Adjustable hinge assembly

A shower door enclosure has fixed and pivotable hinge halves which can be preinstalled to fixed and pivotable panels, respectively. One or both of the hinge halves can be adjusted at the installation site without hinge disassembly. In particular, each hinge half may be mounted to its respective panel via a fastener passing through the panel and into a floating bushing. The floating bushing is received in a seat formed in the body of the hinge half. The bushing and seat are shaped to prevent continuous rotation of the bushing within the seat, allowing the fastener to be tightened against the panel without requiring external access to the bushing. Upon assembly of the door panel to the adjacent fixed panel via the respective hinge halves, the bushings may be allowed to “float” laterally and vertically within the hinge bodies while the panels are adjusted to a proper orientation, and the fasteners may then be tightened to fix the panels in place.

BACKGROUND

1. Technical Field

The present disclosure relates to door hinges, and, in particular, to pre-installed door hinges for shower door enclosures.

2. Description of the Related Art

Bathing enclosures are used to retain water flowing, e.g., from a shower head, within an enclosed area. For example, glass shower enclosures may include one or more glass panels and water resistant walls (e.g., the or fiberglass) and a shower head directed into the enclosure. A glass door may be pivotably attached to one of the glass panels, or to one of the walls, for ingress and egress by the user of the bathing enclosure.

Glass is a favored material for bathing enclosures owing to its ability to be cleaned repeatedly and thoroughly over a long service life, as well as its ability to admit light to the bathing enclosure. However, glass is also a relatively heavy and fragile material, particularly when used for large monolithic panels. In some instances, installation of glass bathing enclosures may be complicated by the competing needs of tight tolerances, e.g., for waterproofness at panel junctions, and adjustability among the various panels, e.g., to account for walls, floors, and or ceilings forming imperfect angles or other geometric relationships.

SUMMARY

The present disclosure provides a shower door enclosure with fixed and pivotable hinge halves which can be preinstalled to fixed and pivotable enclosure panels, respectively. One or both of the hinge halves can be adjusted at the installation site without hinge disassembly. In particular, each hinge half may be mounted to its respective panel via a fastener passing through the panel and into a floating bushing. The floating bushing is received in a seat formed in the body of the hinge half. The bushing and seat are shaped to prevent continuous rotation of the bushing within the seat, allowing the fastener to be tightened against the panel without requiring external access to the bushing. Upon assembly of the door panel to the adjacent fixed panel via the respective hinge halves, the bushings may be allowed to “float” laterally and vertically within the hinge bodies while the panels are adjusted to a proper orientation, and the fasteners may then be tightened to fix the panels in place.

In one form thereof, the present disclosure provides a hinge assembly comprising: a first hinge half fixable to a pivotable door and having a first hinge node; a second hinge half fixable to a stationary panel and having a second hinge node pivotably connectable to the first hinge node by a pivot pin; a recessed bushing seat formed in at least one of the first hinge half and the second hinge half, the bushing seat having a lateral extent and a vertical extent; and a floating bushing received in the bushing seat and sized to allow both lateral travel and vertical travel of the floating bushing within the bushing seat, while limiting rotation of the floating bushing within the bushing seat to a predetermined range.

In another form thereof, the present disclosure provides a shower door assembly comprising: a pivotable door; a stationary panel; a first hinge half fixed to the pivotable door and having a first pair of recessed bushing seats formed in a door-facing surface thereof; a second hinge half fixable to the stationary panel and having a second pair of recessed bushing seats formed in a door-facing surface thereof; and a floating bushing received in each of the recessed bushing seats and respectively captured between the pivotable door and first hinge half and the stationary panel and the second hinge half, each floating bushing sized to allow both lateral travel and vertical travel of each floating bushing within each respective bushing seat, each floating bushing sized to limit rotation of each floating bushing within each respective bushing seat to a predetermined range.

