Abstract: Improved flush garage door panels and a method of constructing them are disclosed. The improved flush garage door panels have a flush roll-formed steel sheet; and a fluted polypropylene plastic sheet laminated to a flat inner surface of the flush roll-formed steel sheet. The end stiles are roll-formed so that they may be glued and metal clinched to the flush roll-formed steel sheet to provide a strong attachment and sound suppression. Each end stile also contains a block of EPS foam therein. Compared to currently used flush garage doors, the improved flush garage door panels use less materials, reduce oil canning, and provide more insulation and sound suppression.

Abstract: A roller with a plastic injection tube to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. Closing the gap between the metal roller shaft and hinge barrel will eliminate the metal-to-metal contact resulting in a very quiet, rolling garage door. Further disclosed is an improved roller wheel having a tire made of material selected from the group consisting of urethane and urethane (PER) on which the roller will roll within a garage door track to significantly reduce the noise of the roller as it rolls inside the garage door tracks as the garage door is raised and lowered. The improved wheel include two plastic wheel sections with a gap therebetween with the tire made of urethane (PER) molded between the two sections and also extending through openings within the two wheel sections to retain the two wheel sections together.

Abstract: A roller with a plastic injection tube to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. Further disclosed is an improved roller wheel having a tire made of material selected from the group consisting of urethane and urethane (PER) on which the roller will roll within a garage door track to significantly reduce the noise of the roller as it rolls inside the garage door tracks as the garage door is raised and lowered. The roller shaft has the treads extending to a distal end of the roller shaft where a plastic washer and a closing cover nut with interior threads are threaded onto the distal end of the roller shaft. The closing cover nut with interior threads is selected from an acorn nut with a nylon insert and a hex lock nut with a nylon insert.

Abstract: Steel garage door decorations made out of powder coated aluminum. The decorations include a decorative hinge, a decorative barn door handle, a decorative knocker assembly and a decorative clavo. Each of the garage door decorations is made out of powder coated aluminum and retains at least one concealed permanent magnet by which the decoration is temporarily affixed to a garage door panel. Each decoration also contains at least one recess where adhesive can be applied after the proper orientation and location of each respective garage door decoration have been finalized.

Abstract: An apparatus and method for forming new and novel portions of a garage door panel. This includes forming at least one decoration into a steel plate section and bonding to it a unique foam core where a mirror image decoration is routed into the foam core to exactly match the decoration. In addition, an aluminum diamond plate sheet with a front surface and a rear surface is bonded to the rear of the foam core. The aluminum diamond plate sheet also includes a sheet of steel affixed to its rear surface which rear surface is bonded to the foam core so that magnetic decorations can be attached to the front of the aluminum diamond plate sheet.

Abstract: A roller with a plastic injection tube to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. Further disclosed is an improved roller wheel having a tire made of material selected from the group consisting of urethane and urethane (PER) on which the roller will roll within a garage door track to significantly reduce the noise of the roller as it rolls inside the garage door tracks as the garage door is raised and lowered. The roller shaft has the treads extending to a distal end of the roller shaft where a plastic washer and a closing cover nut with interior threads are threaded onto the distal end of the roller shaft. The closing cover nut with interior threads is selected from an acorn nut with a nylon insert and a hex lock nut with a nylon insert.

Abstract: An apparatus for a garage door panel which includes a formed metal section with at least one decorative portion on the front surface and having a rear surface. The formed metal section including a top portion with a male tongue and a bottom portion with a female groove. The garage door panel includes an insert combination of a polystyrene section and twin wall polypropylene section. The rear surface of the formed metal section is spray coated with a combination isocyanate and polyol resin which combines to form as hardened polyurethane foam section. The front surface of the polystyrene section is retained against the polyurethane foam section and the rear surface of the twin wall polypropylene serves as the rear surface of the garage door panel. Two metal stiles are respectively affixed at the left or first end and the right or second end.

Abstract: A roller with a Delrin plastic injection to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. The new and improved Delrin plastic coated shaft will be 1 mm larger than industry standard shafts because 10-11 mm industry standard shafts are too loose in the hinge barrels which allows the rattling. This improved roller shaft is 12 mm at finished thickness to reduce the extra space. Closing the gap between the roller shaft and hinge barrel will eliminate the metal-to-metal contact resulting in a very quiet, rolling garage door. By keeping the finished thickness at 12 mm on the new shaft, the roller will still work on new and old garage door hinges and fixtures. This makes the new and improved roller shaft a truly universal product that will work on 90% of garage doors in service and almost all new models. This is a long over-due improvement to garage door rollers.

