Door Closer

Abstract

A door closer having an elongate housing for mounting in a door leaf or door frame, the elongate housing having opposite forward and rear end parts, a plunger disposed in and movable along the housing, the plunger including a ferromagnetic material, a spring biasing element disposed in the housing and applying a first biasing force to bias the plunger inwardly of the housing and away from the forward end part and towards the rear end part, a tension member having a first end connected to the plunger and a second end connected to an anchor element assembly, the anchor element assembly comprising a mounting member for mounting in the other of the door leaf or door frame, the tension member and anchor element forming a tension assembly which extends through the forward end part.

Claims

1. A door closer for mounting between a door leaf and a door frame, the door closer comprising: an elongate housing for mounting in one of the door leaf or door frame, the elongate housing having opposite forward and rear end parts, a plunger disposed in and movable along the housing, the plunger including a ferromagnetic material, a spring biasing element disposed in the housing and applying a first biasing force to bias the plunger inwardly of the housing and away from the forward end part and towards the rear end part, a tension member having a first end connected to the plunger and a second end connected to an anchor element assembly, the anchor element assembly comprising a mounting member for mounting in the other of the door leaf or door frame, the tension member and anchor element forming a tension assembly which extends through the forward end part, and a magnetic biasing element disposed in the housing and applying a second biasing force to the ferromagnetic material to bias the plunger inwardly of the housing and away from the forward end part and towards the rear end part, wherein the spring biasing element is adapted to apply the first biasing force over a first movement range of the plunger within the housing and the magnetic biasing element is adapted to apply the second biasing force over a second movement range of the plunger within the housing, the first movement range defining a forwardmost position of the plunger within the housing and the second movement range defining a rearmost position of the plunger within the housing, and an adjustable fixing mechanism for the magnetic biasing element, the adjustable fixing mechanism being adapted to adjust the second movement range by adjusting a translational position of the magnetic biasing element within the housing, the adjustable fixing mechanism extending externally of the housing so that the adjustable fixing mechanism can be adjusted externally by the user.

2. A door closer according to claim 1 which is a variable power door closer, wherein the second movement range is externally adjustable to adjust a distance over which the second biasing force is applied to the plunger within the housing, the adjustment varying the minimum closing moment when the door leaf is closed by the door closer, and thereby varying the power of the door closer.

3. (canceled)

4. A door closer according to claim 1 further comprising an elongate fixing element slidably fitted to the plunger and extending along the housing and fitted to an end element at the rear end part, and the magnetic biasing element is fixed to the elongate fixing element.

5. A door closer according to claim 4 wherein the magnetic biasing element is movably fixed to the elongate fixing element and can be moved therealong.

6. A door closer according to claim 5 wherein the magnetic biasing element is threadably fixed to the elongate fixing element.

7. A door closer according to claim 6 wherein the elongate fixing element is rotatably fitted to the end element at the rear end part, and rotation of the elongate fixing element causes the magnetic biasing element to be moved translationally along the elongate fixing element.

8. A door closer according to claim 7 wherein the elongate fixing element is freely rotatably fitted to the end element, and further comprising a nut threadably fixed to the elongate fixing element externally of the housing.

9. A door closer according to claim 7 wherein the elongate fixing element and the magnetic biasing element are configured so that forward or rearward adjustment of the translational position of the magnetic biasing element relative to the plunger respectively increase or decrease the application of the magnetic biasing force on the plunger.

10. A door closer according to claim 9 wherein the forward or rearward adjustment of the translational position of the magnetic biasing element relative to the plunger respectively increase and decrease the second movement range and the proportion of the entire movement over which the magnetic biasing force is applied to the plunger.

11. A door closer according to claim 9 wherein the forward or rearward adjustment of the translational position of the magnetic biasing element relative to the plunger respectively increase and decrease the second movement range and the total biasing force applied to the plunger over the second movement range.

12. A door closer according to any one of claim 7 wherein the elongate fixing element and magnetic biasing element are configured so that each 360 revolution of the elongate fixing element increases or decreases the total biasing force applied to the plunger over the second movement range.

13. A door closer according to claim 12 wherein the elongate fixing element and magnetic biasing element are configured so that each 360 revolution of the elongate fixing element increases or decreases the total biasing force applied to the plunger over the second movement range by a biasing force of from 0.5 to 2 Nm, or optionally from 0.75 to 1.5 Nm.

