Knock-Down Weather Seal Assembly for an Overhead Door and Method of Use and Distribution

Abstract

A knock-down seal assembly for an overhead-sectional door having horizontal joints between adjacent panels and a leading lateral edge that seals the lateral leading edge of the door as the door panel closes against the floor or traffic area. The seal assembly includes a pair of retainer rails which do not exceed about 5 to 6 feet in overall length. The retainer rails have one or more seal channels formed in a bottom surface of the rail for receiving a flexible weather seal strip. The rails also have a separate extension channel formed in the bottom surface thereof for receiving an elongate retainer clip. The retainer clip can be used to join the pair of rails to form a single rail of a longer overall length.

Claims

1. A method of distributing a weather seal assembly for an overhead door, the door having a bottom lateral edge, the method comprising the steps of: providing a plurality of sections of retainer rails, the rails being provided in lengths which do not exceed about 5 to 6 feet overall, the retainer rails having at least one seal channel formed in a bottom surface thereof for receiving a flexible elongate weather seal, the retainer rails also having a separate extension channel formed in the bottom surface thereof for receiving an elongate retainer clip, the bottom surface of the retainer rails being defined between a pair of opposing ends of the respective retainer rails; shipping the retainer rails, retainer clips and flexible weather seals from a distribution center to an end use location; joining at least two of the retainer rails together by installing a retainer clip in a selected extension channel provided on a bottom surface of a first one of the retainer rails and then bringing a second one of the retainer rails into proximity with the first rail, so that the retainer clip fits in a pair of aligned extension channels formed in the two retainer rails being joined and so that opposing ends of the respective retainer rails come into contact; installing the flexible weather seal in the at least one seal channel provided on the bottom surface of the joined retainer rails; and installing the assembled retainer rail on the bottom lateral edge of the overhead door.

2. The method of claim 1, wherein the retainer rails are formed of extruded aluminum.

3. The method of claim 1, wherein the retainer rails are formed of a rigid plastic material.

4. The method of claim 1, wherein the weather seal is a bulb type seal.

5. A method of distributing a weather seal assembly for an overhead garage door, the door being a sectional door having a series of hinged panels interconnected along horizontal joints and having a bottom lateral edge, the method comprising the steps of providing a plurality of sections of extruded aluminum retainer rails, the rails being provided in lengths which do not exceed about 5 to 6 feet overall, the retainer rails having a pair of spaced apart seal channels formed in a bottom surface thereof for receiving a flexible elongate weather seal, the retainer rails also having a separate extension channel formed in the bottom surface between the pair of spaced apart seal channels for receiving an elongate retainer clip, the bottom surface of the retainer rails being defined between a pair of opposing ends of the respective retainer rails; packaging a weather seal assembly kit which includes the retainer rails, retainer clips and weather seal; shipping the weather seal assembly kit from a distribution center to an end use location; joining at least two of the extruded retainer rails from the kit together by installing a retainer clip in a selected one of the extension channels provided on a bottom surface of a first one of the retainer rails and then bringing a second one of the retainer rails into proximity with the first rail, so that the retainer clip fits in a pair of aligned extension channels formed in the two retainer rails being joined and so that opposing ends of the respective retainer rails come into contact; installing the flexible weather seal in the at least one seal channel provided on the bottom surface of the joined retainer rails; and installing the assembled retainer rail on the bottom lateral edge of the overhead door.

6. The method of claim 5, wherein a pair of the extruded retainer rails are joined with a retainer clip so that the resulting overall length of the assembled retainer rail has a length in the range from about 16 to 20 feet.

7. A knock-down weather seal assembly kit for an overhead door having a series of hinged horizontal sections and a bottom lateral edge, the assembly kit comprising: at least two extruded retainer rails, the rails being provided in lengths which do not exceed about 5 to 6 feet overall, the retainer rails having at least one seal channel formed in a bottom surface thereof for receiving a flexible elongate weather seal, the retainer rails also having a separate extension channel formed in the bottom surface thereof for receiving an elongate retainer clip, the bottom surface of the retainer rails being defined between a pair of opposing ends of the respective retainer rails; at least one elongate retainer clip selectively sized to be received within a selected extension channel provided on a bottom surface of each of the two extruded retainer rails, whereby the two retainer rails can be assembled at a job site by installing a retainer clip in the extension channel provided in a first one of the retainer rails and then bringing a second one of the retainer rails into proximity with the first rail, so that the retainer clip fits in a pair of aligned extension channels formed on the bottom surface of the retainer rails when the channels are aligned, thereby joining the two retainer rails together so that opposing ends of the respective retainer rails come into contact; and a selected length of a flexible, elongate weather seal which can be cut to fit within the seal channel found on the bottom surface of the retainer rails.

8. The knock-down weather seal assembly of claim 7, wherein the pair of joined extruded retainer rails have a resulting overall length in the range from about 16 to 20 feet.

