Sliding door with wireless-controlled motor housed in jamb

Abstract

A sliding door assembly includes a frame that supports and interfaces directly to a fixed door panel and a moving door panel. The frame includes opposed side jamb portions, a sill portion, and head jamb portion opposite the sill portion. The door assembly includes an electric motor, a wireless motor controller, and a drive belt that is operably coupled to the moving door panel. The drive belt is driven by the electric motor under control of the wireless motor controller. The head jamb portion includes at least one internal channel that accommodates the drive belt. One of the side jamb portions has a first internal compartment that houses the electric motor and the wireless motor controller.

Claims

1. A sliding door assembly comprising: a frame that supports and interfaces directly to a fixed door panel and a moving door panel, wherein the frame includes opposed side jamb portions, a sill portion, and head jamb portion opposite the sill portion; an electric motor; a wireless motor controller; and a drive belt that is operably coupled to the moving door panel, wherein the drive belt is driven by the electric motor under control of the wireless motor controller; wherein the head jamb portion includes at least one internal channel that accommodates the drive belt; wherein one of the side jamb portions includes a top part opposite a bottom part, wherein the top part of the one side jamb portion is disposed adjacent the head jamb portion, wherein the top part of the one side jamb portion has a first internal compartment that houses the electric motor and the wireless motor controller, wherein a bracket is disposed inside the first internal compartment and configured to mount the electric motor to the top part of the one side jamb portion inside the first internal compartment, wherein the bracket is secured to the top part of the one side jamb portion by a plurality of fasteners accessed within the first internal compartment, wherein the top part of the one side jamb portion further includes a first opening and a second opening, wherein the first opening allows for passage of the drive belt between the first internal compartment and the internal channel that accommodates the drive belt, and wherein the second opening is oriented parallel to the fixed door panel and the moving door panel and exposes the first internal compartment and receives a removable access panel; and wherein the removable access panel is removably fixed to the one side jamb portion and has first and second configurations, wherein in the first configuration the access panel is fixed to the one side jamb portion and covers the second opening, and wherein in the second configuration the access panel is disconnected from the one side jamb portion to allow access to the internal compartment through the second opening and to the electric motor and the plurality of fasteners and the wireless motor controller disposed therein.

2. A sliding door assembly according to claim 1, further comprising: first and second guide pulleys that guide movement of the belt between two fixed points that are spaced apart from one another and aligned with the at least one internal channel of the head jamb portion.

3. A sliding door assembly according to claim 2, wherein: a particular one of the first and second guide pulleys is coupled to an output shaft of the electric motor and interfaces to the drive belt such that the drive belt moves in conjunction with rotation of the output shaft of the electric motor.

4. A sliding door assembly according to claim 3, wherein: the particular one of the first and second guide pulleys is housed within the first internal compartment of the one side jamb portion.

5. A sliding door assembly according to claim 3, wherein: the other side jamb portion has a top part opposite a bottom part, wherein the top part of the other side jamb portion is disposed adjacent the head jamb portion, and wherein the top part of the other side jamb portion has a second internal compartment that houses the other one of the first and second guide pulleys.

6. A sliding door assembly according to claim 5, wherein: the top part of the other side jamb portion includes a third opening that allows for passage of the drive belt into the second internal compartment.

7. A sliding door assembly according to claim 1, wherein: the frame is secured to structural members of a building structure, wherein the structural members provide a four-sided opening that supports the frame.

8. A sliding door assembly according to claim 1, wherein: the wireless motor controller includes an RF interface for wireless communication to a remote device and controller circuitry, wherein the RF interface and controller circuitry cooperate to receive commands for operating the sliding door assembly communicated from the remote device.

9. A sliding door assembly according to claim 8, wherein: the wireless motor controller further includes interface circuitry operably coupled between the controller circuitry and the electric motor for electrical control of the electric motor.

10. A sliding door assembly according to claim 9, wherein: the electric motor comprises a DC motor; and the interface circuitry comprises an H-bridge switching circuit that is controlled by electrical signals supplied by the controller circuitry.

