Abstract:
Disclosed is a silent, soft-close compact hinge comprising of a hinge cup pivotally connected to a hinge body via a hinge arm. A set of coil springs biases the hinge to a closed position. A damping mechanism is removably attached to the hinge cup and acted on by the hinge arm. A set of spring sleeves are fitted to the coil springs to insulate the movement of the coil springs on the hinge arm providing the closing bias. The hinge body is comprised of three separate plates adjustably connected to each other with cam screws. The position of the hinge body with respect to the hinge arm is adjustable in three directions without the need for removal or loosening of mounting hardware used to attach the hinge body to a furniture piece.

Description:
FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure relates to compact hinges for furniture products. In particular, the present disclosure relates to a compact hinge, adjustable in three directions, providing silent, soft-close functionality. 
       BACKGROUND OF THE DISCLOSURE 
       [0002]    In the field of cabinetry and mill work, a recurring problem is the uncontrolled speed at which a cabinet door closes. The typical hinged connection includes a hinge cup mounted to a furniture piece and pivotally connected to a hinge arm mounted to another furniture piece. A metal coil spring biases the metal hinge cup toward the metal hinge arm. One result of the coil springs can be uncontrolled and undesired rapid closure of cabinetry doors which results in noise and impact wear of cabinet hinges and cabinet faces. Furthermore, the sliding movement of the coil spring on the metal hinge arm during operation results in unwanted noise and a “grinding” perception by a user which is undesirable. 
         [0003]    Prior art compact hinges have attempted solutions to these problems, but have done so unsatisfactorily. The prior art suffers from various disadvantages including limited adjustability, size, complexity, durability, and high manufacturing cost. 
         [0004]    For example, U.S. Patent Application Publication No. 2015/0315832 to Wu discloses a soft-closing hinge for use in furniture comprising a movable hinge cup coupled to a door panel and a securing member coupled to a wall panel. A hinge arm pivotally attaches the movable hinge cup to the securing member while a spring exerts an opening or closing force to the movable hinge cup. A damper disposed on the movable hinge cup, acts on the hinge arm to soft close the hinge. A cross section of at least one end of the spring is of a non-circular shape and provided with a plastic sliding member. The sliding member acts on the hinge arm when the hinge is opened and/or closed to generate an opening force or a closing force. The securing member is not adjustable in more than two directions without removing mounting hardware. 
         [0005]    U.S. Patent Application Publication No. 2015/0240543 to NG discloses a hinge comprising a movable cup seat mounted to a furniture door body and a regulating base affixed to the main body of furniture. A rotary arm having an arc-shaped surface pivotally attaches the movable cup seat to the regulating base. The rotary arm is connected to the regulating base via a regulating screw and an eccentric regulating rivet. A torsion spring generates a start-stop acting force on the movable cup seat. A sleeve part is fitted to a first supporting leg of the torsion spring and slidably engages the arc-shaped surface. The regulating base is not adjustable in three directions without removing mounting hardware. 
         [0006]    U.S. Pat. No. 9,163,447 to Liang, et al. discloses a hinge comprising a hinge cup, a hinge arm, a spring, and an adjustable damping device. The hinge cup is pivotally connected to the hinge arm and is mounted to the door of a cabinet. The hinge arm is mounted to the fixed portion of the cabinet. The spring and the damping device are mounted in the hinge cup. When the hinge cup is closed with respect to the hinge arm, the hinge cup is subjected to a dampened closing force via the damping device. A cover insulates the spring from the hinge arm. The hinge arm is not adjustable in more than two directions without removing mounting hardware. 
         [0007]    Therefore, a need exists for a silent, soft-close hinge capable of providing positional adjustments in three dimensions even after mounting to cabinetry. 
