Overhead track for suspension of a pocket door

Abstract

An overhead track for suspension of a pocket door is disclosed. The overhead track has one or more troughs for hanging an pocket door by a plurality of gliders. The overhead track has a flat end for mounting at the pocket door opening and a spiked end for mounting against the door jamb within the pocket. The spiked end is forced into the door jamb within the pocket, then the flat end is screwed into the pocket door header for support and to prevent the spikes from disengaging with the door jamb within the pocket.

Description

This application is related and claims priority to U.S. provisional application No. 60/563,246, filed Apr. 15, 2004, entitled “GHOSTRACKS RETRO MODEL S”, the entirety of which is incorporated by reference herein, including all of the documents referenced therein. This application is related and claims priority to U.S. provisional application No. 60/563,248, filed Apr. 15, 2004, entitled “GHOSTRACKS RETRO MODEL B”, the entirety of which is incorporated by reference herein, including all of the documents referenced therein. This application is related and claims priority to U.S. provisional application No. 60/563,249, filed Apr. 15, 2004, entitled “GHOSTRACKS MODEL P”, the entirety of which is incorporated by reference herein, including all of the documents referenced therein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the field of suspending pocket doors, and in particular, a replacement track for suspension of a pocket door.

2. Description of the Prior Art

Pocket doors are widely used where space is at a premium, in that they don't require space a traditional door to swing open. Pocket doors are sliding doors that slide into a hidden cavity in the wall and are generally suspended by an overhead track whereas the track has a trough on which a set of gliders are attached to the top of the overhead door rests, the gliders in some doors have wheels to reduce friction when moving the door in and out of the pocket. The overhead track extends into a cavity within a wall next to the door opening so that opening the door is accomplished by sliding the door into the cavity.

Unfortunately, the overhead track may be damaged, perhaps by something jarring the door while it is open or partially open, thereby causing difficulty in opening or closing the door or, in some cases, bending the overhead track enough such that to door falls off the track when its glider passes the break. Possibly the damage is due to wear or vibration, for example a screw used to hold the overhead track to the header may become loose and interfere with closing the door or perhaps causing the overhead track to sag, resulting in the door rubbing against the floor inside the pocket. When this damage occurs, the overhead track must be replaced with a new track. Unfortunately, the replacement is difficult because the pocket is usually encased in drywall or other covering material, plaster or some other covering material on both sides, preventing attachment of the overhead track to the door header. Current overhead track replacement requires the wall surrounding the pocket to be at least partially cut open to remove the old overhead track and fasten the new overhead track to the door header within the pocket, then patching or replacing the drywall or other covering material, taping and spackling, and painting. This process is very expensive, time consuming and messy.

What is needed is a overhead track that can be installed from outside the pocket without cutting into the drywall or other covering material that encases the pocket.

SUMMARY OF THE INVENTION

In one embodiment, an overhead track for suspension of a pocket door is disclosed including an overhead track with an end for insertion into a pocket and an end for attachment in a door opening. The overhead track has at least one trough for accepting pocket door gliders that are affixed to a pocket door. At the end of the overhead track that is inserted into a pocket, there are spikes configured to be forced into a door jamb within the pocket, thereby supporting that end of the overhead track. At the end for attachment in a door opening there are holes for fastening the overhead track to a header of the pocket door opening.

In another embodiment, a method of installing an overhead track for suspension of a pocket door is disclosed including the steps of inserting an overhead track into a pocket, the overhead track having spikes at the end that is inserted into the pocket and screw holes at the end that is outside of the pocket and angling the overhead track within the pocket so that the spikes meet with a door jamb located within the pocket. Next, forcing the overhead track towards the door jamb located within the pocket so the spikes pierce the door jamb located, thereby supporting the end of the overhead track that is inserted into the pocket, then pressing the overhead track against a pocket door header at the end of the overhead track that extends outside of the pocket and screwing the overhead track into the header at that end.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a three-dimensional view of an embodiment of the present invention.

FIG. 2 illustrates an end-view of an embodiment of the present invention.

FIG. 3 illustrates a three-dimensional view of an embodiment of the present invention.

FIG. 4 illustrates a three-dimensional view of an embodiment of the present invention.

FIG. 5 illustrates a broken overhead track for suspension of a pocket door that needs repair.

FIG. 6 illustrates the repair of a broken overhead track for suspension of a pocket door using an overhead track of an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. In all figures, the materials used to make the overhead track may be any sufficiently sturdy material including aluminum, steel, copper and a sturdy plastic.