11. A sliding door assembly according to claim 8, wherein: the electric motor includes a shaft encoder that supplies feedback signals to the controller circuitry, wherein the feedback signals are used by the controller for electrical control of the electric motor.

12. A sliding door assembly according to claim 1, further comprising: an electrical power source the supplies DC power signals to the wireless motor controller.

13. A sliding door assembly according to claim 12, wherein: the electrical power source comprises an AC-DC transformer.

14. A method of operating a sliding door assembly, the method comprising: a) providing a sliding door assembly comprising: a frame that supports and interfaces directly to a fixed door panel and a moving door panel, wherein the frame includes opposed side jamb portions, a sill portion, and head jamb portion opposite the sill portion; an electric motor; a wireless motor controller; and a drive belt that is operably coupled to the moving door panel, wherein the drive belt is driven by the electric motor under control of the wireless motor controller; wherein the head jamb portion includes at least one internal channel that accommodates the drive belt; wherein one of the side jamb portions includes a top part opposite a bottom part, wherein the top part the one side jamb portion is disposed adjacent the head jamb portion, wherein the top part of the one side jamb portion has an internal compartment that houses the electric motor and the wireless motor controller, wherein a bracket is disposed inside the internal compartment and configured to mount the electric motor to the top part of the one side jamb portion inside the internal compartment, wherein the bracket is secured to the top part of the one side jamb portion by a plurality of fasteners accessed within the first internal compartment, wherein the top part of the one side jamb portion further includes a first opening and a second opening, wherein the first opening allows for passage of the drive belt between the internal compartment and the internal channel that accommodates the drive belt, and wherein the second opening is oriented parallel to the fixed door panel and the moving door panel and exposes the internal compartment and receives a removable access panel; and wherein the removable access panel is removably fixed to the one side jamb portion and has first and second configurations, wherein in the first configuration the access panel is fixed to the one side jamb portion and covers the second opening, and wherein in the second configuration the access panel is disconnected from the one side jamb portion to allow access to the internal compartment through the second opening and to the electric motor and the plurality of fasteners and the wireless motor controller disposed therein; b) wirelessly receiving a door movement command to move the door from a first position to a second position; c) in response to receiving the door movement command, d) applying power to the electric motor to drive the drive belt in a direction to move the moving door in a direction from the first position towards the second position; and d) reconfiguring the access panel from the first configuration to the second configuration to access the internal compartment through the second opening and access the electric motor and the plurality of fasteners and the wireless motor controller disposed therein for maintenance or repair.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a portion of a wooden building structure that defines a rough opening to receive a sliding door assembly.

(2) FIG. 2 shows a portion of a brick or masonry building structure that defines a rough opening to receive a sliding door assembly.

(3) FIG. 3 shows an exploded assembly view of portions of a prior art door frame, which can be installed in the rough openings shown in FIG. 1 or 2.

(4) FIG. 4a is an isometric view of a sliding door assembly in accordance with an aspect of the disclosure, viewed from a front side, top side, and left side thereof. In FIG. 4a, the sliding door assembly is shown with a moving door panel in a fully closed position.

(5) FIG. 4b is a detailed cutaway view of a portion of the sliding door assembly shown in FIG. 4a.

(6) FIG. 4c shows the sliding door assembly shown in FIG. 4a with a head jamb portion in FIGS. 4a and 4b removed for clarity of illustration to show a drive belt.

(7) FIG. 5a is an exploded assembly view showing details of the portion of FIG. 4c labeled FIG. 5c, shown with the drive belt omitted for clarity of illustration.

(8) FIG. 5b shows the components of FIG. 5a in a partially assembled state.

(9) FIG. 5c shows the components of FIG. 5a in a fully assembled state and coupled to the drive belt as shown in the portion of FIG. 4c labeled FIG. 5c.

(10) FIG. 6a is an exploded assembly view showing details of the portion of FIG. 4c labeled FIG. 6b, shown with the drive belt omitted for clarity of illustration.

