Abstract:
A door assembly comprises a stationary frame, a movable frame, and an adjusting assembly. The adjusting assembly comprises an adjusting element detachably connected with the stationary frame and having a rod portion; a fixing element connected with the movable frame and having a cavity for receiving the rod portion; and a cam member disposed adjacent to the cavity and movable between an open position in which the movable frame is movable relative to the stationary frame and a closed position in which the movable frame is fixed relative to the stationary frame. The door assembly can be assembled without drilling, minimizing risk of damage to the frames, and can be assembled by a single person.

Description:
CROSS-REFERENCE TO RELATED DOCUMENT 
     This application claims priority benefit from Chinese utility model application No. 201320256871.0 filed on 13 May 2013 in the name of Foshan Ideal Co., Ltd., the disclosure of which is incorporated herein by reference in its integrity. 
     FIELD OF THE INVENTION 
     The present invention relates to a door assembly, and in particular, to an adjusting assembly used therein for the adjusting of a stationary frame and a movable frame of the door assembly. 
     BACKGROUND OF THE INVENTION 
     Doors, such as shower doors or balcony doors, are often mounted against wall surfaces and the doors thus mounted are kept as vertical as possible. However, the wall surfaces of buildings are often not exactly vertical, for example, titled toward outside/inside by an angle. Therefore, if the doors are mounted completely along the wall surface, the doors may not be smoothly opened or closed. In this regard, it is necessary to adjust the distances between the top/bottom end of a door and a wall surface so as to keep the door in a vertical position. 
     To achieve this adjustment, a door assembly usually comprises a stationary frame to be attached to a wall surface, and a movable frame connected with a door panel, such as a glass door panel. The stationary frame is firstly attached to the wall surface and then the movable frame is moved toward the stationary frame, during which the distances between the top and bottom ends of the movable frame, and the stationary frame are such adjusted that the movable frame is in a vertical position, and in turn, the door panel is also in a vertical position. The stationary and movable frames are finally connected to each other by drilling thereon and by using fasteners. 
     However, in one aspect, the drilling operation requires at least two people to cooperate and is very time-consuming. In another aspect, the drilling may inadvertently cause damages to the surfaces of the frames (generally made of aluminum materials), which is undesirable to consumers. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a door assembly which can be mounted without drilling. Another object of the invention is to provide a door assembly that can be mounted by a single person. 
     To achieve the objectives, a door assembly is provided which comprises a stationary frame and a movable frame. The door assembly further comprises an adjusting assembly comprising an adjusting element detachably connected with the stationary frame and having a rod portion; a fixing element detachably connected with the movable frame and having a first cavity at its top for receiving the rod portion and a second cavity at one side; and a cam member receivable in the second cavity, the cam member being rotatably connected to the fixing element and movable between an open position and a closed position. 
     When the cam member is in the open position, it does not interfere the movement of the rod portion such that the latter is freely extendable and retractable within the first cavity. The distance between the stationary and movable frames is thus variable. When the cam member is in the closed position, it applies a force to one sidewall of the rod portion such that the other sidewall of the rod portion will apply a force to the fixing element. Finally, the cam member, rod portion and fixing element are secured together, so that the stationary and movable frames are also secured. 
     Preferably, the fixing element further comprises a cushion received within the first cavity for contacting with the rod portion to increase the friction force there between. Preferably, the cushion is made of rubber or plastic materials. 
     Preferably, the cushion has at least one wing, and the fixing element has correspondingly at least one recess for accommodating the at least wing such that the cushion will not displace in axial direction. 
     Preferably, the cushion has a transversal fixing portion for coupling with the fixing element in transverse direction. 
     Preferably, the rod portion has at least one sidewalls provided with engaging elements, for engaging with the cam member and/or fixing element and/or the cushion. The engaging elements are preferably teeth. 
     Preferably, the cam member comprises a handle and a cam portion formed at one end of the handle and substantively perpendicular to the handle. The cam portion has a bulge at its free end, for contacting with and pressing against the rod portion. The surface of the bulge that is in contact with the rod portion preferably has engaging elements, such as teeth. 
