Hinge mounting system

A hinge that has a first mounting base for attachment to a first hinged object. The hinge also has first and second hinge members pivotally connected together. The first hinge member and the first base are configured and dimensioned for cooperatively positioning and aligning the first hinge member in a plurality of mounted positions along the base length. At least one first locking member is associated with the first hinge member and the first base for locking the first hinge member to the first base in one of the mounted positions. The hinge may also be segmented. A positioning tool may be connected to at least the first base with an attachment portion and configured for positioning the first base and attachment portion on a first hinged object at a predetermined distance from the second hinge member.

 

What is claimed:

1. A positioning tool for mounting a hinge comprising:

a first base positioner configured and adapted for receiving a first hinge mounting base, the first base for mounting to a first hinged object;

a detachable second base positioner configured and adapted for receiving a second hinge mounting base, the second base for mounting to a second hinged object; and

a connecting means for releaseably holding the first and second mounting base positioners together.

2. The positioning tool of claim 1 wherein the connecting means is a fastener.

3. The positioning tool of claim 1 further comprising the first and second base positioners each having a base retaining portion for placement over the first and second bases, respectively, and a handle portion angularly disposed to the retaining portion.

4. The positioning handle of claim 3 wherein the handle portions are angularly disposed to the retaining portions at an angle of about 90 degrees.

5. The positioning tool of claim 3 further comprising an offset means for releaseably positioning and holding the base retaining portion of the first base positioner in an offset position from the base retaining portion of the second base positioner.

6. The positioning tool of claim 5 wherein the offset means comprises the handle portion of the first base positioner having a round opening for receiving the connecting means, and the handle portion of the second base positioner having an elongated slot for receiving the connecting means, wherein the handle portions are slidably engaged to each other to create an offset.

7. The positioning tool of claim 5 further comprising a hinged object spacer releaseably attached to the tool, the spacer projecting a distance outwards from the positioning tool for placement into a gap formed between a first hinged object and a second hinged object.

8. The positioning tool of claim 7 further comprising an adjustment means for varying the projection distance.

9. A segmented positioning tool comprising:

a longitudinal axis; and

a first and second base positioners configured and adapted for receiving a first and second hinge mounting bases for mounting to a first and second hinged object, respectively;

wherein the tool is segmented into at least first and second longitudinal segments.

10. The positioning tool of claim 9 further comprising at least one hinge arranged laterally to the longitudinal axis and holding the at least first and second segments in a pivotable and foldable relationship.

11. The positioning tool of claim 9 further comprising a positioning tool restraining means to hold the at least first and second segments in a straight substantially axially-aligned configuration.

12. The positioning tool of claim 9 further comprising the tool being segmented into at least four segments of at least two different lengths, wherein the segments are releaseably held together and the length of the segments are cooperatively sized to provide an assembled length.

13. A positioning tool comprising:

a first half having a handle and a stop;

a second half having a handle and a stop;

a releaseable fastener connecting the first and second halves; and

a blade disposed between the first and second halves and protruding from the stops, wherein the depth that the blade protrudes from the stops is adjustable.

14. A positioning tool comprising:

a first base positioner configured and adapted for receiving a first hinge mounting base, the first base for mounting to a first hinged object;

a second base positioner configured and adapted for receiving a second hinge mounting base, the second base for mounting to a second hinged object;

wherein the first and second base positioners are hingedly connected together to allow the mounting bases to lie flat against the surfaces of the hinged objects.

FIELD OF THE INVENTION

The present invention relates to hinges, and more particularly to segmented hinges and hinges with tools and methods to mount and align hinges to hinged objects.

BACKGROUND OF THE INVENTION

When a hinge is mounted to objects to be hinged with respect to each other, care must be taken to ensure proper alignment and mounting of the hinge and hinged objects. Doors that are in need of repair are often retrofitted with various types of hinges that are known for their increased strength among other factors. Hinges that are applied in the field are often installed under less than ideal conditions. To complete a quality field installation of a door, for example, the door must be maintained in proper alignment with the frame, requiring a prescribed set of clearances at each side of the door and at its top and bottom edges. If this is not done, the door may potentially rub against the frame or drag on the threshold, increasing the difficulty for persons entering or leaving the building as well as imposing additional stress and wear on all of the door hardware, such as locksets and automatic door closers.

Uniform industry standards for the design of butt hinges have been applied to doors and frames in the form of cutouts, or receiving mortises, that allow butt hinges to be fastened directly into these recesses. However, not all of the door alignment requirements are assured when the doors and frames are manufactured. Sometimes, particularly if the doors and frames arrive at the job site from different manufacturing sources, the cutouts or recesses may not correspond, creating misalignment problems that can affect the operating clearances. Also, the installation of frames can be affected by improperly dimensioned or misaligned wall openings, resulting in frame distortion that contribute to door misalignment. To install continuous hinges such as disclosed in my U.S. Pat. Nos. 3,092,870; 3,402,422; 4,976,008; 4,996,739; 4,999,878; 4,999,879; 4,999,880; 5,001,810; 5,201,902; 5,778,491 and 5,991,975, especially those types that are applied to the exterior faces of doors and frames when they are in need of hinge replacement, the installer typically must carefully remove the damaged hinges and mark and drill for the new fastener locations on both the door and the frame as best he can. All too often, when transferring the new screw hole locations from the continuous hinge to the door and frame, the hinge can shift, or the drill point can slide from the mark, contributing to poor door alignment when the installation is complete. Such fastener hole misplacements occur with even greater frequency when large holes are required for through-bolting, especially when hidden internal door reinforcements are encountered by the installer.

U.S. Pat. No. 1,346,029 teaches a butt hinge intended to be quickly and accurately hung. The hinge has channel portions which attach to a door with barbs and screws. Swinger members can be slid on or off the base plates for quick assembly and removal.

Also, it is often desirable that a continuous hinge match the door height so that resistance to the various forces acting on the door will be enhanced. Also, the sealing against the penetration of light, sound, and weather through the hinged edge of the door can be optimized when the hinge length is approximately equal to the door height. A wide variety of door heights exists, however. For instance, minimum residential door heights are typically 6'-8", while doors for commercial and institutional applications are commonly 7' or larger. It has been traditionally difficult to manufacture, handle, and store the many hinge lengths required to properly fit a variety of doors designed for architectural use.