14.-24. (canceled)

25. A door closer according to claim 1 wherein the first movement range defines a length of motion of the plunger within the housing and the second movement range overlaps with a rear part of the first movement range, and in the overlap of the first and second movement ranges the first and second biasing forces are additive to provide a total biasing force higher than the individual first and second biasing forces and wherein the first movement range defines the entire length of motion of the plunger within the housing and all of the second movement range overlaps with the rear part of the first movement range or wherein the first movement range defines a majority of the length of motion of the plunger within the housing and a front part of the second movement range overlaps with the rear part of the first movement range.

26.-27. (canceled)

28. A door closer according to claim 1 wherein the first movement range defines a length of motion of the plunger within the housing located towards the forward end part and the second movement range is adjacent to, and does not overlap with, the first movement range, and defines a length of motion of the plunger within the housing located towards the rear end part.

29. A door closer according to claim 1 wherein an entire movement range of the plunger from the forwardmost position to the rearmost position defines an angle of opening of a door.

30. A door closer according to claim 1 wherein the second biasing force is higher than the first biasing force.

31. A door closer according to claim 1 wherein a total biasing force over the second movement range is higher than the first biasing force.

32.-41. (canceled)

42. A door closer according to claim 1 mounted between a door leaf and a door frame, wherein the door leaf has a closing angle which decreases to a closing angle of 0 as the door leaf is closed, and the magnetic biasing element is adapted to apply the second biasing force over only the range from 4 to 0 as the door leaf is closed.

43. A door closer according to claim 42 wherein over the range from 4 to 0 as the door leaf is closed the door closer applies a closing force on the door leaf of at least 13 Nm, or from greater than 13 Nm to up to 25 Nm, or from greater than 13 Nm to up to 21 Nm.

44.-45. (canceled)

46. A door closer according to claim 42 wherein over the range of at least 5 as the door leaf is closed the door closer applies a closing force on the door leaf which is lower than the closing force over the range from 4 to 0.

47.-50. (canceled)

Description

[0020] An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0021] FIG. 1 is a rear perspective cross-sectional side view of a door closer according to an embodiment of the present invention in a partly open configuration;

[0022] FIG. 2 is a perspective front view of the door closer of FIG. 1;

[0023] FIG. 3 is a cross-sectional side view of the door closer of FIG. 1 in the partly open configuration which also illustrates a first relationship between the first and second biasing forces in accordance with an embodiment of the present invention;

[0024] FIG. 4 is a cross-section through the magnetic biasing element in the door closer;

[0025] FIG. 5 schematically illustrates a second alternative relationship between the first and second biasing forces in accordance with another embodiment of the present invention;

[0026] FIG. 6 schematically illustrates a third alternative relationship between the first and second biasing forces in accordance with another embodiment of the present invention; and

[0027] FIG. 7 schematically illustrates the door closer of FIG. 1 mounted between a door leaf and a door frame.

[0028] FIGS. 1 to 4 show a door closer 2 according to the present invention that can be used for urging an opened door towards its closed position relative to a door frame. The door closer 2 is adapted for mounting between a door leaf and a door frame. The door closer 2 comprises an elongate housing 4 for mounting in one of the door leaf or door frame. The elongate housing 4 has opposite forward and rear end parts 6, 8. The housing 4 is a cylindrical tube, typically of steel. The housing 4 has a mounting plate 10 affixed thereto, the mounting plate 10 having holes 12 extending therethrough for receiving fixing screws. In use, the housing 4 is received in an elongate horizontal cavity in a door leaf (not shown), and the mounting plate 10 is rebated into the edge of the door leaf and affixed thereto, for example by screws.

[0029] A plunger 14 is disposed in and movable along the housing 4. The plunger 14 further comprises a hydraulic damper 16 for damping, or decelerating, the movement of the plunger 14 within the housing 4. The hydraulic damper 16 includes a chamber 17 filled with hydraulic fluid 19 which causes damping of the door closer 2. The hydraulic damper 16 comprises a restrictor valve 18 having a threaded adjuster pin 20 for adjusting the damping operation of the hydraulic damper 16, as disclosed for example in the Applicant's earlier WO-A-2005/1 24079, WO-A-2008/102115, WO-A-2009/034310, WO-A-2011/051317 and WO-A-2012/076662.

