to be pushed outwards from the garage door recess. In this case, as shown in Figure 11, the door 2 is urged against the door frame 8, which provides a strong and stable support of the door 2. [0052] In the opposite blow-in situation, the high pressure is applied to the outside of the door, urging the door inward toward the garage recess. In this situation, the door frame 8 cannot provide any additional support to resist inward deflection of the door. [0053] During initial testing, it was demonstrated that the axle 5 of the guide wheel 4, which couples the door 2 to the guide 6, was found to be the weak link. Well before reaching the specified simulation loading, the axle 5 bent permanently and almost to right angles. This caused the guide wheels 4 to dislodge from the guide 6 before the specified load, which is a fail and is shown in Figure 12(a). [0054] The aim of the current invention is to provide the guide wheel 4 and axle 5 with additional support but still allow the garage door to be raised and lowered with the support in place. In this way, the extra support can be in place at all times and does not need manual end-user intervention to comply with the high wind conformance requirements. [0055] Currently the guides 6 are held in place with track mounting brackets 7 (jamb brackets) mounted along the length of the guide 6. The guide 6 is not parallel to the wall 8 and to cater for this there are adjustable mounting slots 35 in the mounting brackets 7 as shown in Figure 13(b). [0056] Currently it is proposed to replace the track mounting bracket 7 with a Z shaped mounting and support bracket. This bracket would allow mounting of the guide 6 and provide extra support to the guide wheel axles 5 as shown in Figure 14. The critical gap 10 allows the guide wheel 4 and its axle 5, and correspondingly the garage door 2, to travel up and down unhindered when the door is raised or lowered. However, it is constructed to limit the deflection of the guide wheel axle 5 to maintain load bearing capacity and ultimately to prevent the guide wheel 4 from dislodging from the guide 6.

H:\gl\ntenvoven\NRPortbl\DCC\LGL\5859814_1 doc-3/12/2013 - 10 [0057] Testing has shown that this system is quite successful and passes the high wind standard conformance testing. It was also demonstrated that the Z-bracket deflects with the door 2 and guide wheel axle 5 within elastic limits instead of being too rigid. This is also an important feature of the design. [0058] While the present invention is primarily designed to reduce the chance of damage to a door due to high wind forces, the invention will also provide protection against damage from many other forces as well. These may include, but are not limited to, impacts from vehicles, other accidental impacts and forces applied intentionally, such as criminal actions including vandalism or attempted forced entry. [0059] Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention.

Claims (5)

1. A brace for use with a door that is coupled to guides using guide wheels, wherein an engaging portion of the brace is located such that in the event of a normal loading condition the engaging portion is spaced apart from the door and where in the event of deflection of the door during loading the engaging portion contacts the door.

2. The brace according to claim 1, wherein the brace can be fitted to an existing guide.

3. The brace according to claim 1, wherein the brace is configured to attach to a door frame and the guide is mounted on the brace.

4. The brace according to any one of claims 1 to 3, wherein the brace includes a U shaped cross section.

5. An overhead sectional door and frame including a brace according to any one of claims 1 to 4.