Roller shutter for opening and closing a doorway

Abstract

The invention relates to a roller shutter (10, 32, 42, 51) for opening and closing a doorway having a door leaf (11) and side rails (17) for guiding the door leaf (11), and having a coiling device (14) for selectively rolling up the door leaf (11) for opening the doorway and unrolling the door leaf (11) for closing the doorway. For reducing or avoiding the risk of creating a polygon effect and for providing a roller shutter (10, 32, 42, 51) comprising a door leaf having rigid shutter elements with an increased height and/or with the possibility of applying an increased speed for opening and/or closing the door leaf the roller shutter (10, 32, 42, 51) is characterized in that a separate guiding device (21, 33, 43) is provided for guiding the door leaf (11) in the area between the side rail (17) and the coiling device (14), wherein the guiding device (21, 33, 43) is arranged to adjust to an increasing diameter and to a decreasing diameter of the coiling device (14).

Claims

1. A roller shutter for opening and closing a doorway, the roller shutter comprising: a door leaf; side rails for guiding the door leaf; a coiling device for selectively rolling up the door leaf for opening the doorway and unrolling the door leaf for closing the doorway; and a separate guiding device for guiding the door leaf in the area between the side rail and the coiling device; wherein the guiding device is arranged, between the side rail and the coiling device, adjacent an inner side of the door leaf facing the coiling device, to adjust to an increasing diameter of the coiling device as the door leaf is rolled up on the coiling device and to a decreasing diameter of the coiling device as the door leaf is unrolled from the coiling device, wherein a first end of the guiding device is configured to engage the side rail and a second end of the guiding device, which is turned away from the first end, is configured to engage the coiling device; wherein the door leaf comprises several rigid shutter elements; wherein the shutter elements comprise end pieces which are provided for gliding within the side rail and for being guided by the guiding device; wherein the guiding device comprises an elongated guiding track for guiding and supporting the door leaf; and wherein the guiding track has an abutment face for contacting the door leaf, and the abutment face is directed towards the inner side of the door leaf.

2. The roller shutter as claimed by claim 1; wherein each side rail is fitted with one guiding device; wherein one side rail is arranged on each side of the door leaf; and side rails extend in the vertical direction in regard to their longitudinal axis.

3. The roller shutter as claimed by claim 1; wherein the guiding track is linear or curved.

4. The roller shutter as claimed by claim 1; wherein the shutter elements are designed as lamellae or panels; wherein the guiding track rests on the outer surface of a sliding guide or on a slide face of an up rolled end piece; wherein each end piece comprises a spacer and a coiling rest; and wherein a carrying strap is clamped between the spacer and the coiling rest.

5. The roller shutter as claimed by claim 4; wherein each end piece and/or spacer comprises at least one spacer bar for providing a contact face for arranging end pieces onto each other in an at least partial up rolled position of the door leaf; and wherein the spacer bars extend to the directly adjacent end pieces for bridging a gap between directly adjacent end pieces.

6. The roller shutter as claimed by claim 1; wherein the abutment face is arranged for contacting the end pieces of the shutter elements; and wherein the guiding device further comprises a counter track with a surface directed towards the abutment face for contacting the end pieces in the area between the said rail and the coiling device.

7. The roller shutter as claimed by claim 1; wherein a first end of the guiding device is configured to engage a funnel arranged on one of the side rails; and wherein an inner side of the funnel merges with the abutment face of the guiding track.

8. The roller shutter as claimed by claim 3, wherein an end of the guiding track is aligned tangentially to a sliding guide of the coiling device or to a slide face of an up rolled end piece; wherein the coiling device comprises a rotatable shaft with at least one spiral disc at each end of the shaft; and wherein a first layer of the end pieces is rollable onto the outer circumferential surface of the spiral disc or onto an outer contact face of at least one layer of the at least partly up rolled door leaf.

9. The roller shutter as claimed by claim 3, wherein the position of the guiding track is adjustable to a change of the diameter of the coiling device for ensuring a tangential transition of an end of the guiding track to a sliding guide and/or slide face of an up rolled end piece.