(11) FIG. 6b shows the assembly of FIG. 6a in an assembled configuration and coupled to the drive belt as shown in the portion of FIG. 4c labeled FIG. 6b.

(12) FIGS. 7a and 7b show exploded assembly views of a clamping arrangement shown in the portion of FIG. 4c labeled FIG. 7d, shown with the drive belt omitted for clarity of illustration.

(13) FIG. 7c shows the clamping arrangement of FIGS. 7a and 7b in a partially assembled configuration with the drive belt of FIG. 4c.

(14) FIG. 7d shows the clamping arrangement of FIG. 7c in a fully assembled configuration and secured to the drive belt.

(15) FIG. 8 is a block diagram showing connections between components of the sliding door assembly of FIG. 4a.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(16) FIGS. 4a to 4c show various features of an embodiment of a sliding door assembly 400 in accordance with an aspect of the disclosure. The sliding door assembly 400 includes a frame 402 that supports and interfaces directly to a fixed door panel 404 and a moving door panel 406. The frame 400 is configured to be secured to structural members of a building structure (e.g., 100, 200) that define a rough opening (e.g., 102, 202) that supports the frame 400.

(17) The frame 402 is a four sided structure that includes opposed side jamb portions 402a (left side jamb portion) and 402b (right side jamb portion), a sill portion 402c, and head jamb portion 402d opposite the sill portion 402c. The portions 402a-402d may be wholly or partially separable members. For example, some or all of the portions 402a-402d may be welded to one another to form a unitary piece. Alternatively, some or all of the portions 402a-402d may be removably fastened to each other with removable fasteners, such as screws. The portions 402a-402d of the frame 400 may be formed of extruded materials, such as aluminum or plastic (e.g., polyvinyl chloride (PVC)). For example, FIG. 4b shows extruded profiles of side jamb portion 402b and head jamb portion 402d, which defines a two extruded channels 414.

(18) The sill portion 402c defines a track 403 that supports the fixed door panel 404 and the moving door panel 406. Specifically, the track 403 supports translation of the moving door panel 406 between a fully closed door position (shown in FIG. 4a), where the moving door panel 406 is engaged with one side jamb portion (e.g., right side jamb portion 402b), and a fully open door position in which the moving door panel 406 is engaged with the opposite side jamb portion (e.g., left side jamb portion 402a).

(19) As shown in greater detail in FIG. 4c, the sliding door assembly 400 also includes a drive belt 412 that is operably coupled to the moving door panel 406, as will be described in greater detail below. When connected to the frame 402, the at least one internal channel 414 (FIG. 4b) of the head jamb portion 402d accommodates the drive belt 412 and a clamp arrangement 700 (FIGS. 7a to 7d), further details of which are described below. Specifically, the one or more channels 414 are configured to accommodate the drive belt 412 and the clamp arrangement 700 and their movement (i.e., translation) in the one or more channels 414 as the moving door panel 406 translates along the track 403.

(20) As shown in FIGS. 5a and 5b, the sliding door assembly 400 further includes an electric motor 408 and a wireless motor controller 410. The side jamb portion 402b defines a first internal compartment 416 that houses the electric motor 408 and the wireless motor controller 410. The wireless motor controller 410 has wires 411 (FIGS. 5a, 5b) for connection to a power source, such as an AC/DC transformer 804 (FIG. 8), which can supply power to the wireless motor controller 410 as well as the electric motor 408.

(21) The motor 408 has an output shaft 408a secured to a first guide pulley 418. The motor 408 is configured to drive the output shaft 408a and the first guide pulley 418. The first guide pulley 418 is configured to couple with, or otherwise interface to, the drive belt 412, as shown in greater detail in FIG. 5c. The drive belt 412 moves in conjunction with rotation of the output shaft 408a of the electric motor 408 and the first guide pulley 418. The drive belt 412 is driven by the electric motor 408 under control of the wireless motor controller 410. The first guide pulley 418 may have gear teeth 418a that are configured to mesh with mating teeth of the belt 412.