       SUMMARY OF THE DISCLOSURE 
       [0008]    A preferred embodiment is comprised of a hinge cup mounted in a cabinet door, a hinge body mounted to a cabinet carcass, and a hinge arm biased by a pair of coil springs. The hinge arm connects the hinge cup to the hinge body and provides a swinging connection between the cabinet door and the cabinet carcass. A damping mechanism is comprised of a housing removably fitted within the hinge cup and a piston within a fluid filled cylinder. The cylinder is slidably engaged with the housing and is acted upon by an abutment section of the hinge arm. One end of each coil spring is disposed in the hinge cup while the other end of each coil spring is fitted with a spring sleeve. The spring sleeves engage cam surfaces on the hinge arm. The hinge body is comprised of an “L” shaped overlay plate adjustably engaged with an adjustment plate adjustably engaged with a mounting plate. Three separate cam screws provide positional adjustability of the hinge body with respect to the hinge arm in three different directions. The overlay plate and the adjustment plate each include access holes aligned with a mounting hole in the mounting plate. Mounting hardware, such as a wood screw, attaches the mounting plate to the cabinet carcass. 
         [0009]    In use, the apparatus controls the closing speed of the cabinet door. As the door closes, the abutment section of the hinge arm contacts the cylinder and forces it through the housing against the bias of the piston moving through the fluid within the cylinder. Rotation of each of the cam screws separately adjusts the position of the cabinet door in a depth direction, a vertical direction, and a horizontal or “overlay” direction without removing the mounting hardware used to mount the hinge body to the cabinet carcass. As the cabinet door is opened or closed, the spring sleeves insulate the contact area of the coil springs on the cams of the hinge arm to eliminate the noise and “grinding” generated by the movement of the springs on the hinge arm. 
         [0010]    Those skilled in the art will appreciate the above-mentioned features and advantages of the disclosure together with other important aspects upon reading the detailed description that follows in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1A  an isometric view of a preferred embodiment. 
           [0012]      FIG. 1B  is an isometric view of a preferred embodiment. 
           [0013]      FIG. 1C  is an exploded isometric view of a preferred embodiment. 
           [0014]      FIG. 2  is an isometric view of an overlay plate of a preferred embodiment. 
           [0015]      FIG. 3  is an isometric view of an adjustment plate of a preferred embodiment. 
           [0016]      FIG. 4  is an isometric view of a mounting plate of a preferred embodiment. 
           [0017]      FIG. 5A  is a sectional view of a hinge body of a preferred embodiment taken along line A-A of  FIG. 1A . 
           [0018]      FIG. 5B  is a sectional view of a hinge body of a preferred embodiment taken along line B-B of  FIG. 1A . 
           [0019]      FIG. 6  is an isometric view of a hinge arm of a preferred embodiment. 
           [0020]      FIG. 7A  is an exploded isometric view of a damping mechanism of a preferred embodiment. 
           [0021]      FIG. 7B  is a partial isometric view of an installed damping mechanism of a preferred embodiment. 
           [0022]      FIG. 8A  is an exploded isometric view of a spring and spring sleeve of a preferred embodiment. 
           [0023]      FIG. 8B  is an exploded isometric view of a spring and spring sleeve of a preferred embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    In the description that follows, like parts are marked throughout the specification and figures with the same numerals, respectively. The figures are not necessarily drawn to scale and may be shown in exaggerated or generalized form in the interest of clarity and conciseness. 
         [0025]    Referring to  FIGS. 1A-1C , hinge  100  provides a pivotal connection between cabinet door  116  and cabinet frame  118 . Hinge  100  includes hinge cup  102  pivotally connected to hinge arm  104  by hinge pin  106 . Hinge body  108  is adjustably connected to hinge arm  104  by overlay adjustment cam screw  110 . Although a pair of springs are shown, at least one spring  112  is disposed in the hinge cup and creates a closing force on the hinge arm. One end of each spring  112  is connected to the exterior hinge cup  102  at hole  120 . Hole  120  is present in both side walls of hinge cup  102 . The opposite end of each spring extends through spring hole  113 , encased by spring sleeve  122 , into the interior of hinge cup  102  and biases hinge arm  108 . Spring hole  113  is present in both side walls of hinge cup  102 . Removably seated in hinge cup  102  is damping mechanism  114 . Damping mechanism  114  snaps into hinge cup  102  beneath tab  134 . Tab  134  extends into the interior of hinge cup  102 . Tab  134  is present on both side walls of hinge cup  102  proximate hole  120 . Damping mechanism  114  acts on the hinge arm during a closing movement to control the closing speed of the cabinet door. 