Referring to FIG. 1, a three-dimensional view of the present invention is shown. The overhead track 100 for suspension of a pocket door is shown having an end 110 configured to attach to the door header 560 using screws that fasten through holes 150 in the overhead track 100 and into the pocket door header 560 at the door opening 515. The pocket end 120 is configured to attach to the door jamb 540 that is within the pocket 505 using spikes 125 formed by cutting or molding the pocket end 120 of the overhead track 100 into a plurality of spikes 125 which can be forced into the door jamb 540 that is within the pocket during installation. The spikes may be cut into angular shapes, preferably having acute angles at the tip for piercing the door jamb 540. For completeness, the tracks that hold the pocket door gliders or wheels are shown formed by flat surfaces 130/135. Although, in this embodiment, the sides of the overhead track and the tracks are shown meeting at right angles, in other embodiments it is anticipated that other shapes may work equally well or better, including rounded edges.

Referring now to FIG. 2, a side view of the present invention is shown. In this the overhead track has a surface on which the pocket door glider can rest 130 and an edge to keep the pocket door glider from falling off 135. Although, in this embodiment, the sides of the overhead track 132, the top of the overhead track 134, the track bottom 130 and the track lip 135 are shown meeting at right angles, in other embodiments it is anticipated that other shapes may work equally well or better, including rounded edges.

Referring to FIG. 3, a three-dimensional view of the present invention is shown. The overhead track 300 for suspension of a pocket door is shown having an end 110 configured to attach to the door header 560 using screws that fasten through holes 150 and into the pocket door header 560 at the door opening 515. The pocket end 120 is configured to attach to the door jamb 540 within the pocket using spikes 340 that are formed from or attached to a plate 310. Although eight spikes are shown in this example, any number may be included. The plate 310 may be fastened to the pocket end 120 of the overhead track 300 using fasteners 330 that past through a flange 320 bent from the plate 310 and through the pocket end 120 of the overhead track 300 or, in another embodiment, the plate 310 may be welded to the pocket end 120 of the overhead track 300. The plate may be attached to the pocket end 120 at approximately right angles to the overhead track. Any fastening means known in the industry may be used to attach the plate 310 to the pocket end 120 of the overhead track 300. The spikes 340 can be forced into the door jamb 540 that is within the pocket 505 during installation.

Referring to FIG. 4, a three-dimensional view of the present invention is shown. The overhead track 400 for suspension of a pocket door is shown having an end 110 configured to attach to the door header 560 using screws that fasten through holes 150 in the overhead track 400 and into the pocket door header 560 at the door opening 515. The pocket end 120 is configured to attach to the door jamb 540 within the pocket 505 using spikes 440 that are formed from or attached to a plate 410. The plate 410 may be fastened to the pocket end 120 of the overhead track 400 using a fastener 430 that past through flanges 435 bent from the plate 410 and through the pocket end 120 of the overhead track 400. Any fastening means known in the industry may be used to attach the plate 410 to the pocket end 120 of the overhead track 400, including sheet metal screws, bolts/nuts and rivets, but in this embodiment, it is important that the attachment means allows the plate 410 to pivot around the attachment means, thereby a rivet may be the best means. Allowing the plate 410 to pivot around the fastener 430 provides greater flexibility for the overhead track 400 to be installed in places where there are uneven door jambs 540. The spikes 440 can be forced into the door jamb 540 within the pocket 505 during installation. The spikes 440 may be separate components having a sharp enough edge to pierce framing materials and have a method of attaching to the plate 410, or may be formed by punching out sharp protrusions from plate 410, as is known in the industry. Although 4 spikes 440 are shown, any number may be used depending on the strength required.

Referring to FIG. 5, a broken overhead track for suspension of a pocket door that needs repair of the prior art is shown. In this example, the broken overhead track is shown with a bend 530 located at the end 110 that is within the door opening 515, though the present invention may be used to replace any broken overhead track. The track is attached to the pocket door header 560 with a plurality of fasteners 550, perhaps wood screws. The end 520 of the overhead track that is installed within the pocket 505 is shown as many existing tracks would appear—that is a flat end 520 that doesn't have mounting spikes. This overhead track is held in place by a series of fasteners 550. Although the pocket door is not shown, its travel within the drywall or other covering material 510 is limited by the door jamb 540 within the pocket 505. In present methods of repairing the overhead track, a hole is cut in the drywall or other covering material 510 surrounding the pocket 505, screws 550 are removed, the faulty overhead track is removed, a new overhead track is inserted and screwed into place and then the drywall or other covering material 510 is replaced, repaired and painted.