(22) A window or opening 424 may be defined in the inner side of the right side jamb portion 402b. Alternatively, the portion 405 shown in broken lines in FIG. 5c may be omitted forming a larger opening or window 424. Also, as another alternative, the top of the side jamb portion 402b may be at or below the top of the moving door panel 406 and the head jamb portion 402d may be longer to extend to the outer side of the side jamb portion 402b to cover the first internal compartment 416.

(23) The window 424 is configured to align with the drive belt 412 and one or both of the channels 414, above the top of the moving door panel 406, as well as the top of the fixed door panel 404 (not shown in FIG. 5a). The motor 408 and the first guide pulley 418 can be secured inside the first internal compartment 416 to the side jamb portion 402b with a bracket 422 and fasteners 420a and 420b so that the first guide pulley 418 is positioned in alignment with the window 424 and one or both of the channels 414 of the header portion 402d. The window 424 allows for passage of the belt 412 to the first compartment 416 and to the first guide pulley 418 housed therein, as shown in greater detail in FIG. 5c.

(24) The sliding door assembly 400 also includes a removable access panel 425 that is removably fixed to the right side jamb portion 402b. As shown in FIG. 5c, the removable access panel 425 has a first configuration where the access panel 425 is fixed to the right side jamb portion 402b and covers at least a portion of the internal compartment 416. Also, as shown in FIGS. 5a and 5b, the access panel 425 has a second configuration where the access panel 425 is disconnected from the right side jamb portion 402b to allow access to the internal compartment 416 and to the electric motor 408, the wireless motor controller 410, and the first guide pulley 418 housed therein.

(25) In addition to the first guide pulley 418, the door assembly 400 may also include a second guide pulley 428, shown in FIGS. 4e and 6. The first and second guide pulleys 418 and 428 guide movement of the belt 412 between two fixed points that are spaced apart from one another and aligned with the at least one internal channel 414 of the head jamb portion 402d. In the embodiment of the door assembly 400, the two fixed points are located in the right and left side jamb portions 402a and 402b. More specifically, the left side jamb portion 402b defines a second internal compartment 426 that houses the second guide pulley 428. The second guide pulley 428 interfaces to the drive belt 412 such that the drive belt 412 moves in conjunction with rotation of the second guide pulley 428. The second guide pulley 428 may have gear teeth 428a that mesh with gear teeth of the belt 412, if present.

(26) A window or opening 434 is defined in the inner side of the left side jamb portion 402a. The window 434 is aligned with window 424, as well as drive belt 412 and one or both of the channels 414 (not shown in FIG. 6). The second guide pulley 428 is disposed inside the second internal compartment 426 and is secured to the side jamb portion 402a with a bracket 432 and fasteners 430a and 430b so that the second guide pulley 418 is positioned in alignment with the window 434. The window 434 allows for passage of the belt 412 to the second internal compartment 426 and to second guide pulley 428 housed therein.

(27) FIGS. 7a to 7d show details of a secure clamping arrangement between the belt 412 and the moving door panel 406 that secures the moving panel 406 to a certain section or portion of the drive belt 412. The clamping arrangement includes a bracket 700 and a clamp 702. The bracket 700 has a first portion 700a and a second portion 700b that may be connected with fasteners 703. The first portion 700a is configured to be fixed to a side 406a (e.g., the left side in FIGS. 7a to 7d) of the moving door panel 406, near a top corner 406b of the moving door panel 406, with fasteners 701, so that an upper portion 700b of the bracket 700 extends into one of the channels 414 in alignment with an inner side of the belt 412, as shown in FIGS. 7c and 7d. As shown in FIG. 7c, the clamp 702 can be positioned on an outer side of the belt 412, opposite the second portion 700b. Then, as shown in FIG. 7d, the clamp 702 can be secured with fasteners 704a and 704b to the second portion 700b to securely clamp the belt 412 between the clamp 702 and the second portion 700b of the bracket 700. As a result of the secure connection between the belt 412 and the bracket 700, and between the bracket 700 and the moving door panel 406, the belt 412 and the moving door panel 406 can move in unison.