         [0026]    Typically, hinge cup  102  is affixed to cabinet door  116  with screws through holes  103  and hinge body  108  is affixed to cabinet frame  118  through slot  109 . It should be noted that the installation orientation with the hinge cup fitted into a bore opening on a door and the hinge arm fitted on to the frame, could be reversed even though this is not the usual practice. In a preferred embodiment, hinge cup  102 , hinge arm  104 , and hinge body  108  are typically constructed of metal such as cast aluminum or steel alloy plate stock and formed by stamping. 
         [0027]    Hinge body  108  comprises overlay plate  124 , adjustment plate  126 , and mounting plate  128 . Overlay plate  124  is adjustably connected to adjustment plate  126  by depth adjustment cam screw  130 . Adjustment plate  126  is adjustably connected to mounting plate  128  by vertical adjustment cam screw  132 . Each adjustment cam screw  110 ,  130 , and  132  comprises a typical cam screw shape having a wider, cylindrical camming portion and a narrow, cylindrical offset portion extending therefrom. The separate plates of the hinge body cooperate with the adjustment can screws to provide positional adjustment of the hinge body relative to the hinge arm in an overlay or horizontal direction  140 , a vertical direction  142 , and a depth direction  144 . 
         [0028]    Referring to  FIG. 2 , overlay plate  124  is generally “L” shaped comprising section  212  generally perpendicularly oriented with section  214 . Section  212  is generally planar having end  219  extending between opposing edges  216  and  217 . Section  212  includes three horizontal planes with sloping sections between. Plane  224  leads to plane  226  along edges  216  and  217  via slope  230 . Plane  226  leads to plane  228  along end  219  via slope  232 . Access opening  218  is irregularly shaped and is present in each of planes  224 ,  226 , and  228 . Plane  228  includes depth adjustment slot  234 . Depth adjustment slot  234  is sized to receive the camming portion of depth adjustment cam screw  130 . Section  214  is generally planar having flanges  220  and  221  extending therefrom. Flanges  220  and  221  are generally aligned with each other and disposed between them is overlay adjustment hole  222 . Overlay adjustment hole  222  is sized to receive the offset portion of overlay adjustment cam screw  110 . 
         [0029]    Referring to  FIG. 3 , adjustment plate  126  is generally planar having opposing ends  302  and  304  extending between opposing edges  306  and  308 . Edge  306  includes surface  310 . Tab  312  extends from edge  306  proximate end  304 . Tab  312  has surface  314 . Edge  308  includes surface  316 . Tab  318  extends from edge  308  proximate end  304 . Tab  318  has surface  320 . Raised seat  322  extends from adjustment plate  126  proximate end  302 . Raised seat  322  includes depth adjustment hole  328  generally aligned with depth adjustment slot  234 . Depth adjustment hole  328  is sized to receive the offset portion of depth adjustment cam screw  130 . Adjustment plate  126  defines access slot  324 . Access slot  324  is aligned with a portion of access opening  218 . Adjustment plate  126  further defines vertical adjustment slot  326 . Vertical adjustment slot  326  is sized to receive the offset portion of vertical adjustment cam screw  132 . 
