Gravity hinge system for use with glass doors

Abstract

A hinge system for use with frameless glass shower doors is presented. The hinge system is self-closing or self-centering and includes angular adjustability in two planes to aid in door alignment. The door hinge system further includes drop-in pivot pins which aid in shower door installation and also includes adapter plates that allow for installation to glass walls and further includes adapter plates that allow door panels equipped with the hinge system to be installed as fixed panels at various angles.

Claims

1. A door hinge system, comprising: a lower hinge, an upper hinge and a door panel; the lower hinge and upper hinge having a pivot axis; the upper hinge including an upper fixed hinge bracket and an upper movable hinge bracket interconnected by an upper pivot pin; the lower hinge including a lower fixed hinge bracket and a lower movable hinge bracket, interconnected by a lower pivot pin; wherein the lower pivot pin is disposed in the lower movable hinge bracket and includes a u-shaped socket; wherein the lower fixed hinge bracket includes an engagement pin, the lower fixed hinge bracket and lower movable hinge bracket configured such that when the engagement pin is centered in the u-shaped socket, the door panel is in a closed position; wherein, rotational movement of the lower movable hinge bracket from the closed position causes a side of the u-shaped socket to ride upwardly on the engagement pin; wherein for rotational movement of the lower movable hinge bracket wherein the u-shaped socket does not ride over the engagement pin, a weight of the lower and upper movable hinge brackets and the door panel connected thereto biases the lower movable hinge bracket to the closed position; wherein for rotational movement of the lower movable hinge bracket wherein the u-shaped socket rides over the engagement pin, the lower movable hinge bracket, upper movable hinge bracket and door panel connected thereto will remain in an open position; and, means for fixing a door panel to the lower and upper movable hinge brackets; wherein the lower hinge further includes an adjusting means for angularly adjusting the lower movable hinge bracket, rotationally about the pivot axis, the adjusting means comprising a slot and a positioner; wherein the slot is formed on an outer surface of the lower pivot pin, parallel to the pivot axis; wherein, the positioner is disposed in the lower movable hinge bracket and includes a disk configured to engage with the slot; wherein rotation of the positioner causes an angular change in the position of the lower pivot pin and the lower movable hinge bracket and door panel connected thereto.

2. The door hinge system of claim 1, wherein the means for fixing the door panel to the upper and lower movable brackets comprises a clamp plate that clamps the door panel to a surface of the upper movable hinge bracket and a clamp plate that clamps the door panel to a surface of the lower movable hinge bracket.

3. The door hinge system of claim 1, wherein the upper and lower movable hinge brackets each include an adjusting means for angularly adjusting the door panel in a plane perpendicular to ground.

4. The door hinge system of claim 3, wherein the adjusting means for angularly adjusting the door panel in a plane perpendicular to ground comprises a boss formed on each of the upper and lower movable hinge brackets where each boss engages in a slip-fit relationship with a hole formed at respective upper and lower ends of the door panel, such that the door panel is rotatable about each boss.

5. The door hinge system of claim 4, wherein the boss of each upper and lower movable hinge bracket is configured with a means for securing a clamp plate.

6. The door hinge system of claim 1, wherein the upper and lower fixed hinge brackets include water seals which engage with surfaces of the upper and lower movable hinge brackets.

7. The door hinge system of claim 1, wherein the upper pivot pin is removably insertable into a bore in the upper fixed hinge bracket; the upper pivot pin including a shoulder and the bore a stop surface, wherein the shoulder of the upper pivot pin indexes with the stop surface; wherein a retainer interfaces with the upper pivot pin and the upper fixed bracket to secure the upper pivot pin in the bore; and wherein the upper movable bracket includes a bearing configured to engage with the upper pivot pin.

8. The door hinge system of claim 1, further including an adapter plate insertable between the upper and lower fixed hinge brackets and their respective upper and lower movable hinge brackets, wherein the plate prevents rotation of the upper and lower movable hinge brackets relative to the upper and lower fixed hinge brackets.

