Mini Slat Folding Door

STATEMENT OF PRIORITY

0001This is a continuation-in-part of patent application Ser. No. 14/487,882, filed on Sep. 16, 2014 which is a regular patent application based upon provisional application No. 61/878,114 filed on Sep. 16, 2013.

FIELD OF INVENTION

0002The invention relates generally to flexible folding door with mini slats that is attachable to a door jamb.

BACKGROUND OF THE INVENTION

0003Folding doors increase the usable area of room that is otherwise taken up by a hinged door that swings open. Folding doors simply fold back accordion style, with the use of many vertical folds, against the door jamb allowing the user to use all the available space in the room, without having to save a clear path for a door to swing open or close. Folding doors are typically an economical and space-saving solution where doors are needed when a standard door would impede upon the function of the room. Folding doors are commonly used as interior doors to separate rooms or for use as a closet door.

0004Folding doors are hung from a track attached to the header of the door jamb. A folding door needs to be sturdy and structurally sound to withstand forces from all directions when the door is being pulled open or closed along a door header. Accordingly, folding doors are often complex and not easy to install. Moreover, if the door and jamb attachment mechanisms are not sturdy, frequent use of the door can damage the attachment mechanisms and impede normal function of the door.

0005Therefore, there is a need in the art for a sturdy and structurally sound folding door that is easy to install on an existing door jamb. There is also a need for a folding door that contains durable and flexible attachment mechanisms that can withstand forces from all directions when the door is being pulled open or closed along the header mechanism.

0006There is a further need for a folding door that is made of material that is flexible, renewable and durable.

SUMMARY OF THE INVENTION

0007The present invention is a folding door adapted to be attached to a door jamb having a forward door jamb, a header, and a rear door jamb. There are a plurality of mini slats adapted to be hung vertically from the door header via a hanging channel track attachable to the header. Each mini slat is horizontally coupled together such that the plurality of mini slats form a flexible folding door panel. The folding door panel is adapted to substantially span and enclose a space between the forward and rear door jamb. The flexible folding door panel has a forward end near the forward door jamb and a rearward end near the rear door jamb. The folding door panel defining, in series, bounded vertical plane door segments interposed between folding seam door segments. Each bounded vertical plane segment has a first subplurality of mini slats maintained in a substantially single vertical plane by a top binder. Each folding seam segment having a second subplurality of mini slats which establish the folding panel seam segments of the folding door. The seam segments are intermediate to the plane segments. The forward end of the folding door panel has a forward edge segment adapted to be adjacent said forward door jamb. The forward edge segment has a door closure element.

0008The forward jamb edge piece is adapted to be fixedly attached to the forward door jamb. The forward jamb edge piece has a complementary closure element adapted to cooperate with the closure element on said forward edge segment permitting the folding door panel to open and close on the forward door jamb. The folding door panel has a rearward edge piece adapted to be attached to the rear door jamb. A plurality of caster assemblies are movably disposed in the hanging channel track, a respective caster assembly attached to a corresponding top binder. Each caster assembly includes: (1) one or more low friction wheels adapted to move in the hanging channel track and (2) a depending stem extending downward below the wheels. The depending stem forms a low friction interface with the adjacent depending track edge. The depending stem has a terminal lower end stop. Each top binder defines an aperture at its upper surface. The depending caster stem extends through the top binder aperture such that the lower stop is below the upper surface of the top binder to capture the stem and the caster assembly atop the top binder. The stem permits three dimensional movement of the vertical plane segments with respect to said hanging channel track.

0009In the preferred embodiment, the mini slats of the folding door are composed of bamboo. In alternate embodiments, any durable, renewable material may be used to compose the mini slats. In the preferred embodiment, the folding door will come in a package almost completely built, so that the end user will simply install the forward jamb edge piece to the forward door jamb, the hanging channel track to the header, the rear edge piece to the rear door jamb, and hang the complete folding door panel with casters.

0010Although the invention is illustrated and described herein in reference to a specific embodiment, it is nevertheless not intended to be limited to only the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. The construction of the invention, however, together with additional objects, features, and advantages thereof will be best understood and appreciated from the following detailed description of the embodiments thereof, selected for purposes of illustration and shown in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

0011<figref idref="DRAWINGS">FIG. 1</figref> is an exploded view of the folding door showing accordion folded segments in accordance with the principles of the present invention.

0012<figref idref="DRAWINGS">FIG. 2</figref> is a front view of the folding door panel in an open state.

0013<figref idref="DRAWINGS">FIG. 3</figref><i>a </i>is a detailed view of the mini slats of the folding door.

0014<figref idref="DRAWINGS">FIG. 3</figref><i>b </i>is a top view of the mini slats of the folding door panel showing an overlap in the mini slats.

0015<figref idref="DRAWINGS">FIG. 3</figref><i>c </i>is a wood grain variation embodiment of the folding door panel.

0016<figref idref="DRAWINGS">FIG. 4</figref> is a detailed view of dual and single caster assemblies operatively coupling the folding door to the door header.

0017<figref idref="DRAWINGS">FIG. 5</figref> is a detailed front view of a dual caster assembly.

0018<figref idref="DRAWINGS">FIG. 6</figref><i>a </i>is a detailed side view of a dual caster assembly.

0019<figref idref="DRAWINGS">FIG. 6</figref><i>b </i>is a cut away view of the caster assembly seated in the hanging channel track (the track attached to the heard) and showing the leg and ring cut away to reveal the position of the stem and the cap.

0020<figref idref="DRAWINGS">FIG. 6</figref><i>c </i>is a cut away view of the caster assembly seated in the hanging channel track showing the cap and stem behind the leg.

0021<figref idref="DRAWINGS">FIG. 6</figref><i>d </i>is a cut away front view of caster assembly seated in hanging channel track the near side wheel being but away to reveal the low friction sleeves on the depending legs of U-shaped member.

0022<figref idref="DRAWINGS">FIG. 7</figref> is a top view of the folding door.

0023<figref idref="DRAWINGS">FIG. 8</figref> is a bottom view of the folding door.

0024<figref idref="DRAWINGS">FIG. 9</figref> is a side view of the fore end of the folding door.

0025<figref idref="DRAWINGS">FIG. 10</figref> is a partial elevational view showing the folding door partially open.

0026<figref idref="DRAWINGS">FIG. 11</figref> is a top view of the magnetic closing mechanism of the folding door.

0027<figref idref="DRAWINGS">FIG. 12</figref> is an exploded view of a clip attachable to the top of the folding door panel, which clip forms a bound panel segment. Multiple clips form multiple spaced apart bound panel segments that fold adjacent each other in a door closed mode.

DETAILED DESCRIPTION

0028Embodiments of the invention are illustrated in the accompanying drawings. The present invention can be best understood by referring to the enclosed drawings and the following explanation.

0029<figref idref="DRAWINGS">FIG. 1</figref> is an exploded view of the folding door showing accordion folded segments in accordance with the principles of the present invention. The folding door system <b>1</b> is attachable to the jamb of the doorway, namely, the forward door jamb <b>26</b>, the header <b>28</b>, and the rear door jamb <b>30</b>. The forward jamb edge piece <b>3</b> is permanently attached to the forward door jamb <b>26</b> with screws as shown by arrows <b>32</b>.

0030The folding door, in one embodiment, is a do-it-yourself kit which the home owner or occupant can easily install. The kit includes door <b>1</b>, forward jamb piece <b>3</b>, track <b>9</b> and certain handle pieces and mounting fixtures (screws, nails, etc.).

0031The hanging channel track <b>9</b> is attached to the header <b>28</b> of the doorway. The hanging channel track <b>9</b> is the track from which the folding door panel <b>21</b> will be vertically hung. The rear edge door piece <b>17</b> of folding door <b>1</b> is permanently attached to the rear door jamb <b>30</b> with screws or other similar attachment means as shown by arrows <b>34</b>. The rear edge door piece <b>17</b> is also attached to the rearward end of the folding door panel <b>21</b>. Accordingly, once the rear edge door piece <b>17</b> is attached to the rear door jamb <b>30</b>, that attachment will form the portion of the folding door panel <b>21</b> that will remain somewhat permanently secured to the rear door jamb <b>30</b>. The fore end leading edge door piece <b>5</b> is the leading edge of the folding door panel <b>21</b>. A dual caster assembly <b>13</b> is attached to the top of the fore end leading edge door piece <b>5</b>. A door handle <b>11</b> is attached to the fore end leading edge door piece <b>5</b>.

0032The terms “forward” and “rear” refer to portions of the door jamb. The “forward” region is where the folding door normally opens, permitting entry and exist into the room. “Rear” or “rearwards” refers to the somewhat permanently a fixed door region at the opposite door jamb.

0033When the folding door panel <b>21</b> is shut, closing the door jamb opening, the forward jamb edge piece <b>3</b> receives the fore end leading edge door piece <b>5</b> and the folding door panel <b>21</b> is removably secured in place. The forward jamb edge piece <b>3</b> has a complementary closure element <b>7</b> adapted to cooperate with the closure element <b>19</b> on the forward edge segment permitting the folding door panel <b>21</b> to open and close on the forward door jamb <b>26</b>. The complementary closure system shown in the preferred embodiment is a magnetic system; however, any appropriate closure system may be used. Alternate complementary closure systems are a hook and eye system, a latch system, a loop and post system, or any other known closure system. As shown, magnetic plates <b>7</b> are seated within the forward jamb piece <b>3</b>. Magnetic buttons <b>19</b> are fixed in the fore end leading edge door piece <b>5</b>. When the folding door panel <b>21</b> is moved to a closed position wherein persons and items cannot pass through the door opening, the magnetic plates <b>7</b> attract the magnetic buttons <b>19</b> and the folding door panel <b>21</b> is secured in the closed position.

0034The folding door panel <b>21</b> is composed of a plurality of segments that are primarily divided between two segment groups: (1) a fixed or bound panel segments <b>25</b><i>a</i>, <b>25</b><i>b</i>, <b>25</b><i>c </i>and (2) a folding panel seam segments <b>23</b><i>a</i>, <b>23</b><i>b</i>. The segments are serially interposed such that each panel is bounded or intermediate a seam segment. These segments create the accordion style fold of the door. Round segments fold next to each other such that <b>25</b><i>a </i>is next to <b>25</b><i>b</i>; <b>25</b><i>b </i>is next to <b>25</b><i>c</i>; when the door is in an open mode operational position.

0035The fixed or bound panel segments include a forward bound panel segment <b>25</b><i>a</i>, a plurality of mid bound panel segments <b>25</b><i>b </i>and rear bound panel segments <b>25</b><i>c. </i>

0036A single caster assembly <b>15</b> is attached to the vertical center line of the mid bound panel segments <b>25</b><i>b</i>. The folding panel seam segments include a forward folding panel seam segment <b>25</b><i>a </i>and a number of mid folding panel seam segments <b>25</b><i>b. </i>

0037<figref idref="DRAWINGS">FIG. 2</figref> is a front view of the folding door panel <b>21</b> in an open operational state. The mini slats <b>53</b> that comprise the door panel <b>21</b> are vertically positioned in the header track channel and the slats overlap to form a highly flexible door panel <b>21</b>. The mini slats <b>53</b> of the preferred embodiment are approximately 2 to 5 millimeters wide, but the slats could be larger as long as they work within the door as designed. One key feature of the many described herein is that a plurality of slats form (a) a bound-together panel segment and (b) another plurality form folding seam segments. The mini slats <b>53</b> can be made from a variety of material, such as bamboo, wood, plastic, or any other suitable materials. In the preferred embodiment, the material used is bamboo as it is a renewable resource and is both strong and flexible. The folding door panel <b>21</b> is designed to be cut to fit the height of the doorway and the width of the doorway. The bottom section of folding door panel <b>21</b> can be cut or sawed off horizontally across the slats to fit the doorway. The wide span of the folding door can be cut by cutting the horizontal attachment threads.

