Vertical and horizontal adjustable hinge assembly

A method and apparatus providing an adjustable hinge configured for a fence post and gate assembly of a fence. The adjustable hinge includes a first bracket operable to be secured to a first portion of the fence and a second bracket operable to be secured to a second portion of the fence. The adjustable hinge also includes a vertical adjustment component, a horizontal adjustment component, a hinge barrel and a collar. The vertical adjustment component is operably coupled to the first bracket and the horizontal adjustment component is operably coupled to the second bracket. The hinge barrel is operable to be rotatably coupled to the vertical adjustment component and the horizontal adjustment component. The collar is operable to be rotatably coupled to the horizontal adjustment component and is operably coupled to the second bracket. With this arrangement, the hinge barrel is operable to be moveable along the vertical adjustment component to vertically adjust the second bracket with respect to the first bracket. Furthermore, the collar is operable to be moveable along the horizontal adjustment component to horizontally adjust the second bracket with respect to the first bracket.

FIELD OF THE INVENTION

The present invention relates generally to hinge technology. More particularly, the present invention relates to a vertically and horizontally adjustable hinge and various means for carrying out vertical and horizontal adjustment of the hinge for proper and accurate alignment of the hinged components.

BACKGROUND OF THE INVENTION AND RELATED ART

Successfully aligning two hinged components or hinged component assemblies together, such as a hinged gate and fence post assembly, in both the horizontal and vertical directions, can be very difficult. The task of aligning is made all the more difficult in the case of assembling hinged components together that are both large and with heavy. For example, aligning double gates to their fence post counterparts often requires multiple installers, including several to position and hold the gates while others fasten and mount the hinges to the fence posts and the gates. This invariably leads to misalignment of the gates with the fence posts once both sides of the gates are mounted. Misalignment may be the result of improper initial alignment due to misjudgment in the position of the hinges on the respective counterparts. Or, misalignment may occur once the gates are allowed to hang under their own weight. Although the gates and the posts may have been aligned initially, the gates, under their own weight, may cause the hinges to sag. This is especially true over time. For instance, significant settling of the fence and/or gate posts may occur, thus contributing to the misalignment. Or, extended use and environmental conditions may contribute to the misalignment. Another contributing factor to misalignment is the change in ground conditions, such as a rise or fall in grass thatch, shifting or elevational changes in sidewalks, driveways, etc.

In any event, the difficulty in properly aligning the gates to the fence posts using prior known hinges and methods can lead to poor work quality and improper operating relationship between the hinged components. This is particularly true if initial alignment is off, which can occur as installers are often under significant time constraints. If the hinged components are not properly aligned, but the components still function, installers will typically consider the job finished. In those circumstances where the hinged components do not function properly, installers must dismount the hinges and then remount such hinges until proper alignment is obtained. This often leaves unsightly marks and/or holes in the hinged components that must be masked if possible. Proper alignment of hinged components is made even more difficult when the hinged components are supported on a sloped elevation.

Recent hinge technology has addressed some of these alignment problems by providing various embodiments of a hinge assembly capable of adjusting one hinged component relative to the other in the horizontal direction. One such exemplary hinge assembly includes a post bracket and a gate bracket, separable from one another, with a horizontal screw fixed to a vertical pin mounted to the post bracket. The gate bracket is slidably mounted to the horizontal screw with a collar. The gate bracket maintains a position with respect to the horizontal screw with two nuts rotatably mounted to the horizontal screw on both sides of the collar. Horizontal movement of the gate bracket is carried out by rotating one nut about the horizontal screw to another position, sliding the collar to abut the one nut and then rotating the other nut against the collar to place the collar in a fixed position. However, this arrangement for horizontal adjustment is difficult due to the tedious nature of rotating each nut to a new position on the horizontal screw. Moreover, due to the design configuration of the gate and post brackets, little room is available for turning and tightening the nuts. Such horizontal adjustment is even more problematic when it is required on multiple hinge assemblies, such as for an upper and lower hinge on each side of a two-panel gate, as is often the case.

Other types of hinges for mounting doors to a doorjamb of a home have also addressed vertical alignment issues. For example, U.S. Pat. No. 6,212,734 to Commons, U.S. Pat. No. 5,933,919 to Miller et al., and U.S. Pat. No. 4,381,580 to Hellstrom et al. each disclose a hinge assembly having a first hinge and a second hinge for mounting to a respective door frame and door. However, the vertical adjustment for each hinge assembly disclosed in these references is limited to under half the effective length of the vertical pin coupling the first and second hinges together. Such limited vertical adjustment does not solve the large vertical adjustments needed for a large and heavy fence and gate assembly and, further, does not solve several inherent operating or functioning issues, such as that of binding the mounting portions of the hinge assembly during operation or actuation of the gate. Binding may occur when one hinge is adjusted more than its complementary hinge. Furthermore, these prior related hinge assemblies are primarily configured for use with lightweight doors in interior settings, rather than for large and heavy hinged components, such as the fence and gate assembly discussed above.

SUMMARY OF THE INVENTION

It has been recognized that it would be advantageous to provide an improved hinge or hinge assembly well suited for any sized and configured hinged component assembly, but that is primarily suited for larger, heavier, and more bulky hinged component assemblies, such as a fence post and gate assembly, wherein the hinged assembly facilitates the selective and ready adjustment of the hinge assembly, and therefore the hinged component assembly, in both the vertical and horizontal directions, thus achieving more efficient, accurate, and proper alignment of the hinged component assembly without requiring the removal or dismounting of the hinge assembly. Further, it would be advantageous to provide a hinge assembly that addresses and accomplishes vertical and horizontal adjustment without binding the joints between the hinge assembly and the hinged component assembly. Still further, it would be advantageous to provide a hinge assembly configured for easy installation and adjustment without the need for multiple installers.

In light of the foregoing, and in accordance with the invention as embodied and broadly described herein, the present invention features an adjustable hinge assembly configured for use with various hinged components or hinged component assemblies. The adjustable hinge assembly comprises: (a) a post bracket operable to be secured to the post of a fence; (b) a gate bracket operable to be secured to a portion of the gate; (c) a vertical adjustment component operably coupled to the post bracket; (d) a horizontal adjustment component operably coupled to the gate bracket; (e) a hinge barrel operable to be rotatably coupled to the vertical adjustment component and the horizontal adjustment component, the hinge barrel operable to be moveable along the vertical adjustment component to vertically adjust the gate bracket with respect to the post bracket; and (f) a collar operable to be rotatably coupled to the horizontal adjustment component and operably coupled to the gate bracket, the collar operable to be moveable along the horizontal adjustment component to horizontally adjust the gate bracket with respect to the post bracket.

The present invention further features an adjustable hinge configured for a post and gate assembly of a fence, the hinge comprising: (a) a first bracket operable to be secured to a first portion of the fence; (b) a second bracket operable to be secured to a second portion of the fence; (c) a vertical adjustment component operably coupled to the first bracket; (d) a horizontal adjustment component operably coupled to the second bracket; (e) a hinge barrel operable to be rotatably coupled to the vertical adjustment component and the horizontal adjustment component, the hinge barrel operable to be moveable along the vertical adjustment component to vertically adjust the second bracket with respect to the first bracket; and (f) a collar operable to be rotatably coupled to the horizontal adjustment component and operably coupled to the second bracket, the collar operable to be moveable along the horizontal adjustment component to horizontally adjust the second bracket with respect to the first bracket.

The present invention further features a vertically adjusting hinge system configured for a post and gate assembly of a fence, the hinge system comprising: (a) a first adjustable hinge operable to be positioned on the fence, the first adjustable hinge including: a first bracket and a second bracket respectively operable to be secured to a first portion and a second portion of the fence; a first vertical adjustment component operably coupled to the first bracket; a first hinge barrel operable to be rotatably coupled to the first vertical adjustment component and operably coupled to the second bracket, the first hinge barrel operable to be moveable along the first vertical adjustment component to vertically adjust the second bracket with respect to the first bracket; a second adjustable hinge operable to be positioned on the fence and spaced vertically from the first adjustable hinge, the second adjustable hinge including: a third bracket and a fourth bracket respectively operable to be secured to a third portion and a fourth portion of the fence; a second vertical adjustment component operably coupled to the third bracket and operable to be substantially vertically aligned with the first vertical adjustment component with a space therebetween; a second hinge barrel operable to be rotatably coupled to the second vertical adjustment component and operably coupled to the fourth bracket, the second hinge barrel operable to be moveable along the second vertical adjustment component to vertically adjust the fourth bracket with respect to the third bracket; a vertical-adjustment tool operable to be removably coupled between the first vertical adjustment component and the second vertical adjustment component, the vertical-adjustment tool operable to facilitate simultaneous rotation of the first vertical adjustment component and the second vertical adjustment component upon rotation of at least one of the first vertical adjustment component and the second vertical adjustment component, the vertical-adjustment tool operable to facilitate simultaneous movement with common linear displacement of the second bracket and the fourth bracket with respect to the first bracket and the third bracket, respectively, through movement of the first hinge barrel and the second hinge barrel along the first vertical adjustment component and the second vertical adjustment component, respectively.

The present invention further features a vertically adjusting hinge system configured for assembling a gate to a fence, the hinge system comprising: (a) a first adjustable hinge having a first portion and a second portion and configured to be operably coupled to the fence; (b) a first vertical adjustment component operably coupled to the first adjustable hinge; (c) a second adjustable hinge having a third portion and a fourth portion and configured to be operably coupled to the fence and spaced vertically from the first adjustable hinge; (d) a second vertical adjustment component operably coupled to the second adjustable hinge; (e) a vertical-adjustment tool operable to be removably coupled between the first vertical adjustment component and the second vertical adjustment component, the vertical-adjustment tool operable to facilitate simultaneous rotation of the first vertical adjustment component and the second vertical adjustment component upon rotation of at least one of the first vertical adjustment component and the second vertical adjustment component to facilitate simultaneous movement with common linear displacement of the second portion and the fourth portion with respect to the first portion and the third portion, respectively.

The present invention further features a vertical-adjustment tool configured to simultaneously vertically adjust an upper hinge and a lower hinge, the upper hinge having a first portion and a second portion with a first vertical adjustment component operably coupled thereto and the lower hinge having a third portion and a fourth portion with a second vertical adjustment component operably coupled thereto, the vertical-adjustment tool comprising: (a) a shaft having a first end and a second end; and (b) at least one extension member operable to be coupled and spring-loaded at the first end of the shaft; wherein the at least one extension member of the shaft is operable to be removably coupled respectively between the first vertical adjustment component and the second vertical adjustment component, the shaft operable to facilitate simultaneous rotation of the first vertical adjustment component and the second vertical adjustment component upon rotation of at least one of the first vertical adjustment component and the second vertical adjustment component to facilitate simultaneous movement with common linear displacement of the second portion and the fourth portion with respect to the first portion and the third portion, respectively.

The present invention further features an adjustable hinge configured for a post and gate assembly of a fence, the hinge comprising: (a) a first bracket operable to be secured to a first portion of the fence; (b) a second bracket operable to be secured to a second portion of the fence; (c) a vertical adjustment component having a longitudinal length, the vertical adjustment component operably coupled to the first bracket so that the vertical adjustment component is vertically positioned and suspended laterally from the first bracket, the vertical adjustment component including a threaded outer surface along at least half the longitudinal length of the vertical adjustment component; and (d) a hinge barrel operable to be rotatably coupled to the vertical adjustment component and operably coupled to the second bracket, the hinge barrel including a threaded inner surface having a thread configuration corresponding to a thread configuration of the threaded outer surface of the vertical adjustment component, the hinge barrel operable to movably traverse along at least half the longitudinal length of the vertical adjustment component upon rotation of the vertical adjustment component to vertically adjust the second bracket with respect to the first bracket.

The present invention further features an adjustable hinge configured for a post and gate assembly of a fence, the hinge comprising: (a) a fixed bracket operable to be secured to a fence post; (b) a movable bracket operable to be secured to a movable portion of the fence; and (c) a vertical adjustment component having a longitudinal length with un upper coupling portion and a lower coupling portion, the vertical adjustment component operably coupled to the fixed bracket at the upper coupling portion and the lower coupling portion so that the vertical adjustment component is vertically positioned and suspended laterally from the fixed bracket; (d) wherein the movable bracket is operably coupled to the vertical adjustment component and operable to movably traverse substantially an entire distance defined between the upper coupling portion and the lower coupling portion along the longitudinal length of the vertical adjustment component so that the movable bracket is vertically movable with respect to the fixed bracket.

The present invention further features an adjustable hinge configured for a post and gate assembly of a fence, the hinge system comprising: (a) a first bracket operable to be secured to a first portion of the fence; (b) a second bracket operable to be secured to a second portion of the fence; (c) a horizontal adjustment component operably coupled to the second bracket and the first bracket, the horizontal adjustment component including a threaded outer surface; and (d) a collar operable to be rotatably coupled to the horizontal adjustment component and operably coupled to the second bracket, the collar including a threaded inner surface operable to substantially match the threaded outer surface of the horizontal adjustment component, the collar operable to be moveable along the horizontal adjustment component upon rotation of the horizontal adjustment component to horizontally adjust the second bracket with respect to the first bracket.

The present invention further features a horizontally adjusting hinge system configured for assembling a gate to a fence, the hinge system comprising: (a) a first adjustable hinge having a first portion and a second portion and configured to be operably coupled to the fence; (b) a first horizontal adjustment component operably coupled to the first adjustable hinge; (c) a second adjustable hinge having a third portion and a fourth and configured to be operably coupled to the fence and spaced vertically from the first adjustable hinge; (d) a second horizontal adjustment component operably coupled to the second adjustable hinge; (e) a horizontal-adjustment tool operable to be removably coupled between the first horizontal adjustment component and the second horizontal adjustment component, the horizontal-adjustment tool operable to facilitate simultaneous rotation of the first horizontal adjustment component and the second horizontal adjustment component upon rotation of at least one of the first horizontal adjustment component and the second horizontal adjustment component to facilitate simultaneous horizontal movement with common linear displacement of the second portion and the fourth portion with respect to the first portion and the third portion, respectively.

