Abstract:
A geared full surface mounted continuous hinge with a hole in a thrust bearing supporting the hinge, said hole adapted to accommodate a flexible tube containing electrical wiring and thereby facilitate the passage of electric current from a frame to appliances in a door connected to the frame using the hinge.

Description:
This application claims the benefit under 34 U.S.C. 119(e) of provisional application No. 61/074,855 filed Jun. 23, 2008 entitled “SURFACE MOUNTED GEAR HINGE WITH ELECTRICAL WIRING”. 
    
    
     BACKGROUND OF THE INVENTION 
     Many buildings are equipped with doors that require transfer of electric power from the door frame to locks, latches, panic devices, alarms, cameras, I.D. readers and the like mounted on or in the door. The prior art provides examples of transfer of electrical power through knuckle hinges (hereinafter referred to as butt hinges) such as those described in U.S. Pat. Nos. 3,838,234; 3,84286; and 4,412,711. U.S. Pat. No. 7,063,042 provides an example of electrical transfer through a continuous gear butt hinge, not a surface mounted hinge. 
     A butt hinge is largely hidden from view when a door employing the hinge is closed. In contrast a surface mounted hinge is almost fully visible. An example of electrical transfer through a surface mounted continuous gear hinge can be found at the Pemko website. The Pemko product passes electricity through a flat cable that passes through a cutout in a portion of the gears. 
     SUMMARY OF THE INVENTION 
     The present invention is a geared surface mounted continuous door hinge with the capacity to provide a conduit for an electric current to pass from the frame in which a door is mounted to appliances in the door through a hole in a thrust bearing. Surface mounted hinges are generally employed as replacements for hinges on heavy doors and/or doors subject to heavy use after butt hinges originally installed with the doors no longer function effectively. Eventually heavy doors and heavy usage combine to cause the screws used to connect the small widely separated leaves of butt hinges to loosen and cause the doors to sag and close unevenly. Since the doors themselves are expensive enough to be worth retaining, it makes sense to replace the hinges rather than the doors. A surface mounted hinge is more durable than a butt hinge, especially when the leaves of a butt hinge are reconnected to the same worn locations in a frame as originally installed. In any case a continuous hinge spreads the load better than a butt hinge. Since doors often contain electrical devices, it is also necessary to find a way to deliver electric current from the building in which a door is mounted to appliances in the door. 
     The present invention differs from the prior art by passing electric wiring enclosed in a flexible tube through channels under the leaves and a hole in a thrust bearing employed in the hinge. The Pemko product passes electric wiring enclosed in a flat, flexible cable through a cutout in the gears employed in the hinge. This arrangement weakens the gears at the point where the cutout occurs. The Pemko design also employs a taller cap than that employed in the present invention to cover the cable and the gears, apparently to provide space for the cable. The taller cap prevents the door on which the Pemko hinge is installed from opening more than 150 degrees. In contrast the tube containing wiring in the present invention passes through a hole in a thrust bearing employed in the hinge. This arrangement permits the use of a cap with a lower profile that in turn allows a door on which the present invention is installed to open a full 180 degrees. The use of a flexible tube to enclose the wiring facilitates the passage of wiring through the hole in the bearing. Less exposure of the wiring also reduces wear and tear as well as the possibility of tampering. The character and advantages of the present invention will become more apparent in the following more detailed description. 
     The present invention consists essentially of a combination for providing a conduit for electrical wiring through a geared full surface continuous hinge adapted for attachment to the outside surfaces of a door and a frame in which the door is mounted. The combination comprises a door leaf and a frame leaf, each leaf having a plate segment and a plurality of geared segments interrupted by thrust bearing segments. The leaves are adapted to pivot around said bearings and meshed geared segments. More specifically the combination comprises (a) at least one thrust bearing having a hole aligned with holes in and channels under the hinge leaf plates, said holes and channels being large enough to allow a flexible tube containing electrical wires to pass sequentially into a first or outer round hole in the frame leaf plate, through the channel under that plate, out a second or inner oval hole in the frame leaf plate, through the hole in the thrust bearing, through a first or inner oval hole in the door leaf plate, through the channel under a door leaf plate and out a second or outer round hole in the door leaf plate, (b) a cap covering and holding the gears and bearings portions of the hinge together and extending for substantially the full length of the hinge and (c) covers extending for substantially the full length of the hinge over the first hole in frame leaf plate and the second hole of the door leaf plate. The covers over the leaf plates also cover the holes through which screws or bolts attach the leaves to the frame and door surfaces. Thus the wiring assembly is both substantially concealed and protected as it passes through the hinge without interfering with a full 180 degree operation of the door on which the hinge is attached. When the holes in the plates and wires are covered, they are also more secure and less subject to tampering, especially important when appliances in a door are designed to make the doors less accessible to unauthorized personnel. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a front view of the surface mounted hinge of the present invention mounted on a door in a frame. An illustrative electrical appliance, namely a keypad for a door lock, is also shown in the door. 
         FIG. 2  is a sectional view taken along lines  27 - 27  of  FIG. 1  showing electrical wiring passing through a thrust bearing and fragments of the door and frame. 
         FIG. 3  is a sectional view taken along lines  28 - 28  of  FIG. 1  through a geared portion of the hinge. 
         FIG. 4  is a front view of a portion of the uninstalled wired hinge without covers over the holes in the leaf plates. 
         FIG. 5  is a view of a portion of the underside of the uninstalled wired hinge. 
         FIG. 6  is a view of the underside of the uninstalled hinge without wiring showing the holes in and channels under the leaves of the hinge. 
         FIG. 7  is a perspective view of the tubing. 
         FIG. 8  is a perspective view of the wires. 
         FIG. 9  is a perspective view of a thrust bearing with a hole suitable for passage of the tube containing electric wires. 
         FIG. 10  is a perspective view of the underside of the gear cap showing cutouts for clearing the wiring when the door is rotated a full 180 degrees. 
         FIG. 11  is a view of the top of a thrust bearing. 
         FIG. 12  is a side view of a thrust bearing showing the hole for wiring. 
         FIG. 13  is a perspective view of a portion of the hinge as it would appear after installation when installed with electrical wiring in place, albeit without the door and the frame. 
     