     The adjusting element preferably has a fixing portion substantively perpendicular to the rod portion, for detachable connection with the stationary frame. The fixing portion preferably has guiding ribs and the stationary frame has a groove, such that the guiding ribs can be inserted into to the groove so as to connect with the stationary frame. 
     The fixing element preferably has slots on its sides, for receiving both sidewalls of the stationary frame. 
     The fixing element preferably has a first through hole, and the movable frame has a receiving tube. In this case, the fixing element is secured to the movable frame by a fastener passing through the first through hole and penetrating into the receiving tube. 
     The fixing element preferably has a second through hole for engaging with a door panel, in particular, a pivot door panel. 
     The door assembly preferably has a decorative element for housing at least a part of the adjusting assembly for purpose of aesthetics. 
     The door assembly of the present invention is preferably shower door, balcony door or other sliding doors, more preferably shower door. 
     The door assembly provided in the present invention can be assembled without drilling operation, minimizing risk of damage to the frames, and can be assembled by a single person. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  shows primary elements and position relationship of an exemplary door assembly according to one embodiment of the invention. 
         FIG. 2  shows the primary elements of an adjusting assembly shown in  FIG. 1 . 
         FIG. 3  shows the detailed structure of an adjusting element shown in  FIG. 1 . 
         FIGS. 4 and 5  show a fixing element and a cam member shown in  FIG. 1  in detail. 
         FIG. 6  shows another embodiment of the fixing element. 
         FIG. 7  shows the fixing element as shown in  FIG. 6  in an assembly state. 
         FIG. 8  shows the top portions of the stationary and movable frames. 
         FIG. 9  shows a decorative element in an illustrative view. 
         FIG. 10  shows a decorative element in another illustrative view. 
         FIG. 11  shows a partial view of door assembly when the cam member is in an open position. 
         FIG. 12  shows a partial view of door assembly when the cam member is in a closed position. 
     
    
    
     Elements that are irrelevant to the spirit of the invention are omitted from the drawings for purpose of clarity. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in more detail in reference to the drawings. It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the,” are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms “and/or” include any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” “comprising” “includes” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
       FIG. 1  shows an exemplary door assembly which is a pivot door assembly used generally in a bathroom. The pivot door assembly comprises a stationary frame  10 , a movable frame  20 , a pivot door panel  30  and an adjusting assembly designated as number  40  in general. The stationary frame  10  is attached to a wall surface by for example providing a through hole on the frame and using a fastener to passing through the hole and penetrating into the wall surface, or by adhesives. It can be contemplated that the stationary frame  10  can be attached to a wall surface through other methods known in the art. 
     In the present example, the movable frame  20  is coupled with the pivot door panel  30  through the adjusting assembly  40 . The adjustments of the distance between the top end of the movable frame  20  and the stationary frame  10  and the distance between the bottom end of the movable frame  20  and the stationary frame  10  will enable the movable frame  20  to be in a vertical position. For example, when the wall surface is in a vertical position, the movable frame  20  will also be in a vertical position when the top and bottom ends of the movable frame  20  equally spaced from the stationary frame  10 . For example, when the wall surface is titled outside by an angle, the movable frame  20  will be in a vertical position when the distance between the top end of the frame  20  and the frame  10  is appropriately larger than that between the bottom end of the frame  20  and the frame  10 . Yet for example, when the wall surface is titled inside by an angle, the movable frame  20  will be in a vertical position when the distance between the top end of the frame  20  and the frame  10  is appropriately smaller than that between the bottom end of the frame  20  and the frame  10 . When the movable frame  20  is in vertical position, the pivot door panel  30  which is connected to the frame  20  is also in a vertical position, such that the door panel  30  can be opened or closed freely. 