In yet another form thereof, the present disclosure provides a method of partially pre-assembling a shower enclosure, the method comprising: adjustably attaching a first hinge half to a pivotable door such that the first hinge half is moveable laterally and vertically, the first hinge half having a first hinge node defining a first longitudinal axis; and adjustably attaching a second hinge half to a stationary panel such that the second hinge half is moveable laterally and vertically, the second hinge half having a second hinge node defining a second longitudinal axis.

DETAILED DESCRIPTION

FIG. 1illustrates shower enclosure10including pivotable door12mounted to the adjacent stationary hinge panel14via a pair of hinge assemblies20. As described in further detail below, each hinge assembly20includes a fixed hinge half24mounted to hinge panel14, and a pivotable hinge half22mounted to door12. Hinge halves22,24may be independently mounted to the respective glass panels12,14at the time of manufacture, rather than at the time of installation. The pre-assembled panels12,14and hinge halves22,24may then be delivered to a place of intended installation of shower enclosure10, and adjusted as needed to provide proper alignment of door12and panel14.

In the illustrative embodiment ofFIG. 1, door12may define a relatively tight tolerance between header40and footer42of the door frame in the final installation. In addition, door12may define a precise fit with edge gasket44mounted along a vertical edge of latch panel16. Yet another tight-tolerance fit may exist between door12and fixed panel14, along edge gasket46(FIG. 3). The adjustability of hinge assembly20facilitates this close-tolerance fitting of door12to its surrounding structures, while maintaining a tight fit at the rotatable junction between hinge halves22and24. In use, this arrangement allows door12to be opened and closed with a minimal effort of the user upon door handle18, while also maintaining a tight, low-vibration, and generally high quality user feel and interface.

AlthoughFIG. 1illustrates a common shower enclosure configuration including door12and panel14which are substantially coplanar when door12is closed, as well as latch panel16forming a generally right angle with door12and hinge panel14, it is contemplated that the methods and apparatuses of the present disclosure may be used in any desired enclosure arrangement, as required or desired for the needs of a particular user. In addition, other modifications may be made to the illustrated arrangement, such as the use of fewer or more numerous hinge assemblies20for door12, the mounting of hinge assemblies inside or outside the shower enclosure, and the like.

FIG. 2illustrates an enlarged view of hinge assembly20, including hinge halves22,24pivotably linked to one another by hinge pin26. As described in further detail below, pivotable hinge half22may be fixed to pivotable door12in a pre-assembly procedure remote from the intended installation of shower enclosure10. Similarly, fixed hinge half24may be pre-assembled to hinge panel14. When shower enclosure10is assembled at the site of intended use, hinge node80of hinge half24may be received between the corresponding hinge nodes84of hinge half22to align the longitudinal axes thereof, and hinge pin26may then be passed through nodes80,84and secured (e.g., by threading into one of nodes84) to pivotably connect door12to hinge panel14. At this point, the position and alignment of door12may be adjusted relative to hinge panel14using the adjustability provided by one or both hinge halves22,24in order to properly align and position door12. Moreover, such adjustment is possible using hinge assembly20while also providing a tight-tolerance fit between hinge pin26, hinge node80, and hinge nodes84, as further described below.

Turning toFIG. 6, the parts and assembly of pivotable hinge22are shown in detail. Pivotable hinge body28includes a pair of pockets or bushing seats38recessed into the otherwise planar door-facing surface of hinge body28. Seats38are sized and configured to adjustably receive a corresponding pair of floating bushings30. In particular, each floating bushing30includes a rounded edge32which can engage a correspondingly rounded edge37in bushing seat38when bushing30is moved to an extreme lateral adjustment point. Opposite rounded edge32, floating bushing30includes pointed protrusion34, formed by a pair of surfaces tapering towards a point as illustrated. Pointed protrusion34is loosely received within a correspondingly pointed recess39of seat38, as illustrated.