The present invention further features a horizontal-adjustment tool configured to simultaneously horizontally adjust an upper hinge and a lower hinge, the upper hinge having a first portion and a second portion with a first horizontal adjustment component operably coupled thereto and the lower hinge having a third portion and a fourth portion with a second horizontal adjustment component operably coupled thereto, the horizontal-adjustment tool comprising: (a) a vertical shaft having a first end and a second end with an extendable portion therebetween; (b) a first gear member coupled to the first end of the vertical shaft and operable to translate rotation between the first horizontal adjustment component and the vertical shaft; and (c) a second gear member coupled to the second end of the vertical shaft and operable to translate rotation between the second horizontal adjustment component and the vertical shaft, wherein the first gear member and the second gear member are operable to be operably coupled respectively to the first horizontal adjustment component and the second horizontal adjustment component, the vertical shaft coupled to the first gear member and the second gear member each operable to act in conjunction to facilitate simultaneous rotation of the first horizontal adjustment component and the second horizontal adjustment component upon rotation of at least one of the first horizontal adjustment component and the second horizontal adjustment component to facilitate simultaneous horizontal movement with common linear displacement of the second portion and the fourth portion with respect to the first portion and the third portion, respectively.

The present invention further features an adjustable hinge system for a post and gate assembly, comprising: (a) a post bracket operable to be secured to the post of a fence; (b) a gate bracket operable to be secured to a portion of the gate; (c) a vertical hinge barrel coupled to the post bracket; (d) a horizontal adjustment component operably coupled to the gate bracket and the vertical hinge barrel; and (e) a horizontal collar movably coupled to the horizontal adjustment component and operably coupled to the gate bracket, the horizontal collar operable to be moveable along the horizontal adjustment component to horizontally adjust the gate bracket with respect to the post bracket.

The present invention further features various embodiments of a gap filler configured to cover the gap between the hinged components, and to improve the visual look of the hinged component assembly. The gap filler typically extends the entire length or height of the gap.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following detailed description of exemplary embodiments of the invention makes reference to the accompanying drawings, which form a part hereof and in which are shown, by way of illustration, exemplary embodiments in which the invention may be practiced. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art practice the invention, it should be understood that other embodiments may be realized and that various changes to the invention may be made without departing from the spirit and scope of the present invention. Thus, the following more detailed description of the embodiments of the present invention, as represented inFIGS. 1 through 54, is not intended to limit the scope of the invention, as claimed, but is presented for purposes of illustration only and not limitation to describe the features and characteristics of the present invention, to set forth the best mode of operation of the invention, and to sufficiently enable one skilled in the art to practice the invention. Accordingly, the scope of the present invention is to be defined solely by the appended claims.

The following detailed description and exemplary embodiments of the invention will be best understood by reference to the accompanying drawings, wherein the elements and features of the invention are designated by numerals throughout.

In general, the present invention describes an adjustable hinge or adjustable hinge assembly for pivotally coupling together various types of hinged components, such as a gate to a fence, a door to a doorjamb, and others. The present invention adjustable hinge provides both horizontal and vertical adjustment of the hinged components with respect to one another through the manipulation of vertical and horizontal adjustment components operable as part of the adjustable hinge assembly. Several different embodiments of the hinge assembly are described and set forth herein, as well as various accessory components and tools operable with the hinge assembly.

As such, the following more detailed description is divided into sections for convenience to the reader.

Vertically and Horizontally Adjusting Hinge Assembly

With reference toFIGS. 1,1-A, and2, illustrated is an adjustable hinge assembly10(hereinafter adjustable hinge10) according to one exemplary embodiment, wherein the adjustable hinge10is configured to be mountable to a hinged component assembly for the purpose of pivotally supporting the separate hinged components making up the hinged component assembly, and for facilitating both the horizontal and vertical alignment of the hinged components with respect to one another. One type of exemplary hinged component assembly comprises a post and gate assembly, such as the one shown and illustrated inFIGS. 1–2, wherein one hinged component is comprised of a post2and the other is comprised of a gate4. The post and gate-type hinged assembly, although exemplary, will be used herein in describing the configurations and functions of the present invention adjustable hinge. Of course, other types, designs, styles, and configurations of hinged component assemblies are contemplated. As such, the post-type and gate-type hinged component assembly should not be construed as limiting in any way.

In effect, the adjustable hinge10is configured to secure in place and align the hinged components relative to one another, as well as to facilitate the pivoting or rotation of at least one hinged component about the other. An advantage of the present invention adjustable hinge10over prior related hinges is that it is also configured to selectively facilitate both vertical and horizontal adjustment of the hinge, and therefore the hinged components, relative to one another by way of the vertical adjustment component50and the horizontal adjustment component80. Vertical and/or horizontal adjustment of the hinge assembly10may be effectuated at any time, such as during installation or after installation at periodic times as needed, by rotating or driving one or both of the vertical and horizontal adjustment components50and80. Moreover, the adjustable hinge10is configured to provide the ability to achieve both considerable or fine adjustments in both the horizontal and vertical directions, depending upon the degree of misalignment of the hinged components. It should be recognized herein that adjustment of the adjustable hinge10, and therefore the hinged components attached or coupled to the adjustable hinge10is achieved by rotating or turning the vertical and horizontal adjustment components50and80. Unlike many prior related hinges or hinge assemblies where the hinge components are stationary, or that require manipulation of the bracket, the spinning nature of the vertical and horizontal adjustment components50and80and their interaction with the fixed structural components on each of the respective post and gate brackets20and30allows these components to be individually and selectively turned to effect adjustment within the adjustable hinge10.

As shown, the adjustable hinge10comprises a post bracket20configured to engage with and be mounted to a post2, and a gate bracket30configured to engage with and be mounted to a gate4. The post bracket20comprises at least one post mounting portion22sized and configured to interface with at least a portion of a surface of the post2. In a more preferred embodiment, such as the one shown, the post bracket20comprises first and second post mounting portions22-aand22-bin the form of flanges that are offset from one another in a substantially perpendicular orientation, wherein each of the post mounting portions22-aand22-bcomprise one or more mounting holes24formed and extending therethrough. The post mounting portions22-aand22-bare sized and configured to engage and abut complementary sides of the post2. The post mounting portions22can be mounted and secured to the post2with any suitable fastener, such as bolts, screws, rivets, etc., through the mounting holes24. The post bracket20also comprises an extension portion26formed between the post mounting portions22-aand22-b. The extension portion26of the post bracket20functions to offset a pivot bracket40coupled thereto, and therefore the vertical adjustment component50, from the post mounting portions22. The pivot bracket40includes a back portion42with arm members44extending orthogonally, in a common direction, from longitudinal ends of the back portion42. The back portion42can be secured to an inside surface of the extension portion26so that the arm members44extend outward from the extension portion26and post2. Each of the arm members44includes an arm opening46defined therethrough so that each arm opening46is aligned with the other. Such arm openings46are sized and configured to receive the vertical adjustment component50so that the vertical adjustment component50is rotatably coupled, end-to-end, within the arm openings46. In this manner, the vertical adjustment component50is positioned vertically between the arm members44and supported laterally away or offset from the post mounting portion22of the post bracket20.

Moreover, the pivot bracket40may be situated on an angle. As shown, the extension portion26supporting the pivot bracket40comprises extension sides of two different lengths, thus allowing the extension portion26to be racked out at an angle. Supporting the pivot bracket40on the extension portion26allows the pivot bracket40to be racked out and oriented on an angle as well. In the exemplary embodiment ofFIG. 2-A, the pivot bracket40is shown oriented on an angle θ with respect to the post mounting portion22-a. As so oriented, the back portion42of the pivot bracket40comprises one edge in contact with the corner of the post2, with the opposing edge offset from the post2.

Having the extension portion26and the pivot bracket40, and therefore the hinge barrel60, racked out at an angle and having an edge of the back portion42in contact with the corner of the post2has several advantages. First, it provides a purchase or register for locating the post bracket20on the post2while mounting adjustable hinge10to the post2. One edge of the back portion42of the pivot bracket40contacts the post2at its corner to set the proper depth for the post mounting portion22-b. Once set, the post mounting bracket20may be properly secured in place. As such, installation accuracy is greatly improved. Second, the geometries and configuration of the adjustable hinge10are improved. Third, greater access is provided for power tools to engage both driving components56and88of the vertical and horizontal adjustment components50and80, thus allowing both vertical and horizontal adjustments to be made with ease. Fourth, the extended geometry reduces the likelihood that the horizontal adjustment component80will bind with the post bracket20before the gate4hits the fence during an overswing situation (such as in the case of a double gate). Fifth, the moment of torque that the adjustable hinge must withstand in the event the gate4does hit the fence is reduced. Other advantages will be apparent to those skilled in the art.

As indicated, the adjustable hinge10comprises a vertical adjustment component50operably coupled to the extension portion26of the post bracket20to facilitate vertical adjustment of the gate4with respect to the post2by rotation of the vertical adjustment component50. As depicted, the extension portion26can extend outward from the post mounting portions22-aand22-bin a racked-out manner so as to off-set the vertical adjustment component50from the surface of the post2at a pre-determined distance. In operation, the vertical adjustment component50is configured to selectively facilitate the vertical adjustment and alignment of the post bracket20with respect to the gate bracket30, and therefore the post2with respect to the gate4as attached thereto, respectively, by rotating or being rotated. Indeed, actuating the vertical adjustment component50effectively functions to raise or lower the gate bracket30, and therefore the gate4, as the post bracket20is typically secured to the post2, which is anchored to the ground. As will be recognized by one skilled in the art however, as configured, actuation of the vertical adjustment component50may function to raise or lower either the post bracket20or the gate bracket30, such as during installation.

The vertical adjustment component50can include a threaded outer surface52. Such threaded outer surface52can extend continuously along at least a portion of the longitudinal length of the vertical adjustment component50and/or extend continuously along substantially an entire distance of the longitudinal length between portions of the vertical adjustment component50coupled to the arm members44of the pivot bracket40. The vertical adjustment component50also includes a driving component56located at each end of the vertical adjustment component50. Such a driving component56can be a recessed portion formed within the ends of the vertical adjustment component50or the driving component56can be an independent structure coupled to the ends of the vertical adjustment component50. In either case, the driving component56is configured to receive with a tool, such as a hex drive bit, capable of rotatably driving the vertical adjustment component50to effectuate vertical adjustment within the adjustable hinge10. The driving component56, or at least the portion thereof receiving the tool, can be configured with any suitable geometric shape, such as a hex shape, that is formed to receive or mate with a common sized and shaped and complementary driving tool, such as a hex shaped hex drive bit.

With respect toFIGS. 1 and 1(a), the vertical adjustment component50can be coupled to a hinge barrel60. The hinge barrel60can include a bore62extending longitudinally therethrough. Such hinge barrel60can include a threaded inner surface64having a thread configuration corresponding to a thread configuration of the threaded outer surface52of the vertical adjustment component50. With this arrangement, as the vertical adjustment component50is caused to be rotated, the hinge barrel60displaces vertically or is vertically displaced about the vertical adjustment component50via the mating relationship between the threaded inner surface64of the hinge barrel60and the threaded outer surface52of the vertical adjustment component50. The hinge barrel60displaces vertically upward or downward depending on the rotational direction induced within the vertical adjustment component50. For example, rotation of the vertical adjustment component50in the direction indicated by rotational arrow51functions to displace the hinge barrel60vertically upward about the vertical adjustment component50, as indicated by arrow61. Likewise, rotation of the vertical adjustment component50in the opposite direction, as indicated by rotational arrow53, functions to displace the hinge barrel vertically downward about the vertical adjustment component50, as indicated by arrow63. As the hinge barrel60is integrally formed with or coupled to the swivel joint70coupling the horizontal adjustment component80, and as the horizontal adjustment component80is operably coupled to the gate bracket30through the collar90, any bi-rotational adjustment or manipulation of the vertical adjustment component50that results in vertical bi-directional movement or displacement of the hinge barrel60, translates into a corresponding vertical bi-directional movement or displacement of the gate bracket30, and therefore the gate4, due to the fact that the post2is typically anchored into the ground and incapable of movement. As such, bi-rotationally adjusting or manipulating the vertical adjustment component50functions to raise or lower the gate4with respect to the post2, thus allowing the gate4and the post2to be properly aligned in the vertical. Of course, as will be recognized by one skilled in the art, in the event the hinged components within a hinge assembly comprise two moveable structures (rather than one being anchored), bi-rotational adjustment or manipulation of the vertical adjustment component50may translate into the vertical bi-directional displacement of either hinged component, depending upon the particular configuration of the hinge assembly.

With reference again toFIGS. 1–2-B, the adjustable hinge10further comprises a horizontal adjustment component80operably coupled to the gate bracket30, wherein the horizontal adjustment component80is configured to facilitate the horizontal adjustment and alignment of the post bracket20with respect to the gate bracket30, and therefore the post2with respect to the gate4as attached thereto, respectively. The gate bracket30comprises at least one gate mounting portion32sized and configured to interface with at least a portion of one or more surfaces of the gate4. In a more preferred embodiment, such as the one shown, the gate bracket30comprises first and second gate mounting portions32-aand32-bin the form of flanges that are offset from one another in a substantially perpendicular orientation, wherein each of the gate mounting portions32-aand32-bcomprise one or more mounting holes34formed and extending therethrough. The gate mounting portions32-aand32-bare sized and configured to engage and abut complementary sides of the gate4. The gate mounting portions32can be mounted and secured to the gate4with any suitable fastener, such as bolts, screws, rivets, etc., placed through the mounting holes34. The gate bracket30further comprises a raised portion36formed with and extending outward from the gate mounting portion32-b. Such raised portion36is configured to support the horizontal adjustment component80. Moreover, the raised portion36is configured to extend outward a distance in order to located the horizontal adjustment component80in an offset manner from the gate mounting portion32-b, as well as to locate and support the horizontal adjustment component80substantially within a common plane as the vertical adjustment component50.

As shown inFIGS. 1–2-B, the horizontal adjustment component80is supported on the raised portion36by a collar90, which is securely coupled to the raised portion36. The collar90can be securely fixed to an outer surface of the raised portion36by any suitable means, such as welding. The collar90includes a collar bore92sized and configured to receive the horizontal adjustment component80. The collar bore92can include a threaded inner surface94, or it may comprise a smooth inner surface and some type of securing means to keep the horizontal adjustment component80in place.

