Abstract:
A universal hatch assembly for accessing an enclosure includes a door. The frame has an opening defined therein that is dimensioned and configured for mounting the door. A hinge apparatus allows pivotal movement of the door about a first axis between a first position in which the door covers the opening and a second open position. The interior side of the door has an elongated channel extending in substantially perpendicular relationship to the first axis. An operating lever for positioning the door, has first and second axial extremities. A first axial part of the operating lever is spaced apart from the second axial extremity which is pivotally connected to the frame. The second axial extremity is dimensioned and configured for sliding meshing engagement with the elongated channel. The hatch assembly includes a lift assembly to provide a favorable counterbalance for the door. The frame may include a peripheral groove extending around substantially the entire frame. At least one module selected from several different modules according to a given application has a mounting surface dimensioned and configured for engaging the peripheral groove.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to building construction and particularly to hatch assemblies. Such hatch assemblies typically include a hatch having a hinged cover. This invention has application to various types of hatches including, but not limited to: 
     (1) exterior sidewalk hatches also known as vault or pit access hatches or horizontal doors; 
     (2) interior floor hatches also known as horizontal floor doors; 
     (3) roof hatches also known as roof scuttles or roof access doors; and 
     (4) automatic fire vents also known as heat and smoke vents. 
     Historically, the construction industry has utilized hatches designed and constructed for specific installations. For example, a roof hatch conventionally is typically manufactured and constructed in a manner that does not facilitate adaptation of that hatch for use as an exterior sidewalk hatch. Known hatch constructions utilize a variety of means to assist the user in opening the door of the hatch assembly. These means include compression springs having either a vertical or a horizontal axis, torsion bars, torsion coil springs, gas struts, and telescoping compression springs. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a hatch assembly having interchangeable installation modules to facilitate installation of the hatch assembly in a variety of different types of physical locations without the necessity of welding structural elements for a given application. 
     Thus, an object of the invention is to provide a hatch assembly that includes interchangeable modular elements that may be configured for use as an exterior sidewalk hatch, an interior floor hatch, or a roof hatch. 
     Another object of the invention is to provide a spring mechanism which imparts favorable counterbalancing characteristics to facilitate opening of the hatch in a reliable consistent manner. 
     Still another object of the invention is to provide a spring mechanism that is compact and disposed and constructed to minimize interference both with the passageway provided in the hatch assembly and with the hinged cover. 
     Yet another object of the invention is to provide apparatus having a more standardized and more uniform characteristic which is also adaptable to a wide range of applications and environments to thereby realize production efficiencies and reduce inventory requirements throughout manufacturing and product distribution channels. 
     A further object of the invention is to provide structure that incorporates a lifting mechanism that is compact and does not extend vertically and which thereby expands possible installation sites by minimizing potential interference between the lifting mechanism and the support structure and the hatch assembly structure. 
     It now has been found that these and other objects of the invention may be attained in a universal hatch assembly for accessing an enclosure which includes a door having a first side and a second side. The frame has an opening defined therein that is dimensioned and configured for engaging the door and the assembly also includes hinge apparatus mounting the door to the frame. The hinge apparatus allows pivotal movement of the door about a first axis between a first position in which the door covers the opening and a second position in which the door does not cover the opening. The first side of the door is disposed in facing relationship to the enclosed chamber when the door covers the opening. The first side of the door has an elongated channel extending in substantially perpendicular relationship to the first axis. The assembly also includes an operating lever for positioning the door. The operating lever has first and second axial extremities. A first axial part of the operating lever spaced apart from the second axial extremity is pivotally connected to the frame. The second axial extremity is dimensioned and configured for sliding meshing engagement with the elongated channel. The lift assembly also includes structure for biasing the pivotal position of the operating lever with respect to the frame including a coil extension spring. The lift assembly further includes a cable extending from the coil extension spring to a second axial part of the operating lever that is spaced apart from the first axial part of the operating lever. 