10. The roller shutter as claimed by claim 3; wherein the guiding track is flexible for adapting to a changing radius of the coiling device, of a sliding guide of a spiral disc, or of the slide face of up rolled end pieces; and/or wherein the guiding track comprises a flexible area or joint located adjacent to the side rail, the guiding track bending around the flexible area depending on the radius of the coiling device, the sliding guide of the spiral disc or of the slide face of up rolled end pieces.

11. The roller shutter as claimed by claim 3; wherein the guiding device comprises a rotation mechanism for aligning an end of the guiding track tangentially to a sliding guide of the coiling device or to a slide face of an up rolled end piece, and for adjusting the position of the end of the guiding track depending on the radius of the coiling device, the sliding guide of a spiral disc, or the slide face of up rolled end pieces.

12. The roller shutter as claimed by claim 11; wherein the rotation mechanism comprises a pivotable support structure having the guiding track, the support structure pivotally mounted around a bearing, the bearing being provided by a holding device extending from an upper end of the side rail in a direction away from the door leaf; and wherein the bearing is located at one end of the holding device which is spaced apart from the upper end of the side rail and from the first end of the guiding track.

13. A roller shutter for opening and closing a doorway, the roller shutter comprising: a door leaf; side rails for guiding the door leaf; a coiling device for selectively rolling up the door leaf for opening the doorway and unrolling the door leaf for closing the doorway; and a separate guiding device for guiding the door leaf in the area between the side rail and the coiling device; wherein the guiding device is arranged between the side rail and the coiling device adjacent an inner side of the door leaf facing the coiling device, wherein a first end of the guiding device is configured to engage the side rail and a second end of the guiding device, which is turned away from the first end, is configured to engage the coiling device; wherein the door leaf comprises several rigid shutter elements; wherein the shutter elements comprise end pieces which are provided for gliding within the side rail and for being guided by the guiding device; wherein the guiding device comprises an elongated guiding track for guiding and supporting the door leaf; wherein the guiding track is linear or curved; and wherein the guiding track has an abutment face for contacting the door leaf, and the abutment face is directed towards the inner side of the door leaf wherein the guiding device is in a fixed position and a rotatable shaft of the coiling device is moveable in a direction perpendicular to the plane of the doorway to adjust to an increasing diameter of the coiling device as the door leaf is rolled up on the coiling device and to a decreasing diameter of the coiling device as the door leaf is unrolled from the coiling device; and wherein the rotatable shaft moved, depending on the radius of the coiling device, the outer circumference of a spiral disc, or the contact face of up rolled end pieces, for aligning an end of the guiding track tangentially to the sliding guide or to the slide face of up rolled end pieces.

Description

(1) The following detailed description, given by way of example and not intended to limit the present invention solely thereto, will best be appreciated in conjunction with the accompanying figures, wherein like reference numerals denote like elements and parts, in which:

(2) FIG. 1 is a schematic cross sectional side view of a first rollup door according to the present invention with an unrolled door leaf,

(3) FIG. 2 is a schematic cross sectional side view of a second rollup door according to the present invention with an unrolled door leaf,

(4) FIG. 3 is a schematic cross sectional side view of a third rollup door according to the present invention with a partly up rolled door leaf,

(5) FIG. 4 is a schematic cross sectional side view of a further rollup door according to the present invention with a partly up rolled door leaf,

(6) FIG. 5 is a front view of the rollup door according to FIG. 1,

(7) FIG. 6 is a schematic front view of one side of the rollup door according to FIG. 5 without a side rail, and

(8) FIG. 7 is a perspective view of an end piece for a rollup door according to the present invention.

(9) The present invention will now be described more fully hereinafter with reference to the accompanying figures in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

(10) The roller shutter will be described as a rollup door selectively blocking or opening a doorway. This recitation is for convenience only. It would be understood by one skilled in the art that such a roller shutter or rollup door is suitable for many embodiments and/or applications, including, but not limited to industrial high speed rollup doors, interior doorway covering, exterior doorway covering, etc.