9. A door hinge, comprising: a fixed bracket and a movable bracket, interconnected by a pivot pin, the movable bracket disposed above the fixed bracket; wherein the pivot pin is disposed in the movable bracket and includes a u-shaped socket; wherein the fixed bracket includes an engagement pin, the fixed bracket and movable bracket are configured such that when the engagement pin is centered in the u-shaped socket, the door hinge is in a closed position; wherein, rotational movement of the movable bracket with the pivot pin from the closed position causes a side of the u-shaped socket to ride upwardly on the engagement pin; wherein for rotational movement of the movable bracket where the u-shaped socket does not ride over the engagement pin, a weight of the movable bracket biases the movable bracket to the closed position; and wherein for rotational movement of the movable bracket where the u-shaped socket rides over the engagement pin, the movable bracket remains in an open position; further including an adjusting means for angularly adjusting the movable bracket, the adjusting means comprising a slot and a positioner; wherein the slot is formed on an outer cylindrical surface of the pivot pin, parallel to a pivot axis of the pivot pin; wherein, the positioner is disposed in the movable bracket and includes a disk configured to engage with the slot; wherein rotation of the positioner causes an angular change in the position of the pivot pin and the movable bracket connected thereto.

10. The door hinge of claim 9, wherein the movable hinge bracket further includes a means for fixing a door panel to the movable bracket, the means comprising a clamp plate that clamps the door panel to a side of the movable bracket.

11. The door hinge of claim 10, further including an adjusting means for angularly adjusting the door panel in a plane perpendicular to a ground plane, the adjusting means for angularly adjusting the door panel in a plane perpendicular to a ground plane comprising a hole in the door panel and a boss formed on the movable hinge bracket, the boss disposed within the hole, wherein the boss is configured to be in a slip fit relationship with the hole such that the door panel is rotatable about the boss.

12. The lower door hinge of claim 11, wherein the clamp plate and boss are configured such that the clamp plate is removably attachable to the boss.

13. The lower door hinge of claim 9, wherein the fixed bracket includes a water seal which engages with the movable bracket and prevents water passage between the fixed and movable brackets.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of the door hinge system of the present invention showing the upper and lower hinges of the system installed on a door panel.

(2) FIG. 2 is an exploded perspective view of the lower hinge of the door hinge system of FIG. 1.

(3) FIG. 3 is an exploded perspective view of the upper hinge of the door hinge system of FIG. 1.

(4) FIG. 4 is a cross-sectional view of the lower hinge taken along the line 4-4 of FIG. 1.

(5) FIG. 5 is a cross-sectional view of the upper hinge taken along the line 5-5 of FIG. 1.

(6) FIG. 6 is a right facing perspective view of the lower hinge of the door hinge system of FIG. 1, with the hinge brackets shown in phantom line to illustrate internal components of the lower hinge.

(7) FIG. 7 is a front view of the lower hinge pin used in the door hinge system of FIG. 1 and illustrated in FIG. 6.

(8) FIG. 8 is a side view of the lower hinge pin used in the door hinge system of FIG. 1 and illustrated in FIG. 6.

(9) FIG. 9 is a left facing perspective view of the lower hinge of the door hinge system of FIG. 1, with the hinge brackets shown in phantom line to illustrate the internal components of the lower hinge.

(10) FIG. 10A is a front view of a positioner used in the lower hinge of the door hinge system of FIG. 1.

(11) FIG. 10B is a side view of a positioner shown in FIG. 10A.

(12) FIG. 11 is a right facing perspective view of the upper hinge of the door hinge system of FIG. 1, with the hinge brackets shown in phantom line to illustrate the internal components of the upper hinge and the hinge pin partially removed for clarity.

(13) FIG. 12 is a partial, perspective view of the upper hinge of the door hinge system of FIG. 1, with the hinge brackets shown in dashed line to illustrate the internal components of the upper hinge of the upper hinge and the hinge pin partially removed for clarity.

(14) FIG. 13 is a cross-sectional view of the upper and lower hinges showing the position of the internal components in the door-closed position.

(15) FIG. 14 is a cross-sectional view of the upper and lower hinges showing the position of the internal components in the door-fully-open position.

(16) FIG. 15 is a cross-sectional view taken along the line 20-20 of FIG. 1 showing a door panel alignment feature of the hinge system of the present invention.

(17) FIG. 16 is top view of the door hinge system of FIG. 1 showing the hinges and door panel in a closed position.

(18) FIG. 17 is top view of the door hinge system of FIG. 1 showing the hinges and door panel rotated clockwise.