Continuous hinges for these applications are subject to damage within the manufacturing environment because of the length and fragility of their component parts and because of consequential damage to the completed assembly during the various stages of shipment and transportation from the manufacturing site through the complex channels of distribution to the point of installation. Packaging, shipping, and shipping damage costs can become high because of the unusual ratio of length-to-girth or width of the package and the stringent requirements for protection against bending. In addition, the inventory storage requirements for these long and fragile hardware items are costly, because they require specialized shelving or racks at every intermediate location.

Costs are also present for obtaining and preserving the long lengths of the required hinge components before the assembly process can begin. The generation of manufacturing-scrap is increased at every stage if a part is dropped, twisted or bent, or if a fabrication or finishing defect appears within its length at any point in the manufacturing sequence. Unlike conventional butt hinges, which are comprised of smaller, easier to handle and cheaper parts, any such defect reduces or destroys the value of an inherently long continuous hinge part which can add substantially to the overall cost of manufacture. While continuous hinges for very tall doors have sometimes been pieced together to form assemblies that are longer than any practical manufactured length, little attention has been paid to properly aligning these segments during installation so that the segments simulate the function of a single hinge.

Further complexity and cost results from the difficulty of maintaining adequate inventory of each and every required length suitable to the variety of door heights used in the construction industry. While it is possible to manufacture continuous hinges in virtually any reasonable length for large orders, the availability of unusual custom lengths is often subject to long delays and high costs at each step of the manufacturing and distribution cycle. The retrofit and door repair industry, which is a very large portion of the market for continuous hinges, is typified by its requirement for the immediate availability of an enormous variety of models and lengths so that schools, hospitals, shopping malls and other commercial locations can have their doors quickly restored to proper operation for reasons of traffic flow, safety, and security.

Also, one of the more difficult steps in continuous hinge installation in the field is the proper marking and preparation of the fastener holes in a way which will insure the alignment of the door to its frame when the installation is complete. Currently, the installation of continuous hinges is dependent upon the skills of the individual installer. While individual butt or mortise hinges are typically fitted into cutouts with pre-threaded bolt holes prepared in both the door and the frame at their respective factories, continuous hinges are more frequently applied to the unprepared surfaces of doors and frames which offer little to assist in their alignment. Repair work in particular, where continuous hinges are used to overcome conditions in which conventional hinges have failed, is more dependent upon the skill level of the installer because the working environment as well as the condition of the door and frame components may be less than ideal, largely because the doors themselves may have suffered damage when their hinges failed and because the work must often be completed very quickly with a minimum of installation tools. Unless all of the fastener locations for a continuous hinge are carefully marked and drilled, the door will interfere with or rub against the frame following installation or shortly thereafter.

SUMMARY OF THE INVENTION

The present invention is directed to a hinge with first and second hinge members pivotally connected together. In one embodiment, a first mounting base having a first base length is provided for attachment to a first hinged object. The first hinge member and the first base are configured and dimensioned for cooperatively positioning and aligning the first hinge member in a plurality of mounted positions along the length of the first base. At least one first locking member is associated with the first hinge member and the first base for locking the first hinge member to the first base in one of the mounted positions, which preferably includes substantially a continuum of mounting positions over at least one range. The hinge may be a pinless hinge.

The preferred hinge has a hinge width with the first and second hinge members pivoted away from each other, and the ratio of the first length to the hinge width is greater than about 1.25, and more preferably greater than about 2. Also, the first base can be of integral construction with the first hinged object or otherwise attached thereto.

The first base of the preferred embodiment includes a ledge. The first hinge member includes a hook portion engageable around the ledge configured for mounting the first hinge member to the first base.

The locking member preferably has a locked position for locking the first hinge member to the first base, an unlocked position for releasing the first hinge member from the first base, and is movable in a locking direction between the unlocked and locked positions. The first base includes a fastening surface disposed at a fastening surface angle to the locking direction. The fastening surface angle is preferably between about 20.degree. and 60.degree., but it is anticipated that various cooperating profiles for hooking and locking the first hinge member and the first base to each other may be used, such as "v" shapes or inverted "v" shapes on each edge of the mounting base. The second mounting base and second hinge member may utilize alternate but functionally similar profiles as the first mounting base and the first hinge member, depending on the requirements and limitations of the door and frame materials and profiles, i.e., the first and second mounting bases need not be the same size or shape to function in a similar manner.

In this embodiment, the first base and the first hinge member have lateral edges that are engageable to each other for mounting the first hinge member to the first base. The hinge has a second mounting base for attachment to a second hinged object and for mounting the second hinge member.

A preferred hinge mounting system of the invention includes a first mounting base attachable to a first hinged object and configured and dimensioned for mounting a first mountable portion of a first hinge member thereto with the first base attached to the first hinged object. A mount assembly for a second hinge member and for attachment to a second hinged object is also provided. Preferably, the mount assembly comprises a second mounting base configured and dimensioned for mounting a second mountable portion of the second hinge member thereto with the second base attached to the second hinged object. The mounting system includes a positioning tool connected to the first base and to a mount assembly of the second hinge member. The mounting tool is configured for positioning the first base and mount assembly at a predetermined distance from each other for placement on and attachment to the hinged objects. The first and second hinge members may further be pivotally connected together.

The mounting system may include the first and second hinge members, for which the first mounting base and the mount assembly are configured and dimensioned for mounting thereto, respectively, being sized and connected together to position the first mounting base and the mount assembly at a mounted distance that is different than the predetermined distance set by the positioning tool. This may be achieved by selecting a first and second hinge member each having a total width when connected together that increases or decreases the spacing between the first mounting base and mount assembly after the hinge members are attached. This aspect of the invention is useful for adjusting the spacing or gap between the first and second hinged objects to be closer or farther apart than the their original spacing before the hinges are mounted.

In the preferred embodiment, the positioning tool is associated with the first base and the mount assembly for substantially restricting a distance between the first base and mount assembly to a preselected maximum or minimum distance. The positioning tool can be adjustable to select the maximum or minimum distance. The tool can include a flexible portion, and it may be substantially rigid.

An embodiment of the mounting tool has a magnet magnetically connecting the positioning tool to the first base. Another embodiment uses non-magnetic means to connect the positioning tool to the first base.

