BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a dual snap-in hinge and a method of using the same.
2. Description of the Prior Art
While snap-in hinges have been used in the past, one leaf of the snap-in hinge has been secured to either a panel or a frame jamb. Accordingly, the barrel of the hinge has always been shipped from the factory attached to either the frame jamb or door. This results in at least two issues. The first is the increased cost and damage caused by having the barrel protrude from the edge of the door panel or jamb. The second is since the barrel is always secured to one of the two members (frame jamb or panel), the color style of the barrel is not easily exchangeable. There is a strong desire to have the finish of the barrel and leaves match other finishes that are used throughout a house. This is not easily done with the prior art as it is well known that once screws from the leaf of a hinge are removed from a door jamb and/or panel, a substantial amount of the structural strength is lost when screws are reinserted into the leaf and then the door jamb and/or panel.
The present invention addresses these two issues and also provides for a simpler and more economical horizontal adjustment mechanism.
SUMMARY OF THE INVENTION
In one embodiment, the invention is a method of manufacturing a door adapted and configured to having a dual snap-in hinge. The method includes forming at least two jamb recesses in a frame jamb. Also, two panel recesses are formed in a panel. A frame jamb receiver is fastened in each of the frame jamb recesses, the frame jamb receiver having a cut out section and a first portion of a snap-in connection. A panel receiver is fastened in each of the panel recesses. The panel receiver has a cut out section and a first portion of a snap-in connection. The frame jamb is secured to the panel with a temporary hinge, the temporary hinge having a frame jamb leaf with a second portion of a snap-in connection. The frame jamb leaf is positioned in the frame jamb receiver cut out section and secured in the frame jamb receiver by the frame second portion of a snap-in connection snapping in the frame first portion of a snap-in connection. The temporary hinge further has a panel leaf with a second portion of a snap-in connection. The panel leaf is positioned in the panel receiver cut out section and secured in the panel receiver by the panel second portion of a snap-in connection snapping in the panel first portion of a snap-in connection. The frame jamb leaf is operatively connected to the panel leaf by a flexible portion, whereby the frame jamb and panel can be moved between an open position to a closed position.
In another embodiment, the invention is a method of manufacturing a door adapted and configured to have a dual snap-in hinge. The method includes forming at least two frame jamb recesses in a frame jamb. At least two panel recesses are formed in a panel. A frame jamb receiver is fastened in each of the frame jamb recesses, the frame jamb receiver having a cut out section and a first portion of a snap-in connection. A panel receiver is fastened in each of the panel recesses, the panel receiver has a cut out section and a first portion of a snap-in connection. The frame jamb is secured to the panel with a hinge. The hinge has a frame jamb leaf with a second portion of a snap-in connection. The frame jamb leaf is positioned in the frame jamb receiver cut out section and secured in the frame jamb receiver by the frame second portion of a snap-in connection snapping in the frame first portion of a snap-in connection. The hinge further has a panel leaf with a second portion of a snap-in connection. The panel leaf is positioned in the panel recess cut out section and secured in the panel receiver by the panel second portion of a snap-in connection snapping in the panel first portion of a snap-in connection. The frame jamb leaf is operatively connected to the panel leaf by a flexible portion, whereby the frame jamb and panel can be moved between an open position to a closed position.
In another embodiment, the invention is a method of installing a door assembly having a panel and a jamb. The method includes installing a door, having a temporary hinge, to a wall. The temporary hinge is removed by releasing a snap fit between a jamb leaf and a jamb receiver and also releasing the snap fit between a panel leaf and a panel receiver. The temporary hinge is replaced with a permanent hinge by snapping a permanent hinge panel leaf into the panel receiver and snapping a permanent hinge jamb leaf into the jamb receiver.