     In some forms of the lift assembly in accordance with the invention, the coil extension spring has a second axis. The second axis may be disposed in generally parallel relationship to the first axis, although in other forms of the invention the second axis may be perpendicular to the first axis or disposed at an oblique angle with respect to the first axis. The opening may have a first side and the first axis and the second axis may be disposed proximate to the first side. In some forms of the invention, the door has a depending flange and an elongated channel is formed in the depending flange. 
     A generally cylindrical member may be dimensioned and configured for sliding meshing engagement with the elongated channel. The assembly may further include a sheave cooperating with the cable. 
     Some forms of the hatch assembly in accordance with the invention may include the features described above in addition to the structural features described below. Other forms of the invention may include only the structural features described below. 
     The structure of the frame may include a first peripheral groove extending around substantially the entire frame. At least one module has a mounting surface dimensioned and configured for engaging the first peripheral groove. Several types of modules each specifically adapted for a given application are provided. 
     The hinge apparatus may include first and second plates, coupled by a hinge pin. The frame is dimensioned and configured for receiving the first plate. The second plate engages the door. The first plate has a second groove. The second groove is disposed in registered aligned relationship with the first peripheral groove to define a continuous uniform groove about the entire periphery of the frame. The frame includes a second peripheral groove extending around substantially the entire frame in some forms of the invention. The second peripheral groove may include a plurality of longitudinally extending ridges, dimensioned and configured for engaging a threaded fastener for securing modules to the frame. The first peripheral groove and the second peripheral groove may be parallel and proximate to each other. The module may take the form of a skirt, a clamp, an integral carpet/tile stop, or a flange for supporting and/or positioning the hatch assembly with respect to an opening. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The invention will be better understood by reference to the accompanying drawing in which: 
     FIG. 1 is a plan view, partly in phantom, of a hatch assembly in accordance with one form of the present invention. 
     FIG. 2 is a perspective view of the hatch assembly of FIG. 1, with the door disposed in the open position. 
     FIG. 3 is a partially sectional view taken along the line  3 — 3  of FIG. 1, illustrating the position of some of the components when the door is in the open position. 
     FIG. 4 is a fragmentary elevational view, illustrating some of the elements when the door is in the closed position. 
     FIG. 5 is a perspective view of the door control lever and the cable that connects to a coil extension spring to provide counterbalancing forces when the door is opened. 
     FIG. 6 is a plan view, partially in phantom, of the door control lever and the cable that connects to a coil extension spring to provide counterbalancing forces when the door is opened. 
     FIG. 7 is an end elevational view similar to FIGS. 5 and 6. 
     FIG. 8 is a side elevational view, partially in phantom and partially broken away, similar to FIGS. 5,  6  and  7 . 
     FIG. 9 is a perspective view of an alternate embodiment having a separate cable connecting to each of two-door control levers. 
     FIG. 10 is a perspective view of another alternate embodiment, having a cable connecting to a door control lever that has a pivot point intermediate to the lever connection to the door, and the lever connection to the cable. 
     FIG. 11 is a perspective view of still another embodiment in which spring bias cables connect to opposing sides of a door control lever. 
     FIGS. 12,  13  and  14  are respectively plan, end elevational and perspective views of the hinge that supports the door, and which also provides part of a continuous circumferential groove about the housing for engagement with a mounting skirt module, FIGS. 12 and 13 being partially in phantom. 
     FIGS. 15,  16  and  17  are sectional views of respective skirt modules and installed in various environments as further illustrated by broken lines. 
     FIGS. 18 and 19 are sectional views of respective flange modules installed in various environments as further illustrated by broken lines. 
     FIGS. 20,  21  and  22  are respective end views of alternate extruded mounting surfaces that cooperate with flange and skirt modules. 
     FIGS. 23 and 24 are respectively to side elevation and perspective views of another member configured for cooperation with respective flange and skirt modules. 