Referring again toFIGS. 1 and 2, similar to the vertical adjustment component50, the horizontal adjustment component80can include a threaded outer surface82having a thread configuration corresponding to a thread configuration of the threaded inner surface94of the collar90. As such, rotation of the horizontal adjustment component80, as indicated by bi-rotational arrow81, facilitates horizontal movement of the collar90about the horizontal adjustment component80, as indicated by bi-linear arrow91, via the threaded inner surface94of the collar90and the threaded outer surface84of the horizontal adjustment component80. The threaded outer surface82can extend continuously along at least a portion of the longitudinal length of the horizontal adjustment component80between a first end portion84and a second end portion86(seeFIG. 3), or the threaded outer surface82can extend continuously along substantially an entire distance of the longitudinal length of the horizontal adjustment component80between the first and second end portions84and86.

The first end portion84of the horizontal adjustment component80can be a free-end, as shown, and can comprise a driving component88located thereon, wherein the driving component88is configured in a similar manner as the driving component previously set forth above in discussing the vertical adjustment component50. As such, the driving component88is configured to receive and be rotationally driven by a tool, such as a drill having a complementary hex drive bit supported therein. Preferably, the driving component56of the vertical adjustment component50is the same as the driving component88of the horizontal adjustment component80for ease and speed of installation.

The second end portion86of the horizontal adjustment component80is operably coupled to the hinge barrel60so that the horizontal adjustment component80and the gate bracket30are allowed to pivot about the hinge barrel60, and more particularly about the vertical adjustment component80and the post bracket20. In one exemplary embodiment, the end portion86of the horizontal adjustment component80is coupled to the hinge barrel60through use of a swivel joint70. The swivel joint is operably coupled to the hinge barrel60via any known attachment or coupling means, such as welding, soldering, etc., and the horizontal adjustment component80is operably coupled to the swivel joint70using any known means for coupling. The swivel joint70functions to prevent separation of the horizontal adjustment component80and the hinge barrel60, while at the same time allowing the horizontal adjustment component80to spin or rotate within the swivel joint70for adjustment purposes. It is also by means of the hinge barrel60and swivel joint70that the post bracket20and gate bracket30are operably coupled to each other such that the gate bracket30is allowed to pivot or rotate about the post bracket30when the adjustable hinge10is properly installed, thus allowing the gate4to open and close.

The swivel joint70can extend orthogonally from the hinge barrel60and can include a swivel bore (not shown) configured to receive an end portion of the horizontal adjustment component80. With this arrangement, the horizontal adjustment component80, as disposed within the swivel joint70and the collar90, and the vertical adjustment component50, as disposed within the hinge barrel60, are positioned substantially orthogonal with respect to one another and are positioned in substantially a common plane.

With the post bracket20and gate bracket30operably coupled to each other via the hinge barrel60and swivel joint70, rotation of the horizontal adjustment component80facilitates movement or displacement of the collar90about the longitudinal length of the horizontal adjustment component80, and thus, horizontal movement of the gate bracket30with respect to the post bracket20, and also the gate4with respect to the post2. The available distance the collar90is allowed to displace or traverse about the horizontal adjustment component80corresponds to the dimensions of the collar90, as well as the number of threads making up the threaded outer surface82. Such a distance can vary depending on the chosen dimensions of the horizontal adjustment component80, the number of threads, and the size of the collar90as long as structural integrity is maintained in the adjustable hinge10and as will be recognized by those skilled in the art.

Likewise, rotation of the vertical adjustment component50facilitates movement or displacement of the hinge barrel60about the longitudinal length of the vertical adjustment component50, and thus, vertical movement of the gate bracket30with respect to the post bracket20, and also the gate4with respect to the post2. The available distance the hinge barrel60is allowed to displace or traverse about the vertical adjustment component50corresponds to the dimensions of the hinge barrel60, as well as the number of threads making up the threaded outer surface52of the vertical adjustment component50. This distance can vary to any suitable distance depending on the chosen dimensions of the vertical adjustment component50, the number of threads, and the size of the hinge barrel60as long as structural integrity is maintained in the adjustable hinge10and as will be recognized by those skilled in the art.

The adjustable hinge10further comprises optional means for biasing the hinged component assembly, such that as one hinged component pivots about the other, it does so in a biased manner. Means for biasing functions to induce a moment force within the adjustable hinge10, which moment force creates a tendency within the adjustable hinge10to pivot the hinged components to a reduced force position, such as a closed position. Means for biasing may comprise any type known in the art, such as a torsion spring, a coil spring, a gravity-cam system, and others. In addition, means for biasing may be configured in several different ways to bias one hinged component with respect to the other. In the embodiment shown, means for biasing comprises an external torsional spring100that is disposed about the vertical adjustment component50and that engages both the post bracket20and the swivel joint70. The external torsional spring100is located below and adjacent the hinge barrel60. In this arrangement, the torsional spring100biases the pivoting gate bracket30with respect to the post bracket20, particularly as the gate bracket30is pivoted away from its closed position. Other torsional spring configurations and placement positions are contemplated, such as above the hinge barrel60, or on both sides of the hinge barrel60. In addition, one continuous double spring may be utilized on both sides of the swivel joint70to add spring strength and durability. In essence, the adjustable spring10allows the gate4to swing open and closed, or pivot, about the post2, while means for biasing functions to induce a force within the adjustable hinge10that tends to cause the gate4to swing or pivot from a respectively increased moment force position (e.g., an open position) to a respectively reduced moment force position (e.g., a closed position). The function and concept of means for biasing, as applied to a hinge or hinge assembly, is well known in the art, and is therefore not discussed in any greater depth herein.

As indicated above, the horizontal adjustment component80is coupled to the swivel joint70using any means for coupling known to those skilled in the art. Several different exemplary means for coupling are presented herein. However, these are not meant to be limiting in any way, but are merely set forth to provide an illustration of some of the different variations of the several possible means for coupling. One exemplary embodiment of means for coupling is illustrated inFIG. 3-A, wherein means for coupling comprises a fastener102having a head portion106and a threaded shaft portion110for coupling to the horizontal adjustment component80. The fastener102is located between the swivel joint70and the horizontal adjustment component80, and functions to securely couple the horizontal adjustment component80within the swivel joint70. Specifically, as shown, the swivel joint70comprises a swivel bore72defined therethrough with the second end portion86of the horizontal adjustment component80at least partially extending and contained within the swivel bore72. In this embodiment, the second end portion86can include a recessed portion formed within the second end portion86configured to receive the fastener102therein. The fastener102is configured to facilitate the rotatable coupling of the horizontal adjustment component80within the swivel joint70in that the head106of the fastener102abuts with and slidably rotates against or about a ledge74defined or formed within the inner surface of the swivel bore72. As such, the head106of the fastener102includes a larger diameter than a diameter of the horizontal adjustment component80. The fastener102can be any suitable fastener, such as a screw, bolt, rivet, etc., and is shown inFIG. 3as a screw.

FIG. 3-Billustrates another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. This embodiment is similar to the embodiment ofFIG. 3-Ain that a bore72is formed or defined with in the swivel joint70, wherein the bore72comprises a ledge74. However, unlike the embodiment ofFIG. 3-Awhere an independent fastener is coupled to the end portion86of the horizontal adjustment member80, in this embodiment, the horizontal adjustment component80comprises a flange portion116located on its end portion86. The flange portion116can be configured as an annular member that extends outward from the end portion86of the horizontal adjustment component80, or it can be configured to comprise segments that extend outward from the end portion86. Similar to the fastener102inFIG. 3-A, the flange portion116is configured to abut with and slidably rotate about or against the ledge74formed in the swivel bore72. In one aspect, the flange116can be formed from the end portion86itself by any suitable method, such as by stamping to form a swage, upset or flare. In another aspect, the flange116may be a separate structural member molded and/or welded to the end portion86. In still another aspect, the flange116may comprise a separate structural member that is removably coupled to the end portion86. In any event, the flange portion116comprises a larger diameter than the horizontal adjustment component80, and suitable to extend over the ledge74to secure the horizontal adjustment component80in place within the swivel joint70.

FIGS.3-C–3-D illustrate still another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. In this embodiment, the horizontal adjustment component80comprises a continuous annular groove120formed in its second end portion86. The inside surface of the swivel joint70comprises a protrusion124sized and configured to correspond with the annular groove120to couple the horizontal adjustment component80to and within the swivel joint70, as well as to facilitate rotation of the horizontal adjustment component80within the swivel joint70. The protrusion124can be formed by any suitable method and may comprise a single annular structure, or one or more individual protrusions. In one aspect, the protrusion124is formed by crimping the swivel joint70, thus forming an annular crimp portion128in its outside surface.FIG. 3-Dillustrates a perspective view of such an annular crimp portion128formed in the swivel joint70as extending orthogonally from the hinge barrel60. Other methods of forming the protrusion124will be recognized by those skilled in the art.

FIG. 3-Eillustrates a perspective view of still another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. In this embodiment, one or more slots132are formed through the swivel joint70extending into the swivel bore72. With the slots132defined in the swivel joint70, an external clip136or wire can be slid over the swivel joint70, such that a portion of the external clip136is disposed within the slots132for the purpose of engaging and rotatably securing the horizontal adjustment component80in place. A complementary groove portion (see annular groove120inFIG. 3-C) is formed in the horizontal adjustment component80to receive the portion of the external clip136extending through the slots132in the swivel joint. The relationship between the clip136and the horizontal adjustment component80functions to keep the horizontal adjustment component80from sliding within the swivel bore72. With the external clip376rotatably coupling the horizontal adjustment component80to the swivel joint70as indicated, the horizontal adjustment component80is allowed to rotate within the swivel joint70to facilitate horizontal adjustment of the adjustable hinge. Moreover, in this embodiment, the clip136can be selectively disengaged from the horizontal adjustment component80and the swivel joint70, thus allowing the horizontal adjustment component80to be removed from the swivel joint70, thereby, allowing easy removal and replacement of the gate from the fence post.

FIG. 3-Fillustrates a perspective view of still another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. In this embodiment, the swivel joint70can include an opening140formed through the swivel joint70extending into the swivel bore72. A post144or any other suitable structure may be inserted into the opening140a distance sufficient to engage a corresponding groove (see annular groove120inFIG. 3-C) formed in the horizontal adjustable component80, similarly as discussed above. The post144is configured to be disposed in the annular groove of the horizontal adjustment component80to facilitate the rotatable coupling of the horizontal adjustment component80to the swivel joint70. The post144can be any suitable post, such as a rivet, threaded fastener, dowel, twist pin, etc. The post144can also be configured to facilitate selective removal and insertion of the horizontal adjustment component80from the swivel joint70, thereby, allowing easy removal of the gate from the post if necessary.

FIG. 3-Gillustrates a perspective view of still another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. In this embodiment, the swivel joint70comprises an opening148formed therein that is sized and configured to receive a pin152configured to extend into and through the opening148to engage an annular groove (see annular groove120inFIG. 3-C) formed in the second portion of the horizontal adjustment component80. The pin152may comprise any configuration capable of securing the horizontal adjustment component80in place within the swivel joint70, while facilitating its selective rotation for purposes of adjusting the adjustable hinge. The pin152is also preferably configured to accommodate easy removal and insertion in the event the horizontal adjustment component80is to be removed from the swivel joint70.

FIG. 3-Hillustrates a cut-away side view of still another embodiment of means for coupling the horizontal adjustment component80to the swivel joint70. This embodiment is similar to the embodiment ofFIG. 3-Ain that a bore72is formed or defined with in the swivel joint70, wherein the bore72comprises a ledge74. However, unlike the embodiment ofFIG. 3-Awhere an independent fastener is coupled to the end portion86of the horizontal adjustment member80, in this embodiment, the end portion86comprises an annular groove120sized and configured to receive a snap ring156as known in the art. The snap ring156is sized and configured to rotatably secure the horizontal adjustment member80in place within the swivel joint70. Similar to the fastener102inFIG. 3-A, the snap ring156is configured to abut with and slidably rotate about or against the ledge74formed in the swivel bore72as it comprises a larger diameter than the horizontal adjustment component80, and is sized and configured to be seated against the ledge74as shown to secure the horizontal adjustment component80in place within the swivel joint70, as well as to facilitate its rotation for horizontal adjustment of the adjustable hinge.

Referring now toFIG. 4, shown is a perspective view of an adjustable hinge according to another exemplary embodiment. Specifically,FIG. 4illustrates the adjustable hinge10as comprising an alternative configuration of the swivel joint70as operably related to the hinge barrel60disposed about the vertical adjustment component50. In this embodiment, the horizontal adjustment component80is inserted within the swivel joint70. Once properly positioned, a crimp128is formed within the swivel joint70, wherein the crimp128forms a protrusion124(seeFIG. 3-C) that extends down into an annular groove120formed within the horizontal adjustment component80.FIG. 4comprises, at the location of the crimp128, a cut-away section in order to illustrate the annular groove120formed in the horizontal adjustment component80. This embodiment is similar to the one described inFIGS. 3-Cand3-D.

FIG. 4further illustrates how the swivel joint70may be integrally formed with the hinge barrel60rather than being a separate and independent structure that is coupled to the hinge barrel60as the embodiment illustrated inFIG. 1. As integral components, the swivel joint70and the hinge barrel60may be machined from a solid block, or cast as a single structure.

With reference toFIG. 5, illustrated is a perspective view of the adjustable hinge embodiment illustrated inFIG. 4having cut-away sections to show the coupling configurations and operating relationships between the various components of the adjustable hinge. Specifically,FIG. 5illustrates adjustable hinge10as comprising a vertical adjustment component50having outer threads52formed therein, such that the vertical adjustment component50is rotatably disposed within a bore62of a hinge barrel60, wherein the bore62has an inner surface with threads corresponding to threads52of the vertical adjustment component50. This configuration and function of these are as discussed above. The adjustable hinge10further comprises a horizontal adjustment component80having outer threads82formed therein, such that the horizontal adjustment component80is rotatably disposed within a bore92of a collar90, wherein the bore92has an inner surface with threads corresponding to the threads82of the horizontal adjustment component80, also as discussed above.