(11) A first embodiment of the rollup door according to the present invention is described with reference to FIG. 1, in which a schematic cross sectional side view of a first rollup door 10 according to the present invention with an unrolled door leaf 11 is shown. The door leaf 11 comprises several shutter elements 12. For a greater clarity only one shutter element 12 provides a reference numeral and not all shutter elements 12 are shown. Further shutter elements 12 may be arranged at the lower end of the door leaf 11. In this embodiment the shutter elements 12 are rigid lamellae 12. The lamellae 12 are at least partly rotatable coupled to each other allowing up and unrolling of the lamellae 12 around a rotatable shaft 13. A drive system (not shown) provides a rotational force or torque to the shaft 13 in one direction as indicated by arrow 30 to raise the door leaf 11 and in a second direction opposite to the direction of arrow 30 to lower the door leaf 11. As shown in FIG. 1 the door leaf 11 is fully unrolled.

(12) The rotatable shaft 13 is part of a coiling device 14. According to this embodiment the coiling device 14 comprises four spiral discs 15. A pair of two spiral discs 15 is fixed to each end of the rotatable shaft 13. According to this figure only one spiral disc 15 is shown. The spiral discs 15 have a continuously increasing radius such that the outer circumference of the spiral discs 15 comprises a mismatch. The smallest radius transitions smoothly to the greatest radius over a rotation of approximately 360 degrees. Furthermore, the two spiral discs 15 of each pair are arranged as mirror images of each other and are connected to each other by a sliding guide 16. Furthermore, the sliding guide 16 is arranged in spiral shape along the outer circumference of the spiral discs 15. The sliding guide 16 is inwardly spaced in regard to the outer circumference of the spiral discs 15. Thus, the radius of the sliding guide 16 is smaller than the corresponding radius of the spiral discs 15. The distance between the sliding guide 16 and the outer circumference of the spiral discs 15 is kept constant.

(13) The rollup door 10 further comprises two side rails 17. In this figure only one side rail 17 at one side of the doorway is shown. The side rails 17 are elongated in a vertical direction and are designed to receive and guide end pieces 18 of the lamellae 12. The side rails 17, provided on either side of the doorway, define the width of the passable doorway and are configured to accept the end pieces 18 within a slot. Each lamella 12 provides two end pieces 18, one end piece 18 at each lamella end. The end pieces 18 comprise an outer convex face 19 and an inner concave face 20. Each end piece 18 comprises a spacer 27 and a coiling rest 39. The spacer 27 has the outer convex face 19 and the coiling rest 39 has the inner concave face 20. In this embodiment the upper two end pieces 18 are not connected with a lamella 12 as this part bridges the gap between the side rail 17 and the coiling device 14 above the doorway.

(14) According to this embodiment the greatest radius of the spiral discs 15 exceeds the smallest radius of the spiral discs 15 by a dimension approximately equal to the thickness of the end piece 18.

(15) The rollup door 10 provides a guiding device 21 arranged between the side rail 17 and the coiling device 14. According to this embodiment the guiding device 21 is configured as an elongated guiding track 22 which may be arcuated or curved. A first end 23 of the guiding track 22 is coupled to the upper inlet of the side rail 17. The guiding track 22 has an abutment face 24 which is directed towards the inner side of door leaf 11, particularly towards the concave face 20 of end pieces 18. In the region of the first end 23 the abutment face 23 may merge with the inner side of the side rail 17. A second end 25 of the guiding track 22 directed away from the first end 23 is assigned to the coiling device 14. In this embodiment the outermost area or edge of the second end 25 rests substantially tangentially on the outer surface of the sliding guide 16 between the spiral discs 15 or on a slide face (not shown) of an up rolled end piece 18. The second end 25 is arranged in a height which is located substantially in the height of the shaft 13.

(16) A carrying strap 31 is affixed with one end to the coiling device 14. In this embodiment the carrying strap 31 is mounted at the spiral discs 15. The carrying strap 31 is connected with the end pieces 18 to roll up and roll down the lamellae 12. One carrying strap 31 is provided on each side of the doorway in conjunction with the end pieces 18. In one rotating direction of the coiling device 14 the carrying strap 31 with end pieces 18 will be hoisted and rolled up, causing the lamellae 12 to be wound up around the coiling device 14, opening the doorway. In second rotating direction of the coiling device 14 turned away from the first direction the carrying strap 31 with the end pieces 18 will unwind from its rolled up position, releasing the lamellae 12 to cover the doorway.

