OVERHEAD DOOR CABLE ADJUSTER SYSTEM AND METHOD

Abstract

The overhead door cable adjuster system includes a tensioning assembly, and a second pulley. The overhead door cable adjuster system is useful for easily installing a garage door cable and adjusting the door height while working on the ground level thus enhancing safety while saving time and expense.

Claims

1. An overhead door cable adjuster system comprising: a tensioning assembly including; a bracket having; a first shaft opening; a second shaft opening; and a plurality of mounting holes; a combination first pulley and gear including; a gear having; teeth along an outer diametric edge; a first pulley having; a cable notch; and an adjustment nut; a combination first pulley and gear retainer; a first shaft; a gear lock having; a lock lobe; a second shaft; a lock retainer; and a second pulley; wherein the tensioning assembly has together in functional combination said bracket, said combination first pulley and gear, said first shaft, said combination first pulley and gear retainer, said gear lock, said second shaft, and said lock retainer for the purpose of retaining an overhead door cable assembly with a set amount of tension based on positioning of said combination first pulley and gear in relation to said gear lock; wherein said second pulley is mounted to a door assembly axle of a door wheel assembly of said overhead door for the purpose of directing said cable assembly to said tensioning assembly; wherein said first pulley accommodates a single spool of cable; wherein said gear lock is removably couplable; wherein said gear lock profile is such that said gear lock can be oriented for applications on right or left sides of overhead doors by inverting said gear lock on said second shaft; and wherein said tensioning assembly and said second pulley work together in functional combination to provide a method by which to apply tension to an overhead door spring via said cable assembly for adjusting said overhead door's height.

2. The overhead door cable adjuster system of claim 1, wherein said first pulley is of a fixed diameter.

3. The overhead door cable adjuster system of claim 2, wherein said combination first pulley and gear is removably couplable.

4. The overhead door cable adjuster system of claim 2, wherein said combination first pulley and gear is available in a plurality of diameters of said first pulley.

5. The overhead door cable adjuster system of claim 1, wherein said first pulley is able to accommodate multiple spools of cable.

6. The overhead door cable adjuster system of claim 1, wherein said gear lock includes a tensioning spring for securing said gear lock into said teeth of said gear.

7. The overhead door cable adjuster system of claim 1, wherein said teeth of said gear comprise a sprocket profile.

8. The overhead door cable adjuster system of claim 1, wherein said lock lobe comprises a sprocket profile to accommodate said teeth of said gear comprising a sprocket profile for securing said gear in a manner that keeps said gear from rotating.

9. The overhead door cable adjuster system of claim 8, wherein said teeth of said gear comprise a beveled profile.

10. The overhead door cable adjuster system of claim 9, wherein said lock lobe comprises a beveled gear profile to accommodate said teeth of said gear comprising a beveled gear profile for securing said gear in a manner that keeps said gear from rotating.

11. The overhead door cable adjuster system of claim 1, wherein said lock lobe is configured to lock in a bidirectional manner as a means for tightening the cable assembly while turning the combination first pulley and the gear while having to disengage the lock lobe from the gear.

12. The overhead door cable adjuster system of claim 1, wherein said lock lobe is configured to lock in a unidirectional manner as a means for tightening the cable assembly while turning the combination first pulley and the gear without having to disengage the lock lobe from the gear.

13. The overhead door cable adjuster system of claim 1, wherein said combination first pulley and gear retainer is a snap ring.

14. The overhead door cable adjuster system of claim 1, wherein said combination first pulley and the gear retainer is a cotter pin.

15. The overhead door cable adjuster system of claim 1, wherein said lock ring is a snap ring.

16. The overhead door cable adjuster system of claim 1, wherein said first pulley is of a varying diameter as one traverses an outer diametric of said first pulley.

17. An overhead door cable adjuster system comprising: a tensioning assembly including; a bracket having; a first shaft opening; a second shaft opening; and a plurality of mounting holes; a combination first pulley and gear including; a gear having; teeth along an outer diametric edge; a first pulley having; a cable notch; and an adjustment nut; a combination first pulley and gear retainer; a first shaft; a gear lock having; a lock lobe; a second shaft; a lock retainer; and a second pulley. wherein the tensioning assembly has together in functional combination said bracket, said combination first pulley and gear, said first shaft, said combination first pulley and gear retainer, said gear lock, said second shaft, and said lock retainer for the purpose of retaining an overhead door cable assembly with a set amount of tension based on the positioning of said first pulley and gear in relation to said gear lock; wherein said second pulley is mounted to a door assembly axle of a door wheel assembly of said overhead door for the purpose of directing said cable assembly to said tensioning assembly; wherein said first pulley accommodates a single spool of cable; wherein said gear lock is removably couplable; wherein said gear lock profile is such that said gear lock can be oriented for applications on right or left sides of overhead doors by inverting said gear lock on said second shaft wherein said tensioning assembly and said second pulley work together in functional combination to provide a means by which to apply tension to a spring of an overhead door via said cable assembly for adjusting height of said overhead door; wherein said first pulley is of a fixed diameter; wherein said combination first pulley and said gear is removably couplable; wherein said gear lock includes a tensioning spring for the purpose of securing said gear lock into the teeth of said gear; wherein said teeth of said gear comprise a sprocket profile; wherein said lock lobe comprises a sprocket profile to accommodate said teeth of said gear comprising a sprocket profile for the purpose of securing said gear in a manner that keeps said gear from rotating; wherein said lock lobe is configured to lock in a unidirectional manner as a means for tightening the cable assembly while turning the combination first pulley and gear without having to disengage the lock lobe from the gear; wherein said combination first pulley and gear retainer is a snap ring; and wherein said lock ring is a snap ring.

