Deployable Shell Roll-up Door
20220081966 · 2022-03-17
Inventors
Cpc classification
E06B9/34
FIXED CONSTRUCTIONS
E06B9/581
FIXED CONSTRUCTIONS
A01G9/16
HUMAN NECESSITIES
Y02A40/25
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E06B9/13
FIXED CONSTRUCTIONS
E06B2009/1566
FIXED CONSTRUCTIONS
E04B7/166
FIXED CONSTRUCTIONS
A01G13/0231
HUMAN NECESSITIES
International classification
Abstract
Two embodiments of a roll-up door system, based on deployable shell designs, are disclosed. Each embodiment consists of: an axle providing continuity to the embodiment, a door panel assembly, two mounting and support assemblies, and two door alignment and support tracks. Each embodiment has the following attributes: large lateral load strength to weight ratio, good natural heat flow insulation, weather tightness and, with proper jamb seals, differential pressure boundary capability.
Claims
1. A roll-up door system with large transverse load capacity to weight ratio, based on a deployable shell design, comprising: a. a solid circular cylindrical axle (28), horizontally oriented, providing continuity to said roll-up door system; b. a flexible door panel assembly (11, 14), comprising: 1. a rectangular inner surface elastic sheet (23) having an upper edge, 2. a rectangular outer surface elastic sheet (24) substantially parallel to said inner surface elastic sheet and having an upper edge, 3. a plurality of elongated hinges (29), 4. a plurality of substantially rigid elongated webs (25) having at least two parallel elongated edges and two ends, each of which is attached in a parallel manner, along both elongated edges, to said inner and outer elastic sheets by means of said hinges, where the spacing of said hinge connections, as measured on the surface of said inner elastic sheet, is less than the spacing of said hinge connections, as measured on the surface of said outer elastic sheet, thus sandwiching said webs between said elastic sheets, 5. a plurality of web support rollers (20) attached to the ends of said webs, 6. a sheet anchor bar (27) to which are attached the upper edges of said inner and outer elastic sheets, 7. a hollow substantially circular cylindrical mandrel (21), having two ends and an outer surface to which is attached said anchor bar so that said inner elastic sheet is nearest said mandrel axis, 8. a first mandrel end (31) attached to the first end of said mandrel and being radially supported by said axle, 9. a second mandrel end (31) attached to the second end of said mandrel and being supported by and attached to said axle; c. a first door mount and support assembly (12) providing radial support of said axle, comprising: 1. a first support frame (30), 2. a first frame bearing (36) being coaxial with said axle and located between said first support frame and said axle; d. a second door mount and support assembly (12) providing radial support of said axle, comprising: 1. a second support frame (41), 2. a bearing support ring (42) attached to said second support frame, 3. a second frame bearing (36) being coaxial with said axle and located between said bearing support ring and said axle; e. a support and guide roller assembly providing guidance of said flexible door panel assembly, comprising: 1. a support and guide roller (22) contacting said flexible door panel assembly, 2. a first guide roller support leg (32) attached to said first support frame and providing elastic spring support of said guide roller, 3. a second guide roller support leg (32) attached to said second support frame and providing elastic spring support of said guide roller; f. a weight balancing spring assembly, comprising: 1. a spring-axle connection flange (44) affixed to said axle, 2. a counter-weight spring (39) coaxial with said axle and attached to said spring-axle connection flange, 3. a spring anchor sleeve (35) coaxial with said axle, passing through said first mandrel end and attached to said counter-weight spring, 4. an inner mandrel bearing (37) located between said axle and said spring anchor sleeve, 5. an outer mandrel bearing (38) located between said spring anchor sleeve and said first mandrel end, 6. a spring anchor plate (33) being coaxial with said axle and contacting said first support frame, 7. a plurality of spring anchor sleeve screws (45) connecting said spring anchor sleeve with said spring anchor plate, 8. a first spring anchor plate bolt (34) and a second spring anchor plate bolt (34) connecting said spring anchor plate to said first support frame, whereby, with said axle temporarily rotationally restrained and said spring anchor plate bolts temporarily removed, said spring anchor plate is rotated until a desired weight preload torque is achieved in said counter-weight spring, whereupon said spring anchor plate bolts are installed; g. a first door alignment and support track (13) and a second door alignment and support track (13), curved along respective longitudinal axes, and entraining and supporting said web support rollers located on common ends of said webs, thus enabling said inner elastic sheet to be planar for said door closed configuration; whereby, application of torsional force to said axle rotates said mandrel resulting in either closure of said roll-up door or opening of said roll-up door, depending on direction of application of said torsional force.