From the cut-away portion, it can be seen that the horizontal adjustment component80comprises a portion thereof contained or supported within the bore72of the swivel joint70that is not threaded, but rather comprises a smooth surface. This non-threaded portion functions to facilitate the free rotation of the horizontal adjustment component80within the swivel joint70. The non-threaded portion is formed about end86, which is rotatably supported within the swivel joint70using one of the means for coupling described above. In the embodiment shown inFIG. 5, means for coupling comprises a flange portion116formed on the end86of the horizontal adjustment component80. This flange portion116engages the ledge74formed within the bore72of the swivel joint70to prevent the horizontal component from sliding out of the swivel joint70. The flange116is also capable of rotating about the ledge74as the horizontal adjustment component80is bi-rotationally manipulated or adjusted.

Again from the cut-away portion, it can be seen that the end86of the horizontal adjustment component80is located and supported in place a distance x1from the vertical adjustment component50. As such, the vertical and horizontal adjustment components50and80never come in contact with one another. This distance x1may vary depending upon the particular configuration of the adjustable hinge10. The relationship between the ledge74and the flange portion116prevents the horizontal adjustment component80from sliding out of the swivel joint70in one direction. To prevent the horizontal adjustment component80from sliding toward and contacting the vertical adjustment component50, a portion of the end86of the horizontal adjustment component80is configured to comprise a smaller diameter than the diameter of the outer threaded portion52. This reduced diameter portion may be integrally formed with the horizontal adjustment component80(e.g., a turned down portion), or it may comprise a separate and independent member coupled or otherwise fixed to the end of the horizontal adjustment component80, each of which are well known in the art. As such, the bore72of the swivel joint also comprises a smaller diameter than the outer threaded portion82of the horizontal adjustment component80, but slightly larger than the diameter of the end86. In this configuration, the distance x2of the reduced diameter portion of the end86of the horizontal adjustment component80is approximately equivalent to the distance from the ledge74to the end of the swivel joint70. Therefore, the horizontal adjustment component80is prevented from bi-directionally displacing or moving within the swivel joint70, and also from coming in contact with the vertical adjustment component50as the outer threaded portion82abuts the outer edge of the swivel joint70. Other means or methods may be employed to prevent such movement as will be recognized by one skilled in the art, each of which are contemplated herein. For example, the adjustable hinge10may further comprise some type of locking means, such as a nylon ball lock placed within the swivel joint70between the vertical adjustment component50and the end86of the horizontal adjustment component80, to further secure the horizontal adjustment component80, and to keep it from sliding toward and into the vertical adjustment component50. As such, the horizontal adjustment component80may or may not comprise the same diameter along its longitudinal length.

FIGS.6-A–6-C illustrate several top views of one exemplary adjustable hinge as coupling together two hinged components in the form of a post and a pivoting gate, and the relationship between the various components of the adjustable hinge, as well as the relationship between the post, a fence (not shown), and the gate, at different operating positions. As shown, the horizontal adjustment component80is adjusted to its maximum horizontally outward and extended position, thus creating the widest possible gap between the post2and the gate4. Moreover, from these figures, it can be seen that the horizontal adjustment component80and the vertical adjustment component50are located in the same plane, which plane is offset from the post bracket20and the gate bracket30, as well as the surfaces of the post2and gate4themselves.

Specifically,FIG. 6-Aillustrates a top view of the adjustable hinge10(the exemplary embodiment ofFIG. 1) as comprising a post bracket20mounted to a post2and a gate bracket30mounted to a gate4, wherein the post2and gate4are shown coupling together the post2and the gate4in a closed gate position. In this position, the post2and the gate4are aligned in a common vertical plane. Moreover, the horizontal adjustment component80is rotated about the vertical adjustment component50at an angle θ≈0°, which consequently means that gate bracket30is not rotated about the post bracket20, nor the gate4about the post2. As shown, a gap6is created between the post2and the gate4. This gap6will vary with the adjustment of the horizontal adjustment component80. As the gap widens, various privacy and security issues arise as these can be significantly impaired. As such, the present invention further features gap fillers, which eliminate such concerns, and which are discussed in detail below.

FIG. 6-Billustrates a top view of the adjustable hinge10as coupling together the post2and the gate4in a fully opened gate position. In the fully opened position, both the fence line and the gate4extend to the left of the adjustable hinge10and its components. As shown, the gate bracket30(and therefore the gate4) pivots or rotates about the post bracket20(and therefore the post2) within a range of rotation angles substantially between 0° and 180°. In effect, the horizontal adjustment component80is rotated about the vertical adjustment component50at an angle θ≈180°, which consequently facilitates the rotation of the gate bracket30about the post bracket20, as well as the gate4about the post2. More or less rotation may be allowed depending upon the particular configuration of the adjustable hinge10and its component parts.

The configuration of the adjustable hinge10limits the rotation of the gate4and prevents binding within the adjustable hinge10as a result of the contact or collision of the gate4with the fence (not shown) coupled to and supported by the post2. The adjustable hinge10is preferably configured so that the gate4collides with the fence upon rotating approximately 180° from the closed position. In essence, because the fence and the gate4both extend outward to the left of the adjustable hinge10in the fully opened position, and as a result of the racked out configuration of the post bracket20, the gate4will collide with the fence before any of the components of the adjustable hinge10collide and bind with one another, namely the swivel joint70or the horizontal adjustment component80with the post bracket20, or the collar90with the post bracket20or the fence or fence post2. In other words, no component of the adjustable hinge10is allowed to bind with any other component of the adjustable hinge10prior to or upon impact of the gate4with the fence as a result of the racket out configuration of the extension portion26of the post bracket20, and/or the adjustability of the horizontal adjustment component80. Moreover, this racked out configuration facilitates the function and operation of the adjustable hinge10in each of the fully opened, fully closed, and overswing positions without any of its component parts binding with one another, or even coming in contact with one another, the fence, or the post2. This is a significant advantage over prior related hinges or hinge assemblies that have a tendency to bind in either or both of the fully opened or the overswing positions, which binding can cause significant damage to or destroy the hinge, or at the very least can mar the paint on the brackets supporting the hinged components. In addition, unlike prior related hinges, the present invention adjustable hinge10.

FIG. 6-Cillustrates a top view of the adjustable hinge10as coupling together the post2and the gate4in an overswing position. In the overswing position, the horizontal adjustment component80is allowed to rotate too far about the vertical adjustment component50, such that the rotation angle θ≈−x°, which consequently results in the over rotation of the gate bracket30about the post bracket20, as well as the gate4about the post2. In prior related hinge assemblies, an overswing position is far more damaging than a fully opened position. Particularly, overswing can cause significant moment forces (e.g., moment torque) within the hinge that can produce damaging results, such as destruction of the hinge itself, ripping of the post and gate brackets from the post and gates, damage to the fence posts and gate components themselves, etc. As such, the positional relationship between the impact point of the hinge or the hinged components and the pivot point of the hinge is crucial in minimizing the severe moments of torque. The configuration of the present invention adjustable hinge10and adjustable nature of its components significantly reduces the potential damage caused by overswing.

In an overswing position in which the present invention adjustable hinge10is utilized, the gate4is caused to rotate past an initial starting position (e.g., where θ≈0°), wherein if the overswing is significant, the gate4will make contact or collide with the post2, as shown. Advantageously, in the event of such overswing, the various component parts of the adjustable hinge10are kept from binding with each other as a result of the racked out extension member26of the post bracket20, as well as the selectively adjusted position of the horizontal adjustment component80. Indeed, because of this advantageous racked out configuration of the post bracket20, the horizontal adjustment component80can be adjusted in a fully outward or maximum outward position, if so desired, which position still facilitates or allows the gate4to collide with the post2before any part of the adjustable hinge10collides or binds with itself. Specifically, the gate4is caused to contact the post2prior to the swivel joint70contacting or binding with the post bracket20. The collision between the gate4and the post2obviously eliminates any further rotation or overswing within the adjustable hinge10in the same direction.

The degree of potential overswing by the adjustable hinge10may be manipulated and varied by making adjustments to the horizontal adjustment component80. For example, with the horizontal adjustment component80adjusted inward from its shown maximum outward position, the degree of rotation within the adjustable hinge10is reduced as the gate4will be caused to contact the post2sooner than if the horizontal adjustable component80is in the maximum outward position. However, the further that the impact point between the post2and the gate4is from the pivot point, the less damage will result to the adjustable hinge10, the gate4, the post2, and the various fence components. Moreover, the further the pivot point is from the impact point and the closer the pivot point is to the center of the gap6, the less the binding torques will be within the hinged assembly. Still, as mentioned, the further the pivot point is from the side of the post2, the greater the ease and ability to make adjustments to the adjustment components50and80with power tools.

With reference toFIG. 7, illustrated is a perspective view of the exemplary hinge ofFIG. 1as coupled or mounted to a fence and gate assembly. As shown, adjustable hinge10comprises a post bracket20mounted to a post2and a gate bracket30mounted to a gate4. A gap6is created between the post2and the gate4, which gap may be widened or narrowed, as desired, by adjusting the horizontal adjustment component80. As described above, the gate4may be lowered or raised, as indicated by the arrows, by rotationally adjusting the vertical adjustment component50. Similarly, as described above, the gate4may be extended from the post2or drawn in toward the post2, as indicated by the arrows, by rotationally adjusting the horizontal adjustment component80.

FIG. 7further illustrates the rotational manipulation or adjustment of the vertical adjustment component50by a hex-type bit160supported and secured within a power drill (not shown). In this way, the hex-type bit160is received by the corresponding hex-type recess of the driving component56located on one or both of the ends of the vertical adjustment component50, wherein the power drill may be actuated to quickly and effortlessly rotate the vertical adjustment component50to raise or lower the gate4. The same applies to the horizontal adjustment component80, which comprises a driving component88also configured to receive the hex-type bit160. As so coupled, the power drill can be actuated to quickly and effortlessly rotate the horizontal adjustment component80to extend or draw in the gate4with respect to the post2.

Referring now toFIGS. 8 and 9, illustrated are perspective and side views, respectively, of an adjustable hinge according to another exemplary embodiment of the present invention. It is noted that the description of the adjustable hinge embodiment set forth above forFIGS. 1–7is incorporated herein for this embodiment, where applicable. As shown, adjustable hinge10comprises substantially the same configuration as the adjustable hinge ofFIG. 1. However, in this embodiment, the adjustable hinge10comprises an alternatively configured swivel joint170, which comprises a linear cylinder or tube-like structure sized and configured to couple the vertical adjustment component50, as well as the horizontal adjustment component80. Means for coupling the horizontal adjustment component80to the swivel joint170are similar to those embodiments described above in relation to FIGS.3-A–3-H.

Specifically, the swivel joint170comprises a longitudinal bore172similar to the one described above for receiving and rotatably supporting therein an end of the horizontal adjustment component80. In addition, transversely oriented with the longitudinal bore172is a lateral bore176extending all the way through the swivel joint170, thus lateral bore176comprises an opening180and an opening184. The lateral bore176is configured to receive and support the vertical adjustment component50and to facilitate vertical adjustment within the adjustable hinge10. The lateral bore176is oriented towards an end of the swivel joint170in order to offset the vertical adjustment component50from the endmost portion of the horizontal adjustment component80so that these two components do not interfere with one another. Although optional, the swivel joint170further comprises an open-end188that facilitates the removal of moisture and debris from the swivel joint170during operation and over time. Of course, the end may be closed in other embodiments.

Openings180and188of the lateral bore176are tapped to comprise threads (not shown) that correspond to the threads52formed in the vertical adjustment component50. As so configured, the swivel joint170functions to allow the vertical adjustment component50to be bi-rotationally adjusted to effectuate vertical bi-directional movement of the swivel hinge170, and therefore the horizontal adjustment component80, the gate bracket30, and finally the gate (not shown). By rotating the vertical adjustment component50, the swivel joint170displaces with respect to the vertical adjustment component50to adjust the hinged components relative to one another. Thus, turning the vertical adjustment component50one way moves the swivel joint170down, while turning it the opposite way moves the swivel joint170up. In essence, the swivel joint170, with its lateral bore176, is intended to function similar to the swivel joint70and hinge barrel60combination ofFIG. 1.

FIGS. 8 and 9further illustrate the internal broached driving configurations194and198of the vertical and horizontal adjustment components50and80, respectively, wherein the driving configurations194and198are formed into the ends of each of these components rather than being a separate structure coupled thereto. As shown, a portion of the end84of the horizontal adjustment component80is turned down to comprise a reduced diameter than the diameter of the threaded outer surface82.

FIG. 10illustrates a front view of the exemplary adjustable hinge10ofFIGS. 8 and 9. As shown, the adjustable hinge10comprises optional means for biasing the hinged component assembly, such that as one hinged component pivots about the other, it does so in a biased manner. Means for biasing functions to induce a moment force within the adjustable hinge10, which moment force creates a tendency within the adjustable hinge10to pivot the hinged components to a reduced force position, such as a closed position. Means for biasing may comprise any type known in the art, such as a torsion spring, a coil spring, and others. In addition, means for biasing may be configured in several different ways to bias one hinged component with respect to the other. In the embodiment shown, means for biasing comprises an external torsional spring206that comprises first and second coils210and212that are disposed about the vertical adjustment component50on either side of the swivel joint170. Integrally extending from the first and second coils210and212is first rest214that is configured to engage and rest against the post bracket20. Also integrally extending from the first and second coils210and212is second rest218that is configured to engage and rest against the swivel joint170. In this arrangement, the torsional spring206biases the pivoting gate bracket30with respect to the post bracket20, particularly as the gate bracket30is pivoted away from its closed position. As stated above, other torsional spring configurations and placement positions are contemplated. Use of means for biasing essentially facilitates the automatic closure of the gate from an open or partially open position. Stated differently, means for biasing induces a moment force within the adjustable hinge10that tends to cause the gate to swing or pivot from a respectively increased moment force position (e.g., an open position) to a respectively reduced moment force position (e.g., a closed position).