18. The overhead door cable adjuster system of claim 17, further comprising set of instructions; a tensioning assembly; and a second pulley; wherein said overhead door cable adjuster system is arranged as a kit with a plurality of said combination first pulley and gear sets each having said first pulley with a unique fixed circumference and fixed outer diameter; and wherein said overhead door cable adjuster system is arranged as a kit with a plurality of said combination first pulley and gear sets each having said first pulley with a unique varying circumference and varying outer diameter.

19. A method of use of an overhead door cable adjuster system; said overhead door cable adjuster system comprising a second pulley, a first pulley including a cable notch, a tightening nut, and a gear lock including a lock lobe; the method comprising the steps of: installing said overhead door cable adjuster system; wrapping said cable assembly around said second pulley; inserting said cable assembly into said cable notch; tightening said adjustment nut; and locking said gear lock by rotating lock lobe into gear.

20. The method of claim 19, further comprising the steps of adjusting height of said overhead door; turning said adjustment nut to achieve a proper height for said overhead door; and locking said gear lock by rotating a lock lobe into gear.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The figures which accompany the written portion of this specification illustrate embodiments and methods of use for the present disclosure, an overhead door cable adjuster system, constructed and operative according to the teachings of the present disclosure.

[0015] FIG. 1 is perspective view of the overhead door cable adjuster system during an in-use condition, according to an embodiment of the disclosure.

[0016] FIG. 2 is a perspective view of the overhead door cable adjuster system of FIG. 1, according to an embodiment of the present disclosure.

[0017] FIG. 3A provides a more detailed perspective view of the overhead door cable adjuster system of FIG. 1, according to an embodiment of the present disclosure.

[0018] FIG. 3B provides another detailed perspective view of the overhead door cable adjuster system of FIG. 1, according to an embodiment of the present disclosure.

[0019] FIG. 4 is yet another perspective view of the overhead door cable adjuster system of FIG. 1, according to an embodiment of the present disclosure.

[0020] FIG. 5 is a flow diagram illustrating a method of use for an overhead door cable adjuster system, according to an embodiment of the present disclosure.

[0021] The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.

DETAILED DESCRIPTION

[0022] As discussed above, embodiments of the present disclosure relate to garage doors and more particularly to an overhead door cable adjuster system as used to improve the act of replacing and overhead door cable assembly and properly adjusting the door height. Generally speaking, cable replacement on overhead doors can be performed faster and safer by using the system and method disclosed herein. The disclosure also offers improved ability to adjust overhead door height.

[0023] Referring now more specifically to the drawings by numerals of reference, there is shown in FIGS. 1-4, various views of a overhead door cable adjuster system 100.

[0024] FIG. 1 shows an overhead door cable adjuster system 100 during an in-use condition 150, according to an embodiment of the present disclosure. Here, the overhead door cable adjuster system 100 may be beneficial for use by a user 140 to easily replace a cable assembly 24 (FIG. 3a) and adjust the height of an overhead door 10. As illustrated, the overhead door cable adjuster system 100 may include tensioning assembly 110 and second pulley 160. Tensioning assembly 110 includes combination first pulley and gear 120 for user 140 to adjust spring tension via cable assembly 24 in an overhead garage door 10. User 140 is shown grasping gear lock 130 prior to disengaging from the lock position in order to allow combination first pulley and gear 120 to be rotated thereby adjusting the height of an overhead door 10. Upon achieving proper height of door 10 user 140 secures lock 130 into combination first pulley and gear 120. The disclosure enables door 10 adjustment at ground level using simple tools thus avoiding work at an elevated level using levers under spring pressure.

[0025] Referring now to FIG. 2 according to one embodiment, the overhead door cable adjuster system 100 may be arranged as a kit 105. In particular, the overhead door cable adjuster system 100 may further include a set of instructions 155 and a plurality of combination first pulley and gear 120 sets with varying diameters (sizes) of first pulley 124. The instructions 155 may detail functional relationships in relation to the structure of the overhead door cable adjuster system 100 (such that the overhead door cable adjuster system 100 can be used, maintained, or the like, in a preferred manner).

[0026] Referring further to FIG. 2 a high level perspective view of an overhead door cable adjuster system 100 is shown according to an embodiment of the present disclosure. As illustrated, the overhead door cable adjuster system 100 may include tensioning assembly 110 and second pulley 160 that work together in functional combination for the purpose of adjusting the height of overhead door 10.