       FIG. 2  shows the adjusting assembly  40  in detail, which comprise an adjusting element  42 , a fixing element  44  and a cam member  46 . As shown in  FIGS. 1 and 2 , the adjusting element  42  is connected with the stationary frame  10 , the fixing element  44  is connected with the movable frame  20 , and the cam member  46  is connected with the fixing element  44 .  FIG. 3  shows in detail the adjusting element  42 . The adjusting element  42  comprises a fixing portion  421  and a rod portion  422  substantively perpendicular to the fixing portion  421 . The fixing portion  421  is used for detachably connected with the stationary frame  10 . In the present example, the fixing portion  421  has guiding ribs  427 , and the frame  10  correspondingly has a groove  16  (see  FIG. 8 ). The guiding ribs  427  can insert into the groove  16  such that the adjusting element  42  is connected to the frame  10 . 
     The rod portion  422  has two sidewalls  423 ,  424 , which are distributed with teeth  425 . It can be contemplated that the teeth  425  can also be absent. The sidewalls  423 ,  424  can also be smooth surfaces. Alternatively, the teeth  425  can exist on only one of the sidewalls. The teeth  425  are provided to make the engagement between the rod portion and other parts stronger and reliable. In this example, a notch  426  is formed at free end of the rod portion  422 , for cooperation with the pivot door panel  30 , which will be described in detail later on. It will be appreciated that when the pivot door panel is connected to the movable frame in a different form, or when different door panels are used, the notch  426  may not be necessary. 
       FIGS. 4 and 5  show the detailed structures of the fixing element  44  and the cam member  46 . The fixing element  44  comprises two sides  441 ,  442 , a first cavity  443  located at its top, and a second cavity  444  formed on one side  442 . The first cavity  443  is used for receiving the rod portion  422 . When the rod portion  422  is not interfered, it can freely extend into and exit from the first cavity  443 , such that the relative position between the stationary frame  10  and the movable frame  20  can be freely changed. The second cavity  444  is used for receiving the cam member  46  and has a same shape as the contour of the cam member  46 . The cam member  46  can be connected to and rotate around the fixing element  44 , and can be movable between an open position, in which the cam member  46  does not interfere with the rod portion  422 , and a closed position, in which the cam member  46  applies a force to the sidewall  423  of the rod portion  422  such that the other sidewall  424  of the rod portion  422  applies a force to the side  441  of the fixing element  44 . The rod portion  422 , fixing element  44  and the cam member  46  are thus secured together. The stationary frame  10  and the movable frame  20  thus can not displace with respect to each other. 
     The cam member  46  has a handle  461  and a cam portion  462  formed at one end of the handle  461  and substantively perpendicular thereto. The cam portion  462  has a through hole  464  which cooperates with two pin holes  447  provided on the side  442  of the fixing element  44  to enable the cam member  46  to rotate with a pin (not shown). The cam portion  462  has a bulge  463  for contacting with and pressing against the rod portion  422  in the closed position. In this example, the surface of the bulge  463  that is in contact of the rod portion  422  is a smooth surface. It can be contemplated that the surface can also be provided with engaging elements such as teeth, to facilitate the engagement between the bulge  463  and the sidewall  423  of the rod portion  422 . The sidewall  423  and said surface can both have teeth, such that the engagement of the teeth makes the coupling between the cam member  46  and the adjusting element  42  more stable and reliable. 
       FIG. 6  shows another form of the fixing element of the invention. In this example, the fixing element  44  further comprises a cushion  450  which is receivable in the first cavity  443 . The cushion  450  has at least one wing  451 , and the side  441  of the fixing element  44  has at least one recess  453 . The wing  451  can be embedded into the recess  453  such that the cushion will not displace in the longitudinal direction X (see  FIG. 7 ). 