     FIG. 25 is a diagrammatic view of an extension spring actuating mechanism. 
     FIG. 26 is a diagrammatic view of an alternate extension spring actuating mechanism. 
     FIG. 27 is a diagrammatic view of a frame section in accordance with a preferred form of the invention. 
     FIGS. 28,  29 ,  30 , and  31  are diagrammatic views of elements that may engage the frame section illustrated in FIG.  27 . 
     FIG. 32 is a diagrammatic view of the frame section illustrated in FIG. 27 showing a forward in place installation, the most common installation method, for exterior sidewalk hatches in new construction. 
     FIG. 33 is a diagrammatic exploded view of the frame section illustrated in FIG. 27, together with a mating element and screw fastener for a drop in installation, the most common installation method, for interior floor hatches or exterior sidewalk hatches where an opening already exists prior to installation. 
     FIG. 34 is a diagrammatic view of the apparatus illustrated in FIG. 33 fully assembled and dropped into an existing opening. 
     FIG. 35 is a diagrammatic exploded view of the frame section of FIG. 27 in combination with associated elements for a common roof installation. 
     FIG. 36 is a diagrammatic view of the elements shown in FIG. 35, fully assembled and installed on an associated roof. 
     FIG. 37 is a diagrammatic view of the frame section shown in FIG. 27, supported by a support angle fixed to a concrete slab. 
     FIG. 38 is a diagrammatic view of a surface mount installation of the frame section illustrated in FIG. 27 in combination with a generally planar associated structure and which illustrates the clearance between the lifting mechanism and the support structure. 
     FIG. 39 is a diagrammatic view, illustrating a retrofit installation of an existing industry standard hatch assembly with a frame section, and a lifting mechanism in accordance with the present invention. 
     FIG. 40 is a diagrammatic view of a roof hatch installation with a full exterior skirt. 
     FIG. 41 is a diagrammatic view of a drainage channel frame profile in accordance with one form of the present invention. 
     FIGS. 42 and 43 are diagrammatic views of angle frame profiles used on drainage frames commonly used for interior floor hatches. 
     FIG. 44 is a diagrammatic view of a roof hatch curb having a capped flashing for waterproofing. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A universal hatch assembly in accordance with present invention may assume a wide number of configurations. Each hatch assembly has a frame that includes mounting surfaces to enable easy attachment of various load-bearing flanges, weather-sealing gaskets and cap-flashing modules without the need for welding or other specialized manufacturing steps. In a preferred embodiment, the hatch assembly includes a compact, horizontally mounted, extension coil spring, lifting mechanism suitable for retrofits and replacement applications as well as original installations. Advantageously, the appropriate modules may be assembled at the job site without the cost and long fabrication times associated with factory custom-made constructions. 
     Referring now to FIGS. 1-8, there is shown a hatch assembly  10  in accordance with one form of the present invention that employs the same lift assembly  11  as that shown diagrammatically in FIG.  25 . This hatch assembly  10  includes a cover or door  12  having a stiffener  14  fixed to the interior face thereof. The stiffener is provided with an elongated slot  16  that is rectilinear except for an L-shaped axial extremity  17  (shown in FIG. 3) for locking the door  12  in the open position. Hinges  18  mount the door  12  to the frame  20 . An operating lever or hold open arm  22  is pivotally connected by a bolt  29  at a first axial extremity to the frame  20 . A second axial extremity of the lever  22  is provided with a cylindrical follower  26  dimensioned and configured for meshing sliding engagement with the slot  16 . A coil extension spring assembly  24  is connected by a cable  27  to an axial point  28  on the operating lever  22  intermediate the first and second axial extremities. A sheave  25  guides the cable  27  around the right angle intersection of the sides of the frame  20 . 