FIG. 11-Aillustrates a front view of the exemplary adjustable hinge10ofFIGS. 8 and 9, with cut-away portions showing the coupling arrangement or configuration between the horizontal adjustment component80and the swivel joint170. As can be seen, the horizontal adjustment component80is coupled to the swivel joint170using a snap ring156. The swivel joint170comprises a longitudinal bore172formed transverse to the lateral bore176configured to receive and support the vertical adjustment component50. The longitudinal bore172comprises two different diameter sections to form a ledge74therein, which ledge74is configured to engage the snap ring156. Specifically, the end portion86comprises an annular groove120sized and configured to receive the snap ring156as commonly known in the art. The snap ring156is sized and configured to rotatably secure the horizontal adjustment member80in place within the swivel joint170by abutting with or seating against the ledge74. The snap ring, being of a larger diameter than the diameter at the ledge74when inserted into the annular groove120, functions to slidably rotate about or against the ledge74to secure the horizontal adjustment component80in place within the swivel joint70, as well as to facilitate its rotation for horizontal adjustment of the adjustable hinge. It is recognized herein that the ledge74prevents the horizontal adjustment component80from sliding in only one direction, namely out of the swivel joint170. Therefore, at least a portion of the horizontal adjustment component80, and particularly at least a portion of the end86, comprises a smaller diameter than the threaded outer surface82of the horizontal adjustment component80. This reduced diameter portion may be integrally formed with the horizontal adjustment component80(e.g., a turned down portion), or it may comprise a separate and independent rod coupled or otherwise fixed to the end of the horizontal adjustment component80, each of which are well known in the art. As so designed, the larger diameter outer thread portion82abuts the edge of the swivel joint170, thus preventing the horizontal adjustment component80from sliding toward the vertical adjustment component50, thus maintaining a distance x1 between the vertical and horizontal adjustment components50and80. Alternatively, the adjustable hinge10may further comprise some type of locking means, such as a nylon ball lock placed within the swivel joint170between the vertical adjustment component50and the end86of the horizontal adjustment component80, to further secure the horizontal adjustment component80, and to keep it from sliding toward and into the vertical adjustment component50. As such, the horizontal adjustment component80may or may not comprise the same diameter along its longitudinal length.

FIGS. 11-Aand11-B further illustrate an annular groove76formed in the longitudinal bore172of the swivel joint170to receive and support, from opposing sides, the snap ring156as contained within the annular groove120of the horizontal adjustment component80. The annular groove76is indicated by the dotted lines, particularly detailed inFIG. 11-B, and comprises a ledge75formed opposite the ledge74to create a gap making up the annular groove76. In this configuration, the annular groove76secures the horizontal adjustment component80in place and limits its longitudinal or bi-directional displacement within the swivel joint170. Particularly, the relationship between the annular groove76and the snap ring156prevents the horizontal adjustment component80from sliding toward and into the vertical adjustment component50or away from the vertical adjustment component50and out of the swivel joint170altogether. The annular groove76is sized and configured to receive the snap ring156as known in the art and to maintain the distance x1between the vertical and horizontal adjustment components50and80. The concept of an annular groove formed in the bore of the swivel joint is equally applicable to the exemplary adjustable hinge embodiment ofFIGS. 1–7set forth above.

FIG. 12illustrates a front view of the exemplary adjustable hinge10ofFIGS. 8 and 9, with cut-away portions showing an alternative means for coupling arrangement or configuration between the horizontal adjustment component80and the swivel joint170. In this embodiment, the horizontal adjustment component80comprises outer threads82formed along its entire longitudinal length. A snap ring156is situated within an annular groove120formed within the horizontal adjustment component80, wherein the snap ring156is subsequently captured within the annular groove76formed within the longitudinal bore172of the swivel joint170. In this configuration, the diameter of the bore172is slightly greater than the outside diameter of the horizontal adjustment component80.

It is noted herein, that other means for coupling the horizontal adjustment component80to the swivel joint170are contemplated herein, such as those set forth above inFIGS. 1–5, each of which are incorporated for the adjustable hinge embodiment ofFIGS. 8 and 9.

Referring now toFIGS. 13 and 14, illustrated is a perspective view and a top view, respectively, of an alternative embodiment of the adjustable hinge ofFIGS. 8–12. Specifically, illustrated is an alternative bracket configuration for the adjustable hinge10. As shown, adjustable hinge10comprises a post bracket220and a gate bracket230. The post bracket220is similar in its configuration and function as the post bracket20set forth above. However, gate bracket230comprises an alternative design configuration. In this embodiment, gate bracket230comprises gate mounting portions232-aand232-bthat are configured to be mounted to corresponding sides of a gate (not shown). Extending and offset from gate mounting portion232-bis an extension portion236. Extension portion236comprises a first sidewall237having an aperture240formed therein, which aperture240is sized and configured to receive and support the horizontal adjustment component80therethrough. Extension portion236further comprises a second sidewall239opposite and complementary to the first sidewall237. The second sidewall239also comprises an aperture244, which aperture244is coaxially oriented with the first aperture240and is also sized and configured to receive and support the horizontal adjustment component80. Apertures240and244are preferably extruded to obtain as much surface area as possible for the threads of the outer perimeter.

A portion of the extension portion236is shown cut-away to illustrate the second aperture244. Each of the first and second apertures240and244further comprise a tapped or threaded perimeter, which threads correspond to the outer threads82of the horizontal adjustment component80. In essence, the extension portion236with its tapped apertures240and244functions similar to the collar90discussed above in relation toFIGS. 1–12. Namely, the horizontal adjustment component80and the gate bracket230are capable of selectively and controllably bi-directionally displacing with respect to one another as a result of rotating the horizontal adjustment component80in a clockwise or counterclockwise direction, thus effectuating horizontal adjustment of the gate bracket230with respect to the post bracket220, and therefore the gate (not shown) with respect to the post (also not shown) as discussed above. First and second sidewalls237and239are supported by a bridge248, although this bridge248may be optional if the gate bracket230is structurally sound otherwise, particularly as assembled with the horizontal adjustment component80.

FIGS. 13 and 14further illustrate the swivel joint170used to couple the vertical and horizontal adjustment components50and80together as comprising a tapered end portion178. Tapered end portion178functions to enhance the swing clearance of the gate bracket230about the post bracket220, and therefore the gate about the post, by providing additional travel before the swivel joint170contacts the post bracket220.

FIG. 14illustrates a top view of the adjustable hinge10, wherein the extension portion236comprises, alternatively, a bridge248with a surface250having threads252formed therein, which threads252correspond to the threads82of the horizontal adjustment component80, as well as the threaded apertures240and244of the first and second sidewalls237and239, respectively. Threads252function to assist the adjustment of the gate bracket230by providing greater surface contact of the gate bracket30with the horizontal adjustment component80. This is advantageous when the wall thickness of the extension portion236is thin, therefore only accommodating a limited thread count within each of the apertures240and244of the first and second sidewalls237and239, respectively. The threads252further function to ensure that the threads within the apertures240and244are supported and are not stripped as a result of continuous operation and adjustment of the hinged assembly, namely the gate and the post.FIG. 14further illustrates the common vertical plane in which lie both the vertical and horizontal adjustment components50and80as provided by the specific configuration of the post and gate brackets220and230.

FIG. 15illustrates a perspective view of another exemplary adjustable hinge10having an alternative bracket configuration. In this embodiment, the post bracket320and the gate bracket330each comprise an alternative configuration. Specifically, post bracket320comprises a planar form with post mounting portion322configured to be mounted to a post2via mounting holes324. Extending from the planar post mounting portion322is pivot bracket340having arm members44-aand44-bextending therefrom to support the vertical adjustment component50, each similar to the pivot bracket40described above with respect toFIGS. 1–8. In this embodiment, pivot bracket40and post bracket320may be one integral piece, or the pivot bracket40may comprise a separate component that couples to the planar post mounting bracket320.

The gate bracket330comprises a gate mounting portion332-aformed perpendicular to a gate mounting portion332-b, wherein each are mounted to the gate4via mounting holes334. Extending from the gate mounting portion332-bare first and second tabs336and338sized and configured to support the horizontal adjustment component80in a plane common with the vertical adjustment component50, as supported by the post bracket320. First and second tabs336and338each comprise an aperture formed therein, namely apertures340and344, respectively, that comprise a threaded perimeter with threads that correspond to the threads82of the horizontal adjustment component80. As such, first and second tabs336and338function in a similar manner as first and second sidewalls237and239ofFIGS. 13 and 14, which description is incorporated herein. As can be seen, first and second tabs336and338comprise segments formed from each of the gate mounting portions332-aand332-b, respectively. Tab336is formed from the gate mounting portion332-aand rotated approximately 180° to extend perpendicularly from the gate mounting portion332-b. Likewise, tab338is formed from the gate mounting portion332-b, and is rotated approximately 90° to also extend perpendicularly from the gate mounting portion332-b. In another aspect, rather than being components formed from the gate mounting portions332-aand332-b, tabs336and338may be separate components that are welded, or otherwise fixed, directly to the gate mounting portion332-b.

FIG. 16illustrates a perspective view of yet another exemplary adjustable hinge10having an alternative bracket configuration. In this embodiment, the post bracket420supports the vertical adjustment component50via pivot bracket40having arms44-aand44-b. In addition, the post bracket420comprises post mounting portion422and mounting holes424that are each similar in form and function to the post bracket320ofFIG. 15, which description is therefore incorporated herein. However, the gate bracket430comprises still another alternative configuration. Specifically, gate bracket430comprises a planar form with gate mounting portion432configured to be mounted to a gate4via mounting holes434. Extending from the gate mounting portion432are first and second tabs436and438sized and configured to support the horizontal adjustment component80in a plane common with the vertical adjustment component50, as supported by the post bracket420. First and second tabs436and438each comprise an aperture formed therein, namely apertures440and444, respectively, that comprise a threaded perimeter with threads that correspond to the threads82of the horizontal adjustment component80. As such, first and second tabs436and438function in a similar manner as first and second sidewalls237and239ofFIGS. 13 and 14, which description is incorporated herein. As can be seen, first and second tabs436and438are formed from the gate mounting portion432. However, first and second tabs436and438may be separate components that are welded, or otherwise fixed, directly to the gate mounting portion432.

FIG. 17illustrates a perspective view of still another exemplary adjustable hinge10having an alternative bracket configuration. Similar to the embodiment illustrated inFIG. 16, in this embodiment, the post bracket520supports the vertical adjustment component50via pivot bracket40having arms44-aand44-b. In addition, the post bracket520comprises post mounting portion522and mounting holes524that are each similar in form and function to the post bracket320ofFIG. 15, which description is therefore incorporated herein. However, the gate bracket530comprises still another alternative configuration. Specifically, gate bracket530comprises a substantially planar form with gate mounting portion532configured to be mounted to a gate4via mounting holes534. Gate mounting portion532further comprises an extension portion526sized and configured to receive or engage with and support a u-shaped bracket535therein. Gate mounting portion532further comprises first and second slots527-aand527-badjacent the extension portion526as shown. The u-shaped bracket comprises first and second tabs536and538extending therefrom, each with threaded apertures540and544, similar to the tabs336and338ofFIG. 15described above, which description is incorporated herein. The gate bracket530is assembled by inserting first and second tabs536and538through the slots527-aand527-bfrom the rear of the gate mounting portion532so that the u-shaped bracket535engages and is supported by the extension portion526, as shown. The u-shaped bracket535may be coupled to the extension portion526using any known means in the art, such as welding, bolts, screws, and others.

It is noted herein that the various exemplary bracket configurations just described in relation toFIGS. 13–17are equally applicable to the exemplary adjustable hinge configuration set forth inFIGS. 1–7above, and are therefore incorporated therein.

Referring now toFIG. 18, illustrated is a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. In this embodiment, adjustable hinge10comprises a post bracket20, a gate bracket30, and a pivot bracket40similar to those discussed above, which descriptions are incorporated herein. Operably coupled to the pivot bracket40is a vertical adjustment component550in the form of a cylindrical rack having a plurality of grooves552formed therein. Disposed about the vertical adjustment component550is a swivel joint570having a pinion gear574rotatably supported therein by a driving component56configured to facilitate rotation of the pinion gear574. The pinion gear574comprises a plurality of teeth578sized and configured to engage the grooves552formed on the vertical adjustment component550. Rotation of the pinion gear574causes the swivel joint570to move with respect to the vertical adjustment component550to effectuate vertical adjustment of the gate bracket30with respect to the post bracket20, and therefore the gate component with respect to the post component. A set screw558or other means for securing or locking the swivel joint570in a position is also provided. Therefore, once a desirable position or alignment is obtained, the set screw558may be caused to press against the shaft of the vertical adjustment component550.

The adjustable hinge10further comprises a similar adjustment configuration for effectuating horizontal adjustment. As shown, the adjustable hinge10comprises a horizontal adjustment component580in the form of a cylindrical rack having a plurality of grooves582formed therein. The horizontal adjustment component580is supported on the gate bracket30by a rack clamp590, which is coupled to the gate bracket30and functions in a similar manner as the clamping component870ofFIG. 29. The horizontal adjustment component580is also supported in a fixed manner within the swivel joint570. The rack clamp590may be selectively loosened to allow the horizontal adjustment component580to displace bi-directionally therein, or the rack clamp590may be selectively tightened to lock the horizontal adjustment component580in a desired alignment position. Rack clamp590is selectively loosed or tightened via clamping bolts592.

The horizontal adjustment component580is adjusted by actuating the pinion gear594rotatably supported by the gate bracket30. The pinion gear594is situated adjacent the horizontal adjustment component580and comprises a plurality of teeth598configured to engage with corresponding grooves582formed on the horizontal adjustment component580. Rotation of the pinion gear594via the driving component588formed therein, functions to bi-directionally displace the horizontal adjustment component580and the gate bracket30with respect to one another, thus effectuating horizontal adjustment of the gate bracket30with respect to the post bracket30, and therefore the gate (not shown) with the post (not shown), respectively. The horizontal adjustment component580may be fixed or otherwise coupled to the swivel joint570using any known technique or configuration described or suggested herein.

Referring now toFIG. 19, illustrated is a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. In this embodiment, adjustable hinge10comprises a post bracket20, a gate bracket30, a pivot bracket40, a swivel joint70, and horizontal and vertical adjustment components50and80, each similar to those discussed above, which descriptions are incorporated herein. However, in this embodiment, operably coupled to the pivot bracket40is a rotating or helical gear608having a plurality of teeth610formed therein that correspond to and mate with threads604of the worm602. The worm602functions as a driving component having a hex recess606formed therein configured to receive a hex bit from a hand or power tool.

The helical gear608is further coupled to the vertical adjustment component50. By rotating the worm602, the corresponding helical gear608is rotated, which consequently causes the vertical adjustment component50to rotate, thus effectuating vertical adjustment within the adjustable hinge assembly10.