     The cushion  450  is made of rubber or plastic materials in this example. It is to be contacted with the side  424  of the rod portion  422  to increase the friction force there between, in order to ensure that the adjusting element  42  is not displaced in the longitudinal direction X. Preferably, the side  424  is also provided with engaging elements such as teeth, such that the teeth will pierce into the cushion  450  to secure the rod portion with the cushion  450 . The cushion  450  can be coupled with the fixing element  44  in suitable manners. In the present example, the cushion  450  has a transversal fixing portion  452 , generally in sheet form, so as to fit the bottom of the first cavity  443  and be able not to block the movement of the rod portion  422 . The transversal fixing portion  452  further has a through hole  454  for achieving the connection between the fixing element  44  and the movable frame  20 . It can be contemplated that the cushion  450  can be connected with the fixing element  44  in a different manner such that the transversal fixing portion  452  may be omitted or replaced. 
     The fixing element  44  can be detachably attached to the movable frame  20  in suitable manners. In one example, as shown in  FIG. 7 , the fixing element  44  has a through hole  448 . Correspondingly, as shown in  FIG. 8 , the movable frame  20  has a receiving tube  22 . The through hole  454  of the transversal fixing portion  452 , the through hole  448  of the fixing element  44  and the receiving tube  22  are aligned such that a fastener can pass through the holes  454 ,  448  and inserting into the receiving tube  22 , such that the cushion  450  and the fixing element  44  are disposed at the top end of the movable frame  20 . It can be contemplated that the cushion, fixing element and the movable frame can be detachably connected with each other by other methods known in the art. The fixing element  44  also can be provided with a through hole  449  for passing through of the shaft  32  of the pivot door panel  30 , so as to secure the panel  30 , movable frame  20  and the fixing element  44  together. 
     In the present invention, the door assembly comprises two adjusting assemblies  40 , located at top and bottom ends of the stationary/movable frame respectively. The description above is set forth with reference to the arrangement of the adjusting assembly on the top ends of the frames. It can be contemplated that the arrangement of the adjusting assembly at the bottom ends can be carried out in a same or similar way. 
     As shown in  FIGS. 9 and 10 , the adjusting assembly can also comprise a decorative element  48  for covering at least a part of the adjusting assembly  40  so that the fixing element and adjusting element are not visible from outside, for the purpose of aesthetics. 
     During assembly, the stationary frame  10  is attached to a wall surface, and the adjusting element  42  is then attached to the stationary frame  10 . The movable frame  20 , cam member  46 , fixing element  44 , door panel  30 , and, optionally, the cushion  450  are connected together, and keep the cam member  46  in open position. The movable frame  20  is then moved toward the stationary frame  10 . As the cam member  46  is in open position, it will not interfere the movement of the rod portion  422 . The rod portion  422  can inserted into the first cavity  443 , and in the meantime, the two sidewalls  12 ,  14  (see  FIG. 8 ) of the stationary frame  10  are inserted into the slots  445 ,  446  of the fixing element  44 . The distances between the top/bottom ends of the movable frame  20  and the stationary frame  10  are such adjusted that the movable frame  20  is in a vertical position. 
     When the movable frame  20  is in a vertical position, the handle  461  is rotated to move the cam member  46  to the closed position. In this position, the bulge  463  applies a force to the rod portion  422 , which in turn directly or through the cushion  450  applies a force to the fixing element  44 , so as to secure the rod portion  422  and fixing element  44  together. 
       FIGS. 11 and 12  show the door assembly when the cam member  46  in open and closed positions respectively. As can be seen, when the handle  461  is completely received within the second cavity  444 , the cam member  46  is closely secured with the rod portion  422 , cushion  450  and the fixing element  44 , so as to secure the relative position between the stationary frame  10  and the movable frame  20 . When the handle  461  is clockwise rotated by 90°, the cam member  46  is moved out of the cavity  444  and the bulge  463  is released from the rod portion  422 , such that the rod portion  422  can again extend into or exist from the first cavity  443  so as to adjust the distance between the stationary frame  10  and the movable frame  20 . The adjusting assemblies disposed at the top and bottom ends of the frames are operated in a similar/same way. 
     It should be understood that various example embodiments have been described with reference to the accompanying drawings in which only some example embodiments are shown. The present invention, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.