0038The fixed or bound segments <b>25</b><i>a</i>, <b>25</b><i>b</i>, <b>25</b><i>c </i>and a folding seam segments <b>23</b><i>a</i>, <b>23</b><i>b </i>are shown in greater detail in <figref idref="DRAWINGS">FIG. 2</figref>. Forward bound panel segment <b>25</b><i>a </i>is shown adjacent to the fore end leading edge door piece <b>5</b>. Forward bound panel segment <b>25</b><i>a </i>is held in a singular segment fixed plane by forward top binder <b>51</b><i>a</i>. See <figref idref="DRAWINGS">FIG. 12</figref>. The top binder <b>51</b> may be a clip, bar, cast elements, metal or plastic bands or other suitable devices that would serve to bind the mini slats <b>53</b> within a fixed plane. Forward top binder <b>51</b><i>a </i>is not connected to a caster assembly, as the forward bound panel segment <b>25</b><i>a </i>falls within the same plane as the fore end leading edge door piece <b>5</b> which contains the dual caster assembly <b>13</b>. A dual caster assembly <b>13</b> is attached to the top edge region of the end piece <b>5</b>. There is no caster assembly on top binder <b>51</b><i>a</i>. Mid bound panel segments <b>25</b><i>b </i>are located in the middle sectional portion of the folding door panel <b>21</b> and are each respectively held in a fixed segmental plane by mid top binder <b>51</b><i>b</i>. There will be as many mid bound panel segments <b>25</b><i>b </i>as required to form the necessary width (or length across the doorway) of the folding door panel <b>21</b>. Rear bound panel segment <b>25</b><i>c </i>is shown adjacent to the rear edge door piece <b>17</b>. Rear bound panel segment <b>25</b><i>c </i>is held in a fixed vertical segment plane by rear clip <b>51</b><i>c</i>. Rear top binder <b>51</b><i>c </i>is not connected to a caster assembly. Forward folding panel seam segment <b>23</b><i>a </i>is located adjacent the forward bound panel segment <b>25</b><i>a </i>and the slats <b>53</b> of the forward folding panel seam segment <b>23</b><i>a </i>are subject to folding action of about 0° to about 180°. Mid folding panel seam segments <b>23</b><i>b </i>are located adjacent and bound, left to right, the mid bound panel segments <b>25</b><i>b </i>and are subject to folding action of about 0° to about 180°. Accordingly, when the folding door panel <b>21</b> is opened, the folding panel seam segments <b>23</b><i>a</i>, <b>23</b><i>b </i>fold to allow the bound or fixed segments <b>25</b><i>a</i>, <b>25</b><i>b</i>, <b>25</b><i>c </i>to collapse against each other and stack against the rear door jamb <b>30</b>.

0039In the preferred embodiment, the folding door system <b>1</b> is a center mount door where each mid bound panel segment <b>25</b><i>b </i>is hung from the top center of that segment by a single caster assembly <b>15</b>. This creates a balanced folding door panel <b>21</b> that is suspended from the hanging track channel <b>9</b>. As shown in <figref idref="DRAWINGS">FIG. 2</figref>, there are designated lengths of certain portions of the folding door panel <b>21</b>. The measurements of the folding door panel <b>21</b> are critical to ensure the door has equal folds when in the closed position. Measurement d<b>1</b> is the length of a folding panel seam segment <b>23</b><i>a</i>, <b>23</b><i>b</i>. Measurement d<b>2</b> is the length of a mid bound panel segment <b>25</b><i>b</i>. Measurement d<b>3</b> is the length of the folding door panel <b>21</b> that is composed of: (1) the forward bound panel segment <b>25</b><i>a</i>, (2) half of the forward folding panel seam segment <b>23</b><i>a</i>, and (3) a number of mini slats that connect the fore end leading edge door piece <b>5</b> with the forward bound panel segment <b>25</b><i>a</i>. Multiple mini slats which respectively form (a) each bond segment and (b) left and right adjacent folding segments, establish the small compact size of the fully open door. Measurement d<b>4</b> is the length of the folding door panel <b>21</b> that is composed of: (1) half (½) of a folding panel seam segment <b>23</b><i>a</i>, (2) mid bound panel segment <b>25</b><i>b</i>, and (3) half (½) of another folding panel seam segment <b>23</b><i>b</i>. Measurement d<b>4</b> is the length (left to right) of the folding door panel <b>21</b> that will remain in a fixed plane and stack up against each other bound segment at the door jamb when the door is fully opened. Measurement d<b>5</b> is the length of the folding door panel <b>21</b> that is composed of: (1) half (½) of a mid folding panel seam segment <b>23</b><i>b</i>, (2) the rear bound panel segment <b>25</b><i>c</i>, and (3) a number of mini slats that connect the rear edge door piece <b>17</b> with the rear bound panel segment <b>25</b><i>c. </i>