In another embodiment, the invention is a dual snap-in hinge and receiver combination. The combination includes a hinge having a jamb leaf rotatably connected to a panel leaf. A jamb receiver is adapted and configured to be secured to a jamb. A panel receiver is adapted and configured to be secured to a panel. The jamb receiver has a first portion of a snap-in connection and a panel receiver has a first portion of a snap-in connection. The jamb leaf has a second portion of a snap-in connection for a snap-in connection to the jamb receiver. The panel leaf has a second portion of snap-in connection for a snap-in connection to the panel receiver, wherein the hinge may be removed both the panel receiver and the leaf receiver without removing any screws.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a temporary hinge showing the underneath side of the temporary hinge;
FIG. 2 is a perspective view of the temporary hinge, shown in FIG. 1, generally viewed from above;
FIG. 3 is a side elevational view of the temporary hinge shown in FIG. 1;
FIG. 4 is a bottom perspective view of the panel receiver and frame receiver;
FIG. 5 is a perspective view of the receivers shown in FIG. 4, shown generally from the top;
FIG. 6 is a side view of the temporary hinge, shown in FIG. 1, secured to a door panel and frame jamb (shown without four assembly screws);
FIG. 7 is a perspective view of the assembled temporary hinge, shown in FIG. 6;
FIG. 8 is a cross-sectional view, taken generally along the lines 8-8 of FIG. 6;
FIG. 9 is a side elevational view of the temporary hinge, shown just before assembly;
FIG. 10 is a perspective view of the temporary hinge, shown in FIG. 9;
FIG. 11 is a cross-sectional view of the temporary hinge shown in FIG. 9, taken generally along the lines 11-11;
FIG. 12 is a side elevational view of the temporary hinge shown in a partially assembled position;
FIG. 13 is a perspective view of the temporary hinge shown in FIG. 12;
FIG. 14 is a cross-sectional view of the temporary hinge shown in FIG. 12, taken generally along the lines 14-14;
FIG. 15 is a perspective view of a portion of the frame jamb, showing a recess for receiving the jamb receiver and installation screw;
FIG. 16 is an enlarged perspective of the assembled temporary hinge to a frame jamb and panel;
FIG. 17 is a perspective view of a factory assembled temporary hinge showing the panel and jamb in a closed position;
FIG. 18 is a cross-sectional view of the factory assembled temporary hinge with the door jamb assembled to a wall taken through the installation screw;
FIG. 19 is a perspective view of the temporary hinge installed with the panel removed;
FIG. 20 is a perspective view of the temporary hinge, shown in FIG. 19, from the other side;
FIG. 21 is a perspective view of a finished hinge;
FIG. 22 is a perspective view of the finished hinge inserted into the frame receiver, with the panel removed;
FIG. 23 is a perspective view of the finished hinge assembled to both the panel and frame jam;
FIG. 24 is a side elevational view of the finished hinge assembled to the frame jamb and panel;
FIG. 25 is a perspective view of the finished hinge shown in FIG. 24, with the panel in a closed position;
FIG. 26 is a cross-sectional view of the hinge shown in FIG. 25, taken generally along the lines 26-26;
FIG. 27 is an exploded perspective showing the component parts of the permanent hinge;
FIG. 28 is a perspective view of a factory door assembly with a temporary hinge; and
FIG. 29 is a perspective view of a door assembly with a permanent hinge.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to the drawings, wherein like numerals represent like parts throughout the several views, there is generally shown at 100 (FIGS. 16 and 28) a factory door assembly. The factory door assembly 100 includes a frame jamb 110 having a frame receiver 120; a panel 130; a panel receiver 140; and a temporary hinge 150. Generally disclosed at 200 (FIGS. 22 and 29) is a permanent door assembly, which includes the same frame jamb 110, frame receiver 120, panel 130 and panel receiver 140. However, a permanent hinge 250 is utilized instead of a temporary hinge 150.
As will be described more fully hereafter, the factory door assembly 100 is secured to a wall 300 and a permanent hinge 250 then replaces the temporary hinge 150. Although, it is understood, that the permanent hinge 250 may replace the temporary hinge 150 prior to being secured to the wall 300. Alternately, the permanent hinge 150 may be installed at the factory and no temporary hinge is used.
The temporary hinge 150 is constructed from a durable material such as plastic, i.e., polypropylene. The temporary hinge 150 as two relatively flat portions, frame jamb leaf 151 and panel leaf 152, operatively connected to a flexible portion 153. The temporary hinge 150 has a generally planar bottom surface 154. The temporary hinge 150, so far described, generally resembles a “living hinge” which is well known in the art. However, the “living hinge” does not have the snap-in capabilities, spacer capabilities or provisions for use of an installation/adjustment screw as does the present temporary hinge, as will be more fully described hereafter. The top surface 151a of the frame jamb leaf 151 is generally planar also, except for protrusion 151b that extends upward. A protrusion 151b is sized and configured to be received, with a snap-in motion, by the jamb receiver 120, as will be discussed more fully hereafter. Similarly, the panel leaf 152 has a generally planar top surface 152a and also a protrusion 152b sized and configured to be received by the panel receiver 140, as will be discussed more fully hereafter. A flexible portion 153 has two grooves 153a and 153b formed therein to make that section of the flexible portion 153 approximately one-half as thick as the remainder of the temporary hinge 150. These grooves 153a and 153b of the leaves 151, 152 must be thin enough to allow the temporary hinge 150 to bend upward to a position as shown in FIG. 18. An elongate section 153c extends upward, as shown in FIGS. 2 and 3. The elongate section 153c acts as a spacer between the panel 130 and frame jamb 110. In addition, the frame jamb leaf 151 has an aperture 155 formed therein. The aperture 155 is utilized for the insertion of an installation screw 290 as will be described more fully hereafter. The aperture 155 could also be a slot so that the opening would extend to the edge of the frame jamb leaf 151.
The frame receiver 120 and panel receiver 140 are each formed from a suitable material such as plastic, i.e., a polyamide such as Nylon™ or acetal, or they may be formed from a suitable metal. The frame receiver 120 is sized and configured to fit into a recess 110a as shown in FIG. 15. The recess 110a is sized so that the frame receiver 120 is flush mounted to a top surface 110b. A plurality of recesses 110a may be formed along the length of the frame jamb 110, depending upon the number of frame receivers that would be used for the permanent door assembly 200. Typically, this would be two to four receivers, depending on the height and weight of the panel 130. Similarly, the panel receiver 140 is sized and configured to fit in recess 130a formed in the panel 130. The panel receiver 140 is also flush mounted to be flush mounted with the side planar surface 130b of the panel 130. The frame receiver 120 is generally rectangular in shape and has two mounting holes 121 extending through the frame receiver 120. A cutout section 122 is sized and configured to receive frame jamb leaf 151 of both the temporary hinge 150 and the frame jamb leaf 251 of the permanent hinge 250. The frame receiver 120 has a further snap opening 123 that is sized and configured to receive protrusion 151b or protrusion 251b of the permanent hinge 250. In addition, an aperture 124 is formed to align with aperture 155 as seen in FIG. 5. The aperture 124 and mounting holes 121 are countersunk.
The panel receiver 140 is sized and configured to fit into a recess 130a as shown in FIG. 16. The recess 130a is sized so that the panel receiver 140 is flush mounted to the side planar surface 130b of the panel 130. A plurality of recesses 110a may be formed along the length of the panel 130, depending upon the number of frame receivers that would be used for the permanent door assembly 200. The panel receiver 140 is generally rectangular in shape and has two mounting holes 141 extending through the panel receiver 140. A cutout section 142 is sized and configured to receive panel jamb leaf 152 of both the temporary hinge 150 and the panel jamb leaf 252 of the permanent hinge 250. The panel receiver 140 has a further snap opening 143 that is sized and configured to receive protrusion 152b or protrusion 252b of the permanent hinge 250. The mounting holes 121 are countersunk.
Referring now to FIGS. 21 through 27, there is generally shown the permanent hinge 250 and the permanent door assembly 200. The permanent hinge 250 includes a frame jamb leaf 251, panel leaf 252, pin 260 and bushings 261. The permanent hinge 250 can be referred to as a dual snap-in hinge. As used in this application a dual snap-in hinge is a hinge that has a snap-in fit for both the frame jamb leaf and the panel leaf. The frame jamb leaf 251 has an extension portion 251a that is sized and configured to be received into the cutout section 122 of the frame receiver 120. Integral with the frame jamb leaf 251 are two circular barrel extensions 251c that have bores that are in alignment. The panel leaf 252 has an extension portion 252a that is sized and configured to be received into the cutout section 142 of the panel receiver 140. A barrel extension 252c is preferably also integral and operatively connected to the extension portion 252a. The barrel extension 252c has a bore formed therein. The bores of the frame jamb leaf 251 and panel leaf 252 are in general alignment. Bushings 261 are placed between the barrel sections and a pin 260 is secured in position to the bores to form the permanent hinge 250. The permanent hinge 250, so far described, is of similar construction to a permanent hinge in the prior art. The permanent hinge 250 has a protrusion 251b extending outward from the extension portion 251a. Similarly, the panel leaf 252 has a protrusion 252b extending outward from the panel leaf 252. The protrusions 251b, 252b are sized and configured to be similar to protrusions 151b, 252b. The protrusions 251b, 252b are sized and configured to have a snap fit with the snap openings 123 and 143, as will be more fully described hereafter. In addition, the frame jamb leaf 251 has an aperture 255 formed therein and is in general alignment with the aperture 124 or a slot. One additional feature of this invention is that the pin 260 and bushings 261 are all constructed from a plastic material such as acetal, thereby eliminating any metal on metal squeaking. While the snap-in connections defined so far have protrusions, as the first portion of the snap-in connection, on the frame jamb leaf 151/251 and panel leaf 152/252 and a second portion of the snap-in connection, openings 123/143. It is understood that, while this is the preferred arrangement, the openings could appear on the leafs and the protrusions on the receivers.
Referring to FIGS. 9 through 11, there is shown the first sequence of assembly of the temporary hinge 150 at the factory. The frame receiver 120 and panel receiver 140 are secured to the hinge jamb 110 and panel 130 by four assembly screws (not shown) through holes 121 and 141.
Referring to FIGS. 12 through 14, the initial assembly of the temporary hinge into the frame jamb 110 and panel 130 is shown. The frame jamb leaf 151 and panel leaf 152 are shown mid insertion. As can be seen in FIG. 14, the leaves 150, 152 cause the receivers 120, 140 to bulge slightly as the protrusions 151b and 152b are inserted.
Now, referring to FIGS. 6 through 8, it can be seen that the leaves 151 and 152 are fully inserted, allowing a snap-in fit of the temporary hinge 150. The protrusions 151b and 152b are captured in the snap openings 123, 143. FIG. 16 shows a perspective view of the temporary hinge 150 assembled to the panel 130 and frame jamb 110.
FIG. 17 shows a perspective view of the panel 130 and frame jamb 110 in a closed position. As can be seen, a small portion of the plastic temporary hinge 150 protrudes, as opposed to a metal barrel, as in the prior art. Also, the spacer elongate section 153c is shown, thereby eliminating a separate spacer, as used in the prior art.
FIG. 18 shows the installation of the door with the temporary hinge installed on the wall 300. An installation/horizontal adjustment screw 290 is inserted through the opening 124 of the receiver 120 and then through the opening 155 of the temporary hinge 150 through the opening 110C of the jamb 110 and into the wall 300. At this point, the head of the screw 290a is sized and configured to go through both of the openings 155 and 124. The ability for horizontal adjustment by use of the installation/adjustment screw will be described more fully hereafter.
FIGS. 19 through 20 show a temporary door assembly 100 fixtured to the wall 300, by suitable fasteners, well known in the art (not shown). The panel 130 has been removed from the figures for clarity so that the receiver 120 and elongated section 153c are shown more clearly, and how the elongate section 153c would act as a spacer.
After the adjustment screw 290 has been inserted, as previously described, the frame jamb leaf 151 and panel leaf 152 are removed from the receivers 120, 140. A screwdriver or similar tool is inserted into the opening 123 or 143, depending on which leaf 151, 152 is to be removed. The receiver is bent upward by the screwdriver, allowing the protrusions 151b, 152b to become free to be pulled out. Then, the permanent hinge 250 is assembled in a manner similar to the previously described temporary hinge 150. That is, the frame jamb leaf 151 is inserted into the receiver 120 by a snap-in action. Then the panel leaf 152 is inserted into the panel receiver 140 by a snap-in action and the permanent door assembly 250 is now installed. FIG. 24 shows a view of the permanent hinge 250 installed. FIGS. 24 through 26 show figures of the permanent hinge 250 installed. As shown in FIG. 26, it can be seen that the head 290a of the screw 290 has a diameter that is greater than the aperture 255. However, the aperture 255 still allows access to the head of the adjustment screw 290. Therefore, the adjustment screw 290 may be rotated, and since the head of the screw is captured by the hinge 250, rotation of the adjustment screw 290 is a very economical horizontal adjustment mechanism. If it is desired to use another permanent hinge, with say a different finish, the hinge 250 is removed with a screwdriver, as previously described with respect to the temporary hinge 150. It is recognized, that if one does not wish to use the installation/adjustment screw 290, other well known ways of installing the door assembly to a wall 300 may be utilized. For example, fasteners such as screws or nails may be inserted through the jamb into the wall 300, adhesives may be utilized to secure the jamb to the wall 300, a trim piece may be secured to the jamb and the trim piece in turn secured to the wall 300, or other suitable well known techniques may be utilized. Further it is recognized that the adjustment screw 290 may be utilized with a snap-in hinge that is not a dual snap-in hinge, but only has one leaf with a snap-in connection. Further it would be preferred that the leaf with the snap-in feature would be the frame jamb leaf.
The following is a list of the features and benefits that may result from the present invention:
Benefits for the Manufacturer:
- 1. Lower cost. Components that are installed at the manufacturer are less expensive than a current commodity steel hinge.
- 2. Easier assembly. The installation of the hinge receivers require only two screws per receiver compared to four per leaf on a commodity hinge. Also, the receivers do not require typical fixturing of the frame to the panel during installation. This is normally the high point (most constricted flow area) of the production line for door manufacturing. Snapping the panel to the frame reduces the time required for this process and also allows more flexibility when balancing the work on the production line. The temporary hinge can include the spacer between the panel and frame, thereby eliminating another component to install.
- 3. Fewer packaging requirements. The removal of the commodity barrel hinge reduces the size of the packaging and eliminates the packaging around the hinge barrels.
- 4. Less damage to adjacent products. Removal of the barrel of the hinge during transport of the door will reduce damage caused by the hinge barrel to adjacent products.
Benefits During Shipping:
- 1. Smaller package. The elimination of the barrel will reduce the size of the manufactured door from about 5.25″ depth to about 4.75″. If the shipping protector for the hinge barrel is included, the reduction is at least 0.25″ greater. That increases the number of doors that can be shipped in the same space by at least 10% and up to 15%, clearly reducing the cost of shipping.
- 2. Barrel removal reduces damage to adjacent products. The removal of the barrel reduces the damage caused by the barrel gouging adjacent products.
- 3. Barrel is not damaged during shipping. The barrel itself is not able to be damaged when it is not included with the shipped door.
Benefits for the Retailer:
- 1. Inventory of door does not need to be maintained with respect to color of any of the hardware. Since the hinge barrel is applied by the end user, the door does not need to be inventoried for various hinge color options, thereby opening inventory room for other products.
- 2. New source of revenue for matched trim hardware. The hinges that are sold to match the handles will be a new source of revenue with a well understood volume potential. Current door volume is well understood and easy to predict in the short term. Increases in market share are likely due to the multiple benefits that this system will provide. Upgraded hinge designs are available with an expected higher cost and profit margin.
- 3. Increased customer satisfaction with matching hinges and trim sets. No removal of screws during installation or replacement process.
- 4. Ability to sell a new feature to differentiate from competitors using old technology. It will be obvious to consumers that this new system has benefits that they will appreciate. It shows market leadership for the retailer.
- 5. Fewer service issues. The design allows installer to use normal installation methods without much learning for them. They will easily understand that the temporary hinges need to be replaced. The frame adjustment mechanism allows very easy adjustment of the frame to repair out of square installations. This feature can be utilized at any time by installing a screw in the installation position of the hinge. The removal of the hinge screws is a consistent problem that is no longer present with the new design.
- 6. Reduction of damage to and by hinge barrel. Similar those issues described in shipping section.
Benefits to the Installer/Contractor:
- 1. Panel is easily removed and set aside during construction process. Temporary hinge is unsnapped from the frame so that power cords and other items do not damage the panels during the construction process.
- 2. Allows panels to be easily removed for painting and staining. No screws are removed. Screws are easily stripped upon reapplication as the screw threads lose about 30% of their strength when carefully applied. They will lose more strength if too much torque is applied. Stripped screws are a nuisance for any commodity door hinge removal and reinstallation.
- 3. Less damage during transport to the jobsite. The barrel of the hinge sticking out is a problem during all of the delivery phases.
- 4. Opportunity to differentiate from competitors that so not have this system. The benefits to the homeowner can be sold as an upgrade over competitors that do not have the features of this new design.
Benefits to the Homeowner:
- 1. An opportunity to easily have all of the hardware on the door match. Upgraded designs can include a variety of styles to match the homes character. Homeowner will no longer have to ignore the difference between the finish of the hinges and the handle.
- 2. Allows easy changing of the hinge appearance in the future for a remodeling update. Installation of hinges is easier than that for the handle.
- 3. Allows easy removal of the panel to prevent damage during move-in or other times that damage might occur.
- 4. No metal to metal contact insures silent hinge operation forever.
- 5. Easily able to adjust an out of square installation with adjustment mechanism.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention.
Patent Grant
11692360