Referring to FIG. 6, the repair of a broken overhead track for suspension of a pocket door using an overhead track of an embodiment of the present invention is shown. In this example, the faulty overhead track has already been removed, perhaps using a crowbar to pull out any screws that held it in place. In this example, the new overhead track of FIG. 1 is shown being installed, though any other overhead track of the present invention may be installed using the same method. To start, the pocket end 120 of the new overhead track is placed inside the pocket 505 with its spikes 125 set against the door jamb 540 and the end 110 configured to be in the door opening 515 is angled down slightly to allow the overhead track to fit between the door jambs 540/570. Next, the overhead track is moved in an upward motion 610 until the spikes 125 start to force themselves into the door jamb 540. At this point, the overhead track may be forced in the direction of the door jamb 540 so as to force the spikes 125 to enter into the jamb 540, perhaps by applying additional vertical force, or by prying the door opening end 110 of the overhead track against the door opening jamb 570. Once the spikes 125 are sufficiently forced into the door jamb 540, the door end 110 of the overhead track may be screwed into the header 560 at the door opening end 110. The spikes will support the pocket end 120 of the overhead track so that it will function when the door is positioned inside the pocket 505.

It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.

Claims

1. An overhead track for suspending a pocket door comprising:

an overhead track having an end for insertion into a pocket and an end for attachment in a pocket door opening, the overhead track having at least one trough for accepting at least one pocket door glider, the at least one pocket door glider affixed to a pocket door;

a plurality of spikes at the end for insertion, said plurality of spikes configured to be forced into a door jamb within said pocket, thereby supporting the end for insertion; and

at least one hole at the end for attachment for fastening the overhead track to a header of the pocket door opening.

2. The overhead track for suspending a pocket door of claim 1, whereas the plurality of spikes comprise sharp ends of the overhead track at the end for insertion.

3. The overhead track for suspending a pocket door of claim 1, whereas the plurality of spikes are formed on a plate and the plate is fastened approximately perpendicular to the overhead track at the end for insertion.

4. The overhead track for suspending a pocket door of claim 3, whereas the plate is fastened to the overhead track with a fastener selected from the group comprising screws and rivets.

5. The overhead track for suspending a pocket door of claim 3, whereas the plate is welded to the overhead track.

6. A method for installing an overhead track into an already existing door pocket comprising:

inserting an overhead track into a pocket, the overhead track having spikes at an end that is inserted into the pocket and screw holes at an end that is outside of the pocket;

angling the overhead track within the pocket so that the plurality of spikes meet with a door jamb located within the pocket;

forcing the overhead track towards the door jamb located within the pocket so that the plurality of spikes pierce the door jamb located within the pocket, thereby supporting the end that is inserted into the pocket;

pressing the overhead track against a pocket door header at the end of the overhead track that extends outside of the pocket; and

screwing the overhead track into the pocket door header at the end of the overhead track that extends outside of the pocket.

7. The method for installing an overhead track into an already existing door pocket of claim 6, whereas the plurality of spikes comprise sharp ends of the overhead track at the end that is inserted.

8. The method for installing an overhead track into an already existing door pocket of claim 6, whereas the plurality of spikes are formed on a plate and the plate is fastened to the overhead track at the end that is inserted.

9. The method for installing an overhead track into an already existing door pocket of claim 8, whereas the plate is fastened to the overhead track with a fastener selected from the group comprising screws and rivets.

10. The method for installing an overhead track into an already existing door pocket of claim 8, whereas the plate is welded to the overhead track at approximately a right angle.

11. The method for installing an overhead track into an already existing door pocket of claim 6, further comprising:

prying a broken overhead track from the pocket door header.

12. The method for installing an overhead track into an already existing door pocket of claim 6, whereas the forcing includes prying the overhead track against a pocket door jamb located outside of the pocket.

13. An overhead track for suspending a pocket door comprising:

an overhead track having an end for insertion into a pocket and an end for attachment in a pocket door opening, the overhead track having at least one trough for accepting at least one pocket door glider, the at least one pocket door glider affixed to a pocket door;

a plurality of spikes formed at the end for insertion, said plurality of spikes configured to be forced into a door jamb within said pocket, thereby supporting the end for insertion; and

at least one hole at the end for attachment for fastening the overhead track to a header of the pocket door opening.

14. The overhead track for suspending a pocket door of claim 13, whereas the plurality of spikes is formed by cutting the end for insertion at angles.

15. The overhead track for suspending a pocket door of claim 13, whereas the plurality of spikes is molded into the overhead track at the end for insertion.

16. The overhead track for suspending a pocket door of claim 14, whereas the angles are acute angles.