     The embodiments illustrated in FIGS. 1-8,  10 ,  25  and  26  each utilizes a single cable  27  connected to a single lever  22  or  40 . FIGS. 9 and 11 illustrate alternative embodiments that each incorporates two discrete coaxial coil springs. In the embodiment of FIG. 9, each of two coil springs (not shown) is anchored at a bolt  120  disposed in between two operating levers  22 . The operating levers  22  are disposed on opposed sides of the hatch assembly. Ordinarily, the use of two operating levers  22 , instead of one operating lever, is reserved for particularly heavy doors  12 . FIG. 11 illustrates another embodiment where two coaxial springs (not shown) are respectively fixed to two discrete cables  22 . The three ends of the cables  22  are fixed to a common bolt  124  that extends through a single lever  22 . This physical arrangement is also most useful when the weight of the door  12  is particularly heavy. 
     Referring now to FIG. 25, there is shown diagrammatically a coil extension spring actuating mechanism lift assembly  11  in which the axis of the coil spring  32  is aligned with the lever  40 . This structure more fully illustrated in FIG. 10 is functionally equivalent to the structure diagrammed in FIG.  25 . This coil extension spring actuating mechanism  30  includes a coil extension spring  32 . In the embodiment of FIG. 25 the geometric axis of the spring  32  is parallel to the direction of elongation of the lever  40 . The left (as viewed) axial extremity of the coil extension spring  32  engages a pin  34 . A housing  36 , having a generally square cross-section, encloses the spring  32 . A plurality of vertically extending holes  38  in the upper and lower surfaces of the housing  36  are dimensioned and configured for retaining the pin  34 , at any of a plurality of axial positions. Since the force produced by the spring  32  is proportional to the linear extension of the spring  32 , it is possible to adjust the operating characteristics of the coil extension spring actuating mechanism  30  by movement of the pin  34  to a different pair of holes  38 . 
     An operating lever  40  is provided with a pivot  42  that is intermediate the axial extremities of the operating lever  40  (unlike the operating lever  22  that is pivotally connected to the frame  20  at an axial extremity thereof). A cable  26  (preferably a multi strand steel cable, although some embodiments may use nylon or other materials) is attached to the second axial extremity of the spring  32 . The cable  26  passes over a guide member  44  and is fixed to the lower (as viewed) axial extremity of the lever  40 . The upper axial extremity (not shown) of the lever  40  is provided with a cylindrical follower  26 , that engages a slot as in the embodiment illustrated in FIGS. 1,  2  and  3 . 
     Accordingly, if the cover or door  12  is heavy and is otherwise restrained in the closed or horizontal position, the lever  40  is rotated fully around the pivot point  42 , in the maximum counterclockwise direction (the direction indicated by the arrow A). The spring  32  is extended to a length corresponding to a spring force necessary to counteract the weight of the cover  12  to provide an efficient and effective counterbalance for the cover  12 . Thus, when the cover  12  is opened, the spring  32 , exerts a force on the cable  27  that exerts a force on the lever  40 , thereby exerting a force on the underside of the cover  12  to lift the cover to the full opening or vertical position. Thus, the mechanism converts a horizontal motion of the extension spring  32  to an upward force. 
     Referring now to FIG. 26, there is shown a lift assembly  13  in which the geometric axis of the spring  32  is perpendicular to the direction of elongation of the lever  22 . (Reference numeral  22  is used herein to identify a lever that is pivotally mounted at an axial extremity of the lever as in the embodiment illustrated FIGS. 1,  2 ,  3 ,  4  and  26 . Reference numeral  40  is used herein to identify a similar lever that is pivotally mounted at a point intermediate the axial extremities of the lever.) The embodiment shown in FIG. 26 enables the spring housing  36  to be disposed in a position that is not in line with the lever  22 . Those skilled in the art will recognize that although the geometric relationship in FIG. 26 is a perpendicular relationship other included angles such as 30, 60, or 120 degrees could be constructed with substantially the same physical structure. 