As best seen inFIG. 7, each bushing30can float or adjust both laterally and vertically within seats38. For purposes of the present disclosure, “lateral” movement is considered to be side-to-side movement as shown inFIG. 7, and would typically correspond with a side-to-side movement of door12in its installed configuration as part of shower enclosure10(FIG. 1). Similarly, a “vertical” movement is an up-and-down movement as shown inFIG. 7. The nominal amount of lateral and vertical adjustment depends upon the overall lateral and vertical extent of seat38as compared to the lesser lateral and vertical extent of bushing30, which in turn provides lateral and vertical clearance between bushing30and seat38. In an exemplary embodiment, the total lateral clearance may be between 0.1 and 0.5 inches, and the total vertical clearance may be between 0.05 and 0.3 inches.

Upon tightening fasteners70to fix hinge half22to door12, as best shown inFIG. 3Aand further described below, bushing30may be urged to rotate within seat38as torque is applied. Referring toFIG. 7A, the amount of rotation of each floating bushing30within seat38is limited to a predetermined angular range Θ in either direction (clockwise or counterclockwise). In particular, pointed protrusion34abuts the wall of pointed recess39at limits of the predetermined range Θ, as shown by a comparison of the left and right bushings30inFIG. 7A, which are respectively illustrated at clockwise and counterclockwise limits of rotation. In this way, protrusions34cooperate with recesses39in order to prevent free rotation of bushings30within seats38regardless of the lateral and vertical position of bushings30within respective seats38.

In particular, the tapered walls of pointed protrusion34define convex tapering surfaces having a radius and extent approximately equal to the corresponding concave surfaces of the walls defining pointed recess39, as illustrated. This convex/concave surface arrangement ensures that floating bushings30may move throughout their intended ranges of lateral and vertical motion, while also ensuring that bushings30cannot freely rotate within seat38. In an exemplary embodiment, the predetermined angular range Θ may be as little as 5 degrees, and as much as 20 degrees in either direction. In the illustrated embodiment, angular range Θ is nominally between 5 degrees and 6 degrees, and expands to between 5 and 10 degrees depending on the vertical and lateral position of bushing30relative to the adjacent sidewalls of pocket38.

Referring again toFIG. 6, retainer plate50may be provided to capture bushings30within their respective seats38. In the illustrated embodiment, hinge body28includes a recess sized to receive plate50such that, when plate50is installed to body28, a flush door-facing surface is formed by both hinge body28and plate50. As shown inFIG. 3A, bushing30may include threaded barrel36which protrudes into respective barrel apertures54formed in plate50when bushing30is received in seat38. Apertures54are oversized relative to the outer diameter of barrels36, such that apertures54do not limit the vertical or lateral travel of barrels36as bushings30laterally or vertically adjust. Plate50may further include retainer bores58which allow retainer screws52be received within threaded bores60to fix retainer plate50to body28. In the illustrated embodiment, bores58are countersunk and receive screws52with correspondingly conical heads to avoid disruption of the generally planar door-facing surface of hinge body28and plate50.

Pressure plate62is mounted to the door-facing surface of hinge body28and plate50, as best shown inFIG. 3. In particular, locating protrusions63(FIGS. 3A and 3B) may be received within corresponding locating apertures56of plate50(FIG. 6). Pressure plate62further includes a pair of mounting apertures64which align with apertures54and allow access to each threaded barrel36of floating bushings30.

Upon assembly, hinge body28with pressure plate62may be abutted to the mounting surface of door12, as shown inFIG. 3, such that hinge-fixation apertures94(FIG. 3B) formed in the glass panel of door12align with apertures64,54of hinge half22. In an exemplary embodiment, pressure plate62is formed of a polymer material, such as polysulfone, nylon, various thermoplastic elastomers, polyvinyl chloride (PVC), and other materials suitable to prevent direct contact between metal components of hinge assembly20and the glass of panels12,14. In particular, the material of pressure plate62may be chosen to slightly deform and/or compress under pressure against the surface of door12, in order to provide a consistent and distributed pressure between the door facing surfaces of hinge body28and retainer plate50on one side and the surface of door12on the opposite side.

At the inner surface of door12, an arrangement of fasteners and bushings may be used to fix hinge half22to door12, as shown inFIGS. 3, 3A, and 3B. First, flexible bushing66is received within each fixation aperture94of door12. As best seen inFIG. 3B, deformable bushing66includes a generally cylindrical portion received within a correspondingly cylindrical portion of bore94, and a frusto-conical portion received within the countersink of bore94. Deformable bushing66is made from a relatively soft and flexible material such as, for example, a relatively flexible polymer. In an exemplary embodiment, the material of bushing66may be polysulfone, nylon, acrylonitrile butadiene styrene (ABS) plastics, polypropylene and other polymer materials which are resistant to fracture due to hoop stresses. Next, bushing68made of a more rigid material than the deformable bushing66(i.e., a material having a higher elastic modulus) is received within and seated against the frusto-conical portion of bushing66. In an exemplary embodiment, rigid bushing68may be made of steel, aluminum or other another metal, or from a more rigid polymer material. Finally, fastener70is passed through bushings68,66, and hinge-fixation aperture94, reaching the outer side of door12. Fastener70continues through aperture64of pressure plate62and engages threaded barrel36of bushing30. Bolt70may then be rotated to tighten hinge half22against door12.

As bolt70is tightened, rigid bushing68centers within flexible bushing66, and may slightly compress and/or deform flexible bushing66to evenly distribute pressure around the countersunk portion of hinge-fixation aperture94and door12. At the same time, pressure plate62provides distributed pressure from bushing30via retainer plate50and the door facing surface of hinge body28, as noted above. In addition, it can be seen fromFIGS. 3A and 3Bthat apertures94,64, and54all provide ample clearance for bolt70and threaded barrel36, with the clearance being sized such that bushing30may move through its full range of lateral and vertical adjustment (as described in detail above) without risking direct contact between bolt70and the glass material of door panel12. In addition, the compressibility and/or deformability of bushing66allows the longitudinal axis of bolt70to be askew from the longitudinal axis of hinge-fixation aperture94upon final installation, while avoiding a high concentration of pressure in the material of door12. Thus, the relatively brittle material of door12is protected from excess pressure by the arrangement of hinge half22and its method of attachment.

Bolt head cover72may be installed as a final step in order to protect the head of bolt70and the material of bushing68from the shower enclosure environment. Notably, as shown inFIG. 3A, the periphery of bolt head cover72is slightly recessed into the countersunk portion of door12, thereby avoiding the periphery of bolt head cover72from sitting proud of the adjacent surface of door12. This arrangement facilitates easy and thorough cleaning over the a long product service life.

Turning now toFIG. 5, fixed hinge half24is shown in a similar fashion to pivotable hinge half22ofFIG. 6. Moreover, bushings30, retainer plate50, pressure plate62, bushings66,68, and fastener70may be used to assemble hinge half24, and to adjustably connect hinge half24to hinge panel14in the same manner as hinge half22and door12described above.

However, fixed hinge half24includes a single hinge node80with hinge bearings76assembled thereto, while hinge half22includes a pair of hinge nodes84each having bearing channel86which receives hinge node80and bearings76, as described in further detail below. Although the illustrated embodiment utilizes a single node80on fixed hinge half24and a pair of nodes84on pivotable hinge half22, it is contemplated that any number of alternating hinge nodes may be used as required or desired for a particular application. Moreover, it is also contemplated that bearings may be mounted to fixed hinge half24or pivotable hinge half22in any combination.

As best seen inFIG. 5, each bearing76includes inner boss77and outer boss82separated by flange79. A non-round shoulder78is disposed between inner boss77and flange79. Bearings76are assembled to each opposing axial end of hinge node80, such that inner boss77is received into hinge bore98and non-round shoulder78engages a correspondingly non-round portion of bore98to prevent rotation of bearings76relative to hinge body74after installation of bearings76and during use of hinge assembly20.