(19) FIG. 18 is top view of the door hinge system of FIG. 1 showing the hinges and door panel rotated counterclockwise.

(20) FIG. 19 is a top view of showing the top profile of the water seal suitable for use with the door hinges of the door hinge system of FIG. 1.

(21) FIG. 20 is an exploded, perspective view showing adapter plates for mounting a door panel equipped with the hinge system of the present invention to a wall panel at a 90 degree angle.

(22) FIG. 21 is a perspective view showing a door panel equipped with the hinge system of the present invention attached to a wall panel at a 90 degree angle with the adapter plates of FIG. 19.

(23) FIG. 22 is a perspective view showing two door panels equipped with the hinge system of the present invention attached to each other at a 180 degree angle using adapter plates in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(24) The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. The invention may, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

(25) With reference to FIGS. 1-5, the door hinge system 10 of the present invention is self-centering or self-closing and includes angular door to doorjamb or ground alignment features, as well as features that door installation and thereby the labor costs of installing a glass door.

(26) The door hinge system 10 of the present invention includes an upper hinge assembly 12 a lower hinge assembly 14 and a door panel 16, connected thereto. The upper and lower hinges assemblies 12 and 14 having a pivot axis 32. In the exemplary embodiment, the door panel 16 is made of glass and features polished peripheral edges. The door panel 16 features upper and lower chamfers 18 and 20, which, in conjunction with the upper and lower hinge assemblies 12 and 14, provide for improved aesthetics of the door panel. Although in the exemplary embodiment, the door panel 16 is a glass panel, door panels made from other materials such as wood, metal and plastic are also suitable. The upper and lower hinges assemblies 12 and 14 may include optional, covers 110, 112, 114 and 116, for protective and aesthetic purposes.

(27) The lower hinge assembly 14 is a gravity style hinge that provides for self-centering or self-closing action of the door panel 16. The lower hinge assembly 14 includes a lower fixed hinge bracket 22 that mounts to a doorjamb or other support structure, a lower movable hinge bracket 24 that interfaces with the door panel 16 and a clamp plate 26 that secures the door panel 16 via gaskets 27 to an inner face of the lower movable hinge bracket 24. The lower fixed hinge bracket 22 and lower movable hinge bracket 24 are interconnected by means of a lower pivot pin 30.

(28) With reference to FIGS. 1-5 and with particular reference to FIGS. 6-8 and 13, the lower pivot pin 30 is mounted coincident with the pivot axis 32 of the door hinge system 10 in the lower movable hinge bracket 24. The lower pivot pin 30 includes an upper pin portion 50 and a lower pin portion 51. The upper pin portion 50 includes a longitudinal slot 44 and set screw flats 33. The longitudinal slot 44 is formed on an outer cylindrical surface of the pivot pin 30, parallel to the pivot axis 32 of the lower pivot pin 30. Set screws 31 which reside in threaded holes in the lower movable hinge bracket 24 bear against the set screw flats 33 to secure the lower pivot pin 30 in the lower movable hinge bracket 24.

(29) The lower pin portion 51 includes a generally u-shaped socket 34 at a lower end. The u-shaped socket 34 interfaces with an engagement pin 36 mounted horizontally in the lower fixed hinge bracket 22. When the engagement pin 36 is centered in the u-shaped socket 34, the lower movable hinge bracket 24 is in an at-rest or zero degree position, which corresponds to the door panel 16 connected thereto being in a closed position. (See FIG. 13.) A set screw 37 secures the engagement pin 36 within the lower fixed hinge bracket 22.

(30) The u-shaped socket 34 of the lower pivot pin 30 allows the lower movable bracket 24 and consequently the door panel 16 connected thereto to rotate to either side of the at-rest position, i.e. clockwise or counterclockwise (see FIGS. 16-18). When the door hinge system 10 is installed in an enclosure, such as a shower enclosure, the at-rest position corresponds to the door panel 16 being closed. The door panel 16 has the ability to rotate about 180 degrees inwardly, i.e. into the shower enclosure, and about 180 degrees outwardly, i.e. exterior of the shower enclosure. Further rotation of the door panel 16 beyond 180 degrees inwardly or outwardly from a closed position is blocked by the lower movable hinge bracket 24 contacting the lower fixed hinge bracket 22.