     The hatch assemblies employ cover lift assemblies  11  or  13  which efficiently redirect the force of a horizontally mounted coil extension spring into a reliable, predictable, upward-lifting force, without imposing unnecessary torque or other stress on the frame, hinges or the cover. Thus, the lift assemblies  11  and  13  offer significant advantages over existing lifting mechanisms in terms of safety, durability, adjustability, and ease of installation. The use of a coil springs is desirable because of the greater precision associated with such coil extension springs as compared to alternative biasing. 
     Referring now to FIG. 27, there is shown a cross-section of the frame  20  that is also shown in FIGS. 1,  2  and  3 . The cross-section illustrated in FIG. 27 is identical throughout the circumferential extent of the frame  20  (except as the parts thereof where the hinges  18  are disposed). Alternative frame cross-sections are shown in FIGS. 20-22. The upper face of the members that form the frame  20  is provided with a plurality of parallel grooves  45 . The grooves  45  will function to prevent slipping if the hatch assembly is installed where people walk. Alternatively, the grooves are decorative. Alternative flange constructions are shown in FIGS. 18 and 19. FIG. 18 illustrates a standard flange  134  for “drop in” installation of interior or exterior floor hatches. FIG. 19 illustrates a flange  136  with an integral carpet/tile stop that is primarily for interior floor hatches. FIGS. 15,  16  and  17 , respectively, illustrate a full exterior skirt  140 , a fixed cap flashing  142 , and a roof material clamp  144 . 
     The four extrusions which constitute the principal support structure of the generally rectangular frame  20  are provided with first and second peripheral grooves  46 ,  48  intended to receive and mount various auxiliary structures. More particularly, the groove  46  has a generally square cross-section in the preferred embodiment. The groove  48  has a generally rectangular cross-section wherein the upper and lower surfaces thereof are provided with longitudinally extending ridges or serrations, as best seen in FIGS. 20-23 and  24 , that are dimensioned and configured for receiving threaded fasteners as best seen in FIGS. 15-19. 
     The various auxiliary structures or modules are intended to convert the basic frame  20  from a standard “pour in place” or “surface mount” floor/sidewalk hatch configuration to a “drop in place” floor/sidewalk hatch configuration, a roof hatch configuration or other possible configurations. The frame components and the modules may be extruded structures. For example, the adapter  56  illustrated in FIG. 29 is intended to convert a standard frame from a standard “pour in place” or “surface mount” floor/sidewalk hatch configuration to a “drop in place” floor/sidewalk hatch configuration. 
     The adapter  54  illustrated in FIG. 28 is intended to convert a standard frame from a standard “pour in place” or “surface mount” floor/sidewalk hatch configuration to a roof hatch configuration. Similarly, the inner face of the frame  20  includes a groove  50  that is also intended to receive and mount various additional structures intended to convert the basic frame  20  for various applications. For example, a weather seal gasket  52  illustrated in FIG. 31 is dimensioned and configured for engagement with the groove  50 . The ease with which alternate configurations are achieved with minimal effort and without special tools, glue or welding either at the factory or in the field is a significant advantage of the apparatus of the present invention. 
     FIG. 30 illustrates a cross-section of the hinge  18  that is also shown in FIGS. 1,  2  and  3 . The left (as viewed in FIG. 30) portion of the hinge  18  is provided with a peripheral groove  60  that is dimensioned and configured for alignment and registration with the groove  46  so that one continuous groove extends completely around the circumferential extent of the frame  20 . FIGS. 12-14 illustrated the hinge  18  in still greater detail. 
     Referring now to FIG. 32, there is shown the cross-section of the frame  20  with poured concrete  66  disposed around the outer and bottom portions of the frame  20 . This is a “poured in place” installation. FIGS. 33 and 34 show respectively the adapter  56 , illustrated in FIG. 29, together with a fastener  68  in exploded relationship with a frame  20 , as well as assembled to the frame  20  in a “drop in” installation. In other words, in a concrete surface  66  defines an opening, such as a sidewalk opening, and the hatch assembly is dropped into the opening. 