         [0030]    Referring to  FIG. 4 , mounting plate  128  is generally planar having opposing ends  402  and  404  extending between opposing edges  406  and  408 . End  402  includes flange  410 . End  404  includes flange  412 . Guide  414  extends from mounting plate  128  proximate the corner of edge  406  and end  402 . Guide  415  extends from mounting plate  128  proximate the corner of edge  408  and end  402 . Guides  414  and  415  are generally equidistant from end  404 . Guide  416  extends from mounting plate  128  proximate the corner of edge  406  and end  404 . Guide  417  extends from mounting plate  128  proximate the corner of edge  408  and end  404 . Guides  416  and  417  are generally equidistant from end  402 . Mounting plate  128  defines access hole  420 . Access hole  420  is generally aligned with depth adjustment hole  328  to allow access to vertical adjustment screw  130  through mounting plate  128 . Mounting plate  128  further defines vertical adjustment hole  422 . Vertical adjustment hole is sized to receive the camming portion of vertical adjustment cam screw  132 . Mounting plate  128  also defines slot  109 . Slot  109  is generally aligned with access slot  324  and access hole  218  to allow access to mounting hardware (for attaching the mounting plate to the cabinet frame) through overlay plate  124  and adjustment plate  126 . 
         [0031]    Referring to  FIGS. 5A and 5B , cross-sections of an assembled hinge body  108  are shown. Adjustment plate  126  is adjacent mounting plate  128 . Ends  302  and  304  of adjustment plate  126  abut flanges  410  and  412  of mounting plate  128 , respectively. Adjustment plate  126  is slidable with respect to mounting plate  128  in vertical direction  142 . 
         [0032]    Plane  228  of overlay plate  124  is adjacent raised seat  322  of adjustment plate  126 . Edges  306  and  308  of adjustment plate  126  abut edges  216  and  217  of overlay plate  124 , respectively. Surfaces  310  and  316  are adjacent plane  226  while surfaces  314  and  320  are adjacent plane  224 . Overlay plate  124  is slidable with respect to adjustment plate  126  in depth direction  144 . 
         [0033]    Referring to  FIG. 6 , hinge arm  104  includes a pair of curved cam portions  602  and cylindrical sleeve  604  connected between the cam portions. Sleeve  604  is sized to receive hinge pin  106 . Hinge pin  106  passes through shaft holes in hinge cup  102  and sleeve  604  to provide a pivotal connection between hinge arm  104  and hinge cup  102 . Hinge arm  104  includes abutment section  606  extending from sleeve  604 . Attachment section  608  is connected to abutment section  606 . Attachment section  608  defines overlay adjustment slot  610 . Overlay adjustment slot  610  is aligned with overlay adjustment hole  222  and is sized to receive the camming portion of overlay adjustment cam screw  110 . Attachment section  608  includes flanges  612  and  613 . Flanges  612  and  613  are sized to slidably engage flanges  220  and  221  of overlay plate  124 . Overlay plate  124  is slidable with respect to hinge arm  104  in overlay direction  140 . 
         [0034]    Referring to  FIG. 7A , damping mechanism  114  comprising cylinder  702  slidable within housing  704 . Cylinder  702  is a fluid filled chamber from which piston rod  708  extends. A piston head attached to piston rod  708  moves through the fluid in cylinder  702  to provide the damping function. Cylinder  702  includes opposing flat sides  718  and  720 . Side  718  has tab  710  and side  720  has tab  711 . In between sides  718  and  720  and disposed opposite of piston rod  708  is face  722 . Housing  704  is generally “T” shaped following the general shape of the interior of hinge cup  102 . Housing  704  comprises arms  707  and  709  extending from base  706 . Arms  707  and  709  form opening  712  sized to receive cylinder  702 . Arms  707  and  709  include lengthwise slots  714  and  716 . Slots  714  and  716  are sized to receive sides  718  and  720 , respectively. Opposite opening  712 , arms  707  and  709  begin with shoulder  724 . Tabs  710  and  711  abut shoulder  724  to prevent the entirety of cylinder  702  from exiting housing  704  through opening  712 . As assembled, face  722  extends through opening  712  and piston rod  708  extends through base  706  to abut hinge cup  102 . In a preferred embodiment, housing  704  and cylinder  702  are typically constructed of injection molded plastic or polyvinyl chloride (PVC). 
