Conductive path in panels of a door

Abstract

In example implementations, a panel is provided. The panel includes a first metal skin, a second metal skin, wherein the first metal skin and the second metal skin comprise at least one cut out and the first metal skin is coupled to the second metal skin to form a body of the panel such that the at least one cut out is located within a same area of the body of the panel, a back frame inserted through the at least one cut-out, an electronic component placed on the back frame, a front frame coupled to the back frame to secure the electronic component to the back frame and within the at least one cut-out, and a conductive path located inside of the body to electrically connect the electronic component to a power supply.

Description

CONDUCTIVE PATH IN PANELS OF A DOORBACKGROUND

[0001] Doors can be used for a variety of applications. For example, doors can be used as in residential locations or doors for bays and entrances to warehouses in commercial locations. Some doors may include sectional doors. One type of sectional door may be garage doors.

[0002] Sectional doors may be made from a plurality of individual sections that are mechanically coupled together or independently movable panels. The size and number of sections may be determined based on a size of the opening of the garage or any other type of location with an opening. Each section may have a roller that can fit into a track. The track may guide movement of each section of the sectional door while opening and closing. The sectional door can be opened and closed manually with the help of a loaded torsion spring or mechanically via a motor or garage door opener.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] FIG. 1 illustrates a front view of an example overhead sectional door of the present disclosure;

[0004] FIG. 2 illustrates an exploded view of an example panel of the overhead sectional door of the present disclosure;

[0005] FIG. 3 illustrates a more detailed exploded view of an example panel of the present disclosure;

[0006] FIG. 4 illustrates a top view of an example panel of the presentdisclosure;

[0007] FIG. 5 illustrates a cross-sectional front view of an example panel of the present disclosure;

[0008] FIG. 6 illustrates a front view of an example panel of the present disclosure;

[0009] FIG. 7 illustrates a cross-sectional side view of an example panel of the present disclosure;

[0010] FIG. 8 illustrates an exploded view of an example frame for a panel of the present disclosure; and

[0011] FIG. 9 illustrates an example wire channel formed in a metal skin of a panel of the present disclosure.DETAILED DESCRIPTION

[0012] The present disclosure provides examples of overhead doors that include conductive paths for electrical components. As discussed above, doors can be used for a variety of different applications. Some doors may be sectional doors that comprise insulation resulting in a 3-layer (or more) structure of metalinsulation-metal, such as those used as garage doors.

[0013] Some sectional doors may include panels with an electronic component. Providing continuous power to the panels can be difficult as the sectional door may move along a track. The movement of the sectional door and the various components of the track may make it difficult to wire the sectional door for power. The wire may become tangled or stuck along the various components of the sectional door and / or track.

[0014] The present disclosure provides a conductive path within a volume of the panel to allow electrical connections to be made between a power source and the electric component in the door panel. The conductive path may be hidden from view so that the overhead door maintains a clean aesthetic design.

[0015] In some embodiments, the conductive path may be deployed as a conductive paste or material that is applied inside of each panel. In other embodiments, the conductive path may include a channel or frame that can be added to the panel. Conductive wiring may be run through such channel orframe that is located within the volume of the door panel.

[0016] FIG. 1 illustrates an isometric view of an example an overhead sectional door system 100 of the present disclosure. The overhead sectional door system 100 may include a door 102 that is comprised of a plurality of panels 104i to 104n(hereinafter also referred to individually as a panel 104 or collectively as panels 104). The door 102 may be opened by moving the panels 104 along a track system 108. The track system 108 may define a path along which the panels 104 may move to open and close the door 102.

[0017] It should be noted that the overhead sectional door system 100 in FIG. 1 has been simplified for ease of explanation. The overhead sectional door system 100 may include additional features that are not shown. For example, the overhead sectional door system 100 may include a rotating shaft, torsion springs, an operator, a user interface to control operation of the sectional door, one or more sensors, and the like.

[0018] In one embodiment, the panels 104 may be vertically stacking panels that are stacked along a horizontal portion of the track system 108. In another embodiment, the panels 104 may be moved into a horizontal position along a horizontal portion of the track system 108 (e.g., a residential garage door).

[0019] In one embodiment, the door 102 may be opened closed via a motor 112. The motor 112 may be connected to a shaft 110. The shaft 110 maybe connected to one or more panels 104 of the door 102. As the motor 112 is activated, the motor 112 may cause the shaft 110 to rotate clockwise or counterclockwise to open and close the door 102. The sectional door 102 may be guided by tracks 110 and 112. The track system 108 may be installed on opposite sides of the door 102. A roller may be inserted into the track system 108 on one end and the second end of the roller is inserted into a bracket attached to the panel 104.