0040<figref idref="DRAWINGS">FIG. 3</figref><i>a </i>is a detailed view of the mini slats <b>53</b> in the folding door panel <b>21</b>. <figref idref="DRAWINGS">FIG. 3</figref><i>b </i>is a top view of the mini slats in the folding door panel showing an overlap in the mini slats. As shown in <figref idref="DRAWINGS">FIG. 3</figref><i>b</i>, the mini slats <b>53</b> overlap each other to form a highly flexible folding door panel <b>21</b>. The mini slats <b>53</b> are secured together with ties <b>75</b> formed by horizontal threading. The ties <b>75</b> run horizontal to tie up the vertically positioned slats <b>53</b>. The ties <b>75</b> may be plastic, fabric, thread, wire or any suitable material that would serve to securely tie the mini-slats together. <figref idref="DRAWINGS">FIG. 3</figref><i>c </i>is a wood grain variation embodiment of the folding door panel. As shown in <figref idref="DRAWINGS">FIG. 3</figref><i>c</i>, the mini slats <b>53</b> may be wood or another material that has been surface treated to look like wood.

0041<figref idref="DRAWINGS">FIG. 4</figref> is detailed view of the dual caster assembly <b>13</b> and the single caster assembly <b>15</b>. As shown, the single caster assembly <b>15</b> and the dual caster assembly <b>13</b> contain nearly the same parts, the only difference being that the dual caster assembly <b>13</b> contains two caster assemblies and is mounted on a dual caster U-shaped base mount clip <b>109</b>. Other shaped top binders or clips may be used to fix castors on the end frame elements and the bound segments. Additionally, although the caster assemblies <b>13</b>, <b>15</b> are shown with two wheels per caster, the caster assembly of the invention may contain only one low friction wheel <b>101</b>. The dual caster assembly <b>113</b> is mounted on the fore end leading edge door piece <b>5</b>. The dual caster assembly <b>13</b> is used in the leading edge of the folding door <b>21</b> because it provides additional strength to the door. The use of the dual caster assembly <b>13</b> allows the leading edge of the door to accommodate the forces that are typically put on a door to open and close it. The single caster assembly <b>15</b> is mounted on the center of mid top binder <b>51</b><i>b</i>. Shown between mid top binder <b>51</b><i>a </i>and the dual caster assembly <b>13</b> is forward top binder <b>51</b><i>a</i>. As used herein, the term “top binder” or “clip” shall apply to all members that serve to bind the mini slats together or to attach the casters to the folding door.

0042As shown in <figref idref="DRAWINGS">FIG. 4</figref> and in further detail in <figref idref="DRAWINGS">FIG. 5</figref>, the caster assemblies <b>13</b>, <b>15</b> are composed of one or more low friction wheels <b>101</b> mounted on a U-shaped frame <b>155</b> having two depending legs <b>105</b>. The low friction wheels <b>101</b> can be made of a variety of materials, such as plastic, nylon, polymers, phenolics, acetal, polytetrafluoroethylene, or like materials. Surrounding the middle of each leg <b>105</b> are low friction sleeves <b>103</b>. The sleeves <b>103</b> make the folding door panel <b>21</b> quiet, as well as smooth to roll, as the caster assembly <b>13</b>, <b>15</b> moves through the hanging track channel <b>9</b>.

0043Although cylindrical sleeves are shown, half pipe sleeves may be used to provide a low friction barrier between legs <b>105</b> and the vertical edge (defining the opening in the channel track) of the channel track.

0044The distal downward portion of each leg <b>105</b> is attached perpendicularly to a ring <b>113</b>. A movable stem <b>107</b> sits in the ring <b>113</b> with a stem cap <b>108</b> that overhangs atop the ring <b>113</b>. The caster assemblies <b>13</b>, <b>15</b> provide a smooth sliding folding door panel <b>21</b> by absorbing forces put on the door through: (1) the pitch, yaw and roll created by the movement in all directions of the stem <b>107</b> within the ring <b>113</b>, (2) the rotation allowed by the stem <b>107</b> in the ring <b>113</b> and (3) the use of low friction material on the sleeves <b>103</b> and the wheels <b>101</b>. In this manner, the bound door segments move in a swivel manner, that is, a swivel connection, with respect to the caster, which moves longitudinally in the header channel track. Vertical movement is permitted between the ring and cap. 360 degree movement is permitted by a small diameter stem in a larger aperture in the ring. The pitch, yaw and roll allows the caster assemblies <b>13</b>, <b>15</b> to move all the way around thus increasing the flexibility and stability of the folding door system <b>1</b>. As used herein, pitch, yaw and roll shall have their customary meanings, namely, pitch is understood to mean the rotation around the side to side axis, yaw is understood to mean the rotation around the vertical axis, and roll is understood to mean the rotation around the front to back axis. The distance between the ring <b>113</b> and the upward leg of dual caster U-shaped base mount clip <b>109</b><i>c </i>is designated as h<b>1</b>. Distance h<b>1</b> is a variable distance that fluctuates due to the yaw, pitch and roll of the stem <b>107</b> seated in the ring <b>113</b>.

