Overhead door frame assembly

Abstract

A frame for supporting a door has a horizontal header connected to tripod legs with splice assemblies. Each tripod leg has two upright columns connected to an upright I-bar. The splice assemblies are fastened to the upright columns.

Claims

1. A frame assembly for supporting a door comprising: a horizontal header having a first end and a second end, said second end being opposite the first end, a first leg having an upright first column and an upright second column laterally spaced from the upright first column, a first connector secured to the upright first column, a second connector secured to the upright second column, said first connector and the second connector being secured to the first end of the header, a second leg having an upright third column and an upright fourth column laterally spaced from the upright third column, a third connector secured to the upright third column, a fourth connector secured to the upright fourth column, and said third connector and the fourth connector being secured to the second end of the header, the upright first column comprising a first tubular column, the first connector comprising a splice having a first body and a first pair of ribs joined to the first body, said first body and the first pair of ribs being located within the first tubular column, and first fasteners operably connected to the first body to urge the first pair of ribs into engagement with the first tubular column, the upright second column comprising a second tubular column, the second connector comprising a second splice having a second body and a second pair of ribs joined to the second body, said second body and the second pair of ribs being located within the second tubular column, and second fasteners operably connected to the second body to urge the second pair of ribs into engagement with the second tubular column, the upright third column comprising a third tubular column, the third connector comprising a third splice having a third body and a third pair of ribs joined to the third body, the third body and the third pair of ribs being located within the third tubular column, and third fasteners operably connected to the third body to urge the third pair of ribs into engagement with the third tubular column, the upright fourth column comprising a fourth tubular column, the fourth connector comprising a fourth splice having a fourth body and a fourth pair of ribs joined to the fourth body, the fourth body and the fourth pair of ribs being located within the fourth tubular column, and fourth fasteners operably connected to the fourth body to urge the fourth pair of ribs into engagement with the fourth tubular column.

2. The frame assembly of claim 1 wherein: the first leg includes an upright first I-bar spaced from the upright first column and spaced from the upright second column, first members secured to the upright first column, the upright second column and the upright first I-bar for connecting the upright first column and the upright second column to the upright first I-bar, the second leg including an upright second I-bar spaced from the upright third column and spaced from the upright fourth column, and second members secured to the upright third column, the upright fourth column and the second I-bar to connect the upright third column and the upright fourth column to the upright second I-bar.

3. The frame assembly of claim 1 wherein: the first leg includes an upright first I-bar spaced from the upright first column and spaced from the upright second column, a first base including a first top wall having a first front section and a first rear section, said upright first column and said upright second column being secured to the first front section of the first top wall of the first base and the upright first I-bar being secured to the first rear section of the first top wall of the first base, first members secured to the upright first column, the upright second column and the upright first I-bar for connecting the upright first column and the upright second column to the upright first I-bar, the second leg including an upright second I-bar spaced from the upright third column and the upright fourth column, a second base including a second top wall having a second front section and a second rear section, said upright third column and the upright fourth column being secured to the second front section of the second top wall of the second base and the upright second I-bar being secured to the second rear section of the second top wall of the second base, and second members secured to the upright third column, the upright fourth column and the upright second I-bar for connecting the upright third column and the upright fourth column to the upright second I-bar.

4. The frame assembly of claim 3 wherein: the first members secured to the upright first column, the upright second column and the upright first I-bar comprise first horizontal plates, and the second members secured to the upright third column, the upright fourth column and the upright second I-bar comprising second horizontal plates.

5. The frame assembly of claim 1 including: a first support assembly secured to the upright first column, the upright second column and an upright first I-bar, and a second support assembly secured to the upright third column, the upright fourth column and an upright second I-bar.

6. The frame assembly of claim 5 wherein: the first support assembly includes a first transverse member secured to the upright first column and secured to the upright second column, and at least one first rib secured to the first transverse member and the upright first I-bar, and the second support assembly including a second transverse member secured to the upright third column and secured to the upright fourth column, and at least one second rib secured to the second transverse member and the upright second I-bar.

7. The frame assembly of claim 5 wherein: the first support assembly includes a first pair of transverse members secured to the upright first column and secured to the upright second column, and a first pair of ribs secured to the first pair of transverse members and the upright first I-bar, and the second support assembly including a second pair of transverse members secured to the upright third column and secured to the upright fourth column, and a second pair of ribs secured to the second pair of transverse members and the upright second I-bar.

8. A frame assembly comprising: a horizontal header having a first end and a second end, said second end being opposite the first end, a first tripod leg connected to the first end of the header, said first tripod leg comprising an upright first column, an upright second column laterally spaced from the upright first column, an upright first I-bar spaced from the upright first column and spaced from the upright second column and first members secured to the upright first column, the upright second column and the upright first I-bar to connect the upright first column and the upright second column to the upright first I-bar, a second tripod leg connected to the second end of the header, said second tripod leg comprising an upright third column, an upright fourth column laterally spaced from the upright third column, an upright second I-bar spaced from the upright third column and spaced from the upright fourth column and second members secured to the upright third column, the upright fourth column and the upright second I-bar to connect the upright third column and the upright fourth column to the upright second I-bar, the upright first column comprising a first tubular column, a splice connecting the first tubular column to the first end of the header and having a first body and a first pair of ribs joined to the first body, the first body and the first pair of ribs being located within the first tubular column, first fasteners operably connected to the first body to urge the first pair of ribs into engagement with the first tubular column, the upright second column comprising a second tubular column, a second splice connecting the second tubular column to the first end of the header and having a second body and a second pair of ribs joined to the second body, the second body and the second pair of ribs being located within the second tubular column, second fasteners operably connected to the second body to urge the second pair of ribs into engagement with the second tubular column, the upright third column comprising a third tubular column, a third splice connecting the third tubular column to the second end of the header and having a third body and a third pair of ribs joined to the third body, the third body and the third pair of ribs being located within the third tubular column, third fasteners operably connected to the third body to urge the third pair of ribs into engagement with the third tubular column, the upright fourth column comprising a fourth tubular column, a fourth splice connecting the fourth tubular column to the second end of the having a fourth body and a fourth pair of ribs joined to the fourth body, the fourth body and the fourth pair of ribs being located within the fourth tubular column, and fourth fasteners operably connected to the fourth body to urge the fourth pair of ribs into engagement with the fourth tubular column.

9. The frame assembly of claim 8 wherein: the first tripod leg has a first base having a top wall with a front section and a rear section, said upright first column and said upright second column being secured to the front section of the top wall of the first base, said upright first I-bar being secured to the rear section of the top wall of the first base, the second tripod leg having a second base having a top wall with a front section and a rear section, said upright third column and said upright fourth column being secured to the front section of the top wall of the second base, and said upright second I-bar being secured to the rear section of the top wall of the second base.

10. The frame assembly of claim 8 wherein: the first members secured to the upright first column, the upright second column and the upright first I-bar comprise first horizontal plates, and the second members secured to the upright third column, the upright fourth column and the upright second I-bar comprising second horizontal plates.

11. The frame assembly of claim 8 including: a first support assembly secured to the upright first column, the upright second column and the upright first I-bar, and a second support assembly secured to the upright third column, the upright fourth column and the upright second I-bar.

12. The frame assembly of claim 11 wherein: the first support assembly includes a first transverse member secured to the upright first column and secured to the upright second column, and at least one first rib secured to the first transverse member and the upright first I-bar, and the second support assembly including a second transverse member secured to the upright third column and secured to the upright fourth column, and at least one second rib secured to the second transverse member and the upright second I-bar.

13. The frame assembly of claim 11 wherein: the first support assembly includes a first pair of transverse members secured to the upright first column and secured to the upright second column, and a first pair of ribs secured to the first pair of transverse members and the upright first I-bar, and the second support assembly including a second pair of transverse members secured to the upright third column and secured to the upright fourth column, and a second pair of ribs secured to the second pair of transverse members and the upright second I-bar.

Description

DESCRIPTION OF THE DRAWING

(1) FIG. 1 is a perspective view of a building equipped with an open overhead door pivotally attached to a frame assembly operable to open and close a doorway of the building;

(2) FIG. 2 is an enlarged perspective view of a closed overhead door and frame assembly of FIG. 1;

(3) FIG. 3 is a left side elevational view of FIG. 2;

(4) FIG. 4 is a right side elevational view of FIG. 2;

(5) FIG. 5 is a perspective view of the hinge assembly pivotally connecting the door frame to the header of the frame assembly;

(6) FIG. 6 is an enlarged sectional view taken along line 6-6 of FIG. 2;

(7) FIG. 7 is a foreshortened front elevational view of the frame assembly of FIG. 2;

(8) FIG. 8 is a perspective view of the double splice assemblies of the frame assembly;

(9) FIG. 9 is a front elevational view, partly sectioned, of the double splice assemblies secured to the upright columns of a tripod leg;

(10) FIG. 10 is a sectional view taken along line 10-10 of FIG. 9;

(11) FIG. 11 is an enlarged sectional view of a splice assembly connected to an upright column of a tripod leg;

(12) FIG. 12 is a front elevational view of a tripod leg of the frame assembly of FIG. 7;

(13) FIG. 13 is a top plan view of FIG. 12;

(14) FIG. 14 is a sectional view taken along line 14-14 of FIG. 12;

(15) FIG. 15 is a left side elevational view of the tripod leg of FIG. 12;

(16) FIG. 16 is a right side elevational view of the tripod leg of FIG. 15;

(17) FIG. 17 is a rear elevational view of the tripod leg of FIG. 15;

(18) FIG. 18 is a sectional view taken along line 18-18 of FIG. 12;

(19) FIG. 19 is a sectional view taken along line 19-19 of FIG. 12;

(20) FIG. 20 is a sectional view taken along line 20-20 of FIG. 12;

(21) FIG. 21 is a sectional view taken along line 21-21 of FIG. 12;

(22) FIG. 22 is an enlarged elevational view of a lower corner section of the door frame; and

(23) FIG. 23 is an enlarged sectional view taken along line 23-23 of FIG. 22.

DETAILED DESCRIPTION OF THE OVERHEAD DOOR

(24) A building 9, shown in FIG. 1, includes a doorway or an upright opening to allow vehicles and equipment to move into and out the interior of the building. Examples of building 9 include aviation hangers, automotive shops, farm and ranch shops, commercial retail and marine buildings, warehouses and manufacturing plants. An overhead door 10 pivotally mounted on a frame assembly 11 is movable in an arcuate path between a horizontal open position, shown in FIG. 1, to an upright closed position, shown in FIG. 2. Linear actuators 16 and 17, shown as hydraulic piston and cylinder mechanisms, are operable to move overhead door 10 between the open and closed positions and hold the door in these positions. A hydraulic fluid pump unit 18 connected with fluid accommodating lines 19 to the dead ends of the piston and cylinder mechanisms 16 and 17 function to supply hydraulic fluid under pressure to control the operation of the piston and cylinder mechanisms 16 and 17 whereby overhead door 10 is selectively moved between the open and closed positions. A control 20 coupled to pump unit 18 is manually operable to regulate the operation of pump unit 18. A remote actuator 21 can also be used to regulate control 20. An example of a hydraulic fluid system for an overhead door associated with hydraulic cylinders is disclosed in U.S. Pat. No. 6,883,273. A linear actuator having a motor operating a screw is disclosed in U.S. Pat. No. 6,742,303.

(25) As shown in FIG. 2, door 10 has a rectangular door frame 22 supporting sheathing and trim 23. Door frame 22 comprises tubular metal top and bottom horizontal members 24 and 25. A horizontal middle member 26 is located between members 24 and 25. Left side upright members 27, 28 and 29 are secured with welds to horizontal members 24, 25 and 26. Right side upright members 31, 32 and 33 are secured with welds to the horizontal members 24, 25 and 26. Upright members 34, 35 and 36 located between the end members 29 and 33 reinforce door 10. Door frame 22 is tubular steel bars welded together. The door frame members can be aluminum or composite materials. Large metal doors have a large amount of weight which require large forces to move the doors between open and closed positions. The frame assemblies for supporting the doors must have adequate strength to accommodate heavy overhead doors and wind forces directed to the doors.

(26) Frame assembly 11, shown in FIG. 7, has a horizontal header 12 extended between and attached to upright tripod legs 13 and 14. Header 12 is a linear tubular steel beam having opposite end sections mounted on tripod legs 13 and 14. As shown in FIG. 2, a first hinge assembly 37 mounted on header 12 in alignment with tripod leg 13 is connected to upright door frame members 27, 28 and 29. A second hinge assembly 38 is also mounted on header 12 in alignment with tripod leg 14. Hinges 39, 40 and 41 are mounted on header 12 between the first and second hinge assemblies 13 and 14. Hinge assemblies 37 and 38 and hinges 39, 40 and 41 have a common horizontal axis allowing door 10 to be moved by linear actuators 16 and 17 between the upright closed position and the horizontal open position.

(27) Tripod leg 13, shown in FIGS. 12 to 21, comprises a base 43 adapted to be secured to a support or floor 48 of building 9. Base 43 is a flat rectangular metal plate having a top wall 44 and a plurality of holes 46. Anchors 47, shown in FIGS. 3 and 4, extend through holes 46 to secure base 43 to floor 48. Tripod leg 13 has a first upright tubular column 49 and a second upright tubular column 51. Columns 49 and 51 are laterally spaced from each other and secured with welds to the front corners of the front section of base 43. An upright I-bar 52 is secured with welds to the middle of the rear section of base 43. Columns 49 and 51 and I-bar 52 have the same upright dimensions and are in parallel triangular orientation. I-bar 51 is an upright I-beam having lateral flanges 53 and 54 jointed with a flat cross member 55. A number of horizontal plates 56, 57, 58, 59, 60, 61, 62 and 63 are vertically spaced between columns 49 and 51 and I-bar 52. Welds secure each plate 56 to 63 to columns 49 and 51 and I-bar 52. A support assembly 64 for linear actuator 16 is located between upright columns 49 and 51 and I-bar 52. Support assembly 64 has flat transverse members 66 and 67 secured together in a right angle shape with the space between members 66 and 67 open to columns 49 and 51. As shown in FIGS. 17 and 18, members 66 and 67 engage columns 49 and 51. Welds secure members 66 and 67 to columns 49 and 51. A rib 68 secured to the inside center of members 66 and 67 has a hole 69 to accommodate a pin 104 connecting the dead end of linear actuator 16 to rib 68. Second and third ribs or right angle flanges 71 and 72 secured to the rear surfaces of members 66 and 67 reinforce members reinforce members 66 and 67. As shown in FIGS. 17 and 18, ribs 71 and 72 are also secured to flange 54 of I-bar 52.

(28) The second tripod leg 14, shown in FIGS. 2, 4 and 7, has the same structure as tripod leg 13. Tripod leg 14 has a base 73 supporting first and second upright tubular columns 74 and 76 and an I-bar 77. Plates 78, 79, 80, 81, 82, 83, 84 and 85 secure columns 74 and 76 to I-bar 77. Columns 74 and 76 and I-bar 77 hold a support assembly 86 for retaining linear actuator 17. A rib 87 on the front center of support assembly 86 accommodates a pin that connects linear actuator 17 to rib 87. An anchor 88 secures base 78 to floor 48.

(29) Proceeding to FIGS. 22 and 23, linear actuator 16 extended between support assembly 64 and a mount 89 is operable to pivot door 22, shown by arrow 90, between an upright door closed position and a horizontal door open position. Mount 89 comprises a flat first plate 91 located between upright door frame members 27 and 28. Welds secure plate 91 to door frame members 27 and 28 whereby the forces of linear actuator 16 are imparted to both door frame members 27 and 28. Plate 91 has three vertically spaced horizontal openings or slots 92, 93 and 94. A bar 96 is located in surface contact with the front of plate 91. A second plate 101 engages the back surface of plate 91. An arm 102 secured to plate 101 accommodates a pin 103 operable to pivotally connect linear actuator 16 to arm 102. A plurality of fasteners 97, 98 and 99, shown as nut and bolt assemblies, extended through slots 92, 93 and 94 clamp bar 96 and plate 101 to plate 91. The second plate 101 and arm 102 are laterally adjustable relative to the first plate 91 to align linear actuator 16 relative to support assembly 64. A second mount 106 secured to door upright members 31 and 32, shown in FIG. 2, has the same structure and functions including the horizontal adjustment as mount 89. Mount 106 is also pivotally connected to linear actuator 17 connected to second tripod leg 14.

(30) Frame assembly 11 has first splice assemblies 107 and 108, shown in FIGS. 8 to 11, that secures tripod leg 14 to header 12. Second splice assemblies secure tripod leg 13 to header 12. The splice assemblies have the same structures and functions.

(31) Splice assembly 107 has a body 109 comprising a flat upright member supporting a pair of upright ribs 111 and 112. Ribs 111 and 112 have flat end surfaces located in surface engagement with a first inside wall 119 of column 74 of tripod leg 14. Body 109 has a first end 113 located in engagement with a second inside wall 123 of column 74. A fastener 116, shown as a threaded bolt, cooperates with a nut 117 retained on body 109 to hold ribs 111 and 112 in upright surface engagement with inside wall 119 of column 74. A second fastener 121, shown as a threaded bolt, extends through a nut 122 secured to column 74. The distal end of fastener 121 engages second end 114 of body 109 and forces first end 113 of body 109 into engagement with second inside wall 123 of column 74. A fastener 124 cooperates with a nut 126 on body 109 and a third fastener 127 cooperating with a nut 128 on body 109 operates in concert with fastener 116 to retain ribs 111 and 112 in surface engagement with inside wall 119 of column 74. A plat 129 secured to body 109 and ribs 111 and 112 is fixed by welds to header 12.

(32) Splice assembly 108 has an upright body 131 supporting a pair of upright ribs 132 and 133. Fasteners 134, 139 and 141 retained on column 76 cooperate with nuts 136, 142, 143 concurrently hold ribs 132 and 133 in upright surface engagement with a first inside wall of column 76. An additional fastener 139 threaded through a nut 138 secured to column 76 has a distal end that contacts body 131 and holds body 131 in engagement with a second inside wall of column 76. Body 131 and ribs 132 and 133 are secured to a plate 144. Welds secure plate 144 to header 12. Splice assemblies 107 and 108 are laterally spaced apart and telescope into the upper ends of tubular columns 74 and 76 of tripod leg 14. Fasteners 116, 124 and 127 secure splice assembly to column 74. Fasteners 134, 139 and 141 secure splice assembly 108 to column 76.

(33) Hinge assembly 38, shown in FIG. 5, comprises a frame assembly unit 146 pivotally connected with a horizontal pin 147 to a door frame unit 148. Frame assembly unit 146 has a horizontal plate 149 secured with welds to the top surface of header 12. A plurality of vertical supports 151, 152, 153, 154, 155 and 156 are secured with welds to the bottom of plate 149. Adjacent supports are laterally spaced apart. First vertical members 157 and 158 located between supports 151 and 152 extend downward on opposite sides of door frame member 33. Second vertical members 159 and 161 located between supports 153 and 154 extend downward on opposite side of door frame member 32. Third vertical members 161 and 162 extend downward adjacent door frame member 31. Welds secure members 157, 158, 159, 160, 161 and 162 to door frame members 33, 32 and 31. Horizontal plates 163 secured to vertical members 157, 158, 159, 160, 161 and 162 retain vertical members 157, 158, 159, 160, 161 and 162 in lateral spaced relationship. Plates 163 also support arms 167, 168, 169 and 170 located between the upper sections of vertical members 158, 159, 160 and 161. Arms 167, 168, 169 and 170 have openings that accommodate cylindrical members or sleeves 171, 172, 173, 174 and 175. Pin 147 extended through supports 151 to 156, the upper sections of vertical members 157 to 162, and sleeves 171 to 175 pivotally connects frame assembly unit 146 to door frame unit 148 and supports an end of overhead door 10. A block 176 secured to support 151 functions to prevent pin 147 from rotating during the opening and closing of overhead door 10. A retainer 177, shown as a cotter key, on the end of pin 147 opposite block 176 limits axial movements of pin 147 relative to supports 151 to 156.

(34) Hinge assembly 37 mounted on the end of header 12 opposite hinge assembly 38 has the same structure and function as hinge assembly 38. Hinge assemblies 37 and 38 are concurrently operative to support overhead door 10 on frame assembly 11 and allow overhead door 10 to be moved with linear actuators 16 and 17 from a door closed position and a door open position. Hinge assemblies 37 and 38 also support overhead door 10 in the open position on frame assembly 11.

(35) Proceeding to FIG. 6, hinge 40 along with hinges 39 and 41 support door frame 22 between end hinge assemblies 37 and 38. Hinges 39, 40 and 41 have the same structure and functions. Hinge 40 is herein described as having a frame unit 178 connected with a horizontal pin 179 to a door frame unit 181. Frame assembly unit 178 comprises a horizontal plate 194 secured with welds to the top surface of header 12 of frame assembly 11. A pair of supports 183 and 184 extended vertically below plate 182 are secured to the bottom of plate 182. Door frame unit 181 has a plate 194 secured with a weld to top member 24 of door frame 22. Upright arms 196 and 197 secured to plate 194 are located adjacent the inside walls of supports 183 and 184. A cylindrical member or sleeve 201 extends through openings 198 and 199 in arms 196 and 197. Pin 179 extended through sleeve 201 and supports 183 and 184 pivotally connects door frame unit 181 to frame assembly unit 178 and supports overhead door 10 on header 12 of frame assembly 11. Pin 179 does not rotate during the pivoting of overhead door 10 between the open position and the closed position. Sleeve 201 has a large inside cylindrical surface that engages pin 179 and distributes forces along the length of pin 179 to reduce wear and shearing of pin 179. A block 191 secured to a first end of pin 179 engages a stop 172 secured to support 184 to prevent rotation of pin 179 relative to frame assembly unit 178. The second end of pin 179 accommodates a retainer 193, shown as a cotter key, to limit axial movement of pin 179 relative to supports 196 and 197.

(36) The foregoing drawing and description of the overhead door frame assembly with tripod legs and splice assemblies is one embodiment of the invention. Persons skilled in the art of overhead doors can make changes and modifications of the structures and materials to the door, frame assembly and hinges without departing from the frame assembly and tripod leg defined in the claims.