(31) With reference to FIGS. 7-8 and 13-14, the u-shaped socket 34 of the lower pivot pin 30 is configured with self-centering ramps 38 and stationary surfaces 40. At approximately 75 degrees of rotation, either inwardly or outwardly, when released, the door panel 16 will automatically close or self-center as the weight of the door panel 16 and the upper and lower movable hinge brackets 68 and 24 causes the self-centering ramps 38 of the u-shaped socket 34 of the pivot pin 30 to ride downwardly over the engagement pin 36 until the engagement pin 36 is centered in the u-shaped socket 34, which corresponds to zero degrees of rotation or the at-rest or closed position of the door panel. At approximately 75 to 180 degrees of rotation, either clockwise or counterclockwise, the door panel 16 will remain stationary when released, as the stationary surfaces 40 of the u-shaped socket 34 now rest upon the engagement pin 36. (See FIG. 14.)

(32) With reference to FIGS. 1-8 and with particular reference to FIG. 9, to account for angular misalignment between the door panel 16 and a sill or post, in a plane parallel to the floor, the lower hinge assembly 14 includes a first angular alignment feature 42, disposed within the lower movable hinge bracket 24. The first angular alignment feature 42 comprises a longitudinal slot 44 formed along the outer cylindrical surface of the upper pin portion 50 of the lower pivot pin 30 and a horizontally disposed positioner 46, located in the lower movable hinge bracket 24. The positioner 46 includes a shaft 52 having and a centrally located disk 54 which engages with the longitudinal slot 44 of the lower pivot pin 30. The positioner 46 is threaded at one end and engages with a threaded hole 48 (see FIG. 2) of the lower movable hinge bracket 24.

(33) The position of the centrally located disk 54 may be adjusted laterally, i.e. inwardly or outwardly from a center position within the lower movable hinge bracket 24 by rotating the positioner 46 either clockwise or counterclockwise. Lateral movement of the positioner 46 causes the centrally located disk 54 to rotate the lower pivot pin 30 and consequently the u-shaped socket 34 formed integrally therewith about the pivot axis 32 and thereby allows the door panel 16 to be angularly aligned with a sill or post in a plane parallel to the floor.

(34) With reference to FIGS. 1 and 15, to account for small amounts of angular misalignment between the horizontal edges 17 of the door panel 16 with respect to a sill, header, or floor, i.e. in a plane perpendicular to the ground, the upper hinge assembly 12 and the lower hinge assembly 14 include a second angular alignment feature 56. The second angular alignment feature 56 comprises a clearance-hole 60 in the door panel 16 into through which is disposed an internally threaded boss 58. An outside diameter of the boss 58 is configured to be a slip fit with an internal diameter of the clearance-hole 60. The clearance between the boss 58 and the clearance-hole 60 provides for the ability to angularly align the door panel 16 in a plane perpendicular to a floor or sill or a post, by rotating the door panel 16 with respect to the floor, sill or post. Disposed on each side of the door panel 16 are gaskets 27 which engage with interior faces 28 of upper and lower movable hinge brackets 68 and 24, and respective clamp plates 26. The gaskets 27 are made of a deformable material and hold the door panel 16 in place via friction when the door panel 16 is fixed into position by tightening a clamp screw 62 which engages with a threaded hole in the boss 58.

(35) With reference to FIGS. 1, 3, 5 and 11-12, the upper hinge assembly 12 of the door hinge system 10 of the present invention includes the upper fixed hinge bracket 66 that mounts to a doorjamb or other door support structure, an upper movable hinge bracket 68 that interfaces with the door panel 16 and a clamp plate 26 that secures the door panel 16 to the upper movable hinge bracket 68. The upper fixed hinge bracket 66 and upper movable hinge 68 bracket are interconnected by means of an upper pivot pin 74.

(36) The upper fixed hinge bracket 66 is configured to receive the upper pivot pin 74. The upper pivot pin 74 is disposed in a bore 76 in the upper fixed hinge bracket 66 and is located or indexes in the bore by means of a shoulder 78 formed at an upper end of the upper pivot pin 74 which rests upon a radial stop surface or pocket 80 in the upper fixed hinge bracket 66. A retainer 82 retains the upper pivot pin 74 within the bore 76 of the upper fixed hinge bracket 66 by means of a boss 75 which engages with a hole 83 in the retainer 82. The retainer 82 is secured to the upper fixed hinge bracket 66 by means of a screw 85 which engages with a threaded hole 87 in the upper fixed hinge bracket 66. A lower end 77 of the upper pivot pin 74 interfaces with a bearing assembly 86 disposed in a bore 89 formed in the upper movable hinge bracket 68. A bearing spacer 81 locates the bearing assembly 86 in the upper movable hinge bracket 68.