    
    
     LIST OF REFERENCE NUMERALS 
     
         
           1  Door 
           2  Frame 
           3  Hinge 
           4  Frame leaf 
           5  Door leaf 
           6  Geared frame leaf plate 
           7  Geared door leaf plate 
           8  Gear 
           9  Thrust bearing with hole for wiring 
           10  Hole in thrust bearing 
           11  Round or outer hole in frame leaf plate 
           12  Oval or inner hole in frame leaf plate 
           13  Round or outer hole in door leaf plate 
           14  Oval or inner hole in door leaf plate 
           15  Tube for enclosing wiring 
           16  Wire(s) 
           17  Gear cap 
           18  Non-removable cover over frame leaf plate holes 
           19  Removable cover over door leaf plate holes 
           21  Set screw to hold the gear cap in place 
           22  Set screw to hold the removable door leaf plate cover in place 
           23   a , 23   b  Rails for frame leaf plate cover 
           24   a , 24   b  Rails for door leaf plate cover 
           25  Bolt holes in door leaf plate 
           26  Screw holes in frame leaf plate 
           27 - 27  Cross section showing wires passing through thrust bearing (see  FIG. 2 ) 
           28 - 28  Cross section through geared portion of hinge (see  FIG. 3 ) 
           29  Channel under frame leaf plate 
           30  Channel under door leaf plate 
           31  Plain thrust bearing (without hole) 
           32   a , 32   b  Projections on each end of thrust bearing 
           33   a , 33   b  Channels in thrust bearings for gear cap 
           34   a , 34   b  Clearance slots in gear cap for tube containing wiring 
           35  Key pad for door lock 
       