(28) FIG. 8 shows further details of the motor 408 and the wireless motor controller 410. The wireless motor controller 410 includes an RF interface 410a that is configured for wireless communication to a remote device 800, and controller circuitry 410b, which may include a microcontroller that includes a processor and memory with programmable input/output peripherals. The RF interface 410a and the controller circuitry 410b cooperate to receive commands 802 for operating the sliding door assembly 400 communicated from the remote device 800. The remote device 800 may be any computing device having a wireless RF interface capable of communicating with the RF interface 410a. In one embodiment, the remote device 800 may be a dedicated remote controller. Alternatively, the remote device 800 may also be any of a cellular telephone, a desktop or laptop computer, tablet computer, and the like having RF communication capability and programmed to wirelessly communicate commands to the RF interface 410a.

(29) The wireless motor controller 410 further includes motor control interface circuitry 410b operably coupled between the controller circuitry 410b and the electric motor 408 for electrical control of the electric motor 408. Such electric control may include controlling the polarity and voltage applied to the electric motor 408 to control the speed and direction of the rotation of the output shaft 408a of the motor 408. As noted above, the motor 408 may include a DC motor and the motor control interface circuitry 410c may include an H-bridge to control the polarity (and thus the rotational direction) of the motor 408. Also, the motor control interface circuitry 410b may include pulse width modulation (PWM) circuitry to control the voltage input to the motor 408 to control the speed of the motor 408.

(30) A rotary encoder 408b is coupled to the output shaft 408a of the motor 408 to monitor the rotational or angular position of the output shaft 408a. The output of the encoder 408b is fed back to the controller circuitry 410b, which can control the electric motor 408 based on the output of the encoder 408b (i.e., on an encoder count). Specifically, the controller circuitry 410b can use the output of the encoder 408b to indirectly measure the linear position of the moving door panel 406 relative to the frame 402. The rotary position encoder 408b is installed on the output shaft 408a of a rotary motor 408 to monitor the shaft position of the output shaft 408a. The encoder 408b provides an output corresponding to the rotation of the shaft 408a, either in terms of voltage pulses when using incremental encoders, or absolute angular position when using absolute encoders. The controller circuitry 410b can convert this encoder output data into a linear length of travel of the moving door panel 406, which can then be added to the initial position to determine a final position.

(31) Thus, a rotational displacement of the output shaft 408a will correspond to a certain linear displacement of the drive belt 412 (and, therefore, the moving door 406) due to the interface between the first pulley 418 and the drive belt 412 and the secure connection between the moving door panel 406 and the drive belt 412. Thus, by monitoring the rotational displacement of the output shaft 408a relative to a default rotational position (i.e., counting the number of rotations of the output shaft 408a), it is possible to accurately know the position of the moving door panel 406 within the door frame 402 relative to an initial or default position of the moving door panel 406 corresponding to the default rotational position (i.e. a closed position shown in FIG. 4a).

(32) As noted above, the electrical motor 408 may comprise a direct-current (DC) motor. The interface circuitry 410c may comprises an H-bridge switching circuit that is controlled by electrical signals supplied by the controller circuitry 410b. As shown in FIG. 8, the sliding door assembly 400 may also include an electrical power source 804 that supplies DC power signals to the wireless motor controller 410. The electrical power source 804 may comprises an AC-DC transformer that receives mains alternating-current (AC) power and outputs DC power to the wireless motor controller 410. Specifically, in one embodiment, the wireless motor controller 410 may include power management circuitry 410d that receives the DC power supplied by the electrical power source 804 and controls the supply of the DC power to the electrically powered components 410a, 410b, and 410c of the wireless motor controller 410. As shown in FIG. 8, the wireless motor controller 410 is electrically connected to the motor 408 and regulates power to the motor 408.

(33) The sliding door assembly 400 can be operated as follows. Assuming that the moving door panel 406 is initially in a closed position shown in FIG. 4a, a user may move the moving door panel 406 to the open position by sending a command to the wireless motor controller using the remote device 800. The RF interface circuitry 410a receives the command and outputs the command to the controller circuitry 410b. The controller circuitry 410b will retrieve the last stored encoder count to determine an initial position of the moving door panel 406 before moving and will then output instructions to the motor control interface circuitry 401c to open the moving door panel 406. The motor control interface 410c can then convert the instructions from the controller circuitry 410b to a polarity and a voltage output to the motor 408, which will cause the motor 408 to rotate the output shaft 408 in a certain rotational direction at a certain speed. As the output shaft 408a rotates, the first pulley 418 will rotate and move the drive belt 412 along with the moving door panel 406 clamped to the drive belt 412. Also, as the output shaft 408a rotates, the encoder 408b will output the encoder signal to the controller circuitry 410b so that the position of the moving door panel 406 can be monitored as it moves. When the encoder 408b outputs a signal to the controller circuitry 410b corresponding to the fully open position of the moving door panel 406, the controller circuitry 410b sends a signal to the motor control interface circuitry 410c to stop the motor 408. The control interface circuitry 410c in turn changes the voltage setting to the motor 408 to zero volts, which turns the motor 408 OFF. The foregoing process can be reversed to close the moving door panel 406 once the user sends a command using the remote controller 800 to close the moving door panel 406.

(34) The controller 410 may be configured to detect whether the moving door 4006 has hit an obstruction in the path of the moving door panel 406. In one embodiment, the controller circuitry 410b is configured to monitor the current drawn by the motor 408 when the motor 408 is ON. Normally, when the motor 408 is ON and the output shaft 408a is rotating to move the moving door panel 406, the current used by the motor 408 is within a certain range. However, when the moving door panel 406 hits an obstruction that inhibits or stops the moving door panel 406 from moving, the current drawn rises above the certain range, which can be detected by the controller circuitry 410b using the motor control interface circuitry 410c. When such a rise in current occurs, the controller circuitry 410b detects the current rise and determines that the moving door panel 406 has hit an obstruction and then sends a signal to the motor control interface circuitry 410c to turn OFF the motor 408 by setting the voltage to zero. Once the motor is OFF, the controller circuitry 410b will wait for the count of the encoder 408b to stop for a certain amount of time (e.g., 10 seconds). If the encoder count does not change for the certain amount of time, it is determined that a user is not manually moving the door panel 406 and the motor 408 remains OFF, until a user issues another command using the remote controller 800. Similarly, if the count of the encoder continues to change once the motor is OFF, it is assumed that the movement of the door panel 406 is caused by manual operation of the door by the user, in which case the motor 408 also remains OFF, regardless of instructions from the remote controller 800.

(35) The sliding door assembly 400 can be installed into a rough opening of a building, such as rough opening 102, which has been provided with access to electrical connections to the AC/DC transformer 804 that is powered by a mains AC power source, as shown in FIG. 8. The sliding door assembly 400 can be positioned in the rough opening 102 and leveled/plumbed in the rough opening 102. Then, the frame 402 can be secured to framing members that define the rough opening 102. For example, fasteners (e.g., screws or nails) can be introduced into and through side jamb portions 402a and 402b to secure them to corresponding side members of the rough opening 102. Also, fasteners (e.g., screws or nails) can be introduced into an through the sill portion 402c, and head jamb portion 402d to secure them to corresponding sill and head jamb portions of the rough opening 102. The connection between the wires 411 of the wireless motor controller 410 to the AC/DC transformer 804 may be made before or after the frame 402 is positioned in the rough opening 102.

(36) There have been described and illustrated various embodiments of a sliding door and a method of use. While particular embodiments have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular drive components for moving a sliding door have been disclosed, it will be appreciated that other drive components may be used as well. For example, while particular types of motors and controllers have been disclosed, it will be understood that other suitable motors and controllers having the same functionality can be used. For example, and not by way of limitation, an AC motor and control may be used in place of a DC motor and controller. Also, while a geared drive belt is preferred, it will be recognized that a smooth drive belt may be used as well. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.