     As shown in FIGS. 35 and 36, the frame  20  is bolted with bolts  70  to a roof  72 . Optional insulation  74  may be installed in the recess  76  and a skirt  78  may be secured with a bolt  80 . The system preferably includes various other caps flashing, flashing clamps and full skirts for various types of waterproof roof constructions. FIG. 37 illustrates still another “drop in” construction, utilizing a support angle  84  that is secured to the side of a concrete wall  82 . The frame  20  is dropped in and rests on the support angle  84  with the top of the frame  20  disposed in substantially flush relationship to the top surface of concrete  82 . The side of the frame  20  is disposed in side abutting relationship to the concrete  82 . 
     FIG. 38 illustrates still another surface mount installation in which the frame  20  is secured by a bolt  86  to a concrete support  82 . A coil extension spring actuating assembly  30  is disposed on the side of the frame. Advantageously, the horizontal mounting of the coil extension spring actuating assembly  30  provides ample clearance for the surrounding structure without compromising access through the hatch assembly. This is notably superior to other mechanisms that assist the user to lift the door  12 . More particularly, such conventional structures often have portions that extend downward and thus, in the case of the specific environment shown, interfere with the concrete  82 , as illustrated in FIG.  38 . 
     Referring now to FIG. 39, there is shown a retrofit installation of one form of the apparatus in accordance with the present invention. In a typical hatch installed outside of a building, the existing structure will include a drain channel  98  that extends around the entire circumferential extent of the hatch assembly. A base  100  and opposed first and second walls  90  and  102  define the drain channel  98 . As seen in FIG. 39, a frame member  96  particularly designed for the retrofit market has a generally L-shaped contour. The frame member  96  is secured by a bolt  97  to the inboard (nearer the center of the hatch assembly) side  102  of the drain channel  98 . More specifically, the frame member  96  is nested within the drain channel  98 . A coil spring actuating mechanism  104 , similar to the coil spring actuating mechanism  30  illustrated in FIG. 25, is secured by fasteners  106  to the outboard wall  90  of the drain channel  98 . Thus, it will be seen that the frame member  96  allows attachments via the circumferential groove  108  and specifically the attachment of a variety of devices in the manner described with respect to the embodiments intended for original equipment hatch assemblies. 
     A roof hatch installation  110  is shown in FIG.  40 . This installation utilizes the same frame member  20  used in other  10  installations. Bolts  112  secure the frame member  20  to the roof  114 . A coil extension spring actuating assembly  30  is fixed to the inboard face of frame member  20 . A full exterior skirt  116  (also referred to as a fully enclosed curb) is secured by a bolt  114  to the frame member  20 . 
     With reference to FIG. 41, some embodiments of the present invention incorporate a drain channel  118  (also known as a gutter or trough frame) having a drain coupling  20  welded to the underside of the drain channel  118  for connection to a drain pipe. This structure has particular application is for exterior sidewalk hatches. Other embodiments of the present invention will incorporate angle frame members such as members  122 ,  124  shown respectively in FIGS. 42 and 43. Such members are commonly used for interior floor hatches. A preferred form of a roof hatch curb  126  is shown in FIG.  44 . 
     As used herein, the term “cable” refers to a multistrand steel cable as well as equivalent means for transferring a tension force, including other metallic, plastic and fiber cables. In the preferred embodiments the cover  12  is provided with a stiffener  14  having an elongated slot  16  formed therein. Those skilled in the art will recognize that various other structures may be utilized including, but not limited to, T-shaped slots to achieve the sliding meshing engagement that is required. 
     While the present invention has been described with reference to the preferred embodiments illustrated in the drawing, the detailed description thereof is not intended to limit the scope of the invention as claimed in the appended claims.