    
     DETAILED DESCRIPTION 
     The preferred embodiments of the present invention consist of the following components as more clearly shown in  FIGS. 1-13 :
         (1) A full surface mount type geared aluminum or equivalent continuous door hinge  3  of any length.   (2) From one to 15 strands of 22 gauge flexible wire  16  in lengths of from 5 to 36 inches.   (3) From at least 1 to about 3 modified thrust bearings  9 .   (4) PVC or equivalent flexible tubing  15  in a diameter suitable to pass through a hole  10  in the modified thrust bearings  9 .   (5) A gear cap  17  to cover the meshed gears  8  and bearings  9 , 31  and two covers  18 , 19  to cover the machined holes  11 , 13 , 25 , 26  in the plates  6 , 7  of the leaves  4 , 5 .   The essential equipment required to convert an ordinary geared continuous full surface hinge into the above embodiments include:   (1) A machine tool capable of repeatedly machining precision holes, channels and the like.   (2) Tooling capable of machining metals.   (3) Work holding fixtures.       

     The work holding fixtures are employed to hold hinge components in place while the machine tool machines the hinge components necessary for wire installation using materials, equipment and procedures known to those skilled in this art. The hole  10  drilled in the thrust bearings  9 , the holes  11 , 12 , 13 , 14  and channels  29 , 30  in the leaf plates  6 , 7  and the tube  15  are large enough to allow passage of 22 gauge wires  16  in sets of 5 or less from the frame  2  side of a door  1  through the hinge  3  to door mounted electrical appliances (only one, a keypad  35 , shown) as illustrated in  FIG. 2 . The round holes  11 , 13  in the geared leaf plates  6 , 7  are ⅜ inch in diameter. The channels  29 , 30  under the leaf plates  6 , 7  are 5/16 inch wide and 3/32 inch deep. The oval shaped holes  12 , 14  in leaf plates  6 , 7  are 3/16 inch× 5/16 inch. The tubing  15  with a diameter of 1 inch conceals sets of individual wires  16  from view. The method of producing the entire hinge  3  with the electrical wiring  16  substantially conceals and protects the wiring from the outside of a door  1  mounted in a frame  2  on which the hinge  3  is installed. A typical 84 inch tall door weighing from 200 to 600 pounds requires a heavy duty hinge containing 32 thrust bearings  31  interspersed between gears  8 . A typical 84 inch tall door weighing up to 200 pounds requires a standard duty hinge containing 18 thrust bearings  31  interspersed between gears  8 . A ¼ inch diameter hole  10  is drilled in from at least 1 to about 3 thrust bearings  9  for passage of electrical wiring  16 , the number and location of bearings  9  with holes  10  depending on the number and locations of appliances contained in the door  1 . The details of the installed hinge  3  are best shown in  FIGS. 2 and 3 . 
     The specifications disclosed herein for the various components of the present invention and associated doors and the frames are illustrative of an especially preferred commercial version of the present invention but are not critical. 
     To prepare the preferred commercial embodiment of the hinge  3  for delivery to an installer, a thrust bearing  9  with a ¼ inch diameter hole  10  replaces a plain bearing  31  that would otherwise be used in the hinge. The bearings  9 , 31  are preferably composed of hard durable plastic material, such as Valox 310SEO, 0.789 inches long, 0.443 inches high and 0.625 inches wide at its widest dimensions albeit with rounding, projections  32   a , 32   b  and channels  33   a , 33   b  as more clearly shown in  FIGS. 11 and 12 . Similar channels for the gear cap  17  are also provided in the gears  8  as more clearly evident in  FIG. 3 . The projections  32   a , 32   b  near the top at each end of the bearings  9 ,  31  provide a better fit over the ends of adjacent gears  8  when the hinge  3  is assembled. With the covers  18 , 19  uninstalled a 2¼ inch long ¼ inch diameter round flexible PVC tube  15  is passed through the oval holes  12 ,  14  in the plates  6 , 7  and the hole  10  in the bearing  9  by placing the hinge  3  over a fixture that will hold the hinge  3  open at a 120 degree angle and pulling the tube  15  through the hole  10  with needle nose tweezers. As many of 22 gauge wires  16  in sets of 5 or less are routed through the tube  15  in and out of the holes  11 , 12 , 13 , 14  in the leaves  4 , 5  as required to service the appliances in a door  1 . The wires  16  can vary in length but must be long enough to extend far enough out of the round holes  11 , 13  in the leaves  4 , 5  to enable the installer to connect them at one end to wires from a power source coming out of a ⅜ inch hole in the frame  2  and at the other end to wires connected to electrical appliances in the door  1  coming out of a ⅜ inch hole in the door face. After the gear cap  17  is installed by sliding it through the channels  33   a , 33   b  provided in the bearings  9 , 31  and gears  8  and secured with a set screw  21 , the tube  15  is inserted and the wires  16  are installed. The clearance slots  34   a , 34   b  on the underside of the cap are 5/16 inch wide×⅛ inch deep. The covers  18 , 19  over the holes  11 , 13 , 25 , 26  in the leaves  4 , 5  can be attached to conceal the wire connections after the hinge  3  is installed. A detailed view of the individual components of the hinge  3  is best shown in  FIGS. 3-13  while  FIGS. 4-5  provide the best view of the wired hinge before installation. 
     Substantially identical instructions for installing unwired full surface mounted hinges are provided by manufacturers and those instructions are incorporated herein by reference. The wired hinges  3  of the present invention are installed like any other such unwired full surface hinge with the following additional steps:
         1) Mark the location in the frame face 1 inch from the frame  2  edge and drill a ⅜ inch hole for the wires.   2) Mark the location in the door face 1⅛ inch from the edge of the door  1  and drill ⅜ inch hole that matches the hole in the frame.   3) Pull wires  16  through the holes in the frame and door faces.   4) Place hinge  3  on frame  2  face and pull wires through the hole  11  in the frame leaf plate  6  lined up with the bearing  9  with a hole  10  for wiring.   5) Attach the hinge  3  to frame  2  and prepare the door  1  in the same way as any other surface hinge.   6) Pull wires  16  through hole  13  in the door leaf plate  7  lined up with the hole  10  in the bearing  9  and then attach the hinge  3  to the door  1 . (The hinge  3  is attached with whatever screws and bolts the installer deems appropriate for frame and door involved).   7) Attach wires  16  at both ends to wires from the source of electric current and wires from appliances in door, slide excess wiring into door  1  and frame  2 , tape in place in cover channels and install leaf covers  18 , 19  carefully to avoid pinching wires.
 
Holes  26  are provided in the frame leaf  4  for screws to fasten the hinge  3  to the frame  2 . Holes  25  are also provided in the door leaf  5  to bolt the hinge  3  to the door  1 . The frame leaf cover  18  is press fitted over oppositely barbed rails  23   a , 23   b  that, once installed, prevent removal of the cover without actually deforming or destroying it. In contrast, the door leaf cover  19  slides into a channel in one rail  24   b  and pivots over a second rail  24   a  in a removable configuration. A setscrew  22  helps to secure the door leaf cover  19 .
       

     In contrast to the Pemko wired hinge, the wiring in the present invention is connected after installation of the hinge itself. The wiring in the Pemko hinge must be connected before installing the hinge. This is accomplished in part by using a bulky connection that increases the chances of pinching the wires when the wiring is covered. 
     Independent testing has proven that sagging doors refitted with the full surface continuous hinges of the present invention can endure 25 million cycles of door opening and closing equivalent to about 50 years of high traffic use. The wiring in the product of the present invention is warranted for a full 5-years. 
     The present invention has been described in its preferred embodiments that are not intended to be limiting. Various alterations and modifications will become readily apparent to those skilled in the art after reading the present disclosure. The scope of the present invention should therefore be limited only by the scope of the appended claims.