2. A roll-up door system with large transverse load capacity to weight ratio, based on a deployable shell design, comprising: a. a solid circular cylindrical axle (28), horizontally oriented, providing continuity to said roll-up door system; b. a flexible door panel assembly (51, 54), comprising: 1. a rectangular inner surface elastic sheet (61) having an upper edge, 2. a rectangular outer surface elastic sheet (62) substantially parallel to said inner surface elastic sheet and having an upper edge, 3. a plurality of elongated hinges (29), 4. a plurality of substantially rigid elongated webs (63) having at least two parallel elongated edges and two ends, each of which is attached in a parallel manner, along both elongated edges, to said inner and outer elastic sheets by means of said hinges, where the spacing of said hinge connections, as measured on the surface of said inner elastic sheet, is less than the spacing of said hinge connections, as measured on the surface of said outer elastic sheet, thus sandwiching said webs between said elastic sheets, 5. a plurality of web support rollers (20) attached to the ends of said webs, 6. a sheet anchor bar (27) to which are attached the upper edges of said inner and outer elastic sheets, 7. a hollow substantially circular cylindrical mandrel (21), having two ends and an outer surface to which is attached said anchor bar so that said inner elastic sheet is nearest said mandrel axis, 8. a first mandrel end (31) attached to the first end of said mandrel and being radially supported by said axle, 9. a second mandrel end (31) attached to the second end of said mandrel and being supported by and attached to said axle; c. a first door mount and support assembly (52) providing radial support and horizontal alignment of said axle, comprising: 1. a first support frame (71), 2. a first linear bearing shaft (75) connected to said first support frame, 3. a first linear bearing (74) and a second linear bearing (74) supported by and coaxial with said first linear bearing shaft, 4. a first frame bearing (36) being coaxial with and located adjacent to said axle, 5. a first bearing support (78) connected to said first and second linear bearings and supporting said first frame bearing, 6. a first cam plate (76) containing a spiral cam groove and being coaxial with and connected to said axle, 7. a first cam pin (77) attached to said first support frame and constrained by said cam plate groove, whereby, rotation of said axle results in corresponding rotation of said first cam plate and, due to spiral shape of said cam groove, a resulting horizontal motion of said axle; d. a second door mount and support assembly (52) providing radial support of said axle, comprising: 1. a second support frame (81), 2. a bearing support ring (42) being coaxial with said axle, 3. a second frame bearing (36) being coaxial with said axle and located between said bearing support ring and said axle 4. a second linear bearing shaft (75) connected to said second support frame, 5. a third linear bearing (74) and a fourth linear bearing (74) supported by and coaxial with said second linear bearing shaft, 6. a second bearing support (83) connected to said third and fourth linear bearings and said bearing support ring, 7. a second cam plate (82) containing a spiral cam groove and being coaxial with and connected to said axle, 8. a second cam pin (77) attached to said second support frame and constrained by said cam plate groove, whereby, rotation of said axle results in corresponding rotation of said second cam plate and, due to spiral shape of said cam groove, a resulting horizontal motion of said axle; e. a support and guide roller assembly providing guidance of said flexible door panel assembly, comprising: 1. a support and guide roller (22) contacting said flexible door panel assembly, 2. a first guide roller support leg (72) attached to said first support frame and providing elastic spring support of said guide roller, 3. a second guide roller support leg (72) attached to said second support frame and providing elastic spring support of said guide roller; f. a weight balancing spring assembly, comprising: 1. a spring-axle connection flange (44) affixed to said axle, 2. a counter-weight spring (39) coaxial with said axle and attached to said spring-axle connection flange, 3. a spring anchor sleeve (35) coaxial with said axle, passing through said first mandrel end and attached to said counter-weight spring, 4. an inner mandrel bearing (37) located between said axle and said spring anchor sleeve, 5. an outer mandrel bearing (38) located between said spring anchor sleeve and said first mandrel end, 6. a spring anchor plate (73) being coaxial with said axle and contacting said first support frame, 7. a plurality of spring anchor sleeve screws (45) connecting said spring anchor sleeve with said spring anchor plate, 8. a spring anchor plate bolt (34) connecting said spring anchor plate to said second bearing support, whereby, with said axle temporarily rotationally restrained and said spring anchor plate bolt temporarily removed, said spring anchor plate is rotated until a desired weight preload torque is achieved in said counter-weight spring, whereupon said spring anchor plate bolt is installed; g. a first door alignment and support track (53) and a second door alignment and support track (53), curved along respective longitudinal axes, and entraining and supporting said web support rollers located on common ends of said webs, thus enabling said outer elastic sheet to be planar for said door closed configuration; whereby, application of torsional force to said axle rotates said mandrel resulting in either closure of said roll-up door or opening of said roll-up door, depending on direction of application of said torsional force.
Description
DRAWINGS—FIGURES
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TABLE-US-00002 Drawings - Reference Numerals 11 door panel assembly, G1 - closed 12 door mount and support assembly, G1 13 door alignment and support track, G1 14 door panel assembly, G1 - open 20 typical roller 21 mandrel 22 support and guide roller 23 inner surface elastic sheet, G1 24 outer surface elastic sheet, G1 25 typical web, G1 26 foot web, G1 27 sheet anchor bar 28 axle 29 typical hinge 30 support frame, G1 - side A 31 mandrel end 32 guide roller support leg, G1 33 spring anchor plate, G1 34 typical spring anchor plate bolt 35 spring anchor sleeve 36 frame bearing 37 inner mandrel bearing 38 outer mandrel bearing 39 counter-weight spring 41 support frame, G1 - side B 42 bearing support ring 43 spacer 44 spring - axle connection flange 45 typical spring anchor sleeve screw 51 door panel assembly, G2 - closed 52 door mount and support assembly, G2 53 door alignment and support track, G2 54 door panel assembly, G2 - open 61 inner surface elastic sheet, G2 62 outer surface elastic sheet, G2 63 typical web, G2 64 foot web, G2 71 support frame, G2 - side A 72 guide roller support leg, G2 73 spring anchor plate, G2 74 typical linear bearing 75 linear bearing shaft 76 cam plate, side A 77 cam pin 78 bearing support, side A 81 support frame, G2 - side B 82 cam plate, side B 83 bearing support, side B 90 cam plate groove 91 typical sheet anchor bar connection screw 92 typical track section 93 typical inner sheet section 94 typical outer sheet section 95 typical hinge section 96 typical web section 101 ratio k and constant C definitions 102 linear dimension x definition, G1 103 curved dimension r definition, G1 104 angle integral definition, G1 105 linear dimension y definition, G2 106 curved dimension s definition, G2 107 angle integral definition, G2 121 roof panel, closed configuration 122 roof panel retracted configuration 123 central roof beam
EMBODIMENT DESCRIPTIONS
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First Embodiment, Door Panel Assembly—FIGS. 1A through 2B, 9A and 9C through 9E
[0054] Overall views of the first embodiment are illustrated in
[0055] Details of the door panel assembly are illustrated in
[0056] A support and guide roller 22, which is connected to the door mount and support assemblies 12, is provided. It is noted that this roller does not transmit a large radial force to the rolled elastic sheets since shell transverse shear force is absent for circular cylindrical bending displacement of the thin elastic sheets.
First Embodiment, Door Mount and Support Assemblies—FIGS. 3A through 4B
[0057] The first embodiment contains two nearly identical mount and support assemblies located at both ends of their respective mandrels. Designs of the assemblies differ due to inclusion of a weight counterbalance spring mechanism. The designs are designated “side A” and “side B” where side A includes a counterweight spring pretension and frame anchor mechanism and side B includes a spring-axle connection. The first embodiment support assembly designs constrain all radial displacement of the axle-mandrel assembly.
[0058] A side view of side A support assembly is shown in
[0059] A side view of the side B support assembly is shown in
Second Embodiment, Door Panel Assembly—FIGS. 5A through 6B, 9A and 9C through 9E
[0060] Overall views of the second embodiment G2 geometry are given in
[0061] Details of the door panel assembly are illustrated in
[0062] A support and guide roller 22, which is connected to the door mount and support assemblies 52, is provided. It is noted that this roller does not transmit a large radial force to the rolled elastic sheets since shell transverse shear force is absent for circular cylindrical bending displacement of the thin elastic sheets.