(17) In the exemplary embodiment the guiding track 22 is configured as a flexible and elastic strip. In more detail the guiding track 22 is almost rigid expect a flexible area 26.

(18) Here the flexible area is located approximately one-third up the first end 23 of the elongated guiding track 22. The part with the first end 23 under the flexible area 26 is fixedly mounted to the rollup door 10. The part above the flexible area 26 with the second end 25 may be bend round a virtual axis provided by the flexible area 26. The virtual axis provided by the flexible area 26 is directed almost parallel to the plane of the door leaf 11 or the axis of the shaft 13. In the position shown in FIG. 1 the part of the guiding track 22 above the flexible area 26 is bent slightly out of the vertical direction and towards the rotatable shaft 13 and the sliding guide 16.

(19) In the position of the door leaf 11 with a partly up rolled door leaf 11, particularly with a first layer of up rolled end pieces 18, the part of the guiding track 22 above the flexible area 26 and with the second end 25 is bent round the virtual axis provided by the flexible area 26 such that the guiding track 22 would be aligned in a substantially vertical direction. In case of more successive layers of end pieces 18 the part above the flexible area 26 with the second end 25 would be bent in a direction away from shaft 13.

(20) FIG. 2 shows a schematic cross sectional side view of a second rollup door 32 according to the present invention with an unrolled door leaf 11. As far as identical elements are concerned reference is made to the above mentioned description.

(21) The rollup door 32 provides a guiding device 33 arranged between the side rail 17 and the coiling device 14. According to this embodiment the guiding device 21 is configured as an elongated and substantially linear guiding track 22. However, in an alternative embodiment the guiding track 22 may be arcuated or curved. The first end 23 of the guiding track 22 is dedicated to the upper inlet of the side rail 17. The second end 25 of the guiding track 22 directed away from the first end 23 is assigned to the coiling device 14. In this embodiment the outermost area or edge of the second end 25 rests substantially tangentially on the outer surface of the sliding guide 16 provided by the outer circumference of the coiling device 14 or on a slide face (not shown) of an up rolled end piece 18.

(22) The guiding device 33 has a rotation mechanism 34 for adjusting the position of the second end 25 of the guiding track 22 depending on the diameter or radius of the coiling device 14 with and without up rolled end pieces 18. For this purpose the rotation mechanism 34 provides a pivotable support structure 35. The guiding track 22 is attached to the support structure 35. In this embodiment less than half of the guiding track 22 adjacent to the first end 23 is affixed to the support structure 35. Furthermore, the support structure 35 is pivotable mounted around a bearing 36. The bearing is spaced apart from the first end 23 of the guiding track 22 and located in a direction away from the side trail 17. The support structure 35 is held by a holding device 37 via the bearing 36. In this embodiment the holding device 37 is a side wall which is connected with side rail 17.

(23) Adjacent to the first end 23 of the guiding track 22 a pressure element 38 is connected with the pivotable support structure 35. The pressure element 38 provides a force directed to the support structure 35 as indicated by arrow F such that the support structure 35 is pushed around the bearing 36 to place the outermost area or edge of the second end 25 of the guiding track 22 on the outer surface of the sliding guide 16 or a slide face (not shown) of an up rolled end piece 18. The pressure element 38 may be a pressure spring or a pressure piston.

(24) FIG. 3 shows a schematic cross sectional side view of a third rollup door 51 according to the present invention with a partly up rolled door leaf 11. The configuration and function of rollup door 51 is similar to the rollup door 32 as shown in FIG. 2. As far as identical elements are concerned reference is made to the above mentioned description.

(25) In the position of the door leaf 11 as shown in FIG. 3 with a partly up rolled door leaf 11, particularly with a first layer of up rolled end pieces 18, the guiding track 22 is pivoted round the bearing 36 such that substantially the whole guiding track 22, preferably the abutment face 24 contacting the end pieces 18 in the area of the concave face 20 of the coiling rest 39, is aligned in a substantially vertical direction. In case of more successive layers of end pieces 18 the guiding track 22 would be pivoted around the bearing 36 in a direction away from shaft 13.