[0030] The restrictor valve 18 is configured to be adjustable after installation, and permits a user readily to achieve fine control of the damping function and the criteria of BS.EN 1154:1997 and EN 1154:1996+A1:2002 E to be achieved over a wide temperature range with a variety of hydraulic fluids. Most particularly, such fine control can be achieved even with a hydraulic fluid of low viscosity, such as 60 centistokes at room temperature, the advantage of such a low viscosity fluid being the minimization of the risk of jamming of the door closer, particularly at lower operating temperatures. The concealed door closer can meet the criteria of BS.EN 1154:1997 and EN 1154:1996+A1:2002 E when using a variety of different hydraulic fluids without requiring a structural modification of the restrictor valve 18 structure dependent upon a selected hydraulic fluid or on the closing force or application of the door closer.

[0031] A spring biasing element 22, typically a helical compression spring 22, is disposed in the housing 4 and applies a first biasing force to bias the plunger 14 inwardly of the housing 4 and away from the forward end part 6 and towards the rear end part 8. The spring biasing element 22 annularly surrounds the plunger 14.

[0032] A rigid tension member 24 has a first end 26 pivotally connected to the plunger 14 at a first pivot 28 and a second end 30 pivotally connected to an anchor element assembly 32 at a second pivot 34. The anchor element assembly 32 comprises a mounting member 36, in the form of a plate 36, for mounting in the other of the door leaf or door frame, and an elongate link member 38, which extends forwardly from the mounting member 36, to which the rigid tension member 24 is connected by the second pivot 34.

[0033] The tension member 24 and anchor element assembly 32 form a tension assembly 40 which extends through the forward end part 6. A hole 42 in the mounting plate 10 permits movement therethrough of the rigid tension member 24 and the link member 38 forming the tension assembly 40. The hole 42 also permits insertion therethrough of a screwdriver or other tool to adjust the threaded adjuster pin 20 of the hydraulic damper 16.

[0034] In FIGS. 1 to 4 the door closer 2 is illustrated in a partly open configuration, in the configuration as sold, in which a U-shaped holder 41 is removably fitted to the tension member 24 in order temporarily to hold the second end 30 of the tension member 24 and the link member 38 out of the forward end part 6, against the bias of the helical compression spring 22, to aid installation of the door closer 2.

[0035] The mounting member 36 is typically rebated into the edge of the door frame and affixed thereto, for example by screws. The second pivot 34 is located at a free end 44 of the link member 38 remote from the plate member 36. The first and second pivots 28, 34 have parallel axes, which in use are typically vertically oriented.

[0036] Conceivably, the mounting positions of the housing 4 and the anchor element assembly 32 may be reversed, with the housing 4 received in the door frame and the anchor element assembly 32 mounted to the door leaf.

[0037] An elongate fixing element 50 is slidably fitted to the plunger 14. The elongate fixing element 50 extends along the housing 4 and through an end element 52 at the rear end part 8. The elongate fixing element 50 is freely rotatably fitted to the end element 52. A nut 54 is threadably fixed to the elongate fixing element 50 externally of the housing 4. A slider mechanism 56, including the hydraulic damper 16, is fitted to the elongate fixing element 50 within the plunger 14.

[0038] A magnetic biasing element 60 is disposed in the housing 4 and is fixed to the elongate fixing element 50. The magnetic biasing element 60 is movably fixed, typically threadably fixed, to the elongate fixing element 50 and can be moved therealong. The elongate fixing element 50 is freely rotatably fitted to the end element 52 at the rear end part 8. Rotation of the elongate fixing element 50 causes the magnetic biasing element 60 to be moved translationally along the elongate fixing element 50 in an inward or outward direction depending upon the direction of rotation of the elongate fixing element 50.

[0039] As shown in FIG. 4 in greater detail, the magnetic biasing element 60 is annular and has a cylindrical outer surface 62 and a central bore 63 with an internal helical thread 65 through which the elongate fixing element 50 extends via the threaded connection.

[0040] The magnetic biasing element 62 comprises a holder 64 composed of non-ferromagnetic material, such as nickel or a nickel alloy, which surrounds a magnet 66 of the magnetic biasing element 60. The holder 64 separates the magnet 66 from an annular wall 67 of the housing 4, to prevent the magnet 66 from inadvertently being clamped to the housing 4 by any magnetic force. The magnet 66 is fitted in a blind recess 68 in the holder 64 so that an exposed face 70 of the magnet 66 is oriented towards the plunger 14. An adhesive moulding compound 69 bonds the magnet 66 within the recess 68. Typically, the magnetic biasing element 60 comprises a Neodymium or NdFeB magnet 66, for example of grade N50 or N52.