An embodiment of the mounting system has a disconnect portion that is frangible and disposed such that severing of the disconnect portion causes the positioning tool to disconnect the first base from the mount assembly. Another embodiment contains one or more pierced openings to allow the installer to peer through the frangible or solid positioning tool to properly align it with the interface between the door and the frame or other hinged objects. The disconnect portion of an embodiment includes a tearstrip configured for severing the positioning tool at the disconnect portion.

An embodiment of the tool further includes a hinged object spacer having a thickness and protruding from the positioning tool at an angle with respect to the direction of the predetermined distance and configured for setting a clearance between the hinged objects depending the thickness of the object spacer.

An embodiment of the tool may include means for adjusting the positioning of the hinged bases to accommodate differences in the attachment planes of the hinged objects.

In one embodiment, at least the first base includes an adhesive configured and disposed for attaching to the first hinged object. In another embodiment, at least one of the first base and the positioning tool includes first and second segments of non-unitary construction.

An embodiment of the hinge is segmented and includes a first hinge member attachable to a hinged object and a second hinge member attachable to another hinged object. The first and second hinged member are pivotally connected together. Preferably, a clamp is provided to pivotally connect the first and second hinge members. At least the clamp or both hinge members of this embodiment are segmented into at least first and second segments disposed in longitudinal series. One embodiment has the first and second hinge members collectively segmented into the first and second segments. The first and second hinge members of an embodiment include at least lateral or longitudinal support configuration, and the support configuration is different in the first and second segments. The support configuration in the first hinge segment is preferably free of longitudinal supports between the hinge members, such that the hinge members in the first segment are is movable longitudinally relative to each other.

In the second hinge segment, the support configuration includes at least one longitudinal support for restricting relative longitudinal movement between the hinge members. Another embodiment has a mounting base configured for attachment to a hinged object, wherein the first hinge member and base are configured and dimensioned for cooperatively positioning and aligning the first hinge member to the base. Preferably, the mounting base is segmented into first and second segments disposed in longitudinal series. In another embodiment, a coupling member is provided that is configured for coupling the first and second segments together with the hinge detached from the hinged objects.

Another embodiment of the hinge is segmented, preferably including a pin pivotally connecting knuckle portions of first and second hinge members. At least one of the first and second hinge members and the pin of this embodiment is segmented into first and second segments disposed in longitudinal series. One embodiment has the first and second hinge members collectively segmented into the first and second segments. The first and second hinge members of an embodiment include at least lateral or longitudinal support configuration, and the support configuration is different in the first and second segments. The support configuration in the first segment is preferably movable longitudinally between the hinge members, accomplished by allowing extra longitudinal spacing between the knuckle of the connected hinge members. In the second hinge segment, the support configuration includes at least one pair of knuckles that restrict relative longitudinal movement between the hinge members.

The preceding pinned hinge is described in U.S. Pat. No. 5,778,491, with particular reference to FIG. 12 therein and the accompanying discussion; this patent being incorporated herein by reference. FIG. 12 depicts a first segment 142 wherein the connected hinge members are movable longitudinally with respect to each other. Second segment 160 depicted in FIG. 12 has a support configuration wherein at least one pair of knuckles restrict relative longitudinal movement between the hinge members. Of course, the present invention may be used with other pinned hinges such as the covered type hinge described in my U.S. Pat. No. 5,991,975, which is incorporated herein by reference.

The mounting base of a segmented embodiment is segmented into first and second base segments disposed in longitudinal series. In an embodiment, at least one of the base members may be mounted to the hinged members in a non-segmented length approximately equal to the full height of a door or a frame. Similarly, at least one of the hinge members may be non-segmented and mounted to base members in which one or both may be segmented in order to accommodate the installation of segmented hinged objects such as "Dutch" doors.

In an embodiment, a hinge has first and second hinge members attachable to first and second hinged objects. A joining member, such as a clamp or a pin, is provided for pivotally connecting the first and second hinge members together in coupled association. At least the joining member or both hinge members are segmented into at least first and second segments. At least one coupling member is also provided that is configured for coupling the first and second segments together with the hinge detached from the hinged objects and coaxially aligned and disposed in longitudinal series. In an embodiment, both the hinge members and joining member are segmented into at least first and second segments that are connected by coupling members.

In a preferred method of mounting a hinge to two hinged objects, a first base is aligned and spaced in a mounting position from a mount assembly of a second hinge member with a positioning tool. The first base is attached to a first hinged object in the mounting position, and a first hinge member that is pivotally connected to the second hinge member is aligned and mounted to the first base. The mount assembly may then be attached to a second hinged object, and the second hinge member may then be attached thereto.

The mounting portion is preferably connected to the first base and the mount assembly in connected association with the positioning tool. The connected association is disconnected, with the first member mounted to the first base.

In some embodiments of the invention, the mounting base for one hinge member and the mount assembly for the other hinge member are positioned with a positioning tool at a predetermined distance. When the hinge members are mounted to the first base and mount assembly, these are positioned at a mounted distance with respect to each other that is different than the predetermined distance.

An embodiment of a mounting base has an attachment portion and a fastening assembly associated with the attachment portion for selectively attaching in a plurality of positions to the hinged object at an attachment position on the hinged object.

In an embodiment, a positioning tool for mounting a hinge is provided having a first base positioner and a detachable second base positioner. The base positioners are configured and adapted for receiving a first and second hinge mounting base; the bases for mounting to a first and second hinged object, respectively. A connecting means, which may be a fastener, releaseably holds the first and second mounting base positioners together. The positioning tool may further comprise the first and second base positioners each having a base retaining portion for placement over the first and second mounting bases, respectively, and a handle portion which is angularly disposed at an angle to the contact portion and may be used to grasp the tool. The angle is about 90 degrees in one embodiment. In one embodiment, the offset means comprises the handle portion of the first base positioner having a round opening for receiving the connecting means and the handle portion of the second base positioner having an elongated opening for receiving the connecting means. This arrangement allows the offset to be formed via the slidable connection between the handle portions.

In another embodiment, the aforementined positioning tool may further have a releasably attached hinged object spacer. The spacer projects a distance outwards from the positioning tool for placement into a gap formed between a first and second hinged object to which hinges are applied. In another embodiment, an adjustment means is provided for varying the projection distance.

A segmented positioning tool in one embodiment, which has a longitudinal axis, has a first and second base positioner that is configured and adapted for receiving a first and second hinge mounting base; the bases for mounting to a first and second hinged object, respectively. The tool is segmented into at least first and second longitudinal segments. In one embodiment, at least one hinge is provided that is laterally arranged on the tool for holding the at least first and second segments in a pivotable relationship.

The present invention eases the task of hinge installation and improves the quality of door operation by enabling pre-alignment of the hinge or hinge segments to the hinged objects before the hinge is installed. Whether the hinge is installed as a single piece or arrives at the installation in multiple lengths to be joined together endwise, this invention allows increased speeds of installation and improved operation of the door opening.

Yet another advantage of this invention is the improved appearance and security of the hinges. Previous to this invention, many continuous hinges utilize full-length moldings whose sole purpose is to conceal fasteners to improve security and appearance. These costly extra moldings can be eliminated because the fasteners that hold the hinges to the door and to the frame can be covered by the hinge members themselves, thereby hindering or preventing unauthorized access to the fasteners or removal of the hinge.

It should be noted that the hinges of the present invention may be mounted in a variety of configurations, several of which are shown in the accompanying drawings. For example, the segmented hinge may be provided, with one or more segments being capable of longitudinal support as shown in FIG. 36. The hinge may utilize segments that are all capable of longitudinal support if desired. In another embodiment, one hinge member may be segmented while its mating hinge member may be of continuous length. In yet another embodiment, the mounting base may be segmented while the hinge members are continuous or divided into sections segmented in different lengths than the mounting base as shown in FIG. 35. Alternatively, one of the two (or more) mounting bases can be continuous while the other(s) is/are segmented. Of course, any of the foregoing combinations may be used; for example, segmented bases with segmented hinge sections, segmented hinge sections with non-segmented bases or vice versa, one of the bases or hinge members being continuous and the other segmented, one or more of the foregoing hinge members being capable of longitudinal support, etc. Preferably, the joints between segments of the mounting bases should not be located at the same vertical location or position (on the door and frame) as the joints between segments of the hinge members.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a hinge constructed according to the invention;

FIG. 2 is a cross-sectional view through a lateral plane in the hinge of FIG. 1;

FIG. 3 is a cutaway underside view of the hinge;

FIG. 4 is a perspective view of an embodiment of a thrust bearing thereof;

FIGS. 5-10 are cross-sectional top views showing steps in the assembly and mounting of the hinge to hinged objects;

FIG. 11 is a perspective view of an alternative embodiment of a positioning tool constructed according to the invention;

FIG. 12a is a cross-sectional view of a positioning tool having a plunger;

FIGS. 12b-c are cross-sectional views of a positioning tool having an adjustable plunger blade;

FIG. 13 shows the positioning tool of FIG. 12a with the plunging inserted between two hinged objects;

FIG. 14 is a cross-sectional top view showing another embodiment of a positioning tool with a width of web between hinged objects;

FIG. 15 is a cross-sectional top view of another embodiment of a positioning tool having hinged portions;

FIG. 16 is a perspective end view of another embodiment of the mount assembly and positioning tool;

FIG. 17 is a cross-sectional top view of another embodiment of the positioning tool, with a removable hinged-object spacer;

FIG. 18 is a cross-sectional view of three object spacers selectively usable with the positioning tool of FIG. 17;

FIGS. 19-21 are cross-sectional top views of positioning tools with adjustable widths and selectable hinged object spacers and means for adjusting such positioning tools to accommodate hinged objects in different planes;

FIGS. 22-24 are perspective views showing alternative embodiments of positioning tools;

FIGS. 25 and 26 are cross-sectional top views of single sided positioning tools;

FIG. 27 is a cross-sectional top view of mounting bases positioned and attached to hinged objects;

FIG. 28 is a cross-sectional top view of a multi-purpose positioning tool with base positioners disposed at an angle with respect to each other so that the positioning tool can be used for positioning each base in a different plane or for positioning bases for hinges of different widths or for hinges assembled from various hinge member combinations;

FIGS. 29-31 are cross-sectional top views of different hinge embodiments with bases preferably welded to the hinged objects to suit various combinations of hinged object mounting surfaces, planes and hinge member locking locations;

FIGS. 32 and 33 are cross-sectional top views showing steps in the mounting of a double hinge to hinged objects;

FIG. 34 is a front view of components employed together for mounting a hinge;

FIG. 35 is a front view of segmented components of different lengths employed together for mounting a hinge;

FIG. 36 is an underside view of several embodiments employing different combinations of hinge segments;

FIG. 37 is a front view of an embodiment of a coupling member;

FIG. 38 is a cross-sectional top view of a coupled hinge segment;

FIGS. 39 and 40 are underside views showing steps in coupling hinge segments;

FIGS. 41-43 are cross-sectional top views of different embodiments of coupled hinge segments;

FIG. 44 is a top cross-sectional view of an embodiment of mounting bases that are of unitary construction with the hinged objects;

FIG. 45 shows cross-sectional top views of embodiments of pinned hinges relative to mounting bases;

FIGS. 46 and 47 show steps in aligning and mounting butt hinges to hinged objects;

FIG. 48 is a perspective cut-away view of another embodiment of a positioning tool;

FIG. 49 is a front view of a hinge mounted in plumb to a door and frame that are out of plumb;

FIG. 50 is a cross-sectional top view of a positioning tool and hinge;

FIGS. 51-52 are front views showing steps of mounting a door in a frame;

FIG. 53 is a cross-sectional top view of another embodiment of a positioning tool and hinge;

FIGS. 54-55 are a front view showing steps of mounting a door with a different positioning tool;

FIG. 56 is a front view of an alternative embodiment of a mounting base;

FIG. 57 is a cross-sectional top view of an alternative embodiment of a hinge;

FIGS. 58 and 59 are front views of mounting bases thereof with a alternative positioning tools;

FIG. 60 is a front view of a hinged positioning tool;

FIG. 61 is a cross-sectional view of a hinged positioning tool;

FIG. 62 is a side view of a hinged positioning tool with a strap embodiment of a restraining means;

FIG. 63 is a top view of a segmented, two-piece positioning tool;

FIG. 64 is a side view of a two-piece positioning tool with an adjustable offset;

FIGS. 65a-f are cross-sectional views of a various embodiments of a two-piece positioning tool with an adjustable offset;

FIG. 66 is a top view of a two-piece positioning tool with a pivoting adjustable depth hinged object spacer;

FIG. 67 is a cross section of a two-piece positioning tool with a pivoting adjustable depth hinged object spacer;

FIG. 68 is a top view of a two-piece positioning tool with slidable adjustable depth hinged object spacers;

FIG. 69 is a top view of a two-piece positioning tool with slidable adjustable depth hinged object spacers;

FIG. 70 is a cross sectional view of a two-piece positioning tool with an alternative embodiment of a slidable adjustable depth hinged object spacer wherein the spacer has elongated open slots;

FIG. 71 is a cross-sectional view of a hinged positioning tool with a handle mounted hinge;

FIG. 72 is a perspective view of an asymmetrical hinge according to the invention in which the pivot point is located substantially over the frame.

FIGS. 73a-b are various views of a stop for a segmented pinless hinge;

FIG. 74 is a plan view of a segmented hinge with single bearings in otherwise longitudinally unsupported segments;

FIGS. 75a-c are various views of one embodiment of a positioning tool having spring clips that may be used with ferrous and non-ferrous mounting bases;

FIGS. 76a-b are cross-sectional views of a two position positioning tool;

FIGS. 77a-b are top cross-sectional views of using a positioning tool with an adjustable planar offset; and

FIGS. 78a-b are top cross-sectional views of using a positioning tool with a positioner spacer and an adjustable planer offset.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, an embodiment of a continuous pinless hinge according to the invention has two hinge members 20,21. The hinge members 20,21 are rotatably engaged to two semi-cylindrical ends 22 of a joining member, such as a clamp 24. The hinge members 20,21 are fixed to hinged objects 26 and 28, which in FIG. 1 are a door and a frame.

The edges of hinge members 20,21 comprise gear segments 30 that extend in a longitudinal direction 29 longitudinally, parallel to the length of the clamp 24. The hinge members 20,21 are pivotally mounted together, as gear segments 30 are pivotally mounted about the semi-cylindrical ends 22 of the clamp 24, which in this embodiment are at the axes of rotation of the hinge members 20,21. The clamp 24 retains the gear segments 30 in mesh and preferably provides lateral support throughout the length of the hinge. Other embodiments do not have meshed gear segments.

In cross-section, the clamp 24 has an internal preferably C-shaped channel 32, as shown in FIG. 2. Recesses 31 extend through the gear segments 30 at various intervals, as shown in FIGS. 2 and 3, and are bound by opposing recess surfaces 33. To restrict, and preferably prevent relative longitudinal movement between the hinge members 20,21, thrust bearings 36, as shown in detail in FIG. 4, are received in the clamp channel 32, within recesses 31 of both hinge members 20,21.

The longitudinal dimensions 35 of the recesses 31 are large enough so that the thrust bearings 36 leave sufficient clearance therebetween for the hinge members 20,21 to pivot without binding on the bearings 36. The bearings 36 are preferably longitudinally thick enough to prevent their shearing by the hinge members 20,21 when they are biased under the opposing loads of the door and the frame.

Bearings 36 are formed with longitudinally extending slots 38 configured to receive the semi-cylindrical clamp ends 22. As seen in FIG. 2, the bearings 36 preferably mostly fill the cross-section of the clamp channel 32.

Each bearing 36 has parallel bearing surfaces 39 disposed on opposite longitudinal sides of the body 46 of the bearing 36. These bearing surfaces 39 abut and support the recess surfaces 33. The recess and bearing surfaces 33 and 39 preferably lie flush with one another to maximize the area of contact therebetween, reducing the pressure and wear on each surface 33 and 39. In another embodiment, these bearing surfaces comprise separate inserts, as disclosed in U.S. Pat. No. 4,976,008, which are assembled to form part of the body 46.

Relative longitudinal movement of the clamp 24 with respect to the hinge members 20,21 is preferably prevented by securing or fastening one or more thrust bearings 36 to the clamp 24, such as by means of a set screw, adhesives, or crimping. Where segmented hinge assemblies are used that contain no thrust bearings 36 in some of the segments (see FIG. 36 and accompanying discussion below), means for providing some longitudinal restriction in movement of the clamp member relative to the hinge members is required to keep the clamp from sliding to the floor in these unsupported segments. A device such as a single thrust bearing 36, a metal tab similar to FIGS. 6-9 shown in U.S. Pat. No. 3,402,422, or similar device may be used for this purpose.

Referring again to FIG. 1, mount assemblies 49 include mounting bases 50,51 are shown attached to the hinged objects 26,28. Each hinge member 20,21 has a mountable portion 23 and its corresponding bases 50,51, respectively, are preferably configured and dimensioned for cooperatively positioning and aligning each hinge member 20,21 in a mounted position with respect to the base 50,51 when mounted thereto.

The bases 50,51 of this embodiment are attached to the hinged objects 26,28 as shown in FIG. 5. The bases 50,51 are connected to a mounting spacer or positioning tool 52, preferably by a layer of adhesive 54. The positioning tool 52 includes a preferably flexible web that is configured for positioning the bases 50,51 at a predetermined distance 56 from each other for placement on and attachment to the hinged objects 26,28 in a mounting position. The web is preferably made of a plastic, foil, paper, or rubber, although other materials are suitable. Another layer of adhesive 58 is disposed on the side of the positioning tool 52 opposite from the bases 50,51. This adhesive 58 can thus be exposed prior to attaching to the hinged objects 26,28. The adhesive layers can comprise double-sided tape.

In use, the bases 50,51 are spread apart from each other to locate them at the desired predetermined distance 56 from each other, to properly relatively position them to accept the hinge members 20,21, which will subsequently be mounted thereto. The positioning tool 52 preferably locates the bases 50,51 substantially parallel to each other and with ends of the bases 50,51 preferably at the same longitudinal height. The bases 50,51 are preferably continuous strips of a length approximating the length of the hinge, but it is anticipated that they could be segmented or composed of short lengths arranged substantially parallel to each other and spaced to a length approximating the length of the hinge. The web of the positioning tool is pulled generally flat, to align the bases 50,51 with respect to each other. One of the bases 50,51 can be attached to one of the hinged objects 26,28 first, then the second of the bases 50,51 can be attached to the other hinged object 26,28. The bases 50,51 can then be firmly attached to the hinged objects 26,28 by drilling a hole in the hinged objects 26,28 through openings 60 in the bases 50,51, and fastening a fastener 62 therethrough, such as a screw or a bolt, or other fastener known in the art.

Although the positioning tool in FIG. 1 is shown being used with a pinless hinge, it will be appreciated that the tool may also be used with pinned or pinned and covered hinges such as those shown in FIG. 45, for example.

As shown in FIG. 6a, the positioning tool is then severed to disconnect the connection between the bases 50,51 through the positioning tool 52. The severing is done through a frangible disconnect portion 64 of the positioning tool 52. This frangible portion 64 is preferably marked by indicia 65, as shown in FIG. 1, such as a solid or segmented line. The frangible portion 64 of this embodiment also preferably comprises a perforated portion of the positioning tool 52, and can be severed by applying localized pressure, such as by a screwdriver blade biased against the positioning tool 52 in the space between the hinged objects 26,28, or can be cut, such as by a utility knife blade.

Each base 50,51 of this embodiment is generally elongated and has a length similar to that of the hinge members 20,21. The bases 50,51 are preferably constructed as rails and made of sheet metal, such as steel, or it may be an extruded metal or plastic part. Each base 50,51 also has a substantially flat attachment portion 67, which includes the fastener openings 60 and which preferably attaches to the hinged objects 26,28, and has a mounting portion 66 configured for aligning and mounting the hinge members 20,21 thereto. The mounting portions 66 preferably include elevated portions such as upturned lateral sides 68 of the bases 50,51 as shown in FIG. 6a, or grooves formed in the sides of extruded or molded bases as shown in FIG. 6b. Referring to FIG. 6a, the upturned sides 68 form ledges with fastening surfaces 72 spaced from the bottom of the mount assembly 49, angled, configured and dimensioned for receiving and securing fastening members of the hinge members 20,21, as described below. For the extruded or molded bases 700, 701 shown in FIG. 6b, the grooves are angled, configured, and dimensioned in a similar way to that shown in FIG. 6a. The cavities 702 on the underside of the mounting bases of FIG. 6b are preferably lined with continuous or segmented strips of double-sided foam adhesive tape for temporarily positioning the mounting bases on the hinged objects.

Referring to FIG. 7, hinge members 20,21 have mounting portions 74, which in the embodiment shown, include inwardly curved hooks 75, configured to be received against the fastening surfaces 72,73. The outer mounting portion of hinge member 21 is placed in the space between the base 51 and the hinged object 28, engaged against the fastening surface 72. The mounting portions 74 of the hinge members 20,21 also include a locking member, preferably fastening members 76, shown retracted in an unlocked or released position, with respect to the adjacent fastening surface 73. The fastening members 76 are movable between the unlocked position shown in FIG. 7 and a locked or engaged position shown in FIG. 8. The fastening members preferably include set screws but may alternatively include other fasteners, adhesives, latches, protrusions and receptacles, or other suitable members, such as locking members that provide a snap-fit locked association between the hinge member and the mounting base. The upturned lateral sides 68 of the bases 50,51 are preferably disposed at an angle 70 (shown in FIG. 6) with respect to the locking direction 77 (shown in FIG. 8) of fastening members 76, which is substantially parallel with the attachment portion 67 of the bases. Angle 70 is preferably less than 90.degree., and more preferably between about 20.degree. and 60.degree., and most preferably around 45.degree.. In an alternative embodiment, such as in which a pivotable latch is used, the locking direction of the locking member can be curved.

As shown in FIG. 8, the hooked hinged member 21 is rotated against the base 51 and may be slid, for longitudinal adjustment, along the length of the base 51 to a selected mounted position with respect to the base, among a substantial continuum of available mounted positions. The hinge members 20,21 are thus preferably infinitely positionable for securement on the bases 50,51. The fastening member 76 is moved to a locked position protruding from the mountable portion 23 of the hinge member 21, preferably towards the interior thereof, and engaged against the fastening surface of the mounting portion 66. Fastening member 76 is tightened to fix and preferably effectively lock the hinge member 21 to the base 51. Thus, the hinge members 20,21 are substantially self-aligning and self-positioning by locking the fastening members 76, which ensure proper alignment and positioning of the hinge members 20,21 on the hinged objects 26,28. The other hinge member 20 is preferably mounted and affixed to the base 50 in a similar manner as hinge member 21 to base 51, as shown in FIGS. 9 and 10. Each hinge member 20,21 of the preferred embodiment is thus mountable to the corresponding base 50,51 without requiring the sliding of the hinge member 20,21 onto the bases 50,51 along substantially the entire length of hinge member 20,21. The hinge members 20,21 can be mounted to the bases 50,51 from the front portion thereof, exposed from the hinged objects 26,28.

The hinge members 20,21 define base receiving spaces 78, as shown in FIG. 8, which are preferably cavities or lengthwise channels on the underside thereof. The spaces 78 are configured and dimensioned to house and cover the corresponding bases 50,51 and base fasteners 62 to provide an attractive exterior appearance when mounted to the hinged objects 26,28.

The preferred fastening members 76 are releasable from their locked position, to enable the position of the hinge to be adjusted on the bases 50,51. Also, the preferred hinge has a plurality of fastening members 76 spaced longitudinally along the hinge members 20,21, however, at least one sufficiently effective fastening member can be employed. In an alternative embodiment, the fastening members extend from the bases.

Referring back to FIG. 1, the hinge members 20,21 are preferably slidable in longitudinally direction 29 along the bases 50,51. Preferably, the longitudinal ends 80 of the bases 50,51 on opposite longitudinal sides thereof are free from a stop that would restrict the positioning of the hinge members 20,21 on the bases 50,51 or prevent the hinge members 20,21 from sliding past the stops. An alternative embodiment, however, incorporates such stops.

In another embodiment, a stop 710 as shown in FIGS. 73a-b, clamped to one of the mounting bases, could effectively keep the joining member of the hinge, which may be a clamp 24 (see FIG. 1), from sliding down to the floor or from rising upward when segmented hinge sections are used at the outside ends of the hinge assembly comprised of a longitudinally supported center section, and a top and a bottom section which are unsupported (as shown in the second drawing from the left of FIG. 36). The stop 710, shown engaged with a mounting base 713, has an engagement portion 714 which connects to the base in a similar fashion to the hinges described heretofore. A fastening member 712 is provided to secure the stop 710 to the base 713. Connected to and opposite the engagement portion 714 is a hooked portion 711 which is intended to contact the clamp (not shown) and prevent it from sliding downwards or upwards depending on whether the stop 710 is affixed to the lower portion or upper portion (not shown) of the base 713. The other base 716 may be provided with a complimentary member (not shown) configured with an engagement portion 714, but without the hooked portion of stop 710 that is secured to the base 716 across from and opposite the stop 710 connected to base 713.

Alternatively, a single bearing block 800 as shown in FIG. 74, equipped with a set screw, rivet or similar fastener securing the block to a hinge joining member, which may be a clamp 24 (see FIGS. 1 and 2), may be used which is located at the juncture between the supported hinge section and each unsupported hinge section. A connector 312 as shown in FIG. 37 may also be used in conjunction with this embodiment as well as other segmented clamp and hinge embodiments.

An alternative embodiment of a flexible positioning tool 82 is shown in FIG. 11.

Positioning tool 82 has a frangible portion 84, including cutouts 86 and a notch 88 at a longitudinal end to facilitate cutting and visual lateral positioning relative to the hinged objects 26,28.

Referring to FIG. 12a, positioning tool 90 includes a plunger 92 and a flexible web 94 adhered to bases 50,51 by an adhesive layer 54. The plunger 92 has a handle 96, a plunging portion 98, and a stop 100 disposed therebetween and configured to cooperate with the hinged objects 26,28 to prevent the plunging portion 98 from being inserted past a predetermined depth between the hinged objects 26,28, as shown in FIG. 13.

In use, the plunging portion 98 is pressed against the web 94 at a predetermined location, which is preferably marked, bringing the bases 50,51 closer to each other to adjust the maximum distance 102 therebetween. The stop 100 prevents further insertion of the web 94 between the hinged objects 26,28 when it contacts the outer surface thereof. By selecting a plunging portion with a different length, the distance between the bases can be selectively adjusted and varied. The plunging portion 98 also has a thickness or width 104 selected to locate and space the hinged objects 26 and 28 from each other, cooperatively with the thickness of the web 94, at a desired predetermined distance 106, to provide proper hinging operation once the hinge is fully installed.

As shown in FIGS. 12b-c, an adjustable positioning tool 730 in another embodiment may be two-piece wherein each piece or half 731, 732 includes a handle 735, stop 736, and an elongated hole 737 through which a fastener 734 may be inserted. A blade 733, also containing an elongated hole 738, is secured between the two positioning tool halves 731, 732, whereby the blade in combination with the tool halves forms an adjustable plunger portion to adjust the depth "D" that the blade protrudes from the stops 736 as shown. This adjustable tool also allows it be used for door and frames having a planar offset or inset from each other. The adjustable tool, in addition to the tool shown in FIG. 12a, may be made of any suitable material which will be readily known in the art, and may include, but is not limited to metal, plastic, a combination thereof, etc.

As shown in FIG. 14, an additional width of web 94 remains between the hinged members 26,28, preferably sufficient to permit operation of the hinge without cutting the web 94 or otherwise disconnecting it from the bases 50,51. In this embodiment, the remaining web 94 is configured and fabricated as a seal to seal the space between the hinged objects 26,28.

FIG. 15 shows another embodiment of a positioning tool 108 with hinged portions 109. The total width of these hinged portions 109 when closed controls the spacing between the hinged objects 26,28, providing a hinged object spacer and additional protection for the mechanism of the hinge and any thrust bearings the hinge may have. In this embodiment, small holes or slots through the hinged portions 109 can be provided aligned axially the fastening members 76 for access to the fastening member 76 during installation.

The embodiment of FIG. 16 has a positioning tool 110 with an integral, preferably unitary, hinged object spacer 112 to position and space the hinged objects 26,28 with respect to each other, and also to facilitate the locating of the bases 50,51 with respect to the edges of the hinged objects 26,28 and the gap 113 therebetween, as shown in FIG. 17. The positioning tool 110 is preferably sufficiently rigid to maintain its shape and retain hinged objects separated by the object spacer 112. The object spacer 112 extends from a connecting portion 116 of the positioning tool 110, which connects the bases 50,51 together. The object spacer 112 has a thickness 117 and protrudes from the positioning tool 110 at an angle 119 to the direction of the predetermined distance between the bases 50,51 and is configured for providing a clearance between the hinged objects, depending upon the thickness 117 of the object spacer 112.

Tearstrips 118, which preferably comprise strings or bands embedded or attached to the connecting portion 116, are configured associated with the positioning tool 110 to sever the connecting portion 116 at frangible portions 120 upon pulling of the tearstrips 118 at an angle to the connecting portion 116. The frangible portions are most preferably located on both sides of the object spacer 112 to permit removal of the entire portion of the positioning tool 110 that includes the object spacer 112. This embodiment also includes adhesive protective backing 122 that are to expose the lower adhesive layers 58 for attaching to the hinged objects.

FIG. 17 shows an alternative embodiment of a substantially rigid positioning tool 124. Positioning tool 124 has a handle 126 and base positioners 128, which preferably extend from opposite sides of the handle 126. The positioners 128 are preferably configured for precisely locating the bases 50,51 with respect to each other. Thus, the preferred embodiment includes receptacles 130 with lateral walls 132 that engage a portion of the bases 50,51, preferably the lateral edges of the upturned sides 68, although the positioners 128 alternatively engage another portion of the bases 50,51. The preferred width of the receptacles 130 is substantially similar to the width of the bases 50,51. The receptacles 130 preferably include channels extending along the length of the positioning tool 124. The positioning tool also includes openings 142 of a larger size or diameter than the openings 60 provided for the base fasteners 62, and alignable therewith.

With continuing reference to FIG. 17, the bases 50,51 are preferably magnetically connected to the positioners 128, by magnets 144 of the positioning tool 124, preferably arranged as strips, although other shapes are suitable. As the bases 50,51 are preferably steel or other ferromagnetic material, the bases 50,51 are retained attached to the positioners 128, held against the hinged objects 26,28, and fasteners are applied through openings 142 and 60, and then the positioning tool 124, along with its magnets 144, is separated from the attached bases 50,51 to permit mounting of the hinge. The magnets 144 may be secured to the positioners by any means known in the art, which may include, but is not limited to the magnetic attraction forces between magnet and positioner alone, adhesives, fasteners recessed in depressions with through-holes provided in the magnets, interlocking and mating members which may be appurtenances provided with the positioner and/or magnet, etc. In general, the connection between the magnet and positioner is preferably stronger than the magnetic attraction between the magnet and mounting bases, so that the positioner with magnet attached may be readily uncoupled from the bases after the bases are fastened to the hinged objects.