[0027] FIG. 3A shows a detailed perspective view of an overhead door cable adjuster system 100 according to an embodiment of the present disclosure. As illustrated, the overhead door cable adjuster system 100 may include tensioning assembly 110 having bracket 112, combination first pulley and gear 120, first shaft 121, combination first pulley and gear retainer 129, gear lock 130, second shaft 132, and lock retainer 134. Combination first pulley and gear 120 includes first pulley 124, adjustment nut 128, and gear 122 together in functional combination for the purpose of retaining and applying tension to cable assembly 24. Combination first pulley and gear 120 includes gear 122 affixed to first pulley 120 which in turn is affixed to adjusting nut 128. The combined assembly works together in functional combination whereas the components rotate together as a single unit in a manner that retains and applies tension to cable assembly 24 for the purpose of adjusting the height of door 10. Combination first pulley and gear 120 is removably couplable from first shaft 121 by removing combination first pulley and gear retainer 129. Gear lock 130 is removably couplable from second shaft 132. Profile of gear lock 130 is such that gear lock 130 can be oriented for applications on right or left sides of overhead doors 10 by inverting gear lock 130 on said second shaft 132. Overhead door 10 leveling is enhanced when incorporating two overhead door cable adjuster systems 100, arranged one overhead door cable adjuster system 100 on each side of an overhead door 10 thus enabling individual height adjustment in an effort to level overhead door 10.

[0028] Combination first pulley and gear 120 rotates about first shaft 121 when a wrench is used to turn adjusting nut 128. Adjusting nut 128 is fastened to first pulley 120 to provide a means by which to spool cable assembly 24 when the combination first pulley and gear 120 is rotated. Combination first pulley and gear 120 includes first pulley 124 having cable notch 126. Cable assembly 24 rides in a groove in first pulley 124 while being secured by cable notch 126. In the preferred embodiment first pulley 124 accommodates a single spool of cable assembly 24. In alternate embodiments, first pulley 124 is capable of accommodating multiple spools of cable assembly 24. Gear lock 130 includes lock lobe 136 with a profile that fits into gear teeth on gear 122 for the purpose of locking gear 122 in place which in turn secures cable assembly 24 with a set amount of tension for final adjustment of the height of door 10. In the preferred embodiment, gear lock 130 includes a lock lobe 136 configured to lock in a unidirectional manner as a means for tightening cable assembly 24 while turning the combination first pulley and gear 120 without having to disengage the lock lobe 136 from gear 122. In an alternate embodiment, gear lock 130 includes a lock lobe 136 configured to lock in a bidirectional manner as a means for tightening the cable assembly 24 while turning the combination first pulley and the gear 120 while having to disengage the lock lobe 136 from gear 122. Combination first pulley and gear 120 is fastened to first shaft 121 by combination first pulley and gear retainer 129. First shaft 121 is mounted to bracket 112. Referring still to FIG. 3A, gear lock 130 pivots on second shaft 132 and is secured to second shaft 132 with lock retainer 134.

[0029] FIG. 3B shows a detailed perspective view of an overhead door cable adjuster system 100 according to an embodiment of the present disclosure. As illustrated, the overhead door cable adjuster system 100 may include bracket 112 which has first shaft opening 114, second shaft opening 116 and a plurality of mounting holes 118. First shaft 121 is rigidly mounted to bracket 112 via first shaft opening 114. Second shaft 132 is rigidly mounted to bracket 112 via second shaft opening 116.

[0030] FIG. 4 shows a detailed perspective view of an overhead door cable adjuster system 100 showing second pulley 160 mounted on axle 22 of door wheel assembly 20 that is further mounted to door 10. Second pulley 160 rides on axle 22 as a means for allowing cable assembly 24 to be directed to tensioning assembly 110. FIG. 4 illustrates how the disclosure accommodates existing door hardware while enabling the advantage of ground level adjustment of cable assembly 24 thus providing the advantages of low additional parts count and additional safety and ease of control for user 140.

[0031] FIG. 5 is a flow diagram 550 illustrating a method of use 500 for an overhead door cable adjuster system 100 according to an embodiment of the present disclosure. Method of use 500 may include one or more components or features of the overhead door cable adjuster system 100 as described above. As illustrated, the method of use 500 for an overhead door cable adjuster 100 includes the steps of: step one 501, installing an overhead door cable adjuster system 100; step two 502, wrapping the cable assembly 24 around the second pulley 160; step three 503, inserting cable assembly 24 in cable notch 126; step four 504, tightening the adjustment nut 128; and step five 505, locking gear lock 130 by rotating lock lobe 136 into gear 122.

[0032] The method of use 500 for an overhead door cable adjuster system 100 may further include the steps of: step six 506, adjusting the height of door 10; step seven 507, turning the adjustment nut 128 to achieve a proper height for door 10, and step eight 508, locking the gear lock 130 by rotating lock lobe 136 into gear 122.

[0033] It should be noted that steps 506, 507, and 508 are optional steps and may not be implemented in all cases. Optional steps of method of use 500 are illustrated using dotted lines in FIG. 5 so as to distinguish them from the other steps of method of use 500. It should also be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of step of should not be interpreted as step for, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. 112(f). It should also be noted that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use or installation for overhead door cable adjuster system (e.g., different step orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc.), are taught herein.

[0034] The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.