9. The assembly kit of claim 7, wherein the retainer rails are formed of extruded aluminum.

10. The assembly kit of claim 7, wherein the retainer rails are formed of an extruded plastic material.

11. The assembly kit of claim 7, wherein the weather seal is provided in the form of a bulb seal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1 is a perspective view of an overhead sectional garage door of the type which uses a bottom weather seal assembly along the bottom lateral edge of the door.

[0014] FIG. 2 is a side view of the weather seal retainer assembly of the invention.

[0015] FIG. 3A is an isolated, perspective view of a portion of one of the retainer rails of the invention with the associated retainer clip being shown in exploded fashion, prior to assembly.

[0016] FIG. 3B is a view similar to FIG. 3A, but showing a pair of the retainer rails with the retainer clip in place on one of the rails prior to assembly with the second rail.

[0017] FIG. 3C is a perspective view of a pair of the weather seal retainer rails with the rails being shown joined together with the retainer clip of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The preferred version of the invention presented in the following written description and the various features and advantageous details thereof are explained more fully with reference to the non-limiting examples included and as detailed in the description which follows. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the principal features of the invention as described herein. The examples used in the description which follows are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.

[0019] FIG. 1 is a simplified view of a section overhead door, referred to generally as 11. The overhead door 11 includes a series of door panels, such as panels 13, 15, that are interconnected along horizontal joints along hinge lines 17. As the door 11 opens or closes relative to a doorway 19, guide members, such as rollers (not shown), guide the movement of the panels along two lateral tracks 21, 23. The tracks 21, 23, may curve between horizontal and vertical, or assume other configurations. For example, the tracks may run generally linearly or only curve slightly, so that when the door opens, the door panels move above doorway 19, but remain in a generally vertical or slightly angled orientation, or they may be approximately horizontal when in the open position. To close door 11, the vertical sections of tracks 21, 23, guide the panels from a horizontal position to a vertical position across doorway 19. The overhead door 11 will also be typically provided with a weather seal strip (designated 25 in FIG. 1) which runs along a bottom lateral edge 12 of the door 11. This seal strip provides a seal between a leading edge of panel 15 and a floor or traffic surface below the doorway. The weather seal also ensures that the bottom of the door is level to the floor when closed.

[0020] The actual structure of panels 13, 15, of the overhead door can vary. For example, at least the lowermost panel 15 could be made of a material which has enough flexibility to recover from a vehicle impact, as it is the lowermost panel that is most susceptible to being struck. Thus, in some embodiments, the lowermost panel 15 can comprise a foam core whose outer faces are each bonded to a tough face panel that is generally harder than foam core. The foam core provides a lightweight panel that provides thermal insulation and a desirable balance of rigidity and flexibility, while face panels offer resistance to wear, weather, and impact. Some preferred materials include polyethylene foam for the core and an ABS or PVC acrylic for face panels. However, it will be understood by those skilled in the relevant arts that a wide variety of other materials could also be used. For example, any of the door panels, such as panels 13, 15, could be formed of sheet metal or aluminum, or even of wood.

[0021] The bottom weather seal strip 25 can conveniently be either a “bulb seal” or a “blade seal”, as will be familiar to those skilled in the art. The bulb seal is essentially a closed seal in the sense that it is secured to the frame component along its longitudinal edges. The bulb seal can be manufactured from a relatively soft and resilient material, such as a suitable rubber or other synthetic that can be compressed to form a seal when the door is closed and that at least partially rebounds when the door is opened. The blade type seal might be formed of a suitable plastic, such as a suitable vinyl plastic.

[0022] FIG. 2 shows a weather seal assembly which incorporates certain of the features of the invention. The weather seal assembly shown in FIG. 2 uses a modified version of Applicant's “Aluminum or Plastic Weather Seal Retainer” sold commercially by National Door Industries, Inc., of Fort Worth, Tex. The Aluminum Weather Seal Retainer Rail is used as a bottom retainer on ship lap or tongue and groove doors. It can be installed with screws, nails or rivets. The Plastic Weather Seal Retainer Rails are commonly used as a bottom retainer rail on 2 inch doors. The available “Style F” has a flat bottom for wood or steel doors while the “Style T” is for tongue and grooved doors. These retainer rails can be conveniently extruded aluminum or vinyl plastic, or the like.

[0023] The weather seal assembly shown in FIG. 2 is generally a “Type F” retainer rail 26 having a base region 27 with a top surface 29 and a bottom surface 31. The base region 27 is joined to an upright region 33. Both the base region 27 and the upright region 33 run longitudinally along the bottom lateral edge (12 in FIG. 1) of the overhead door when installed. Since the retainer rail spans the entire width of the door opening 19, it was generally necessary in the past to provide the rails in relatively longer lengths, such as, for example, 16 to 20 feet lengths. As has been explained, this could cause problems in shipping the rails and also added to the cost of shipping. As will be explained more fully, the modified retainer rails of the invention allow the rails to be provided in relatively shorter lengths, for example, 5 or 6 foot lengths. Such lengths can usually be shipped by commercial carrier without incurring additional excess shipping charges.