Turning again toFIG. 4, bearings76are shown assembled to hinge node80, with flanges79fully seated against the upper and lower axial surfaces of node80. When door12is assembled to hinge panel14, outer bosses82are snugly received into channels86of hinge nodes84. In an exemplary embodiment, the nominal clearance between the outer diameter of outer bosses82and the corresponding inner diameter defined by channels86is between 0.000 inches and 0.020 inches. That is, outer bosses82define a nominal 0.010-inch clearance fit with channels86, and may deviate between a zero-clearance fit and a 0.020-inch clearance fit. When door12is opened, the lack of significant clearance between bosses82and channels86provides for a smooth, tight and low-vibration hinge action that promotes quiet operation and an overall high-quality feel. Given that installation sites can be expected to vary in quality of fit and finish, this tight clearance is facilitated by the adjustable mounting of hinge halves22and24to the respective door panels12and14, which can correct for irregular mounting surfaces without further adjustment being necessary at the pivotable hinge connection itself.

The clearance along the axial direction between the terminal axial ends of outer bosses82and the axial inner ends of hinge nodes84may provide a modest amount of clearance, i.e., as little as 0.025 inches clearance and up to 0.065 inches clearance. This clearance facilitates installation of door12to panel14with hinge halves22,24pre-installed, as described further below. When assembled, the weight of door12tends to pull hinge node80into firm contact with the lower hinge node84, such that the clearance forms a slight gap between hinge node80and the upper hinge node84.

Once hinge nodes80,84are assembled and aligned, hinge pin26may be passed through hinge bores96of hinge nodes84, as well as through hinge bore98and bearings76to rotatably couple door12to fixed hinge panel14. In an exemplary embodiment, are portion of bore96is threaded at both hinge nodes84. This threaded portion threadably receives hinge pin26at both of nodes84, such that hinge pin26may be installed from either direction depending on the configuration of hinge assembly20at the site installation. This allows hinge pin26to always be installed with head27at the top of hinge assembly20, such that hinge pin26is prevented from falling away from hinge assembly20even if pin26comes loose. Head27of pin26may be received in a counterbore portion of the upper hinge node84, while a threaded cover92may be provided at the corresponding counterbore of the lower hinge node84in order to provide a finished look and prevent material from entering bore96from below. In an exemplary embodiment, a chamfered (i.e., frusto-conical) surface may be formed adjacent the hex-shaped drive aperture through cover92. When cover92is received in bore96, this frustoconical surface may engage a correspondingly chamfered surface at the distal end of pin26such that cover92centers pin26and provides a bearing surface therefor.

Optionally, set screws88(FIG. 4) may pass transversely, i.e., along a radial direction with respect to axis A, into each of hinge nodes84in order to engage either head27of hinge pin26or pin cover92after installation. This set screw engagement may provide further assurance against loosening of cover92or hinge pin26over the long service life that may be expected for shower enclosure10.

Turning again toFIG. 5, door stops90may be provided in body74of hinge half24as illustrated. Stops90are spaced radially outwardly from longitudinal axis A of hinge node80, and are positioned to receive contact by pivotable hinge body28when door12reaches a fully opened position. Stops90may be made of a relatively soft polymer or rubber material in order to cushion such contact and thereby soften a forcible opening of door12. In an exemplary embodiment, door stops90may be spring loaded to provide further deceleration potential. In an exemplary embodiment, hinge halves22,24are designed to accommodate between 90 degrees and 135 degrees of total pivotable motion of door12with respect to hinge panel14before door stops90are engaged.

After proper installation and adjustment of door12relative to fixed panel14, as described herein, gasket46mounted to hinge panel14experiences substantially constant and even compression along its vertical extent, which may extent along the entire vertical edge of door12and panel14. Gap G (FIG. 3) is provided between hinge bodies28,74, and the adjacent surfaces of panels12,14to provide clearance for gasket46. In order to provide a desired nominal value for gap G, the thickness of pressure plate62may be increased or decreased as needed. Similar proper compression of gaskets provided at header40, footer42, and/or edge gasket44(FIG. 1) may also be ensured by proper alignment procured by adjustment of hinge halves22and24.