Similarly, the gate bracket comprises a worm gear configuration. As shown, the horizontal adjustment component80has disposed about its threaded portion82first and second stationary collars616and618, which are fixed to the gate bracket30so that they are not allowed to rotate. Disposed about the horizontal adjustment component80and situated between the stationary collars616and618is a helical gear620. The helical gear620comprises threads621that correspond to and mate with the threads624of the worm gear622situated adjacent the helical gear620. The helical gear620is rotatable about the horizontal adjustment component80and therefore comprises a threaded inner portion that corresponds to and mates with the threaded outer portion82of the horizontal adjustment component80. The worm gear622further comprises a driving component626in the form of a hex-type recess configured to receive a driving tool. By driving and rotating the worm gear622, the helical gear620is caused to rotate about the horizontal adjustment component80, which causes the horizontal component to displace with respect to the gate bracket30. Obviously, in this configuration, the horizontal adjustment component80is not configured to rotate, and does not rotate within the helical gear620, nor the swivel joint70.

It is noted that the worm gears602and622are oriented orthogonally to the post and gate brackets20and30, respectively. As such, these brackets do not require a significant offset or extension member26and36as in some of the other embodiments described herein. The orthogonally oriented worm gears602and622allow easy access to the driving components contained thereon without interference from the post or gate brackets20or30or any of the hinged components coupled thereto.

Referring now toFIG. 20, illustrated is a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. In this embodiment, the post bracket assembly is similar to those discussed in relation toFIGS. 8–10, which description is incorporate herein. However, the vertical adjustment component50is shown comprising driving components56in each of its ends. Driving components56are shown as hex-type cap members632, which are essentially shoulder or head-type members that are either screwed or pressed (e.g. as an interference fit) into a corresponding recess formed in the ends of the vertical adjustment component50. These types of driving components56function to couple the vertical adjustment component50to the pivot bracket40as shown.

The gate bracket assembly comprises a gate bracket30having a clamping member640supporting the horizontal adjustment component80. In this embodiment, the clamping component640comprises a barrel portion642having one or more guides644formed therein. Guides644are sized and configured to protrude from the interior surface of the clamping component640to engage the threads82of the horizontal adjusting component80. As so engaged, the clamping component640and the horizontal adjusting component80displace with respect to one another upon driving or otherwise rotating the horizontal adjustment component80. The clamping component640is fixed to the gate bracket30using any known means in the art. In addition, the clamping component640comprises a flange portion646configured to be selectively tightened or loosened to actuate the clamping component640to lock and unlock the horizontal adjusting component80. Upon tightening the fastener645, the clamping component640clamps down upon the horizontal adjusting component80, thus locking it in a desired position. Likewise, to again adjust the horizontal adjustment component80, the fastener645is loosed, whereupon the horizontal adjustment component80may again be rotated to effectuate horizontal adjustment within the hinge assembly10.

Alternative Adjustable Hinge Assembly

The present invention further features other adjustable hinge assembly embodiments having a somewhat different general configuration than the hinge assembly embodiments set forth above and illustrated inFIGS. 1–20. However, it is noted herein, that some of the features and functions of the hinge assemblies discussed above may be applicable to some or all of the embodiments discussed herein, and therefore, such features and/or functions may be incorporated herein, where applicable.

Referring now toFIG. 21, illustrated is a perspective view of an adjustable hinge710according to one exemplary embodiment of the present invention. Specifically,FIG. 21illustrates adjustable hinge710as comprising a post bracket720made up of post mounting portions722-aand722-bthat are orthogonal to one another and configured to engage respective orthogonal sides of a post (not shown) to secure the post bracket720to the post. The adjustable hinge710further comprises a gate bracket730made up of gate mounting portions732-aand732-bthat are also orthogonal to one another and configured to engage respective orthogonal sides of a gate (not shown) to secure the gate bracket730to the gate. The post bracket720is configured to support thereon a vertical hinge barrel760configured to pivot within hinge pins762and764and to facilitate the pivoting of the gate bracket730(and therefore the hinged gate component) about the post bracket720(and therefore the hinged post component). The hinge pins762and764are secured to the post mounting portion722-bas shown, which may further comprise an extension portion726for offsetting the hinge barrel760from the post mounting portion722-aand the post (not shown) a greater distance, for adding stiffness and strength to the post bracket720, and for providing clearance for the horizontal adjustment component780and any means for coupling. The gate bracket730is configured to support thereon a horizontal adjustment component80configured to provide horizontal adjustment of the post bracket720with respect to the gate bracket730, and therefore the coupled post and gate hinged components, respectively. The horizontal adjustment component780is supported within a collar790fixed to the gate bracket730, and particularly to an extension portion736formed in the gate bracket730. The collar790comprises a threaded bore that corresponds to the threads782of the horizontal adjustment component780. Therefore, any bi-rotational adjustment or manipulation of the horizontal adjustment component780will cause the collar790and the horizontal adjustment component780to displace with respect to one another. In effect, rotation of the horizontal adjustment component780in any direction will accordingly displace the gate coupled to the gate bracket730with respect to the post coupled to the post bracket720.

The hinge barrel760further comprises a lateral bore formed therein for receiving and facilitating the coupling and operation of the horizontal adjustment component780. The horizontal adjustment component780comprises a first end784and a second end786. The first end784comprises a driving component788configured to facilitate the bi-rotation of the horizontal adjustment component780for adjustment purposes. The driving component788may be integrally formed within the end784of the horizontal adjustment component780, or it may be a separate member attached thereto. The first end784may also comprise a reduced diameter segment to allow the horizontal adjustment component780to pass all the way through the collar790.

The second end786is sized and configured to operably couple to the hinge barrel760. As shown, the second end786is passed all the way through the lateral bore of the hinge barrel760, and secured in place by means for coupling in the form of a snap ring792seated in an annular groove (not shown) formed within the end786of the horizontal adjustment component780. Means for coupling allows the horizontal adjustment component780to rotate within the lateral bore of the hinge barrel760. Other means for coupling the horizontal adjustment component780to the hinge barrel760are contemplated herein, many of which are discussed above.

FIG. 22illustrates a rear perspective view of the exemplary adjustable hinge assembly710ofFIG. 21. As shown, the post bracket720comprises open apertures802and804sized and configured to receive and secure at least a portion of the hinge pins762and764of the hinge barrel760shown inFIG. 21. Similarly, the gate bracket730comprises open apertures sized and configured to receive and secure the collar790shown inFIG. 22. These open apertures may function to locate the respective hinge barrel and collar components, and may comprise various sizes, or may comprise different counts, as will be recognized by one skilled in the art. Moreover, these apertures may be optional, as the hinge barrel and collar components may be secured to the outer surfaces of their respective brackets. The post bracket720may further comprise a clearance hole820sized and configured to receive therein the end portion786of the horizontal adjustment component780, as well as any means for coupling, such as the snap ring792, coupled thereto during pivoting of the gate bracket730about the post bracket720under normal operating conditions of the hinged post and gate components.

FIG. 22further illustrates mounting holes724and734formed in the post bracket720, which mounting holes724and734are offset from one another so as to not interfere or come in contact with one another once the post and gate brackets720and730are installed. The particular position of the mounting holes724and734may vary with particular bracket configuration or otherwise, as needed.

FIG. 23illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 23illustrates adjustable hinge710as comprising a similar configuration as set forth above inFIGS. 21 and 22, which description is incorporated herein. However, rather than utilizing a single fixed or stationary collar and a horizontal adjustment component780that rotates therein to effectuate adjustment of the adjustable hinge, the adjustable hinge710in this embodiment comprises dual stationary collars830and832mounted or otherwise fixed to the gate bracket730a distance apart from one another so as to provide a space therebetween. Stationary collars830and832comprise bores formed therethrough for receiving the horizontal adjustment component780therein. These bores preferably comprise smooth surfaces as the collars830and832are not intended to rotate. Disposed within the space provided between the stationary collars830and832is a spinning or rotating collar834comprising an inner bore configured to receive the horizontal adjustment component780therein. The inner bore comprises threads (not shown) that correspond to the threads782of the horizontal adjustment component780. The spinning collar834may comprise any configuration, but is preferably a hex-type structure to accommodate a wrench for easy and assisted rotation.

Furthermore, the horizontal adjustment component780comprises an end786that is fixed to the hinge barrel760so as to prevent the horizontal adjustment component780from rotating. As such, horizontal adjustment is effectuated by rotating the spinning collar834in either direction to move the gate bracket730, and therefore the gate (not shown) with respect to the post bracket, and therefore the post (not shown). The function of the stationary collars830and832is to retain the spinning collar834and to displace the horizontal adjustment component780as is known in the art. The gate bracket730may further comprise open apertures812and814formed therein at a location proximate the spinning collar834, which open apertures812and814function to provide clearance for a tool suitable for manipulating or rotating the spinning collar834, such as an open-end wrench.

The end786of the horizontal adjustment component780may be fixed to the hinge barrel760using any means known in the art, such as welding, a press or interference fit, soldering, bolts, etc. The stationary collars830and832may be mounted or otherwise fixed to the gate bracket using similar means.

FIG. 24illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 24illustrates adjustable hinge710as comprising a similar configuration as set forth above inFIG. 23, which description is incorporated herein. However, in this embodiment the adjustable hinge710further comprises a vertical adjustment component50that operates to provide vertical adjustment of the gate bracket730, and therefore the gate (not shown) with respect to the post bracket720, and therefore the post (not shown). The vertical adjustment component is supported by a pivot bracket740, and is operably retained within a hinge barrel760as discussed in detail above. Similar to the embodiment illustrated inFIG. 23, the horizontal adjustment component780is fixed so that it cannot rotate. The horizontal adjustment component780is fixed or otherwise mounted to the hinge barrel760using any known coupling means, such as welding. Therefore, horizontal adjustment is achieved by rotating the spinning collar834disposed and retained between stationary collars830and832as discussed above.

FIG. 25illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 25illustrates adjustable hinge710as comprising a sliding solid or tube-like horizontal adjustment component780having a smooth surface and that is supported within a collar790having an inner bore also with a smooth surface, wherein the collar is fixed or otherwise mounted to the gate bracket730and configured to receive the horizontal adjustment component780. The horizontal adjustment component780comprises a second end786that is fixed or otherwise mounted to a hinge barrel760supported on a post bracket720, as shown, such that the horizontal adjustment component780is not prevented from rotating. In this embodiment, the horizontal adjustment component780is configured to bi-directionally slide within the collar790to effectuate horizontal adjustment within the adjustable hinge assembly710.

The collar790further comprises means for locking or securing the horizontal adjustment component780in place therein. Means for securing may comprise any type known in the art. In one exemplary embodiment, means for securing comprises a set screw configuration, wherein one or more set screws840is disposed within the collar790and configured to press against the surface of the horizontal adjustment component780when the proper position has been achieved. The set screws may be oriented orthogonally with the horizontal adjustment component780, or they may be oriented tangential thereto, with a slight interference fit to achieve a wedging effect. The form and function of a set screw is well established and therefore, not detailed herein.

FIG. 26illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 26illustrates adjustable hinge710as comprising a sliding solid or tube-like horizontal adjustment component780having a smooth or threaded surface and that functions similar to the one embodied inFIG. 25and described above. However, in this embodiment, the adjustable hinge710further comprises a cam component850disposed between stationary collars830and832fixed or otherwise mounted to the gate bracket730. The cam component850is configured to lock or secure the horizontal adjustment component780in a desired position. Upon sliding the horizontal adjustment component780through the stationary collars830and832, as well as the cam850, and attaining a desired horizontally adjusted position, the cam can be rotated a pre-determined distance, which causes the cam850to push against the gate bracket730, thus forcing the horizontal adjustment component780against the inside walls of the stationary collars830and832, and thus locking or securing the horizontal adjustment component780in place. The cam850is rotated in the opposite direction to once again free the horizontal adjustment component780where it may be slide to another position. As indicated, the horizontal adjustment component780may comprise a smooth or threaded surface.

To actuate the cam, the cam850may comprise adjustment holes854configured to receive one or more tools specifically designed to adjust and operate the cam850. Alternatively, the cam may comprise one or more flattened portions858configured to receive an open-end wrench, wherein one of the flattened portions858is indicated by the dotted lines.

FIG. 27illustrates a rear perspective view of an exemplary adjustable hinge assembly710, wherein the post and gate brackets720and730, respectively, comprise open apertures for accommodating the operating components of the adjustable hinge710. Specifically, post bracket720comprises open apertures802and804configured to receive hinge pins762and764therein. Post bracket720further comprises open aperture806for receiving hinge barrel760therein. Each of these open apertures802,804, and806function to allow the same diameter hinge barrel and hinge pins to be used, if applicable, while also providing clearance for the pivoting hinge barrel760.

Similarly, the gate bracket730comprises an open aperture808configured to receive the stationary collars830and832, as well as the spinning collar834or cam850. The hinge pins, stationary collars, and any other non-rotating hinge components may be secured within their respective open apertures by any known means, such as welding, etc.

FIG. 28illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 28illustrates adjustable hinge710as comprising an alternative means for locking or securing a slidable horizontal adjustment component780in place in the form of a clamping component870. The clamping component is secured to the gate bracket730using any known means, such as by one or more tabs872and873that are inserted through receiving apertures formed in the gate bracket730, as shown, and are supported above the surface of the gate (not shown) to which the gate bracket730is mounted by an extension portion736. The clamping component comprises a barrel874sized and configured to slidably receive therein the horizontal adjustment component780. Extension member878, preferably integrally formed with barrel874, provides the ability to force the barrel874against the surface of the horizontal adjustment component780, thereby securing or locking the horizontal adjustment component780in a desired position. Extension member878comprises apertures882configured to receive a fastener therein that may be selectively tightened and loosened to effectuate the clamping of the horizontal adjustment component780, and therefore the horizontal adjustment thereof.

FIG. 28further illustrates the use of a pivot bracket740separate from but supported by the post bracket720. Use of a separate pivot bracket provides improved geometries within the adjustable hinge710, use of dissimilar materials, if desirable, and the ability to select from different aesthetic options. The separate pivot bracket740may be formed of one continuous part, or it may be comprised of separate components (namely separate arm components) that operate together to secure the hinge barrel760in place. The particular hinge barrel760illustrated and featured herein comprises a solid hinge barrel that includes a sloped section888for easy snap-in and snap-out interchangeability with the pivot bracket740.

