The present invention relates to a compact hinge for furniture products. In particular, the present invention relates to a compact overlay hinge that is capable of adjustment in three dimensions.
Cabinet doors for cabinets generally must be individually adjusted to compensate for manufacturing tolerances. Adjustment is usually required in more than one dimension. If the door has two or more hinges, as is usually the case, adjustments must be carried out on each hinge with respect to the other hinges. A “vertical adjustment” is required when the door does not seat properly with respect to the top and bottom of the cabinet frame. An “overlay adjustment” is a lateral or “side to side” adjustment required when the door does not properly align with the sides of the cabinet frame. A horizontal or an “in and out” adjustment required when the door does not lay flush with the cabinet frame.
Prior art hinges suffer from various disadvantages including difficulty in installation, insufficient adjustment capabilities, instability of the adjustments made, complicated construction, and high manufacturing costs.
U.S. Pat. No. 6,647,591 to Domenig et al. discloses a low profile, partial door overlay hinge having a hinge cup, an intermediate base hinge and top hinge arm segments. In order to accomplish adjustments in three dimensions, this device requires a complicated assembly necessitating several assembly connection points. Further, multiple cam screws or eccentric cam screws are required to effectuate the adjustments. All of the above increases the manufacturing complexity and cost of the device.
U.S. Pat. No. 6,694,567 to Domenig et al. discloses an overlay hinge having a hinge cup, a base hinge arm segment and an L-shaped hinge arm segment. This device requires multiple plate hinge arm segments to achieve the three-dimensional adjustment capability. The device of the '567 patent also requires multiple intricate and expensive pieces requiring complex assembly steps and hardware to function as an adjustable hinge.
U.S. Pat. No. 5,920,958 to Domenig, et al. discloses an adjustable furniture hinge having a hinge cup, a hinge arm and a hinge plate. The hinge arm is pivotally connected to both the hinge cup and the hinge plate. The number of hinge arm segments is lessened, but the intricate parts and the complex assembly remains while the hinge only accommodates a vertical adjustment and a horizontal overlay adjustment.
U.S. Pat. No. Re. 34,995 to Domenig discloses an adjustable recessed door hinge having a hinge cup in a bore in a door member and a hinge arm securable to a cabinet member. The hinge cup has two slotted holes for receiving attachment screws that guide displacement of the hinge cup for a side-to-side adjustment. The invention of the '995 patent requires the adjustment of at least two mounting screws per hinge used to mount the hinge cup in order to effectuate a horizontal overlay adjustment. After repeated adjustment as is required to secure and adjust a door, the fit of newly inserted screws becomes unstable which ultimately results in an insecure mounting of the door on the cabinet.
The present invention addresses the need for a simply designed and adjustable self closing compact hinge, particularly one including the capability of adjustments in three dimensions with a minimum number of components that can be easily and economically manufactured and installed.
Accordingly, an embodiment of the present invention provides an adjustable self closing compact hinge that includes a cup for mounting in a door and a hinge arm assembly pivotably connected to the cup by means of a hinge pin. The hinge arm assembly includes a hinge arm that is slideably coupled to a fastener plate. The fastener plate is attachable to the frame of a cabinet by a mounting screw through an elongated hole oriented vertically in the fastener plate. The elongated hole in the fastener plate facilitates a vertical adjustment parallel to the axis of the hinge pin. The fastener plate and the hinge arm are slidably engaged to each other and through an eccentric cam can accommodate a horizontal adjustment perpendicular to the axis of the hinge pin. The fastener plate includes a first planar surface for contact with the frame of a cabinet and a second planar surface for engagement with the hinge arm. The first planar surface and the second planar surface of the fastener plate are interconnected by a semi-cylindrical elastically flexible hinge section that allows the distance between the first planar surface and the second planar surface to be selectively adjusted by an adjustment screw which facilitates a lateral adjustment.
A benefit of the present invention includes the requirement of fewer component parts to obtain the three dimensional adjustment functionality, specifically; there is no independent intermediate structure between the hinge arm and the component part that becomes attached to the cabinet frame as in the prior art. Additionally, there is no hinge pin needed to couple the hinge arm and any various mounting plates or intermediate plates.