0045In an alternate embodiment, the caster assembly <b>13</b>, <b>15</b> may use one or more low friction wheels <b>101</b> adapted to move in the hanging channel track <b>9</b>. A depending stem <b>107</b> extends downward below the wheel(s) <b>101</b>. The depending stem <b>107</b> forms a low friction interface with the adjacent depending hanging channel track edge <b>9</b>. The depending stem <b>107</b> has a terminal lower end stop. Each top binder <b>51</b><i>b </i>has an aperture on its upper surface. The depending stem <b>107</b> extends through the top binder <b>51</b><i>b </i>aperture such that the lower stop is below the upper surface of the top binder <b>51</b><i>b </i>to capture the stem <b>107</b> and the caster assembly atop the top binder <b>51</b><i>b</i>. The stem <b>107</b> permits three dimensional movement of the vertical plane segments or door panels with respect to the hanging channel track <b>9</b>. Additionally, the alternate embodiment may also include caster assembly wheel(s) <b>101</b> that rotate about an axis that runs through a hub <b>155</b>. The hub <b>155</b> has depending legs <b>105</b> which define a ring <b>113</b>. The hub legs <b>105</b> define an upper stem element <b>107</b> carrying the low friction interface. A lower stem <b>107</b> element has an upper stop <b>108</b> disposed at the lower terminal end of the lower stem <b>107</b> below the upper surface of the top binder <b>51</b><i>b</i>. The lower caster stem element <b>107</b> extends through the ring <b>113</b> and through the top binder aperture such that the upper stop <b>108</b> is above the ring <b>113</b> and the lower stop <b>125</b> is below the upper surface thereby permitting vertical movement of the caster assembly ring with respect to the top binder <b>51</b><i>b</i>. The swivel movement of the bound door segments with respect to the caster is accomplished by this simplified stem construct.

0046<figref idref="DRAWINGS">FIG. 5</figref> is a detailed front view of the dual caster assembly with the dual caster U-shaped base mount clip <b>109</b> cut away to reveal a retaining pin <b>125</b> securing the stem <b>107</b> within the ring <b>113</b> and thereby attaching the dual caster assembly <b>13</b> to the dual caster U-shaped base mount clip <b>109</b> of the folding door panel <b>21</b>. A retaining pin <b>125</b> is also used to attach a single caster assembly <b>15</b> to a mid clip <b>51</b><i>b </i>on the mid bound panel segments <b>25</b><i>b</i>. The retaining pin <b>125</b> can be a cotter pin, clip, rivet, bolt, screw or any suitable device to secure the stem <b>107</b> within the ring <b>113</b> and in the top binder <b>109</b>, <b>51</b><i>b</i>. The wheels <b>101</b> rotate or spin in both directions as indicated by arrows <b>130</b>. There is also vertical movement of the caster assembly <b>13</b> as indicated by arrow <b>133</b>.

0047<figref idref="DRAWINGS">FIG. 6</figref><i>a </i>is a detailed side view of the dual caster assembly <b>13</b> cut away to show the placement of the stem <b>107</b>. This view shows the low friction wheels <b>101</b> attached to a fixed axle <b>157</b>. Alternatively, the wheels could rotate on a fixed axle mounted horizontally in frame <b>155</b>. U-shaped frame <b>155</b> has two depending legs <b>105</b>. The low friction sleeve <b>103</b> surrounds the depending leg <b>105</b>. The stem <b>107</b> is seated in the ring <b>113</b>. The stem <b>107</b> proceeds through the upward leg of dual caster U-shaped base mount clip <b>109</b><i>c</i>. The front side of the dual caster U-shaped base mount clip <b>109</b><i>a </i>faces to the front of the folding door panel <b>21</b> and the rear side of the dual caster U-shaped base mount clip <b>109</b><i>b </i>faces to the rear of the folding door panel <b>21</b>. The stem <b>107</b> contains a lateral pin hole <b>153</b> for receiving a pin, rivet, or any device capable of securing the stem <b>107</b> within the ring <b>113</b> and onto the fore end leading edge door piece <b>5</b>. Three dimensional movement of the caster assembly <b>13</b> in the hanging channel track <b>9</b> is shown by arrow <b>135</b>.