FIG. 29illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 29illustrates adjustable hinge710as comprising the clamping component870ofFIG. 28as used in combination with the vertical adjustment component750and hinge barrel760ofFIG. 24, each of which corresponding descriptions is incorporated herein. As so configured, the adjustable hinge710provides for both selective vertical and horizontal adjustment by adjusting any one or both of the vertical and horizontal adjustment components750and780.

FIG. 30illustrates a partial perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 30illustrates adjustable hinge710as comprising an alternative embodiment to the clamping component870ofFIG. 28. In this embodiment, the gate bracket730comprises an small extension portion892having apertures therein for receiving the tabs872and873of the clamping component870. Providing the small extension portion892functions to eliminate the need to raise an entire section of the gate bracket730so that the tabs872and873clear the surface of the gate onto which the gate bracket730is mounted. The clamping component870functions as otherwise indicated inFIG. 29, which description is incorporated herein.

FIG. 31illustrates a perspective view of an adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 31illustrates adjustable hinge710as comprising a dual sliding configuration as applied to both the vertical and horizontal adjustment components750and780. As shown, vertical adjustment component750comprises a slidable collar902disposed about its outer surface, wherein the slidable collar902is configured and functions to facilitate vertical adjustment to the adjustable hinge710. Likewise, the horizontal adjustment component780comprises a slidable collar912disposed about its outer surface, wherein the slidable collar912is configured and functions to facilitate horizontal adjustment of the adjustable hinge710. Each of the slidable collars902and912further comprise means for locking or securing the collars902and912in a desired position about the respective horizontal and vertical components750and780. Means for locking or securing comprises any known in the art, such as a set screw configuration904and914similar to the one described above. The horizontal adjustment component780is coupled to the collar902using any known coupling means described or suggested herein, and/or known in the art. In operation, to vertically adjust the adjustable hinge710, the set screw configuration904is loosened and the collar902adjusted directionally up or down along the vertical adjustment component750. Directional adjustment of the collar902causes vertical adjustment of the horizontal adjustment component780and the gate bracket730coupled thereto about the post bracket720, and therefore the gate (not shown) coupled to the gate bracket730about the post (also not shown). Likewise, vertical adjustment is achieved by loosening the set screw configuration914of the collar912and directionally adjusting the collar912horizontally back and forth along the horizontal adjustment component780. This causes the gate bracket730to also directionally displace in a horizontal manner, and therefore the gate attached thereto with respect to the post.

FIG. 32illustrates a perspective view of still another adjustable hinge assembly according to still another exemplary embodiment of the present invention. Specifically,FIG. 32illustrates adjustable hinge710as comprising an alternative gate bracket assembly, wherein the gate bracket displaces both in the vertical and horizontal directions. The post bracket assembly is similar in function and form as that set forth above in relation toFIGS. 21–23, which description is incorporated herein.

As shown, the gate bracket assembly comprises a gate bracket730having a vertical adjustment bracket920coupled thereto. The vertical adjustment bracket920is fixed to the gate bracket730, but is slidably retained within a track940having a collar790mounted thereto for rotatably securing the horizontal adjustment component80. The collar790comprises an inner threaded bore that corresponds to the threads82formed on the horizontal adjustment component to effectuate horizontal adjustment of the gate bracket730with respect to the post bracket720, as discussed above.

The vertical adjustment bracket920comprises a back portion922, as well as extension members924sized and configured to be inserted into the corresponding channels944formed within the track940. The relationship between the extension members924and the channel944allow the vertical adjustment bracket920to be slidably coupled to the track940. The vertical adjustment bracket920further comprises a vertical adjustment component930retained by retention tabs926, which extend from the back portion922. The vertical adjustment component930comprises threads932formed thereon, which threads correspond to threads946cut or pressed into the inner surface of the track940. As such, rotation of the vertical adjustment component930via the driving component934functions to displace the vertical adjustment bracket920, and therefore the gate bracket730and the attached gate (not shown), with respect to the track940, and therefore the post bracket720and attached post (not shown). Indeed, the vertical adjustment component930may be rotated in any direction to effectuate the vertical adjustment of the gate bracket730with respect to the post bracket720.

Horizontal adjustment of the adjustable hinge assembly710is achieved by rotating the horizontal adjustment component780, as coupled to the collar790.

Gap Fillers and Hinge Covers

The present invention further features a variety of gap fillers to conceal the gap formed between the hinged components upon installing the adjustable hinge of the present invention. These gap fillers are designed to comprise a limited amount of flexibility in order to accommodate the different vertical and horizontal adjustments that are possible by the present invention adjustable hinge, as well as the pivoting operation of the adjustable hinge and the hinged components between an open and closed position. As such, the gap fillers may be made out of any suitable material, such as plastic, aluminum, etc.

The purpose of the gap filler is to conceal the gap between the hinged components, which can often be quite large. Gap fillers provide many significant advantages. First, they function to increase privacy by eliminating possible visual sight lines into the fenced area. Second, they eliminate unsightly gaps in the fence, thus improving the overall aesthetic appeal of the fence. Other advantages will be apparent to those skilled in the art.

With reference toFIG. 33-A, illustrated is a perspective view of a gap filler according to one exemplary embodiment of the present invention. As shown, adjustable hinge assembly10is operably mounted or attached to post and gate hinged components2and4. Formed between the post2and the gate4is a gap6. To conceal the gap6, a gap filler1002is positioned between the post2and the gate4to span the gap6. The gap filler1002comprises a u-shaped structure that mounts directly to the surface of the post2and the gate4. The gap filler1002may be mounted under the post and gate brackets20and30, as shown. Alternatively, the gap filler1002may be mounted over these brackets. Even still, in the event the post and gate are made of a plastic material, the gap filler1002may be adhered to their surfaces using some type of adhesive. InFIG. 33-A, gap filler1002is positioned to extend away from the adjustable hinge10. There are several possible ways of attaching or securing the gap fillers in place to conceal the gap6, as will be recognized by one skilled in the art.

FIG. 33-Billustrates the same gap filler embodiment ofFIG. 33-A, only the gap filler1002is positioned in a reverse configuration to be proximate the adjustable hinge10. As can be seen, the particular orientation of the gap filler1002may vary from assembly to assembly.

FIGS.34-A–34-F illustrate several different embodiments of a gap filler1002that may be used to conceal or fill the gap between hinged components. Specifically,FIG. 34-Aillustrates gap filler1002as comprising a standard depth triple corrugated configuration.FIG. 34-Billustrates gap filler1002as comprising an extended depth double corrugated configuration.FIG. 34-Cillustrates gap filler1002as comprising a u-shaped configuration similar to the u-shaped configuration described above.FIG. 34-Dillustrates gap filler1002as comprising a standard depth quadruple corrugated configuration.FIG. 34-Eillustrates gap filler1002as comprising a shallow depth and triple corrugated configuration.FIG. 34-Fillustrates gap filler1002as comprising a shallow depth corrugated configuration having several tight segments.

The present invention further features various hinge cover configurations designed and configured to cover and/or conceal the various components of the adjustable hinge assembly, and particularly the individual post and hinge bracket assemblies, as well as to facilitate operation and adjustment of the hinge while attached. The covers are designed to cover the hinge assembly for various purposes, such as for improved aesthetics, as well as to protect the hinge components from adverse weather conditions. The covers are preferably configured to provide free movement of the hinge assembly, meaning that, as attached, they do not interfere with the normal operation of the adjustable hinge. As such, sufficient clearance must be provided within the covers themselves. In addition, the covers are configured to facilitate easy and quick access to the hinge components to effectuate adjustment of both the vertical and horizontal adjustment components without requiring removal of the covers. Several designs are contemplated herein, some of which are discussed below.

With reference toFIG. 35, illustrated is a perspective view of an adjustable hinge assembly having hinge covers attached thereto according to one exemplary embodiment of the present invention. Specifically,FIG. 35illustrates the post bracket assembly as comprising a cover1012that comprises a flat section1016that couples to and covers the post mounting portion, as well as a raised section1020sized and configured to cover the pivoting hinge component. The raised section1020is shown comprising a slot1024formed therein configured to allow the horizontal adjustment component80to pivot about the vertical hinge component, namely the hinge barrel60, without the cover1012interfering with the horizontal adjustment component80. The cover1002may further comprise an aperture1028formed in the top of the raised section1020, or other slots, apertures, etc., to facilitate adjustment of the vertical adjustment component50.

The gate bracket assembly also comprises a cover1032comprising a box-like structure that couples to the gate bracket and that covers the components of the gate bracket assembly, namely at least a portion of the horizontal adjustment component80and the structure supporting the horizontal adjustment component80on the gate bracket. As shown, the cover1032comprises a first aperture1044and a second aperture1048for receiving the horizontal adjustment component80therethrough, which allows the cover1032to facilitate adjustment of the horizontal adjustment component80without having to remove the cover1032.

Covers1012and1032are preferably snap-on covers that snap onto the respective post and gate brackets. However, other means for coupling the covers to the respective post and gate bracket assemblies is contemplated herein, such as by a tongue and groove configuration that allows the covers to be slid over the post and gate bracket assemblies, a quick-connect fitting, by fasteners of various kinds, and others. In addition, the covers1012and1032may be formed of any suitable material, such as plastic, aluminum, etc., although plastic is preferred.

Horizontal and Vertical Adjustment Tools

The present invention further features one or more tools to assist the installer and/or owner of the hinge assembly in both installing and adjusting the adjustable hinge assembly at periodic times after installation.

Referring now toFIGS. 36 and 37, there is illustrated a perspective view of a vertical adjustment tool according to one exemplary embodiment of the present invention. Specifically,FIGS. 36 and 37illustrate vertical adjustment tool1100configured to be removably coupled between a top vertical adjustment component50-aand a bottom vertical adjustment component50-bof a respective top adjustable hinge10-aand bottom adjustable hinge10-b, which are accordingly spaced vertically apart and each mounted to a hinged post2and gate4component assembly. Such a vertical adjustment tool1100is configured to facilitate simultaneous vertical adjustment of the top and bottom vertical adjustment components50-aand50-bto effectuate simultaneous displacement of the top and bottom gate brackets30-aand30-bwith respect to the top post bracket20-aand bottom post bracket20-b, and therefore the gate4with respect to the post2, respectively.

The vertical adjustment tool1100comprises a tube member1104with a center crimp portion1108and outer crimp portions1112spaced from the center crimp portion1108. The center crimp portion1108and outer crimp portions1112can extend annularly around the tube member1104. The tube member1104comprises independent spring members1116disposed therein. Each spring member1116can be positioned in the tube member1104between the center crimp portion1108and each outer crimp portion1112. The center crimp portion1108and the outer crimp portions1112form stopper portions defined about the inner surface of the tube member1104. Such stopper portions retain the spring members1116in position between the center crimp portion1108and the outer crimp portions1112, respectively.

The vertical adjustment tool1100further comprises drive shafts1120, one disposed or located on each end portion1128of the tube member1104. The drive shafts1120can include an external configuration so as to match the driving components56-aand56-bof the vertical adjustment components50-aand50-b, respectively, previously set forth above with respect toFIGS. 1–20. The drive shafts1120can include a stopper member at end portions thereof to bias against the spring member1116, wherein the stopper portion is situated or disposed between the spring member1116and the outer crimp portion1112defined in the tube member1104. Such drive shafts1120are linearly displaceable within the tube member1104with the spring member1116biasing against the drive shaft1120in a spring-loaded arrangement. At the end portions1128of the tube member1104, a shaft bushing1124can be fixedly disposed therein with a bore having an internal configuration to correspond with the external configuration of the drive shaft1120. In another embodiment, instead of shaft bushing1124inserts, the end portions1128of the tube member1104can be formed to include an inner surface to match and correspond with the external configuration of the drive shaft1120. In either case, the drive shaft1120can slide linearly against the spring member1116within the spring-loaded arrangement. Further, any rotation placed on one drive shaft1120, translates rotation to the tube member1104which also translates rotation to the other drive shaft1120disposed in the opposite end portion1128of the tube member1104.

As previously indicated, the vertical adjustment tool1100can be positioned between the top and bottom vertical adjustment components50-aand50-bspaced vertically about a common axis on post2. Each drive shaft1120disposed in the end portions1128of the tube member1104can be displaced linearly a distance corresponding with the spacing between the top and bottom vertical adjustment components50-aand50-b, in which the drive shafts1120are spring-loaded to linearly bias outward and to fit within the driving components56-aand56-b, respectively, as shown inFIG. 37, between the top and bottom vertical adjustment components50-aand50-b. With the vertical adjustment tool1100positioned between the top and bottom vertical adjustment components50-aand50-b, a user can rotatably drive one of the top or bottom vertical adjustment components50-aand50-bby inserting, for example, a hex drive bit1204coupled to a power drill1200, into an opposing end of either of the driving components56-aor56-bof the top or bottom vertical adjustment components50-aand50-b, as shown. The hex drive bit1204includes a configuration so as to mate with the driving component56-aor56-bof the top or bottom vertical adjustment component50-aor59-b. In the illustration ofFIG. 37, the hex drive bit1204is shown being inserted into the driving component56-aof the top vertical adjustment component50-a. In this manner, rotatably driving or adjusting the top vertical adjustment component50-asimultaneously rotates and adjusts the bottom vertical adjustment component50-bwith the vertical adjustment tool1100disposed therebetween. As such, each of the top and bottom hinge barrels60-aand60-bthat are rotatably coupled to the respective top and bottom vertical adjustment components50-aand50-bvertically displace in a simultaneous manner, thereby, also simultaneously vertically moving the top and bottom gate brackets30-aand30-bwith respect to the top and bottom post brackets20-aand20-b, and therefore the gate4with respect to the post2. With this arrangement, the gate4can be raised and lowered, depending on the rotation placed on either of the top and bottom vertical adjustment components50-aand50-b, without binding the mounting portions of the top and bottom adjustable hinges10-aand10-bwith the post2and gate4hinged component assembly. The vertical adjustment tool1100can be advantageously implemented at the time of installation. In addition, due to various degrees of misalignment that can occur over time as a result of extended use, settling, or sagging of the gate4under its own weight, the vertical adjustment tool1100may be used periodically and repeatedly to again vertically align the gate4with the post2.