         [0035]    As shown in  FIG. 7B , damping mechanism  114  is removably fitted to the interior of hinge cup  102 . The side portions of base  706  snap in place under two opposing tabs  134  extending from side walls  732  and  733  of hinge cup  102  into the interior of hinge cup  102 . Tabs  134  are stamped into the side walls of hinge cup  102  during manufacturing. When damping mechanism  114  is in position in hinge cup  102 , piston  708  abuts back wall  734  of hinge cup  102 . Face  722  is positioned proximate hinge arm  104 . 
         [0036]    Referring to  FIGS. 8A and 8B , springs  112  and spring sleeves  122  are shown. In the preferred embodiment, two springs and two spring sleeves are used on opposing sides of the hinge cup. Therefore, the springs and spring sleeves depicted in  FIGS. 8A and 8B  are mirror images of each other correlating to opposite sides of the hinge cup. For brevity, since the functions of each spring and spring sleeve combination will be the same, only one set will be discussed. However, in another preferred embodiment one spring and one spring sleeve could also be employed. Spring  112  comprises curved leg  802  connected to coiled section  804  connected to straight leg  806 . Coiled section  804  forms cylindrical cavity  808 . Cavity  808  has an exterior opening  810  and an interior opening  812 . The cross-section of spring  112  is generally angular so as to prevent rotation of spring sleeve  122  relative to spring  112 . In one preferred embodiment, the cross section is rectangular. The cross-section of spring  112  is consistent throughout curved leg  802 , coiled section  804 , and straight leg  806 . Curved leg  802  engages hole  120  in the side wall of the hinge cup. Straight leg  806  passes through spring hole  113  and abuts cam portion  602 . 
         [0037]    Spring sleeve  122  comprises attachment portion  820  connected to stabilizing portion  822  connected to insulating portion  824 . Attachment portion  820  includes head  826 . Head  826  is sized to engage cavity  808  of spring  112 . Stabilizing portion  822  is generally arc shaped and sized to follow the exterior curvature of coiled section  804  of spring  112  to distribute the load across the coiled section of the spring. Insulating section  824  includes chamber  828 . Chamber  828  is sized to receive straight leg  806  of spring  112 . The cross-section of chamber  828  is generally square or rectangular and matches the cross-section of straight leg  806 . The cross-section of insulating section  824  is generally square or rectangular. One end of insulating section  824  includes curved tip  830 . In a preferred embodiment, spring sleeve  122  is typically constructed of injection molded plastic or rubber. 
         [0038]    Spring sleeve  122  is attached to spring  112 . Straight leg  806  fits within chamber  828 . Head  826  fits in interior opening  812  of cavity  808  while stabilizing portion  822  abuts coiled section  804 . Curved tip  830  follows the curvature of cam portions  602  creating additional spring bias in order to provide a stable open position. 
         [0039]    In use, hinge  100  provides a pivotal connection between cabinet door  116  and cabinet frame  118 . Hinge cup  102  is mounted in a bore in the cabinet door through holes  103  and hinge body  108  is mounted to the cabinet frame through slot  109  with typical mounting hardware such as wood screws. Hand tools gain access to slot  109  via access opening  218  and access slot  324 . Guides  414 ,  415 ,  416 , and  417  abut the cabinet frame. 
         [0040]    Hinge  100  provides adjustment in three directions after mounting without removing or loosening the mounting hardware. One direction of adjustment is the depth movement of the cabinet door. This adjustment is required when the inside face of the door does not lay flush with the cabinet frame thus impeding the opening and closing action. To effect the depth adjustment, depth adjustment cam screw  130  is rotated. As depth adjustment cam screw  130  is rotated, the camming portion of depth adjustment cam screw  130  abuts, rotates within, and slides along depth adjustment slot  234  while the offset portion of depth adjustment cam screw  130  rotates within depth adjustment hole  328 . During manufacture, the offset portion of depth adjustment cam screw  130  was mushroomed via access hole  420  to prevent depth adjustment cam screw  130  from backing out of depth adjustment hole  328 . Rotation of depth adjustment cam screw  130  causes hinge arm  104  and overlay plate  124  to move together in direction  144  relative to adjustment plate  126  and mounting plate  128  and the cabinet frame. Once the desired position is achieved, rotation of depth adjustment cam screw  130  is ceased. 
         [0041]    Another direction of adjustment is the horizontal or “overlay” adjustment of the cabinet door. This adjustment is required when the vertical edges of the cabinet door do not align with the vertical edges of the cabinet frame or the vertical edges of an adjacent cabinet door or drawer. To effect the overlay adjustment, overlay adjustment cam screw  110  is rotated. As overlay adjustment cam screw  110  is rotated, the camming portion of overlay adjustment cam screw  110  abuts, rotates within, and slides along overlay adjustment slot  610  while the offset portion of overlay adjustment cam screw  110  rotates within overlay adjustment hole  222 . During manufacture, the offset portion of overlay adjustment cam screw  110  was mushroomed to prevent removal of overlay adjustment cam screw  110  from overlay adjustment hole  222 . Rotation of overlay adjustment cam screw  110  causes hinge arm  104  to move in direction  140  relative to hinge body  108  and the cabinet frame. Once the desired position is achieved, rotation of overlay adjustment cam screw  110  is ceased. 
         [0042]    Another direction of adjustment is the vertical adjustment of the cabinet door. This adjustment is required when the horizontal edges of the cabinet door do not align with the horizontal edges of the cabinet frame or the horizontal edges of an adjacent cabinet door or drawer. To effect the vertical adjustment, vertical adjustment cam screw  132  is rotated. As vertical adjustment cam screw  132  is rotated, the camming portion of vertical adjustment cam screw  132  abuts, rotates within, and slides along vertical adjustment slot  326  while the offset portion of vertical adjustment cam screw  132  rotates within vertical adjustment hole  422 . During manufacture, the offset portion of vertical adjustment cam screw  132  was mushroomed to prevent removal of vertical adjustment cam screw  132  from vertical adjustment hole  422 . Rotation of vertical adjustment cam screw  132  causes hinge arm  104 , overlay plate  124 , and adjustment plate  126  to move together in direction  142  relative to mounting plate  128  and the cabinet frame. Once the desired position is achieved, rotation of vertical adjustment cam screw  132  is ceased. 
         [0043]    During a closing motion, springs  112  provide a closing force. Damping mechanism  114  opposes the closing force and controls the closing speed of the cabinet door so that the cabinet door does not slam. Damping mechanism  114  is removably snapped into hinge cup  102  as base  706  fits under tabs  134 . As the cabinet door closes, abutment section  606  abuts face  722  and forces cylinder  702  through housing  704  while housing  704  remains stationary relative to hinge cup  102 . Since piston rod  708  abuts back wall  734 , as cylinder  702  moves through housing  704 , the piston head attached to piston rod  708  moves through the fluid in cylinder  702  to provide the soft-close functionality. 
         [0044]    The closing force provided by springs  112  is a result of straight leg  806  biasing hinge arm  104  via cam portion  602 . In a typical setup, during a closing movement, straight leg  806  rides on cam portion  602 . Hinge  100  includes spring sleeve  122 . Straight leg  806  is encased by insulating portion  824  of spring sleeve  122 . With spring sleeve  122  installed on spring  112 , insulating portion  824  rides on cam portion  602  instead thus reducing wear on and extending the usable life of spring  112  and hinge arm  104 . Spring sleeve  122  also eliminates any noise created by the movement of spring  112  along cam portion  602 . 
         [0045]    It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the appended claims.