0048<figref idref="DRAWINGS">FIGS. 6</figref><i>b </i>and <b>6</b><i>c </i>both show a caster assembly <b>13</b> seated in the hanging channel track <b>9</b>. <figref idref="DRAWINGS">FIG. 6</figref><i>b </i>is a cut away view of the caster assembly <b>13</b> seated in the hanging channel track <b>9</b> also showing the depending leg <b>105</b> and ring <b>113</b> cut away to reveal the position of the stem <b>107</b> and cap <b>108</b>. The low friction wheels <b>101</b> are seated in the hanging channel track <b>9</b>. The depending leg <b>105</b> extends down from the U-shaped frame <b>155</b>. Surrounding the depending leg <b>105</b> is a sleeve <b>103</b> composed of low friction material. The sleeve <b>103</b> engages the edges of the hanging track channel and reduces friction that is caused by the caster assemblies being slid back and forth in the hanging track channel <b>9</b> as the door is opened and closed. This reduces the noise of the caster assembly <b>13</b>, <b>15</b> and creates a smooth glide in the hanging channel track <b>9</b>. The depending leg <b>105</b> and ring <b>113</b> is cut away to show the position of the cap <b>108</b> and stem <b>107</b> set within the ring <b>113</b>. Distance h<b>1</b> is the amount of pitch or vertical movement that is allowed by the stem <b>107</b> between the ring <b>113</b> and the upward leg of the dual caster U-shaped base mount clip <b>109</b><i>c</i>. <figref idref="DRAWINGS">FIG. 6</figref><i>c </i>is cut away view of the caster assembly <b>13</b> seated in the hanging channel track <b>9</b>, but the leg <b>105</b> and ring <b>113</b> are not cut away thus showing the normal view of the cap <b>108</b> and stem <b>107</b> behind the leg <b>105</b>.

0049<figref idref="DRAWINGS">FIG. 6</figref><i>d </i>is a cut away front view of caster assembly <b>13</b>, <b>15</b> seated in the hanging channel track <b>9</b>, the near side wheel <b>101</b> being cut away to reveal the low friction sleeves <b>103</b> on the depending legs <b>105</b> of the U-shaped member <b>155</b>. The low friction wheel <b>101</b> is shown seated in the hanging channel track <b>9</b> with the legs <b>105</b> surrounded by sleeves <b>103</b>. The low friction wheel <b>101</b> is cut away to reveal the second low friction wheel <b>101</b> sitting behind the first wheel in the hanging channel track <b>9</b>. Also shown by the low friction wheel <b>101</b> being cut away is the U-shaped frame <b>155</b> that connects the two depending legs <b>105</b> and the fixed axle <b>157</b> to which the wheels are attached. Distance d<b>8</b> is a variable length of distance of the low friction wheel <b>101</b> above the hanging channel track <b>9</b>. The legs <b>105</b> attach to the ring <b>113</b> through which sits stem <b>107</b>. The cap <b>108</b> of the stem <b>107</b> retains the stem <b>107</b> in the ring <b>113</b> as does pin <b>125</b>, which secures the bottom of the stem <b>107</b> in the ring <b>113</b>. The use of the cap <b>108</b> and pin <b>125</b> cause there to be a significant amount of pitch, yaw and roll within the caster assembly <b>13</b>, <b>15</b>.