[0041] The plunger 14 includes a ferromagnetic material 72. In the illustrated embodiment, the plunger 14 has an outer body 74 which is composed of steel which provides at least some of the ferromagnetic material 72 in the plunger 14. Optionally, as shown in FIG. 5, a second magnet 76 is fitted to a rear end 78 of the plunger 14 and the second magnet 76 provides at least some of the ferromagnetic material 72 in the plunger 14. Typically, the second magnet 76 comprises a Neodymium or NdFeB magnet, for example of grade N50 or N52, or an iron or steel magnet.

[0042] The magnetic biasing element 60 applies a second biasing force to the ferromagnetic material 72 to bias the plunger 14 inwardly of the housing 2 and away from the forward end part 6 and towards the rear end part 8.

[0043] Referring to FIG. 3, the spring biasing element 22 is adapted to apply the first biasing force over a first movement range R1 of the plunger 14 within the housing 4 and the magnetic biasing element 60 is adapted to apply the second biasing force over a second movement range R2 of the plunger 14 within the housing 4. The first movement range R1 defines a forwardmost position of the plunger 14 within the housing 2 and the second movement range R2 defines a rearmost position of the plunger 14 within the housing 2.

[0044] The elongate fixing element 50 and the magnetic biasing element 60 are configured so that forward or rearward adjustment of the translational position of the magnetic biasing element relative to the plunger 14 respectively increase or decrease the application of the magnetic biasing force on the plunger 14.

[0045] The forward or rearward adjustment of the translational position of the magnetic biasing element 60 relative to the plunger 14 respectively increase and decrease the second movement range R2 and the proportion of the entire movement over which the magnetic biasing force is applied to the plunger 14.

[0046] The forward or rearward adjustment of the translational position of the magnetic biasing element 60 relative to the plunger 14 also respectively increase and decrease the second movement range R2 and the total biasing force applied to the plunger 14 over the second movement range R2.

[0047] The elongate fixing element 50 and magnetic biasing element 60 are configured so that each 360 revolution of the elongate fixing element 50 increases or decreases the total biasing force applied to the plunger 14 over the second movement range R2. Typically, each 360 revolution of the elongate fixing element 50 increases or decreases the total biasing force applied to the plunger 14 over the second movement range R2 by a biasing force of from 0.5 to 2 Nm, optionally from 0.75 to 1.5 Nm.

[0048] The preferred embodiments of the present invention therefore provide that the concealed door closer 2 has an adjustable power size. In particular, the concealed door closer 2 is adapted so that the user is able to adjust the minimum closing moment when the door leaf is closed, which is achieved by providing that the second movement range R2 is adjustable by adjusting the translational position of the magnetic biasing element 60 within the housing 4 by operation of an adjustable fixing mechanism, exemplified by the elongate fixing element 50, for the magnetic biasing element 60, the adjustable fixing mechanism extending externally of the housing 4. The adjustable fixing mechanism, exemplified by the elongate fixing element 50, can be accessed by a user so that the device can be adjusted externally by the user. External adjustment of the second movement range R2 adjusts the distance over which the second biasing force is applied to the plunger 14 within the housing 4. This adjustment varies the minimum closing moment when the door leaf is closed, and thereby adjusts the power size of the concealed door closer 2.

[0049] In the embodiment shown in FIG. 3, the first movement range R1 defines a length of motion of the plunger 14 within the housing 4 over which the first biasing force from the spring is applied, for example over an opening range of from 0 degrees to greater than 90 degrees, and the second movement range R2, over which the second biasing force from the magnet(s) is applied, for example over an opening range of from 0 degrees to up to 4 degrees, overlaps with a rear part of the first movement range R1, and in the overlap of the first and second movement ranges R1, R2 the first and second biasing forces are additive to provide a total biasing force higher than the individual first and second biasing forces. The first movement range R1 typically defines the entire length of motion of the plunger 14 within the housing 4 and all of the second movement range R2 overlaps with the rear part of the first movement range R1.

[0050] Alternatively, as shown in FIG. 5, in another embodiment, the first movement range R1 defines a majority of the length of motion of the plunger 14 within the housing 4 and a front part of the second movement range R2 overlaps with the rear part of the first movement range R1.

[0051] In another embodiment, as shown in FIG. 6, the first movement range R1 defines a length of motion of the plunger 14 within the housing 4 located towards the forward end part 6 and the second movement range R2 is adjacent to, and does not overlap with, the first movement range R1, and defines a length of motion of the plunger 14 within the housing 4 located towards the rear end part 8.

[0052] The entire movement range of the plunger 14 from the forwardmost position to the rearmost position defines an angle of opening of the door.

[0053] Typically, the second biasing force is higher than the first biasing force. Typically, a total biasing force over the second movement range R2 is higher than the first biasing force.

[0054] Typically, the first biasing force is from 8 to 13 Nm, more typically from 8 to 10 Nm, such as from 8 to 9 Nm. Typically, the second biasing force is from 8 to 13 Nm. Typically, the total biasing force over the second movement range R2 is at least 13 Nm, more typically from greater than 13 Nm to up to 25 Nm, such as from greater than 13 Nm to up to 21 Nm.

[0055] In use, as shown in FIG. 7, the door closer 2 is mounted between a door leaf 90 and a door frame 92.

[0056] The door leaf 90 has a closing angle a which decreases to a closing angle of 0 as the door leaf 90 is closed, and the magnetic biasing element 60 is adapted to apply the second biasing force over only the range from 4 to 0 as the door leaf 90 is closed.

[0057] Over the range from 4 to 0 as the door leaf 90 is closed the door closer 2 applies a closing force on the door leaf 90 of at least 13 Nm, typically from greater than 13 Nm to up to 25 Nm, more typically from greater than 13 Nm to up to 21 Nm.

[0058] Over the range of at least 5 as the door leaf 90 is closed the door closer 2 applies a closing force on the door leaf 90 which is lower than the closing force over the range from 4 to 0. For example, over the range of at least 5 as the door leaf 90 is closed the door closer 2 applies a closing force on the door leaf 90 which is less than 13 Nm, typically from 8 to less than 13 Nm, more typically from 8 to 10 Nm, such as from 8 to 9 Nm.

[0059] When the door leaf 90 is opened relative to the door frame 92 about the axis of one or more door hinges 94, the plunger 14, being attached to the door frame 92, is pulled in a direction outwardly of the housing 4. Accordingly, the helical compression spring 22 is progressively compressed, as a result of a compression force acting thereon by the plunger 14, and exerts an inward biasing force acting against the opening pulling force on the door leaf 90. For the initial opening movement from the closed position, the magnetic biasing element 60 provides a magnetic attractive force on the plunger 14 which resists the opening motion. After the door leaf 90 has been opened by an initial angle from the closed position, for example up to 4, the magnetic attractive force is minimal, and becomes negligible, and only the spring bias from the helical compression spring 22 resists further opening of the door leaf 90.

[0060] The helical compression spring 22 provides a low resisting moment, for example within the range of 8 to 13 Nm, in which case the spring can effectively act as a power size 1 door closer over the majority of the opening angle after the initial opening angle from the closed position, for example up to 4.

[0061] After the door leaf 90 is released, the biasing force of the helical compression spring 22 acts to bias the rigid tension member 24 and the plunger 14 inwardly of the housing 4, for closing the door. When the door leaf 90 is subsequently closed relative to the door frame 92 about the axis of the one or more door hinges 94, the plunger 14 is pushed in a direction inwardly of the housing 4 by the compressed helical compression spring 22 which exerts the inward biasing force acting as a closing force on the door leaf 90. For the initial opening movement from the open position, for example until the opening angle is as low as just above 4, the sole closing moment applied by the door closer 2 on the door leaf 90 is applied by the helical compression spring 22.

[0062] As the door leaf 90 approaches the fully closed position, for example at which the door leaf 90 is at an opening angle of as low as 4, the magnetic biasing element 60 acting on the plunger 14 provides an additional closing force on the plunger 14, additional to the spring bias from the helical compression spring 22 which assists the closing motion.

[0063] The combination of the helical compression spring 22 and the magnetic biasing element 60 provides a high closing moment, for example within the range of 13 to 18 Nm, in which case the combination can effectively act as a power size 2 door closer over the final few degrees of the closing angle, for example up to 4. Alternatively, the combination of the helical compression spring 22 and the magnetic biasing element 60 provides an even higher closing moment, for example within the range of 18 to 25 Nm, in which case the combination can effectively act as a power size 3 door closer over the final few degrees of the closing angle, for example up to 4.

[0064] These enhanced power sizes can provide increased closing power over the last few degrees of closing without increasing the opening resistance over the majority of the opening angle. The increased closing power can provide enhanced closing forces to overcome any resistance to closing by a latch or locking member for the door leaf 90 in the door frame 92.

[0065] The hydraulic damper 16 may provide a reduced damping force at the end of the closing operation so as to provide an enhanced closing velocity for overcoming any latch resistance so that the door leaf 90 is securely latched when closed.

[0066] Various modifications to the illustrated embodiment will be apparent to those skilled in the art.