In an exemplary production method, hinge halves22,24are installed to pivotable door12and hinge panel14respectively prior to shipping the components of shower enclosure10to an end user, installer or other intermediary. In the initial adjustment, hinge bodies28,74may be generally centered over hinge fixation apertures94, such that panel mounting bolt70is generally coaxial with hinge fixation aperture94and floating bushing30is generally centered in bushing seat38. However, it is noted that manufacturing tolerances, such as those specified for hinge-fixation apertures94, need not be controlled within an extremely tight tolerance because substantial adjustability is designed into hinge assembly20. Hinge halves22,24may be tightened onto door12and panel14prior to shipping, or may be left secured but slightly loose.

Upon arrival at the installation site, hinge panel14may be installed to its adjacent support surfaces in a conventional manner. Door12may then be installed to panel14by laterally advancing hinge nodes84over hinge node80as described in detail above. The tapered opening provided at channels86, as shown inFIG. 4, may facilitate the alignment of bearing bosses82with channels86. Once hinge nodes80,84are substantially axially aligned, hinge pin26may be installed to fix door12to panel14.

At this point, door12may be moved laterally and/or vertically using the adjustability provided by hinge assemblies20, as described above. When a desired alignment between door12and panel14has been achieved, fasteners70are tightened to fix door12in the desired position.

Turning now toFIGS. 8 and 9, an alternative hinge embodiment is illustrated in which hinge assembly120provides angular adjustment between the longitudinal axes of hinge nodes80and84. In particular, hinge assembly120is configured to allow the longitudinal axes of hinge halves122and124to be askew within a predetermined range of adjustability, thereby providing yet another mode of adjustment between door12and panel14.

Hinge assembly120includes floating bushings30captured in bushing seats38by retainer plates50, in the same manner as described in detail above with respect to hinge assembly20. Moreover, hinge assembly120is similarly constructed to hinge assembly20, and corresponding structures and features of hinge assembly120have corresponding reference numerals to hinge assembly20, except with100added thereto.

However, hinge assembly120utilizes pivot pin126having a spherical head127as illustrated inFIG. 8. As best seen inFIG. 9, spherical head127is received within a correspondingly spherical seat within hinge bore196of pivotable hinge body128. Pin cover192also includes a spherical seat for the top portion of spherical head127, and is threadably received within hinge bore196to axially capture hinge pin126within bore196. The cylindrical shaft of hinge pin126passes through hinge bearings176and hinge bearing sleeve177, both of which are coupled to hinge node180in a similar fashion to bearings76and hinge node80as described above. Moreover, bearings76may also be used in connection with pin126as required or desired for a particular design, and bearing nodes180and184may be modified to include the tolerancing and assembly features described above with respect to nodes80and84.

The distal end of hinge pin126receives a second bushing or spherical insert127A having a shape and size similar to spherical head127. A second pin cover192may be threaded into the second bearing node184as illustrated inFIGS. 8 and 9. At this point, hinge halves122and124are pivotably coupled to one another in a similar fashion to the pivotable coupling of hinge halves22and24described above. However, the spherical shape of pin head127and bushing127A cooperate with their correspondingly spherical seats to allow the longitudinal axes of hinge node80and nodes84to be non-coaxial (i.e., askew), forming an angle relative to one another within predetermined limits.

In particular,FIG. 9illustrates oversized cylindrical bores197which receive the cylindrical portion of hinge pin126with substantial clearance. In an exemplary embodiment, for example, the outer diameter of pin126may be smaller than the adjacent inner diameter of bore197to define a total clearance between 0.030 and 0.070 inches. In the illustrated embodiment, for example, this clearance is 0.050 inches (such that the gap between pin126and bore197is 0.025 inches on either side of pin126when centered). Hinge halves122and124may therefore be angled with respect to one another until the wall of one or both of hinge bores197impact the outer surface of hinge pin126. In an exemplary embodiment, this angular adjustment may be up to 3 degrees, 5 degrees, or 7 degrees in either direction, for example.

Upon installation, each hinge assembly120may be adjusted angularly to accommodate the desired spatial arrangement between door12and the surrounding structures, including hinge panel14, header40, footer42, and latch panel16. When both hinge assemblies120(i.e., the upper and lower hinge assemblies) are fixed into place with respect to door12and hinge panel14, the angular adjustment is also fixed.