0050<figref idref="DRAWINGS">FIG. 7</figref> is a top view of the folding door system <b>1</b> and <figref idref="DRAWINGS">FIG. 8</figref> is a bottom view of the folding door system <b>1</b>. Both of these views show the folding door panels <b>21</b> in the closed or extended position. The dual caster assembly <b>13</b> is attached onto the fore end leading edge door piece <b>5</b> followed by a number of unbound mini slats <b>53</b> that are adjacent the forward top binder <b>51</b><i>a</i>. Forward top binder <b>51</b><i>a </i>holds together the mini slats of forward bound panel segment <b>25</b><i>a</i>. There is no caster assembly on the forward top binder <b>51</b><i>a</i>. Following forward top binder <b>51</b><i>a </i>is forward folding panel seam segment <b>23</b><i>a </i>and then mid top binder <b>51</b><i>b</i>. Mid top binder <b>51</b><i>b </i>holds together the mini slats of the mid bound panel segments <b>25</b><i>b</i>. There is a single caster assembly <b>15</b> attached to the mid top binder <b>51</b><i>b</i>. Following mid top binder <b>51</b><i>b </i>is mid folding panel segment <b>23</b><i>b</i>. As shown, the number of mid top binder <b>51</b><i>b </i>or mid bound panel segments <b>25</b><i>b </i>and mid folding panel segments <b>23</b><i>b </i>are determined by the desired length of the folding door panel <b>21</b>. Following the required number of mid bound panel segments <b>25</b><i>b </i>and mid folding panel segments <b>23</b><i>b</i>, is rear top binder <b>51</b><i>c</i>. Rear top binder <b>51</b><i>c </i>holds together the mini slats of the rear bound panel segment <b>25</b><i>c</i>. There is no caster assembly on rear top binder <b>51</b><i>c</i>. The rear bound panel segment <b>25</b><i>c </i>is followed by a number of unbound mini slats that are adjacent the rear edge door piece <b>17</b>.

0051<figref idref="DRAWINGS">FIG. 9</figref> is a side view of the fore end of the folding door panels <b>21</b>. The dual caster assembly <b>13</b> is shown attached to the top of the fore end leading edge piece <b>5</b>.

0052<figref idref="DRAWINGS">FIG. 10</figref> is a partial elevational view showing the folding door system <b>1</b> partially open. In this view, a single caster assembly <b>15</b> is shown seated in the hanging channel track <b>9</b>. The single caster assembly <b>15</b> is attached to mid top binder <b>51</b><i>b</i>. Preceding mid top binder <b>51</b><i>a </i>is forward top binder <b>51</b><i>a </i>to which no caster assembly is attached.

0053The closing mechanism of the folding door system <b>1</b> is shown in <figref idref="DRAWINGS">FIG. 11</figref>. The forward jamb edge piece <b>3</b> is attached to the forward door jamb <b>26</b>. Seated on the outward edge of the forward jamb edge piece <b>3</b> are magnetic plates <b>7</b>. Attached onto the fore end leading edge door piece <b>5</b> are magnetic buttons <b>19</b>. As the folding door closes, the forward jamb edge piece <b>3</b> receives the fore end leading edge piece <b>5</b> and secures the folding door in a closed position through the contact of the magnetic buttons <b>19</b> with the magnetic plates <b>7</b>. A tongue and groove mount is created with the magnets holding together the forward jamb piece <b>3</b> and the fore end leading edge piece <b>5</b>.

0054<figref idref="DRAWINGS">FIG. 12</figref> is an exploded view of a top binder <b>51</b><i>b </i>attachable to the top of the folding door panel <b>21</b>, which top binders form a bound panel segment <b>25</b><i>b</i>. The mid top binder <b>51</b><i>b </i>contains serrated teeth <b>203</b> that serve to grip the mini slats <b>53</b> and hold the mid top binder <b>51</b><i>b </i>in place. The mid top binder <b>51</b><i>b </i>holds a segment of mini slats <b>53</b> together to form mid bound panel segments <b>25</b><i>b</i>. Forward folding panel seam segment <b>23</b><i>a </i>proceeds mid bound panel segment <b>25</b><i>b </i>and mid folding panel seam segment <b>23</b><i>b </i>follows mid bound panel segment <b>25</b><i>b</i>. Accordingly, there is a folding panel seam segment <b>23</b><i>a</i>, <b>23</b><i>b </i>surrounding each mid bound panel segment <b>25</b><i>b. </i>

0055In an alternate embodiment, there are double folding door panels <b>21</b> that close in the middle of the door way. A double folding door would likely be designed for larger than normal door ways.

0056Although described above in connection with a specific embodiment, this is not meant to be limiting, as other folding door systems can be made in accordance with the description herein. As such, although the invention is illustrated and described herein, various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.