Overhead door torsion spring assembly and method

A torsion spring assembly for overhead doors, comprising an elongated helical torsion spring having a multiplicity of coils which are normally spaced apart when said spring is in an untensioned state;

• said spring having radially inwardly turned hook portions at opposite ends thereof;
• a shaft extending through the coils of said spring having end portions projecting beyond said spring;
• a first spring-mounting collar having a bore rotatably receiving one of said end portions of said shaft;
• said first collar having a neck portion extending into the coils at one end of said spring;
• said neck portion of said first collar having a generally axially-extending slot receiving one of said hook portions of said spring for anchoring said one end of said spring and said first collar against independent relative rotation;
• means secured to said shaft for preventing outward axial movememt of said first collar upon said shaft;
• a second spring-mounting collar having a bore receiving the other end of said shaft;
• said second collar having a neck portion extending into the coils at the other end of said spring opposite from said one end;
• said neck portion of said second collar having a generally axially extending slot receiving the othe of said hook portions of said spring for anchoring said other end of said spring and said second collar against independent relative rotation;
• and removable locking means securing said second collar against independent axial and rotational movement relative to said shaft;
• said means for preventing outward axial movement of said first collar including a locking ring affixed to said one end portion of said shaft and providing a bearing surface for rotatably engaging an outwardly facing surface of said first collar;
• said locking ring being affixed to said shaft by a removable drive pin;
• said drive pin extending through aligned transverse bores in said locking ring and said one end portion of said shaft;
• said first collar including a cylindrical chamber receiving said locking ring;
• said chamber preventing removal of said drive pin when said locking ring is received therein.

A method of constructing a torsion spring assembly for counterbalancing an overhead door, comprising the steps of forming an elongated helical torsion spring with a multiplicity of coils that are normally spaced apart when said spring is in an untensioned state, said spring having radially-inwardly turned hook portions at opposite ends thereof;

• fitting said spring upon a shaft having a length greater than said spring, said shaft having a collar mounted at one end thereof with an inwardly-facing neck portion having an axial slot;
• said fitting step including inserting the hook portion at the distal end of said spring into the slot of said neck portion to interlock the same against independent relative rotation;
• then axially compressing said spring to position the coils thereof in substantially contiguous relation;
• then, while said spring is so compressed, mounting a second collar upon the opposite end of said shaft at a distance from said first collar exceeding the length of said spring in its compressed state but less than the length of said spring in an untensioned state;
• said step of mounting said second collar including fixing the same against axial movement in opposite directions upon said shaft, said second collar including a neck portion facing said spring having an axial slot adapted to receive the hook portion of said spring at the proximal end thereof;
• and thereafter removing the compressive forces from said spring, to allow the same to expand, while directing said hook portion at said proximal end into the slot of said neck portion of said second collar;
• one of said first and second collars being secured against rotation relative to said shaft and the other of said collars being freely rotatable upon said shaft.