[0020] The track system 108 may be coupled to a wall or other structure support around the opening where the door 102 is installed. Support beams (not shown) that may be coupled to the wall may further help to stabilize the track system 108.

[0021] In one embodiment, at least one of the panels 104 may include anelectrical component 1061 to 106m(hereinafter also referred to individually as an electrical component 106 or collectively as electrical components 106). The electrical component 106 may be electrically activated smart glass. For example, the smart glass may transition from clear to opaque when powered on. In other examples, the electrical component 106 may be lights in or around a glass pane.

[0022] Regardless of what the electrical component 106 is, the present disclosure may provide a conductive path within a volume of the panel 1042 to allow the electrical component 106 to be conductively connected to a power supply 114. The conductive path may be hidden from view, may be located internally to the panel 1042, or may be located on an interior surface of the panel without impacting the manufacturing process of the panel 1042. The power supply 114 may be any source of power such as an external power source, a solar panel connected to the door 102 or glass in the door 102, and the like.

[0023] Although FIG. 1 illustrates an overhead sectional door system 100, it should be noted that the panels 104 may be part of other door systems. For example, the conductive path may be provided within a panel volume for a divider that moves horizontally left to right, rather than vertically up and down, and a building fagade or movable panels exterior or interior to a building.

[0024] FIG. 2 illustrates an exploded view of an example of the panel 1042. In an embodiment, the panel 1042. In one embodiment, the panel 1042 may include a first metal skin 204 and a second metal skin 212. The first metal skin 204 and the second metal skin 212 may be formed from rolled sheets of metal, such as aluminum or steel. The first metal skin 204 may include an interior surface and an exterior surface. The second metal skin 212 may include an interior surface and an exterior surface.

[0025] The first metal skin 204 may include a plurality of cut-outs 208i to 208m. The second metal skin 212 may include a plurality of cut-outs 214i to 214m. The cut-outs 208 and 214 may be sized to be similar to the dimensions (e.g., a length and a width) of the electronic component 106. In some embodiments, the cut-outs 214 may be sized to be similar to the dimensions of a window or fan that includes the electronic component 106 that is to beinstalled in the panel 1042.

[0026] The electronic component 106 may be any electronic device that can be installed in the panels 104. For example, the electronic component 106 may also include sensors, auxiliary devices such as lights, fans, glass tinting, and the like, safety devices, activation devices, and the like.

[0027] The first metal skin 204 and the second metal skin 212 may be coupled together via end stiles 218 and 220 to form a body of the panel 1042. For example, the end stiles 218 may couple together the left side of the first metal skin 204 and the second metal skin 212 and the end stiles 220 may couple together the right side of the first metal skin 204 and the second metal skin 212.

[0028] A plurality of back frames 202i to 202mmay be inserted through each one of the cut-outs 208i to 208mof the first metal skin 204 and through each one of the cut-outs 214i to 214mof the second metal skin 212. An electronic component 106 may be placed on at least one of the back side frames 202i to 202m. In some examples, the electronic component 106 may be placed on each one of the back frames 202i to 202m. In other examples, the electronic component 106 may be placed on the back frame 2022 and the remaining back frames 202i and 202mmay receive a plane of glass.

[0029] A plurality of front frames 216i to 216mmay be coupled to each one of the back frames 202i and 202mto secure the electronic component 106 or a plane of glazing material within the cut-outs 208i to 208mof the first metal skin 204 and the cut-outs 214i to 214mof the second metal skin 212.

[0030] In one embodiment, an insulation layer 210 may be present in the interior volume of the panel 104 formed by the combination of the first metal skin 204 and the second metal skin 212. In some embodiments, the optional insulation layer 210 may selected from polystyrene, polyurethane, or a combination thereof.

[0031] It should be noted that the other panels 104i and 104s to 104nmay be fabricated in a similar fashion. However, the other panels 104i and 104s to 104nmay not include the cut-outs 208i to 208mor the cut-outs 214i to 214m. Thus, the other panels 104i and 104s to 104ndo not have an electrical component

[0032] As noted above, the insulation layer 210 may make it difficult to pass wiring through the panel 1042 to the electronic components 106. Attempting to cut an opening to pass wiring through longitudinally through a length of the panel 1042 after the insulation is present can be very difficult. Thus, the present disclosure provides a conductive path that can be deployed to the panel 1042 (or any other panel with an electronic component 106) with minimal disruption to the manufacturing process of the panels 104.

[0033] In one embodiment, a conductive path 206 may be present in the interior volume of the panel 1042. In one example, the conductive path 206 may be applied on the interior surface of the first skin 204 as shown in FIG. 2. In another example, the conductive path 206 may be a frame that can be added around the back frames 202i to 202m, as shown in FIG. 8 and discussed below. In another example, the conductive path 206 may be formed into the interior surface of the first metal skin 204 or the interior surface of the second metal skin 212, as illustrated in FIG 9 and discussed below.