It will be appreciated that in another embodiment, a non-magnetic positioning tool 124 may be used, such as, but not limited to aluminum, austenitic stainless steel, plastic, fiberglass, composites, etc. Consequently, the bases 50, 51 may be connected to the positioners 128 by alternative, non-magnetic releasable means. For example, spring clips, latches, set or thumb screws, velcro, or other suitable means (including even chewing gum) may be used to temporarily hold the bases 50, 51 to the positioners 128 while the bases are being installed. Alternatively, magnets may be secured to the non-magnetic positioning tool by some of the methods discussed above (with the exception of relying only on the magnetic force between the magnetic and positioner).

In FIGS. 75a-c, a non-magnetic positioning tool 740 embodiment is shown which utilizes spring clips and may be used for positioning tools made from either ferrous or non-ferrous materials. The positioning tool 740 in this embodiment is a two-piece adjustable tool with two halves 747, 748 with a spring-loaded fastener 745 that may be used to compensate for a door and frame having a planar offset. It should be recognized that the a one-piece, non-adjustable postioning tool as described previously herein may also be used. The positioning tool shown also includes a positioner spacer 746 with an integral hinged object spacer; however, the invention is not limited to non-magnetic positioning tools 740 having a spacer 746. The tool 740 has spring clips 741 which pass through openings 749 in the tool that allow the clips to be temporarily secured to mounting bases 744. The clips 741 are secured to the positioning tool 740 on one end and have an opposite end that is configured and adapted to be secured to mounting bases 744. At least one spring clip 741 is provided for each positioning tool half 747, 748; preferably, a plurality of spring clips are provided for each tool half. The spring clip 741 may be of any suitable configuration and made from any appropriate material commonly used which is readily known in the art.

The non-magnetic positioning tool 740 is secured by the spring clips 741 to two mounting bases 744 that are adapted and configured to receive the clips. The mounting bases 744 may include, but do not require, one-sided foam adhesive tape 743 which is attached to the mounting bases by adhesive on one side of the tape. The mounting bases 744 preferably include a plurality of mounting holes 750 in each base through which base mounting fasteners (not shown) may be inserted to secure the bases to hinged objects (e.g., door and frame).

The non-magnetic positioning tool 740 is used by securing the tool to the mounting bases 744 with the spring clips 741 that engage the bases. The tool 740 with mounting bases 744 are then placed over hinged objects, positioned, and the mounting bases are secured to the hinged objects using fasteners inserted through the mounting holes 750. The tool 740 is then pulled off the bases 744 which disengages the spring clips 741 and allows the tool to be removed from the bases, leaving the bases mounted to the hinged objects. Hinges 782, 783 may then be attached to the bases 744 as shown in FIGS. 6c-d, respectively. FIG. 6c depicts a door 780 mounted flush with the face of the frame 781. FIG. 6d depicts a door 780 mounted inset from the face of the frame by using one hinge leaf that has a greater height or depth than the other hinge leaf.

It should be recognized that the non-magnetic positioning tool may also be used with segmented mounting bases as shown in FIG. 35.

A hinged object spacer 134 or shim is connected to the connecting portion 123 of the positioning tool 124. A plurality of object spacers 134-136, as shown in FIG. 18, is preferably provided, and each is selectively associable with the positioning tool 124 (FIG. 17) to preselect the distance between the hinged objects 26,28, while maintaining the same distance between the bases 50,51 when attached to the hinged objects 26,28. Object spacers 135 and 136 have a different width at their spacing portions 138 than at their connecting portions 140, which is configured for connecting to the positioning tool 124.

The embodiment of a positioning tool 146 of FIG. 19 is constructed by fastening two half base positioners 148 with at least one, but preferably a plurality, of fasteners 150. A positioner spacer 152 is disposed between the base positioners 148 to control and select the relative position and spacing between the bases 50,51. The positioner spacer 152 also includes a hinged object spacer 154.

The positioning tool 156 of FIG. 20 has a narrower positioner spacer 158 sandwiched between the base positioners 148 to provide a smaller distance between the bases 50,51. This positioning tool 156 does not employ a hinged object spacer to permit the hinged objects to be placed against each other, or to employ another method of aligning the hinged objects themselves. Similarly, the positioning tool 160 of FIG. 21 does not employ a hinged object spacer. Positioning tool 160 also has base positioners in abutment with each other, as no positioner spacer is used either.

When using a positioning tool with two half base positioners 148 as shown in FIGS. 19-21, many alternative embodiments for a positioning spacer and hinged object spacer are possible. For example, FIGS. 66 and 67 show an adjustable depth hinged object spacer, which in this embodiment, has a substantially cam-shaped disk 640 that is pivotally attached to a positioning tool 641. The disk 640 may have a straight, generally cylindrically-shaped bushing 642 or similar member which is fixedly attached to the disk to prevent relative rotation between both members. The bushing 642 may have a round, hexagonal, or other exterior shape in cross section. The length of the bushing 642 is sized such that it projects from either side of the disk 640 (as shown in FIG. 67) a sufficient amount so as to protrude through holes 643 disposed in each of the two half base positioners 148 when the two halves are connected together as shown in FIG. 19. The bushing 642 preferably has a hexagonal-shaped internal socket for application of an Allen wrench, which can be used to rotate the disk around the pivot point formed by the coaxially-aligned bushing and holes 643, thereby allowing the projected depth 645 of the disk to be adjusted. As shown in FIG. 66, the pivot point is offset from the center of the disk. At least one disk 640 is provided for the positioning tool, preferably a plurality of disks are provided. The disks are interspersed between the fasteners 50 that hold both half base positioners together as shown in FIG. 19.

FIG. 68 shows another adjustable depth hinged object spacer embodiment of a positioning tool 650 having two half base positioners 148 as shown in FIG. 19. Separate object spacers 651 may be disposed between the fasteners 652 that hold both halves of the base positioners