Second Embodiment, Door Mount and Support Assemblies—FIGS. 7A through 8B, 9A, 9B
[0063] The second embodiment contains two nearly identical mount and support assemblies located at both ends of the mandrel. Designs of the assemblies differ due to inclusion of a weight counterbalance spring mechanism. The designs are designated “side A” and “side B” where side A includes a counterweight spring pretension and frame anchor mechanism and side B includes a spring-axle connection. The second embodiment support designs allow for horizontal displacement of the mandrel-axle assembly.
[0064] A side view of side A support assembly is shown in
[0065] The significant difference between the first and second embodiment supports is that, for the second embodiment, the axle-mandrel assembly moves horizontally relative to the framework via a linear bearing assemblies and is regulated by cam systems. The reason for this movement is to assure correct tracking of the web rollers during operation of the door. A linear bearing assembly consists of two linear bearings 74 guided by a linear bearing shaft 75 and affixed to a linear bearing support 78 which, in turn, supports the frame bearing 36. Horizontal movement of the axle is controlled by a grooved cam plate 82,
[0066] Side and cross-section views of the second embodiment side B support assembly are shown in
First and Second Embodiments—Materials and Operation
[0067] The elastic surface sheets, 23, 61 and 24, 62, may be comprised of homogenous metallic material or of composite fiber reinforced polymer (FRP) construction. The webs, 25, 63, are subject to only in-plane stresses due to bending stress relief of the hinges 29, and may thus be constructed of light homogeneous materials or a FRP wrapped core. The hinges may be conventional mechanical hinges or constructed of flexible polymer composite. Various methods may be employed for hinge attachment to sheets and webs, including mechanical (rivets or spot welds) or adhesives. Also, the webs may be designed to include the hinge elements so that the only assembly attachments required are web-to-sheets.
[0068] Operation of both door embodiments is very simple where a torsional force is applied to either end of the axle which results in rotation of the axle-mandrel assembly and associated vertical motion of the door.
First and Second Embodiments—Design Considerations—FIG. 10
[0069] A representative section of the rolled-up door is shown in
[0070] Maximum elastic strain, e, in a circular cylindrically bent thin elastic sheet is given by the following well known relationship:
e=t/(2R),
where t is the sheet thickness and R is the cylindrical bend radius of the sheet. Maximum open embodiment strain, emax, is then,
emax=max{ti/(2Ri),to/(2Ro)}.
[0071] From this relationship, design t/R ratios are determined by equating emax with the sheet material design strain, as determined in the preceding paragraph.
[0072] After selection of Ri, Ro and web dimension W, constants k and C are computed according to relations 101,
[0073] For first embodiment designs (geometry G1), the clear opening height, see
Additional Embodiments—FIGS. 11 through 12B
[0074] Due to its very large lateral load resistance to weight ratio and weather tightness, the deployable shell is an excellent candidate for retractable roof design bases.
[0075] An additional retractable roof application embodiment is illustrated in
First and Second Embodiments—Advantages
[0076] A number of advantages are evident in the first and second embodiments described above:
[0077] (a) Very high stiffness and strength to weight ratios of the closed configurations enable light weight embodiments to carry large environmental transverse loads, such as pressure induced by wind.
[0078] (b) Embodiment continuous sheet surfaces enable the closed embodiments to be weather tight and capable of forming static pressure boundaries.
[0079] (c) Air confined in the cells of the closed configurations enables natural insulation of transverse heat transfer in the embodiments.
[0080] (d) Embodiment construction is extremely easy with no requirements for use of specialized equipment.
[0081] (e) Embodiment installation and operation utilizes existing commercially available equipment.
CONCLUSION, RAMIFICATIONS AND SCOPE
[0082] Two deployable shell roll-up door embodiment designs are disclosed herein. The embodiment designs are simple in concept and construction, yet have many potential uses which take advantage of the designs' unique capabilities: [0083] in their closed configurations, they have a very large stiffness to weight ratio which enables applications requiring low weight, deformations and flutter; [0084] in their closed configurations, they have a very high lateral load strength to weight ratio which enables applications requiring low weight and high resistance to lateral environmental loading; [0085] in their closed configurations, they have good natural insulation to transverse heat flow due to air confined in the internal cells of the shell; [0086] in their closed configurations, they are weather tight and capable, with proper edge sealing, of forming a differential pressure boundary such as could be used in an ultra-clean environment; [0087] in their open configurations, they are compact cylinders; and [0088] they are capable of rapid and quiet operation.
[0089] Although the above discussion contains many specificities, these should not be construed as limiting the scope of the embodiments, but as providing illustrations of some of several possible applications.