Those skilled in the art will appreciate the above-mentioned features and advantages of the invention together with other important aspects upon reading the detailed description that follows in conjunction with the drawings.
In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals. The drawing figures are not necessarily drawn to scale and certain figures may be shown in exaggerated or generalized form in the interest of clarity and conciseness. Copyright protection is claimed to the extent that protection is provided by copyright law.
Hinge cup 12 is shown in
Eccentric cam 32 includes eccentric cam face 344 and eccentric cam base 346, a circular shaft located to one side of the axial center of eccentric cam 32. Adjustment screw 28 includes a threaded section adjustment screw thread 340 and an end section adjustment screw base 342.
At one end of hinge arm 14 is arm hook 330. Arm hook 330 separates a pair of projections, cam surface 331 and cam surface 332. Arm hook 330 leads to arm section 334 that is connected to hinge arm top 350. Situated approximately perpendicular to and along the lateral edges of hinge arm top 350 are hinge arm sidewalls 322 and 323. Hinge arm sidewall 322 and hinge arm sidewall 323 lie in generally parallel planes. Hinge arm sidewall 322 includes an inward facing set of flanges 326. Similarly, hinge arm sidewall 323 includes a set of inward facing of flanges 327. The height of flanges 326 and 327 is generally equal to slots 328 and 329 and in the preferred embodiment are approximately 1.5 millimeters. Hinge arm top 350 further includes an elongated aperture hinge arm eccentric cam hole 324, a generally rectangular shaped hinge arm hole 338, having a section forming a generally semicircular shaped adjustment screw access hole 336.
Referring to
Hinge pin 18 is a solid shaft formed into a generally three sided rectangular shape. Hinge pin 18 is shaped to accommodate the semicircular shape of brim 162 through the inclusion of angled corner 163. In the preferred embodiment, the diameter of hinge pin 18 is approximately three millimeters. Hinge pin 18 includes spring hub arm 702 and arm hub 704. Arm hub 704 provides an axle for pivotally connecting hinge arm 14 to hinge cup 12. Spring hub arm 702 provides an axle for pivotally supporting coil spring 42 with respect to hinge cup 12. Spring hub arm 702 and arm hub 704 simultaneously fit through and are seated in spring hub arm holes 164 and 165 and arm hub holes 166 and 167 respectively. Those skilled in the art will recognize that spring hub arm 702 and arm hub 704 can be replaced by separate keeper pins or cotter keys.
Referring to
The self-closing function of compact adjustable hinge 700 is accomplished by coil spring 42 biasing the hinge in either an open or a closed position. As hinge arm 14 pivots, coil spring ends 706 and 707 of coil spring 42 move over cam surfaces 332 and 331 respectively forcing compact adjustable hinge 700 to tend to rest on one side or the other of the cam surfaces in either the fully open position or the fully closed position.
Compact adjustable hinge 700 is constructed such that its overall longitudinal length is minimized. In a preferred embodiment, hinge cup 12 and hinge arm 14 each have a longitudinal length of approximately 34 to 36 millimeters and an overall length of approximately 65 to 68 millimeters when assembled. However, other lengths are acceptable as well within the scope of the invention. It is of course to be understood that the present invention is not limited to the identified connecting components and that other connecting components may be used. For example, it is known in the art to use a four bar linkage system comprised of multiple hinge arm elements connected to the fastener plate. The fastener plate and hinge arm can be adapted to this configuration.
In the preferred embodiment, hinge cup 12, fastener plate 24, and hinge arm 14 are typically constructed of metal such as cast aluminum or steel alloy plate stock and formed from casting or stamping but can also be made of injection molded plastic or nylon. In the preferred embodiment, the material used to construct hinge cup 12 is approximately 0.8 millimeters thick and the material used to construct fastener plate 24 and hinge arm 14 is approximately 1.5 millimeters thick.
In operation, hinge arm assembly 48 provides three dimensional adjustability for hinge 700. Having multiple adjustment capabilities contributes to proper closure of the door member thereby prolonging cabinet and hinge useful life. One direction of adjustment is the vertical movement of door member 902. This adjustment is required when the top and bottom edges of door member 902 do not align with the top and bottom edges of cabinet member frame 904 or an adjacent door member. Hinge arm assembly 48 is attached to the cabinet member frame 904 with wood screw 908 through fastener plate mounting hole 306. The elongated shape of fastener plate mounting hole 306 allows for vertical adjustments of the door member with respect to the cabinet frame. Door member 902 may be vertically adjusted to the proper height of an adjacent door member or adjoining cabinet member by loosening wood screw 908 and repositioning door member 902 to the desired height and retightening the wood screw. Fastener plate access hole 320 in fastener plate top 304 is positioned to permit access to the screw regardless of the screw's location in fastener plate mounting hole 306. For additional connection strength, additional wood screws may be used in the mounting hole to attach fastener plate 24 to the cabinet frame.
Another direction of adjustment is the horizontal movement of door member 902. This adjustment is required when the inside face of door member 902 does not lay flush with cabinet member face 906 impeding the opening and closing action. Eccentric cam 32, when turned, causes eccentric cam face 344 to engage the edge of hinge arm eccentric cam hole 324 in hinge arm top 350. Eccentric cam base 346 is engaged with fastener plate eccentric cam hole 360 of fastener plate top 304. The force of eccentric cam face 344 on hinge arm eccentric cam hole 324 converts the rotational movement into a horizontal movement resulting in the horizontal adjustment as between the door member and the cabinet frame member. As eccentric cam 32 is turned, hinge arm 14 slides horizontally with respect to fastener plate 24 resulting in door member 902 traveling horizontally with respect to cabinet member frame 904. In the preferred embodiment, a quarter turn of eccentric cam 32 translates into approximately three millimeters of horizontal travel.
A further direction of adjustment is the lateral movement of door member 902. This adjustment is also referred to as an overlay adjustment. This adjustment is required when the vertical edges of door member 902 do not align with the vertical edges of cabinet member frame 904 or the vertical edges of an adjacent door member. In most applications, more than one hinge 700 is used to mount a door member. Providing different lateral adjustments on two different hinges provides an angular adjustment to the cabinet door with respect to the cabinet member frame.
The lateral adjustment is achieved through the use of adjusting screw 28 which has adjustment screw thread 340 threadably engaged with threaded hole 318 and with adjustment screw base 342 rotatably affixed to adjustment screw mounting hole 312. Adjustment screw base 342 is expanded in order to retain it to fastener plate 24. Turning adjustment screw 28 clockwise advances it through threaded hole 318 and causes the screw to abut seat 316. Adjustment screw base 342 freely rotates in and is guided by adjustment screw mounting hole 312. Further clockwise rotation of adjustment screw 28 results in fastener plate top 304 rotating about the longitudinal axis of hinge sections 308 and 309 with respect to fastener plate bottom 302 by bending the hinge sections. Clockwise rotation of adjustment screw 28 increases the distance between fastener plate top 304 and fastener plate bottom 302 at the location of the adjustment screw, while counter-clockwise rotation decreases the distance. As the distance between the two fastener plates increases or decreases, by virtue of the fastener plates being attached to the cabinet member frame and hinge arm 14, a lateral movement of the door member with respect to the cabinet member frame is achieved.
Further, those skilled in the art will realize that the invention provides a stable long term adjustment because the hinge sections 308 and 309 are semi-permanently deformed by advancement of adjustment screw 28 and will hold an adjustment virtually indefinitely thereby eliminating the need for periodic readjustment. The elimination of a sufficient amount of material represented by gap 307, allows hinge sections 308 and 309 to be elastically bendable about a longitudinal axis parallel to the rotational axis of the hinge pin 18. The amount of space represented by gap 307 controls the amount of elasticity and the effort needed to impart the bending of the hinge sections. In the preferred embodiment, gap 307 is approximately sixteen millimeters.
It should be noted that the installation orientation with hinge cup 12 fitted into a bore opening on the door of a cabinet and the hinge arm assembly fitted on to the frame of a cabinet, could be reversed even though this is not the usual practice. In addition, the self closing compact adjustable hinge of the present invention may be used in other applications that require a hinge treatment, including furniture, overhead flipper doors mounted on shelves, and the like.
It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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