FIG. 38illustrates an exemplary horizontal adjusting tool1300configured to removably couple with a top and bottom horizontal adjustment component80-aand80-bcoupled to respective top and bottom adjustable hinges10-aand10-b, each being spaced vertically apart and mounted to a post2and gate4hinged component assembly. The horizontal adjusting tool1300can include first and second tube members1302and1304with a drive shaft1306coupled therebetween. The first and second tube members1302and1304each include an end having a gear member1310coupled thereto. With this arrangement, each end of the horizontal adjusting tool1300includes one gear member1310configured to couple with the first end portion of the top horizontal adjustment component80-aand the other gear member1310configured to couple with the bottom horizontal adjustment component80-b. The first and second tube members1302and1304and/or the shaft can include a telescoping configuration to be positionable between the top and bottom adjustable hinges10-aand10-b.

Similar to the vertical adjusting tool previously described, a hex drive bit1204coupled to a power tool1200can rotatably drive, for example, the top horizontal adjustment component80-a. With the horizontal adjustment tool1300in position, the rotation of the top horizontal adjustment component80-atranslates rotation through the upper gear member1310to the first and second tube members1302and1304and drive shaft1306, which simultaneously translates rotation through the lower gear member1310and to the bottom horizontal adjustment component80-b. In this manner, a user can simultaneously horizontally adjust, with common linear displacement, the top gate bracket30-aand bottom gate bracket30-bwith respect to the top post bracket20-aand bottom post bracket20-b, respectively, and therefore the gate4with respect to the post2. Such is accomplished due to the simultaneous rotation of the top and bottom horizontal adjustment components80-aand80-b, which simultaneously horizontally move the respective top and bottom collars90-aand90-bcoupled to the respective top and bottom gate brackets30-aand30-b.

FIGS. 39 through 41depict various embodiments of the gear member1310, shown without the gear housing, coupleable to the first end portion84of the horizontal adjustment component80. Turning first toFIG. 39, the gear member1310is coupled to the tube member1302and drive shaft1306. The gear member1310can include a vertical gear1312and a horizontal gear1314. The vertical gear1312can include an extension portion1318configured to mate with the driving component88at the first end portion84of the horizontal adjustment component80. The vertical gear1312also includes a bit receptacle1316configured to receive a hex drive bit (not shown) sized for such bit receptacle1316. The vertical and horizontal gears1312and1314are positioned and configured such that rotation of, for example, the vertical gear1312will simultaneously rotate the horizontal gear1314. Further, rotation of the vertical gear1312can simultaneously rotate the horizontal adjustment component80via the extension portion1318mateable with the horizontal adjustment component80. The horizontal gear1314is coupled to the tubing1302so that as the horizontal gear1314rotates the tube member1302and drive shaft1306also rotate.

FIG. 40depicts another embodiment of the gear member1330having the vertical gear1332and the horizontal gear1334. In this embodiment, the vertical gear member1332includes an opening1336extending therethrough which can mate with an external surface of the first end portion84of the horizontal adjustment component80. The driving component (not shown) of the horizontal adjustment component80can then receive the hex drive bit1204coupled to a power tool1200to directly rotate the horizontal adjustment component80. Such rotation of the horizontal adjustment component80rotates the vertical gear1332, which simultaneously translates rotation to the horizontal gear1334, thereby, rotating the tube member1302and so forth to the other horizontal adjustment component (not shown) spaced vertically therefrom, as previously set forth.

FIG. 41depicts still another embodiment of the gear member1340configured to translate simultaneous rotation of one horizontal adjustment component to the other horizontal adjustment component spaced vertically apart from each other. In this embodiment, the gear member1340includes a vertical gear1342and a horizontal gear1344. The vertical gear1342includes an opening1346extending therethrough, which is sized and configured to match the driving component (not shown) of the horizontal adjustment component80. With this arrangement, the vertical gear1342is positioned adjacent the horizontal adjustment component80so that a hex drive bit1204coupled to a power tool1200can slide through the opening1346in the vertical gear1342and directly into the driving component of the horizontal adjustment component80. In this manner, as the drill1200simultaneously rotates both, for example, the top horizontal adjustment component80and the vertical gear1342, the vertical gear1342translates such rotation to the horizontal gear1344, which simultaneously rotates the tube member1302to the other gear member (not shown) coupled to the bottom horizontal adjustment component (not shown) spaced vertically therefrom.

Referring now toFIG. 42, shown is another exemplary hinged component assembly utilizing a continuous vertical adjustment rod1400extending between top and bottom free spinning post brackets1410-aand1410-b, as well as top and bottom gate brackets1414-aand1414-bhaving internal threads formed therein. The free spinning post brackets1410-aand1410-band the gate brackets1414-aand1414-bcomprise the top and bottom adjustable hinge assemblies10-aand10-b, respectively. The vertical adjustment rod1400comprises a rigid rod1404having threaded portions1408formed therein. The free spinning post brackets1410-aand1410-bfunction to hold the vertical adjustment rod1400in a suspended state, while the threaded portions1408engage the threaded gate brackets1414-aand1414-bto provide and facilitate vertical adjustment of the hinged assemblies10-aand10-b, and therefore the gate4with respect to the post2. Essentially, rotation of the vertical adjustment rod in either direction causes the gate brackets1414-aand1414-bto displace with respect to the free spinning post brackets1410-aand1410-b, thus raising or lowering the gate4with respect to the post2. The particular configuration of the post and gate brackets1410and1414may be any described herein, or others known in the art.

FIG. 43illustrates the vertical adjustment rod1400ofFIG. 42as used on another exemplary type of adjustable hinge assembly, shown as adjustable hinge assemblies10-aand10-b. In this embodiment, the vertical adjustment tool is situated between top and bottom free spinning post brackets1410-aand1410-b, as well as top and bottom gate brackets1414-aand1414-bhaving internal threads formed within the top and bottom hinge barrels1418-aand1418-bsupported thereon, respectively. Vertical adjustment rod1400functions similar as that described above in relation toFIG. 42, only the gate brackets1414-aand1414-bcomprise hinge barrels, which are similar in form and function as those described above with respect toFIGS. 21–32, and which description is incorporated herein.

It is noted herein that the post and gate brackets, as well as the vertical adjustment rod1400, may be mounted in other positions in order to close the gap between the post and gate portions2and4.

Installation Tool

The present invention further comprises an installation tool to assist the installer in installing the gate and post hinged component assembly. Referring now toFIGS. 44 and 45, shown are respective perspective and front views of an installation tool according to one exemplary embodiment. The installation tool1500is shown as comprising a base frame component1504and a top rail1508disposed about and extending perpendicularly from the top of the base frame component1504. The base frame component further comprises a plurality of eccentric components1512, such as cam components, as well as spacers1516, situated about the base frame component1504. The base frame1504is configured to receive a post and gate hinged component assembly between the eccentric components1512, as these are appropriately situated about the installation tool1500. With the installation tool1500in place about the post and gate, the eccentric components1512are actuated to secure the post and gate components in place with respect to one another. At this time, the particular adjustable hinge assemblies to be utilized to couple together the post and the gate may be installed.

The top rail1508functions to align the tops of the gate and post components prior to mounting of the hinged assembly, and also the mating edges of a double gate. The eccentric components provide the ability to clamp materials of varying size and are capable of being actuated and adjusted very rapidly for easy and efficient gate installations. The spacers1516provide a backstop for the clamping of the ends of the gate. These may be adjustable or interchangeable to provide varying gap settings between the gate and the post. The initial gap setting is not critical and may change when the installation tool is removed and the full weight of the gate is allowed to be placed on the post through the installed hinge assembly. At this time, the gate may be further adjusted as described herein to achieve proper alignment of the gate with respect to the post.

FIGS. 46 and 47illustrate perspective and front views, respectively, of the installation tool ofFIGS. 44 and 45as coupled with the post and gate hinged components2and4, respectively. As can be seen, the eccentric components1512are actuated to push against the sides of the post2and gate4from one side, while opposing sides of the post2and gate4are pushed against spacers1516, thereby defining the initial gap between the post2and gate4. Top rail1508maintains the horizontal alignment of the post2with respect to the gate4, while the base frame1504maintains the vertical alignment of the post2with the gate4. As so situated, the installation tool1500functions to provide an accurate and efficient first alignment of the post2with the gate4prior to mounting the adjustable hinge assemblies thereto. As such, only minimal “fine tuning” of the gate4with respect to the post2should be needed after installation of the adjustable hinge assemblies.

Adjustable Concealed Hinge Assembly

The present invention further comprises an adjustable concealed hinge assembly configured so that it is substantially concealed between the gate and the post to improve the aesthetic appeal of the hinged component assembly. The concealed hinge assembly further functions to reduce binding, which occurs when the gate rotates more than 180° about the post.

Referring now toFIGS. 48 and 49, illustrated is a perspective view of an adjustable concealed hinge assembly according to one exemplary embodiment of the present invention. As shown, the adjustable concealable hinge assembly1610comprises a post bracket1620and a complementary gate bracket1630. The post bracket1620is configured to be mounted to a post2via mounting holes1624formed within post mounting portions1622-aand1622-boriented orthogonally to one another. Post mounting portions1622-aand1622-bare configured to engage corresponding orthogonal surfaces of a post.

The post bracket1620further comprises a post bracket component1626configured to support a bushing1640and vertical adjustment component1650therein. The post bracket component1626may be a separate structural component coupled to the post bracket1620, but is preferably integrally formed from the post bracket1620itself, as shown. In such an embodiment, the post bracket1620may extend to form the post bracket component1626by providing a curled segment1628sized and configured to receive the bushing1640and vertical adjustment component1650therein. Preferably, the post bracket component1626has formed therein a cut-out segment, which is discussed in greater detail below.

The concealed hinge assembly1610further comprises a center bracket1670supported between a collar1660fixed to the post bracket1620and a horizontal adjustment barrel1680. The center bracket1670may be extended to form a portion of the horizontal adjustment barrel1680, or the horizontal adjustment barrel1680may comprise a separate piece coupled thereto. As shown, the center bracket1670forms upper and lower portions1682and1684of the horizontal adjustment barrel1680, with the gate bracket1630extending to form the mid portion1686. The horizontal adjustment barrel1680further comprises locking interfaces1690configured to lock the center bracket1670with respect to the gate bracket1630.

The vertical adjustment component1650functions in a similar manner as those discussed above, which descriptions are incorporated herein, where applicable. In essence, the vertical adjustment component1650is supported within the fixed collar1660, which comprises an inner threaded surface that corresponds to the threads of the vertical adjustment component1650. Thus, by driving or otherwise rotating the vertical adjustment component1650within the post bracket component1626via the driving component1656, the collar1660, and therefore the center bracket1670displace with respect to one another, thereby raising or lowering the gate bracket1630and the gate4attached thereto.

The horizontal adjustment barrel1680is configured to provide horizontal adjustment within the concealed hinge assembly1610, and particularly between the gate4and the post2. As such, the horizontal adjustment barrel1680further comprises means for locking the center bracket1670with respect to the gate bracket1630at locking interfaces1690. Means for locking functions to prevent horizontal displacement of the hinge or the hinged components by preventing the rotation of the center bracket1670about the horizontal adjustment barrel1680. In the embodiment shown, means for locking comprises one or more interlocking interfaces1690, which are actuated by a fastener, such as a bolt, that extends from the top to the bottom of the horizontal adjustment barrel1680through the interlocking interfaces1690. The locking interface1690may comprise a radial pattern of teeth or serrations, or it may comprise any other known types of locking interfaces.

As can be seen inFIG. 49, the adjustable concealed hinge assembly1610may be utilized to couple a gate4to a post2, and to substantially eliminate the gap distance between these two components. As configured, the horizontal adjustment barrel1680and the vertical post bracket component1626are contained outside of the vertical plane in which the post2and the gate4lie. As such, with the right horizontal adjustment, the adjustable concealed hinge1610may be substantially hid between the post2and the gate4when mounted thereto.FIG. 49illustrates an alternative bracket configuration for the post and gate brackets1620and1630, in that they are comprised of a single planar flange that couples to the side surface of the post2and gate4, respectively, as shown. The horizontal adjustment capabilities of the concealable hinge1610allow the gap between the post2and the gate4to be varied, as needed or desired.

FIGS. 50 and 51illustrate top views of the exemplary concealed hinge assembly1610ofFIGS. 48 and 49.FIG. 50illustrates the gate4in a partially opened position, whileFIG. 51illustrates the gate4in a fully opened position. In this particular embodiment, as the gap widens between the gate4and the post2with the adjustment of the horizontal adjustment barrel1680, the post and gate mounting portions1622and1632move further and further out of plane. This is referred to herein as the horizontal adjusting offset. The greater the distance between the horizontal adjustment barrel1680and the post bracket component1626, the less the horizontal adjusting offset.

FIG. 52illustrates another exemplary embodiment of the adjustable concealed hinge assembly1610. In this embodiment, the post bracket component1626and the horizontal adjustment barrel1680are disposed on the same side of the gap formed between the post2and the gate4.

FIG. 53illustrates another exemplary embodiment of the adjustable concealed hinge assembly1610. In this embodiment, the post bracket component1626is contained without the hinged components, while the horizontal adjustment barrel1680is disposed within a recess or opening formed within each of the post2and gate4. Providing openings within the sides of the post2and gate4allows the concealable hinge assembly1610to comprise different types of configurations without sacrificing a reduction in gap distance.FIG. 53further illustrates post mounting portions1620and1630in a nested relationship as a result of various cut-out segments (not shown) formed in one or both of the post mounting portions1620and1630.

FIG. 54illustrates a perspective view of two complementary concealed hinge assemblies1610as mounted to a post2and gate4hinged component assembly. As can be seen, the two concealed hinges1610are operable with the vertical adjustment tool1100described above used to simultaneously adjust the vertical adjustment component1650of each hinge1610, thus simultaneously adjusting the gate4with respect to the post2as taught above.

More specifically, while illustrative exemplary embodiments of the invention have been described herein, the present invention is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. For example, in the present disclosure, the term “preferably” is non-exclusive where it is intended to mean “preferably, but not limited to.” Any steps recited in any method or process claims may be executed in any order and are not limited to the order presented in the claims. Means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) “means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are expressly recited. Accordingly, the scope of the invention should be determined solely by the appended claims and their legal equivalents, rather than by the descriptions and examples given above.