(26) The outer face of each end piece 18 or spacer 27 comprises a convex face 19. In an up rolled position the convex face 19 serves as a contact face on which subsequent end pieces 18, namely the concave face 20, can rest. In this embodiment each spacer 27 comprises two spacer bars 40. The end pieces 18 of all embodiments as disclosed by the figures of this application may comprise such spacer bars 40. In this cross sectional side view only one spacer bar 40 can be seen. The outer faces of the spacer bars 40 form the convex face 19 of the end pieces 18. The outer face of the spacer 27 between the spacer bars 40 forms the slide face (not shown) for the second end 25 of the guiding track 22. When the end pieces 18 are rolled up round the shaft 13 and a first layer of end pieces 18, namely the concave face 20, is aligned on the outer circumference of the spiral discs 15 the slide faces of the up rolled end pieces 18 form a continuation of the sliding guide 16 as well as the convex surface 19 of the spacer bars 40 form a continuation of the spiral outer circumference of the spiral discs 15.

(27) In FIG. 3 one layer of end pieces 18 on the spiral discs 15 is shown. In this configuration the first layer of end pieces 18 on the spiral discs 15 follows a smooth curve as preset by the outer circumference of the spiral discs 15. Each successive layer of end pieces 18 lies smoothly atop the convex contacting face 19 of spacers 27 as a part of the continued outer spiral circumference of the preceding layer of end pieces 18. The end pieces 18 have a substantially flattened arcuated C shape in cross section. The end pieces 18 cross section is chosen to substantially correspond to the outer circumference of the spiral discs 15 and of the layers of up rolled end pieces 18 respectively. This allows successive layers of end pieces 18 wound onto the spiral disc 15 and onto preceding layers of end pieces 18 to present a smooth wound outer surface and a compact rolled up door leaf 11. In this regard a geometric relationship has to be considered which combines the height of the door opening, the configuration of the spiral discs 15 and the height as well as the cross section of the end pieces 18. Each layer of rolled up end pieces 18 creates a greater diameter or radius of the coiling device 14 for successive layers to wind up onto, resulting in deviating cross sections, convex faces 19 and concave faces 20 for each end piece 18 in a row. Preferably a fully wound up door will require two, three or more 360 degrees turns of the shaft 13 depending on the height of the door leaf and/or doorway.

(28) The outermost area or edge of the second end 25 of the guiding track 22 rest substantially tangentially on the slide face adjacent to the spacer bars 40 of the spacer 27 of the end pieces 18 rolled up as a first layer round the spiral discs 15. The convex slide face of the rolled up end pieces 18 forms a continued sliding guide 16 for the guiding track 22.

(29) Each spacer bar 40 has a thickness which is at least slightly thicker than the thickness of the guiding track 22. The guiding track 22 is positioned between two spacer bars 40 which are aligned in a longitudinal direction adjacent to each other. The distance between two adjacent spacer bars 40 is at least slightly greater than the width of the guiding track 22. Thus, the guiding track 22 is guided within each pair of spacer bars 40 of each end piece 18.

(30) The spacer bars 40 of each end piece 18 extend over the spacer 27 to the spacer 27 of a preceding and following end piece 18. Thus, the spacer bars 40 of two adjacent end pieces 18 overlap, thereby bridging a gap 41 between adjacent or two end pieces 18 in a row.

(31) FIG. 4 shows a schematic cross sectional side view of a further rollup door 42 according to the present invention with a partly up rolled door leaf 11. As far as identical elements are concerned reference is made to the above mentioned description.

(32) The rollup door 42 provides a guiding device 44 arranged between the side rail 17 and the coiling device 14. According to this embodiment the guiding device 44 has an elongated and substantially linear guiding track 22. However, in an alternative embodiment the guiding track 22 may be arcuated or curved. The first end 23 of the guiding track 22 is dedicated to the upper inlet of the side rail 17. The second end 25 of the guiding track 22 directed away from the first end 23 is assigned to the coiling device 14. In this embodiment the outermost area or edge of the second end 25 rests substantially tangentially on the outer surface of the sliding guide 16 provided by the outer circumference of the coiling device 14 or a slide face (not shown) of an up rolled end piece 18.