[0024] Referring back to FIG. 2, the weather seal assembly of the invention is thus provided with at least two retainer rails such as the rail shown. As with the traditional extruded rails, the rail in FIG. 2 has at least one seal channel formed in the bottom surface 31 thereof for receiving one of the flexible elongate weather seals such as the seal 35 shown. Preferably, a pair of seal channels 37, 39, are formed in spaced-apart fashion on the bottom surface 31 and run for substantially the length of the bottom surface 31. They are adapted to slidingly receive the tab portions 41, 43, of the weather seal element 35, thereby forming the bulb-shaped region 44. In the example shown in FIG. 2, the weather seal strip 35 also has external ribs 45 running along the exterior thereof.

[0025] The weather seal assembly of FIG. 2 differs from the prior art in also having an additional elongate extension channel 47, formed at the time the retainer rail was extruded in the bottom surface 31 of the retailer rail. The extension channel 47 is adapted to receive an elongate retainer clip, shown as 49 in FIG. 3A. As shown in FIG. 3A, the extension channel is located approximately mid-way between the seal channels 37, 39, on the the bottom surface of the retainer rails 26. The extension groove has a length which is defined between a pair of opposing ends of the respective retainer rails, such as the ends 51, 53, shown in the broken off portion of the extension rail 26.

[0026] The retainer clip (49 in FIG. 3A) used in the practice of the invention is selectively sized to be received within a selected extension channel (such as channel 47) provided on the bottom surface 31 of each of two mating retainer rails, such as the two retainer rails 26, 28, shown in FIG. 3B. It is conveniently friction fit within the selected extension channel. The preferred retainer clip 49 shown in FIG. 3A is an elongate element which in the example shown is about 8 to 20 inches long and which has opposing side rail surfaces 55, 57, opposing end surfaces 59, 61, and a central raised tunnel region 63.

[0027] As perhaps best seen in FIG. 3B, the retainer clip 49 is used to join a first retainer rail 26 to a second retainer rail 28 by first inserting one end of the retainer clip 49 into the extension channel 47 formed on the bottom surface of the retainer rail 26. The opposing side rail surfaces 55, 57, fit snugly in the extension channel 47 being captured by the ear regions 62, 64, of the extension channel 47, while the central tunnel region 63 of the retainer clip occupies the upwardly facing opening (generally at 65 in FIG. 3B).

[0028] As illustrated in FIGS. 3B and 3C, the two retainer rails 26, 28, can be then assembled at a job site by installing the retainer clip 49 in the extension channel 47 provided in a first one of the retainer rails 26 and then bringing a second one 28 of the retainer rails into proximity with the first rail, so that the retainer clip 49 fits in a pair of aligned extension channels (such as channels 47 and 67 shown in FIG. 3B) formed on the bottom surface of the retainer rails when the channels are aligned. Bringing the two rails 26, 28, together then joins the rails so that the opposing ends 51, 69, of the respective retainer rails come into contact. This allows an extension rail to be assembled of a greater overall length, for example, resulting overall length in the range from about 16 to 20 feet. More than two extension rails could also be assembled in the same fashion.

[0029] The extension clips are generally only needed to hold the two extension rail sections together firmly until they can be installed on the bottom edge of the overhead door. Thus, convenient regions, such as region 71 shown in FIG. 3B, may be provided with apertures, such as screw holes or slots, for securing the retainer rails to the door. The screw holes or slots may be disposed on essentially any portion of the frame components, however. Alternatively, one or both of the frame components may be manufactured with a groove and/or with indentations that provide a guide for forming screw holes during installation.

[0030] It will also be appreciated from the foregoing discussion that an improved distribution technique is also shown for distributing a weather seal assembly of the type previously described. The aforementioned component parts, i.e., the retainer rails, retainer clips and flexible weather seal materials, are shipped from a distribution center to an end use location. Once at an end use location, at least two of the retainer rails are joined together as previously described using the retainer clips and retainer channels. The result is a single retainer rail of a relatively longer overall length, say 16 feet for a typical garage door. A flexible elongate weather seal can then be installed in one or more grooves provided on the bottom surface of the joined retainer rails. The assembled retainer rail can then be installed on the bottom lateral edge of an overhead door. Alternatively, the retainer rail could be installed on the garage door first, followed by installing the weather seal material.

[0031] An invention has been provided with several advantages. The knock-down weather seal assembly of the invention provides a simple and money saving solution to the problem of shipping longer length weather seal retainer rails. The knock-down nature of the product allows an end user to assemble two or more shorter lengths of retainer rail into one longer overall assembly at a job site or other location. In addition to saving shipping costs, the distribution method of the invention also lessens the probability that product will be damaged during shipment.

[0032] While the invention has been shown in only one of its forms, it will be appreciated that it is not thus limited, but is susceptible to various changes and modifications without departing from the spirit thereof.