Abstract: A roller with a Delrin plastic injection to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. The new and improved Delrin plastic coated shaft will be 1 mm larger than industry standard shafts because 10-11 mm industry standard shafts are too loose in the hinge barrels which allows the rattling. This improved roller shaft is 12 mm at finished thickness to reduce the extra space. A roller wheel connected to a roller shaft being a portion of a hinge affixed to a garage door, the roller wheel adapted to roll within a track of a garage door, the roller wheel including at least one ball bearing and a collar retained in a circumferential cylindrical middle cover seal and the circumferential cylindrical middle cover seal covered with a steel cover, the steel cover covered with 50-90 durometer soft urethane plastic.

Abstract: A roller with a plastic injection tube to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. Closing the gap between the metal roller shaft and hinge barrel will eliminate the metal-to-metal contact resulting in a very quiet, rolling garage door. Further disclosed is an improved roller wheel having a tire made of material selected from the group consisting of urethane and urethane (PER) on which the roller will roll within a garage door track to significantly reduce the noise of the roller as it rolls inside the garage door tracks as the garage door is raised and lowered. The improved wheel include two plastic wheel sections with a gap therebetween with the tire made of urethane (PER) molded between the two sections and also extending through openings within the two wheel sections to retain the two wheel sections together.

Abstract: An addition to reduce noise made by a garage door hinge by incorporating two Delrin or hard plastic injection molded washers placed between the two halves of the hinges and slide it over the hinge barrel. This provides a friction reducing pivot point and holds in lubricant. An additional improvement is to hold the barrel in place and reduce the problem of the barrel moving side to side. The improvement will stop or at least significantly reduce the extra noise of the garage door hinge as the garage door moves and provide smoother operation of the hinge.

Abstract: A roller with a Delrin plastic injection to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. The new and improved Delrin plastic coated shaft will be limn larger than industry standard shafts because 10-11 mm industry standard shafts are too loose in the hinge barrels which allows the rattling. This improved roller shaft is 12 mm at finished thickness to reduce the extra space. Closing the gap between the roller shaft and hinge barrel will eliminate the metal-to-metal contact resulting in a very quiet, rolling garage door. By keeping the finished thickness at 12 mm on the new shaft, the roller will still work on new and old garage door hinges and fixtures. This makes the new and improved roller shaft a truly universal product that will work on 90% of garage doors in service and almost all new models. This is a long over-due improvement to garage door rollers.

Abstract: A roller with a Delrin plastic injection to coat the steel shaft wherein the plastic coated shaft eliminates the metal-to-metal contact that creates the noise. The new and improved Delrin plastic coated shaft will be 1 mm larger than industry standard shafts because 10-11 mm industry standard shafts are too loose in the hinge barrels which allows the rattling. This improved roller shaft is 12 mm at finished thickness to reduce the extra space. A roller wheel connected to a roller shaft being a portion of a hinge affixed to a garage door, the roller wheel adapted to roll within a track of a garage door, the roller wheel including at least one ball bearing and a collar retained in a circumferential cylindrical middle cover seal and the circumferential cylindrical middle cover seal covered with a steel cover, the steel cover covered with 50-90 durometer soft urethane plastic.

Abstract: An addition to reduce noise made by a garage door hinge by incorporating two Delrin or hard plastic injection molded washers placed between the two halves of the hinges and slide it over the hinge barrel. This provides a friction reducing pivot point and holds in lubricant. An additional improvement is to hold the barrel in place and reduce the problem of the barrel moving side to side. The improvement will stop or at least significantly reduce the extra noise of the garage door hinge as the garage door moves and provide smoother operation of the hinge.

Abstract: A decorative insert for a garage door panel comprising a multiplicity of decorative shapes, each respective decorative shape having exterior retaining taps extending transversely to an exterior surface of each decorative shape. The garage door panel includes a transparent sheet of material affixed to the back of the garage door panel by a frame member and a garage door frame is affixed to the front surface of the garage door panel with a gap between an interior surface of the garage door frame and the transparent sheet of material so that at least a portion of the retaining tabs of the decorative insert can be retained within the gap between the interior surface of the garage door panel frame and the transparent sheet of material to retain the decorative insert at spaced apart locations.

Abstract: A stiffening strut to be used in conjunction with a rear surface of a garage door panel having a given width-wise length, formed in a generally U-shaped body. First and second sidewalls each with a bottom side edge and a top side edge, a front edge and a rear edge, the bottom side edge extends to first lengthwise mounting sleeve having an interior edge aligned with said bottom side edge, the first mounting sleeve having an outer edge parallel to the inner edge, the first lengthwise mounting sleeve having a given width, the first lengthwise mounting sleeve having a multiplicity of spaced apart openings by which fastening means affix the stiffening strut to the top of a garage door panel.