(33) In this embodiment the guiding track 22 is rigid and mounted to a fixed base 44 which is part of the guiding device 43. Thus, the guiding device 43 is in a fixed position and the guiding track 22 cannot change its position. To allow an adjustment in regard to a changing diameter or radius of the coiling device 14 dependent of the amount of up rolled layers of lamellae 12 or end pieces 18 the shaft 13 is moveable seated. As indicated by arrow 45 the shaft 13 is moveable in a direction perpendicular to the plane of the doorway or the longitudinal direction of the side rails 17.

(34) FIG. 5 shows a front view of the rollup door 10 according to FIG. 1. However, the following description of this embodiment is also valid for rollup doors 32, 42, 51. Thus, the guiding device 10 may be interchanged with one of the guiding devices 33 or 43. The line of sight is directed to the inner side of the door leaf 11.

(35) One end of the shaft 13 is connected to a drive system 46. The drive system 46 provides a rotational force or torque to the shaft 13 to raise or lower the door leaf 11.

(36) Each spiral disc 15 comprises a damping profile 47 on its outer circumference leading to a reduction of noise when end pieces 18 are rolled on or rolled up the spiral discs 15. In this embodiment the damping profiles 47 are made of rubber leading to an anti-slip function which avoids movements of up rolled end pieces 18. Furthermore, the wear of the concave face 20 of the end piece 18 is reduced.

(37) Between two pivotable connected lamellae 12 a sealing 48 is provided avoiding the entry of moisture and/or dirt into the connection. The sealing 48 is flexible and in this embodiment the sealing 48 is made of an elastomer, preferably EPDM (Ethylene Eropylene Diene Monomer).

(38) FIG. 6 is a schematic front view of one side of the rollup door 10 according to FIG. 5 without a side rail 17. It is shown that the upper end of carrying strap 31 is fixed between the pair of spiral discs 15 by a pin 49. The pin 49 is aligned parallel to the axis of shaft 13.

(39) Each end piece 18 has a pair of spacer bars 40 on the outer surface of the spacer 27. Between the spacer bars 40 of each end piece 18 a slide face 50 for contacting the second end 25 of the guiding track 22 is provided. The spacer bars 40 of directly adjacent end pieces 18 are overlapping and extend to the outer surface of the directly adjacent end piece 18 or spacer 27. In this embodiment the spacer bars 40 of each pair are inclined to each other. In an alternative embodiment the spacer bars 40 of each pair may be aligned parallel and/or shifted to each other.

(40) FIG. 7 shows a perspective view of an end piece 18 for a rollup door 10, 32, 42, 51 according to the present invention. The width of the coiling rest 39 is slightly larger than the width of the spacer 27. In this embodiment the spacer 27 is fixed to the coiling rest 39 on a side turned away from the concave face 20 of the coiling rest 39. The coiling rest 39 is fixed to an end cap 28. The end cap 28 is substantially U-shaped and fixed to an end of the lamella 12. The lamella 12 comprises in this embodiment a foamed core 29. The slide face 50 or outer surface of the spacer 27 has a similar convex shape as the convex face 19 of the spacer bars 40. In this embodiment the convex face 19 of the spacer bars 40 comprise a damping material similar to the damping profiles 47 of the spiral discs 15 to reduce noise and/or wear when end pieces 18 are rolled onto or rolled up from each other.

(41) Although preferred embodiments of the present invention and modifications thereof have been described in detail herein, it is to be understood that this invention is not limited to these precise embodiments and variations and may be effected by one skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.

(42) TABLE-US-00001 Reference Numerals: 10 rollup door 11 door leaf 12 shutter element 13 rotatable shaft 14 coiling device 15 spiral disc 16 sliding guide 17 side rail 18 end piece 19 convex (outer) face 20 concave (inner) face 21 guiding device 22 guiding track 23 first end 24 abutment face 25 second end 26 flexible area 27 spacer 28 end cap 29 foamed core 30 arrow 31 carrying strap 32 rollup door 33 guiding device 34 rotation mechanism 35 support structure 36 bearing 37 holding device 38 pressure element 39 coiling rest 40 spacer bar 41 gap 42 rollup door 43 guiding device 44 base 45 arrow 46 drive system 47 damping profile 48 sealing 49 pin 50 slide face 51 rollup door