[0034] In one embodiment, the conductive path 206 may be applied to the interior surface of the first metal skin 204 or the interior surface of the second metal skin 212 in a longitudinal, vertical, grid, or concentric pattern to the interior surface.

[0035] In one embodiment, the conductive path 206 may provide the electrical connection. For example, the conductive path 206 may be a conductive ink, adhesive, tape, fabric, or elastomer that is added to an inside or inner side of the first metal skin 204 or the first metal skin 212. The conductive ink, adhesive, tape, fabric, or elastomer may be applied after the first metal skin 204 or the second metal skin 212 is cut and formed prior to the insulation layer 210 being incorporated into the panel 1042.

[0036] A conductive ink may be a liquid or a paste-like material containing conductive particles, such as silver, copper, or carbon, dispersed in a solvent. The conductive ink may be applied to the first metal skin 204 or the second metal skin 212 using techniques such as screen printing, inkjet printing, spray coating, and the like.

[0037] A conductive adhesive may be adhesive materials infused with conductive particles. The conductive adhesives may be available in a paste or film form and can be applied to a metal surface to create electrical connections.

[0038] A conductive tape may be adhesive tapes with conductive properties. For example, the conductive tape may be composed of a flexible backing material, such as polyester or polyimide, coated with a layer of conductive material, such as copper or aluminum.

[0039] A conductive fabric may be textiles woven or coated with conductive fibers or threads, such as, silver-coated nylon or stainless-steel fibers. The conductive fabric may be applied to metal surfaces by sewing, bonding, or laminating.

[0040] A conductive elastomer may be rubber-like materials infused with conductive particles, such as carbon black or metal fillers. The conductive elastomer can be molded, extruded, or applied as a coating onto a surface of the first metal skin 204 or the second metal skin 212.

[0041] FIG. 3 illustrates a more close-up view of the conductive path 206 on the inside of the first metal skin 204. An electrical connection can be made between the conductive path 206 and the electrical component 106mheld in place by the back frame 202mand the front frame 216m. For example, the conductive path 206 may contact the electrical connections or contacts of the electrical component 106m. Notably, after the insulation layer 210 is added the conductive path 206 can be easily connected to the power supply 114 to deliver power to the electronic component 106m.

[0042] FIG. 4 illustrates a top view of the panel 1042. A cross-sectional front view of the panel 1042 is shown in FIG. 5 cut along the line shown by the arrows in FIG. 4. FIG. 5 illustrates how the insulation layer 210and the conductive path 206 after insulation is incorporated into the panel 1042.

[0043] FIG. 6 illustrates a front view of the panel 1042. A cross-sectional side view of the top portion of the panel 1042 is shown in FIG. 7 cut along the line shown by the arrows in FIG. 6 and in the top portion 602. FIG. 7 illustrates the conductive path 206 contacting the electrical component 106mto provide electricity or power from the power supply 114.

[0044] FIG. 8 illustrates an exploded view of an example frame 802 that can be deployed as a conductive path 206 for the panel 1042. For example, the frame 802 may be assembled around the electrical component 106 and dimensioned to fit between the back frame 202 and the front frame 216.

[0045] Although the frame 802 is illustrated as being a rectangle in FIG. 8, it should be noted that the frame 802 may be deployed in any desired shape. For example, the frame 802 may be deployed to surround the cutout / window or electrical component 106 with irregular shapes such as a circle, octagon, triangle, or any other shape.

[0046] The frame 802 may include a top portion 804, a bottom portion 808 a left portion 810 and a right portion 806. The top portion 804 may be connected to the left portion 810 via a connector 820. The top portion 804 may be connected to the right portion 806 via a connector 814. The bottom portion 808 may be connected to the left portion 810 via a connector 818. The bottom portion 808 may be connected to the right portion 806 via a connector 816. The connectors 814, 816, 818, and 820 may have an L shape or may be bent at 90 degrees to allow the top portion 804, the right portion 806, the bottom portion 808, and the left portion 810 form a rectangle similar in dimensions (e.g., length and width) as the electrical component 106.

[0047] In one embodiment, the top portion 804, the right portion 806, the bottom portion 808, and the left portion 810 may be fabricated from polymeric resin. The top portion 804, the right portion 806, the bottom portion 808, and the left portion 810 have “C” shape or a closed rectangular shape with a central opening to receive a wire or wires 812. The wires 820 may run through the top portion 804, the right portion 806, the bottom portion 808, and the left portion 810 to electrically connect the electrical component 106 to other electrical components 106 in the panel 1042 and to the power supply 114.

[0048] FIG. 9 illustrates an example where the conductive path 206 may be a wire channel 902 roll formed as an integral part of the first metal skin 204 of a panel 104. In one embodiment, the wire channel 902 may be roll formed into the first metal skin 204 or the second metal skin 212. For example, when the first metal skin 204 is cut from a roll of aluminum or steel and punched / roll-formed / stamped, etc, the wire channel 902 may also be formed / stamped / molded / punched into the first metal skin 204.

[0049] As a result, the wire channel 902 may still allow the insulation layer 210 to be added to the panel 104 when panels are made in a continuous process. The wiring may then be electrically connected to the electrical component 106 after the panel is constructed to provide an electrical connection from the power supply 114, through the panel 104, and to the electrical component 106.

[0050] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims

CLAIMS1 . A panel of an overhead door, comprising: a first metal skin; a second metal skin, wherein the first metal skin and the second metal skin comprise at least one cut out and the first metal skin is coupled to the second metal skin to form a body of the panel such that the at least one cut out is located within a same area of the body of the panel; a back frame inserted through the at least one cut-out; an electronic component placed on the back frame; a front frame coupled to the back frame to secure the electronic component to the back frame and within the at least one cut-out; and a conductive path located inside of the body to electrically connect the electronic component to a power supply.

2. The panel of claim 1 , further comprising: insulation inside of the body between the first metal skin and the second metal skin.

3. The panel of claim 1 , wherein the conductive path comprises a conductive material applied to an interior side of the first metal skin or the second metal skin.

4. The panel of claim 3, wherein the conductive material comprises at least one of a conductive ink, a conductive adhesive, a conductive tape, a conductive fabric, or a conductive elastomer.

5. The panel of claim 4, wherein the conductive ink comprises a liquid or paste including conductive particles.

6. The panel of claim 1 , wherein the conductive path comprises a wire channel formed in the first metal skin or the second metal skin and a wire placedin the wire channel.

7. The panel of claim 1 , wherein the conductive path comprises a frame installed inside of the body between the first metal skin and the second metal skin and a wire placed in the frame.

8. A panel of an overhead door, comprising: a first metal skin; a second metal skin, wherein the first metal skin and the second metal skin comprise at least one cut out and the first metal skin is coupled to the second metal skin to form a body of the panel such that the at least one cut out is located within a same area of the body of the panel; a back frame inserted through the at least one cut-out; an electrically activated smart glass placed on the back frame; a front frame coupled to the back frame to secure the electrically activated smart glass to the back frame and within the at least one cut-out; and a conductive path located inside of the body to electrically connect the electronic component to a power supply.

9. The panel of claim 8, further comprising: insulation inside of the body between the first metal skin and the second metal skin.

10. The panel of claim 8, wherein the conductive path comprises a conductive material applied to an interior side of the first metal skin or the second metal skin.11 . The panel of claim 10, wherein the conductive material comprises at least one of a conductive ink, a conductive adhesive, a conductive tape, a conductive fabric, or a conductive elastomer.

12. The panel of claim 11 , wherein the conductive ink comprises a liquid orpaste including conductive particles.

13. The panel of claim 8, wherein the conductive path comprises a wire channel formed in the first metal skin or the second metal skin and a wire placed in the wire channel.

14. The panel of claim 8, wherein the conductive path comprises a frame installed inside of the body between the first metal skin and the second metal skin and a wire placed in the frame.

15. An overhead door system, comprising: a track system; and a door movably coupled to the track system, the door comprising: a plurality of panels, wherein at least one of the plurality of panels, comprises: a first metal skin; a second metal skin, wherein the first metal skin and the second metal skin comprise at least one cut out and the first metal skin is coupled to the second metal skin to form a body of the panel such that the at least one cut out is located within a same area of the body of the panel; a back frame inserted through the at least one cut-out; an electronic component placed on the back frame; a front frame coupled to the back frame to secure the electronic component to the back frame and within the at least one cut-out; and a conductive path located inside of the body to electrically connect the electronic component to a power supply.

16. The overhead door system of claim 15, wherein the at least one of the plurality of panels, further comprising: insulation inside of the body between the first metal skin and the secondmetal skin.

17. The overhead door system of claim 15, wherein the conductive path of the at least one of the plurality of panels comprises a conductive material applied to an interior side of the first metal skin or the second metal skin.

18. The overhead door system of claim 17, wherein the conductive material comprises at least one of a conductive ink, a conductive adhesive, a conductive tape, a conductive fabric, or a conductive elastomer.

19. The overhead door system of claim 15, wherein the conductive path of the at least one of the plurality of panels comprises a wire channel formed in the first metal skin or the second metal skin and a wire placed in the wire channel.

20. The overhead door system of claim 15, wherein the conductive path of the at least one of the plurality of panels comprises a frame installed inside of the body between the first metal skin and the second metal skin and a wire placed in the frame.

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