(37) With reference to FIGS. 2-6, 9, 11 and 14-19, the upper fixed hinge bracket 66 features a water seal 88A and the lower fixed hinge bracket 22 features a water seal 88B. The water seals 88A and 88B are retained in the upper and lower fixed hinge brackets 66 and 22 by means of dovetail grooves 120 formed in each of the upper and lower fixed hinge brackets, (see FIGS. 2 and 3) which engage with dovetails 90 formed in the water seals 88A and 88B. Each of the water seals 88A and 88B includes a scraper blade 91. The scraper blade 91 of the upper water seal 88A, installed on the upper fixed hinge bracket 66, engages which with a curved surface on 93A of the upper movable hinge bracket 68. (See FIG. 3.) Similarly, the scraper blade 91 of the lower water seal 88B, installed on the lower fixed hinge bracket 22 (see FIG. 2), engages which with a curved surface on 93B of the lower movable hinge bracket 24 (best shown in FIG. 9). The water seals 88A and 88B function to prevent water ingress or egress from between the fixed and movable hinges brackets, i.e. to prevent water from exiting a shower enclosure from between the fixed and movable hinge brackets of the upper and lower hinges.

(38) With reference to FIGS. 3, 5 and 11-12, a hollow cylindrical water seal 84 serves to enclose a portion of the upper pivot pin 74 and prevent water intrusion into the bearing assembly 86 which supports a lower end of the pivot pin.

(39) The door hinge system 10 of the present invention also includes adapter plates that allow door panels fitted with the hinge system of the present invention to be connected to walls, typically glass walls, at a 90 degree angle and further allow door panels to be connected back to back at 180 degree angles.

(40) With reference to FIGS. 20-21, an adapter plate 92 for connecting the hinges of the door hinge system 10 of the present invention to a wall panel at a 90 degree angle are shown. Each adapter plate 92 includes a pair of bosses 94 which are spaced to match with holes 108 in the upper and lower fixed hinge brackets 66 and 22 of the door hinge system 10 of the present invention. The bosses 94 include internal threads so that the upper and lower fixed hinge brackets 66 and 22 of may be attached to the adapter plates 92 by means of screws 118. A bottom plate 96 may, optionally, also be used to prevent the lower movable hinge bracket 24 from rotating relative to the lower fixed hinge bracket 22, which has the effect of preventing the door panel 16 from swinging. The bottom plate 96 is configured to attach to a bottom surface of the lower fixed hinge bracket 22 and the lower movable hinge bracket 24, via screws or other mechanical fasteners.

(41) With reference to FIG. 22, adapter plates 98 for interconnecting two doors, i.e. a first door and a second door, fitted with the door hinge system 10 of the present invention at a 180 degree angle are shown. Each adapter plate 98 includes a pair of clearance holes 100 and a pair of threaded holes 102. The clearance holes 100 of each adapter plate 98 serve to attach the adapter plates 98 to the upper movable hinge bracket 68 and the lower movable hinge bracket 24 of the first door, via screws 104.

(42) The upper and lower fixed hinge brackets 66 and 22 of the second door are connected in a back-to-back relationship to the upper and lower fixed hinge brackets 66 and 22 of the first door via screws 106, which pass through the holes 108 of the upper and lower fixed hinge brackets 66 and 22 of both doors and engage the threaded holes 102 of the adapter plates 98. The second door may then be attached to via its respective upper and lower movable hinge brackets 68 and 24 by positioning the upper and lower movable hinge brackets 68 and 24 into place on the upper and lower fixed hinge brackets 66 and 22 and inserting the upper pivot pin 74 through the upper fixed hinge bracket 66 and into the upper movable hinge bracket 68. In this manner, multiple door panels equipped with the hinge system of the present invention may be interconnected to form a stationary wall.

(43) While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept.