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CROSS-REFERENCES 
       [0001]    This application is related to U.S. provisional application No. 62/108,284, filed Jan. 27, 2015, entitled “CONTINUOUS HINGE”, naming Damond Maurice Smalls as the inventor. The contents of the provisional application are incorporated herein by reference in their entirety, and the benefit of the filing date of the provisional application is hereby claimed for all purposes that are legally served by such claim for the benefit of the filing date. 
     
    
     BACKGROUND 
       [0002]    A continuous hinge for a pivoting door is shown and described and, more particularly, a continuous hinge configured such that no portion of the hinge can be used as a ligature point and for minimizing the danger of pinching. 
         [0003]    A door is typically attached to a frame using a plurality of discrete hinges such that the door pivots relative to the frame via the hinges. Door hinges are well-known in the hardware industry and are generally constructed of a pair of leaves respectively applied to an edge of the door and a rabbet of the door frame or a door jamb. Each leaf has one or more longitudinally-spaced knuckles configured as barrel-shaped sleeves extending from an edge. The spacing and size of the knuckles are such that the knuckles of the leaves interlock to form a cylindrical sleeve for receiving a hinge pin around which the leaves rotate. Bearings are sometimes positioned between the knuckles. Typical hinges allow the door to rotate in one direction relative to the door frame or door jamb. 
         [0004]    Continuous hinges are generally applied to the entire length of a door. A continuous hinge also has leaves that are secured to the door and to the door frame. The leaves of the continuous hinge have a series of interlocking knuckles connected by a hinge pin extending the length of the door. Continuous hinges utilizing intermeshing gear teeth are also used in certain applications, particularly for relatively durable and high strength hinged connections or where some sealing action is desired. 
         [0005]    When a door hinge is mounted to a door so that the door can open in one direction, the aligned knuckles are often physically accessible from the side of the door toward which the door is opened. This allows a person to remove the hinge pin from the hinge assembly or to use the protruding knuckles as a ligature point. Further, when the door is in an open position, gaps are formed between the hinged edge of the door and the door frame on both sides of the door. Fingers, limbs and other objects can fit into the gaps and be crushed by the edge of the door coming into close contact with the door frame. 
         [0006]    For the foregoing reasons, there is a need for a new hinge for a pivoting door. The hinge should prevent a person from being able to gain access to the knuckles or hinge pins of the door hinge. The hinge should also minimize the possibility of pinching of a person or an object between the adjacent edges of the hinged members and the door and door frame. 
       SUMMARY 
       [0007]    A continuous hinge is provided for connecting between a first member and a second member, wherein at least one of the first member or the second member is movable relative to the other member. The hinge comprises an elongated first leaf having an inner edge defining a partially enclosed longitudinal channel portion extending continuously along the length of the first leaf, the first leaf adapted for attachment to one of the first or second movable member, and an elongated second leaf having an inner edge defining a partially enclosed longitudinal channel portion extending continuously along the length of the second leaf, the second leaf adapted for attachment to the other of the first or second movable member. A plurality of barrels define longitudinal bores open at each end, each of the barrels including a longitudinally extending flange projecting from a peripheral surface, the flange configured to be received in the channel portion of either the first leaf or the second leaf. Means for attaching the flanges of the barrels in the channel portions of the first and second leafs is provided, wherein the barrels in the first and second leafs may be placed in closely spaced end-to-end relation for axially aligning the bores of the barrels. A pivot pin extends through the bores of the barrels, the pivot pin configured to be coextensive with the barrels for joining together the barrels and the first and second leaves for relative pivoting movement about the pivot pin. The barrels attached to the first leaf are interspersed between the barrels attached to the second leaf in alternating relationship. 
         [0008]    In an aspect, each of the first and second leafs comprises a pair of elongated planar walls terminating in free inner edges in spaced relation for at least partially defining the channel portion of each leaf. A longitudinal web extends coextensively with and interconnects the walls of the leafs intermediate the transverse dimension of the walls. The web extends in a plane parallel with longitudinal axis of the first and second leaves and normal to a central transverse plane of the first and second leaves for at least partially defining the channel portions of each of the first and second leafs. The pair of walls of the first and second leafs terminates in outer edges in spaced relation, and further comprises a flange extending transversely in opposite directions from the outer edges of the pair of walls, the flanges being adapted to be secured to one or the other of the first and second movable members. The adjacent walls of the first and second leafs abut for maintaining the leafs in predetermined spaced apart relation when the leafs are rotated about the pin, a maximum spaced relation limiting the opening of the hinge to a maximum included angle between the leaves of less than about 105 degrees. 
         [0009]    In another aspect, the longitudinally extending flange of each of the barrels comprises a pair of planar walls extending coextensively with the barrel in parallel spaced relation for defining a channel. The attaching means comprises at least one threaded fastener inserted through the web of the first or the second leaf for threaded engagement between the walls of the flange of the barrel for securing the barrel in the channel portion of the leaf 
         [0010]    In a further aspect, a plurality of bearings are configured to be disposed in the bore at each end of the barrels such that bores in the bearings are axially aligned with the bores of the barrels for slidingly receiving the pivot pin. The bearings longitudinally fill each of the spaces between the ends of the barrels and are configured to engage one another to facilitate relative rotation of the adjacent barrels. 
         [0011]    In yet another aspect, an insert is configured to be disposed in the bore at each end of the barrels such that a bore of the insert is axially aligned with the bore of the barrel. The insert defines at least one longitudinal slot. The bearing further comprises a radial projection, and the slot is configured for slidingly receiving the projection for preventing relative rotation of the barrel and bearing. Each bearing may comprise a tongue at an outer end, the tongue extending normal to the longitudinal axis of the bearing for covering the end of the channel portion of each leaf when the bearing is disposed in the end of the barrel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    For a more complete understanding of the continuous hinge, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings: 
           [0013]      FIG. 1  is cut-away perspective view of an embodiment of a continuous hinge in position on a door. 
           [0014]      FIG. 2  is perspective view of a portion of an embodiment of a hinge assembly with a portion of door and adjacent door frame in dashed lines with the door in a closed position. 
           [0015]      FIG. 3  is an exploded perspective view of the hinge assembly as shown in  FIG. 2 . 
           [0016]      FIG. 4  is a longitudinal cross-section of the hinge assembly as shown in  FIG. 2 . 
           [0017]      FIG. 5  is a transverse cross-section of the hinge assembly taken along line  5 - 5  of  FIG. 2 . 
           [0018]      FIG. 6  is a perspective view of an embodiment of a knuckle for use with the hinge assembly as shown in  FIG. 2 . 
           [0019]      FIG. 7  is a perspective view of an embodiment of a bearing for use with the hinge assembly as shown in  FIG. 2 . 
           [0020]      FIG. 8  is a top plan view of the hinge assembly including portions of the door and the frame as shown in  FIG. 2 . 
           [0021]      FIG. 9  is a top plan view of the hinge assembly and portions of the door and the frame as shown in  FIG. 6  with the door in an open position. 
           [0022]      FIG. 10  is a perspective view of the hinge assembly and portions of the door and the frame as shown in  FIG. 8 . 
           [0023]      FIG. 11  is a perspective view of the hinge assembly and portions of the door and the frame with the door in an open position opposite to  FIG. 9 . 
           [0024]      FIG. 12  is a close-up perspective view of the hinge assembly in a position corresponding to an open position of the door as shown in  FIG. 11 . 
           [0025]      FIGS. 13A, 13B and 13C  is a perspective view, a side elevation view and a bottom plan view, respectively, of another embodiment of a bearing for use with the hinge assembly as shown in  FIG. 2 . 
       
    
    
     DESCRIPTION 
       [0026]    Certain terminology is used herein for convenience only and is not to be taken as a limitation on the continuous hinge shown and described. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the FIGS. Indeed, the components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. 
         [0027]    As used herein, the term “open position” for a door means a door position other than a closed position, including any position between the closed position and a fully open position as limited only by structure around the door frame, which can be up to 180.degree. from the closed position. 
         [0028]    Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, an embodiment of a continuous hinge assembly is shown in  FIG. 1  and generally designated at  20 . The continuous hinge  20  is secured between a door  28  and a door frame  30  for pivoting movement of the door  28  relative to the frame  30  between a closed position and an open position for opening and closing an opening through a building wall to allow a user to travel from one side of the wall to the other side of the wall. The door  28  and door frame  30  can be composed of wood, metal, plastic or other suitable material. For the purpose of this description, only a portion of the door  28  and the door frame  44  are shown. 
         [0029]    Referring to  FIGS. 2-4 , the hinge assembly  20  comprises a pair of elongated leaves  22  and  24 , each leaf  22 ,  24  having along an inner edge at least one knuckle, or barrel  26 , in which a pin  28  may be received for pivotally mounting the leaves  22 ,  24  together for relative rotation. A first leaf  22  is secured to an edge of a door  28  by any suitable fastening means, such as screws, and is hereinafter referred to as the door leaf. A second leaf  24  is secured by similar fastening means to an adjacent door frame or jamb  30 , and is hereinafter referred to as the frame leaf. Each of the leaves  22 ,  24  extends the full height of the door  28  and the door jamb  30 , respectively ( FIG. 1 ). 
         [0030]    As best seen in  FIG. 5 , the leaves  22 ,  24  of the hinge assembly  20  are generally H-shaped in transverse cross-section, each leaf  22 ,  24  comprising opposed walls  23 ,  25  which taper outwardly from an inner portion to an outer portion. The walls  23 ,  25  are interconnected by respective planar transverse webs  32 ,  33  intermediate the length of the walls  23 ,  25 . The webs  32 ,  33  extend longitudinally the length of the leaves  22 ,  24  thereby forming with the walls  23 ,  25  a pair of U-shaped longitudinal channels  34 ,  35 ,  36 ,  37  on the inner and outer sides of the webs  32 ,  33 . The outer edge of the walls  23 ,  25  include mounting portions comprising base flanges  40 ,  42  extending transversely outwardly from the walls  23 ,  25 . The base flanges  40 ,  42  have substantially planar mounting surfaces  41 ,  43  configured to sit flush against the edge surface of the door  28  and the surface of the jamb  30 , respectively, for fastening. The leaves  22 ,  24  may be secured to the door  28  and the door jamb  30  using a a plurality of longitudinally spaced fasteners passing through the base flanges  40 ,  42  and into the door  28  and the door jamb  30  ( FIG. 1 ). 
         [0031]    The continuous hinge assembly  20  may be formed from aluminum in order to provide high strength together with lightweight and a high degree of resistance to corrosion. A variety of other rigid durable materials are also suitable for the hinge assembly  20  including, but not limited to, brass, steel, stainless steel, titanium, or alloyed metals; synthetic resins and plastics including polyimides, polytetrafluoroethylenes, polyacetals (both homopolymers and copolymers with silicones) and polypropylene; composites; or any other suitable material as is known and used in the art. The hinge assembly  20  may be manufactured by conventional techniques such as, but not limited to, roll forming, extruding, casting, molding, and the like. For example, the leaves  22 ,  24  may be conveniently formed by extrusion since the profile of the leaves  22 ,  24  is uniform over the length thereof. Other techniques, such as milling, machining, boring, drilling, tapping, punching and the like may also be used to prepare the hinge assembly  20 . The selection of materials and manufacturing techniques are well within the purview of those of ordinary skill in the art and will not be expounded upon herein. 
         [0032]    Referring now to  FIG. 6 , each barrel  26  is generally cylindrical and defines a substantially circular passageway which extends longitudinally through the barrel  26 . The barrels  26  have an integral pair of spaced parallel planar arms  44  extending longitudinally along the outer surface of the barrel  26 . The arms  44  extend the full length of the barrel  26 . The diameter of each barrel is configured to be larger than the width of the inner channels  34 ,  36  of the leaves  22 ,  24 . The distance between the outer surfaces of the pair of arms  44  corresponds to the width of the inner channels  34 ,  36  of the leaves  22 ,  24 . As shown in  FIG. 5 , the inner channels  34 ,  36  of the leaves  22 ,  24  are configured for slidably receiving the arms  44  of the barrels  26  in closely spaced relationship. The barrels  26  may be slid longitudinally in the channels  34 ,  36  along the length of the leaves  22 ,  24  to a selected position with respect to the leaf. In one embodiment, the barrels  26  are fixed in position in the channels  34 ,  36  using threaded fasteners extending through the webs  32 ,  33  and into the space defined by the arms  44  of the barrel  26 . The fasteners are accessible and operable via the outer channels  35 ,  37  of the leaves  22 ,  24  using a driver, such as screwdriver. The webs  32 ,  33  may have an array of longitudinally spaced apertures through which the fasteners may be advanced for securing the position of the barrels  26  on the leaves  22 ,  24 . 
         [0033]    An embodiment of a bearing for use with the hinge assembly  20  is shown in  FIG. 7  and generally designated at  50 . The bearing  50  comprises an elongated cylindrical portion  52  having a circular planar cap  54  at one end. The cap  54  has a larger diameter than the cylindrical portion  52  and projects laterally from the outer surface of the cylindrical portion. The outside diameter of the cap  54  is substantially the same as the outside diameter of the barrels  26 . The intersection between the cylindrical portion  52  and the cap  54  forms an annular surface or shoulder  56 . The bearing  50  may preferably be formed from any appropriate plastic material, such as nylon. 
         [0034]    The bearing  50  comprises a key  58  extending longitudinally along the outer surface of the cylindrical portion  52  of the bearing  50 . In the embodiment shown, the key  58  extends the full length of the bearing  50 . The bearing  50  defines a central longitudinal bore for receiving the pin  27  when the bearing is inserted into the barrel  26 . 
         [0035]    A star-shaped insert  64  is configured to be disposed in the ends of the barrels  26  for receiving the bearings  50  ( FIGS. 5 and 6 ). The insert  64  is retained by a press fit, but other means of securing the insert in the barrel  26  may be used including, for example, adhesives, welding, soldering, or any other means within the skill in the art. The insert  64  has six radially extending points  66 , each of which defines a slot. It is understood that any number of points and slots may be provided. The inner surfaces of the points  66  are disposed circumferentially about an opening in the insert  64  and configured to receive the cylindrical portion  52  of the bearing  50  between the points  66 . The slots defined by the points  66  of the insert  64  are sized and configured to slidably receive the key  58  on the bearing  50  when the bearing  50  is press fit into the insert  64  in the barrel  26 . This arrangement functions as a mechanical locking mechanism for causing the bearing  50  to rotate with the barrel. The inner annular surface  56  of the end cap  54  fits against the end of the barrel  26  to prevent the bearing  50  from sliding into the barrel. The bearings  50  are diposed between adjacent ends of the barrels  26  for longitudinal support of the barrels during relative rotation of the leaves  22 ,  24 . The bearings  50  allow the barrels  26  to turn in unison without binding with one another or with the pin  27 . 
         [0036]    Another embodiment of a bearing for use with the hinge assembly  20  is shown in  FIGS. 13A-13C  and generally designated at  70 . The bearing  70  comprises an elongated cylindrical portion  72  having a circular planar cap  74  at one end. The end cap  74  has a larger diameter than the cylindrical portion  72  and projects laterally from the outer surface of the cylindrical portion. The outside diameter of the cap  74  is substantially the same as the outside diameter of the barrel  26 . A planar tongue  75  extends from the cap  74  in the same plane as the cap  74 . The configuration of the tongue  75  corresponds to the transverse dimension of the pair of planar wall  23 ,  25  extending from each leaf  22 ,  24 . The intersection between the cylindrical portion  72  and the cap  74  forms an annular surface or shoulder  76 . The bearing  70  may preferably be formed from any appropriate plastic material, such as nylon. 
         [0037]    The bearing  70  comprises a key  78  extending longitudinally along the outer surface of the cylindrical portion  72  of the bearing  70 . In the embodiment shown, the key  78  extends the full length of the bearing  70 . The bearing  70  defines a central longitudinal bore  80  for receiving the pin  27  when the bearing is inserted into the barrel  26 . 
         [0038]    The bearing  70  also has five radially spaced projections  79  extending longitudinally from the cap  74  along the outer surface of the cylindrical portion  72  of the bearing  70  parallel to the key  78 . The key  78  and the projections  79  are sized and configured to slidably fit between the points  66  of the insert  64  when the bearing  70  is press fit into the insert  64  in the barrel  26 . This arrangement functions as a mechanical locking mechanism for causing the bearing  70  to rotate with the barrel. The inner annular surface  76  and tongue  75  of the end cap  74  fit against the end of the barrel  26  and the arms  44  to prevent the bearing  50  from sliding into the barrel and for covering the gap between the arms  23 ,  25  of each leaf  22 ,  24 . The bearings  70  are disposed between adjacent ends of the barrels  26  for longitudinal support of the barrels during relative rotation of the leaves  22 ,  24 . The bearings  70  allow the barrels  26  to turn in unison without binding with one another or with the pin  27 . 
         [0039]    In lieu of the insert  64 , as described above, the barrels  26  may be provided with one or more longitudinal slots which are cooperatively configured and sized to receive the key  58 ,  78  on the bearing  50 ,  70 . Other suitable alternatives may also be used to fix or secure the bearings  50 ,  70  to the barrels  26 , for example, a set screw or pin, threaded fasteners, adhesives, welding, soldering, or other means within the skill in the art. 
         [0040]    The pin  27  is configured to be received in the substantially coaxially aligned bores  60  of the bearings  50 ,  70  disposed in the inserts  64  in the barrels  26 . The aligned bores  60 ,  80  form a sleeve for receiving the circular pin  27 . When disposed in the bearings  50 ,  70 , the pin  27  pivotally connects the barrels  26  and associated leaves  22 ,  24  so that the leaves  22 ,  24  may be rotatably moved through an angular displacement. The length of the pin  27  is adapted to be slightly less than the total length of the hinge assembly  20  such that the ends of the pin  27  do not extend beyond the ends of the end barrels  26 . Accordingly, when the pin  27  is disposed in the barrels  26 , the ends of the pin will be within the bores  60 ,  80  of the outermost bearings  50 ,  70 . After the pin  27  is disposed in the hinge assembly  20 , a set screw  68  is threaded into each of the ends of the hinge assembly  20  to fix the position of the pin  27  ( FIG. 8 ). 
         [0041]    In use, the barrels  26  are assembled and attached to the leaves  22 ,  24  in end-to-end contact in a longitudinal alternating sequence so that the total combined length of the barrels  26  is substantially the same as the length of the leaves  22 ,  24 . As shown in  FIGS. 2-4 , the top and bottom barrels  26  are attached to the frame leaf  24 . The barrels  26  of the hinge assembly  20  can be manufactured in standard sizes and combined to provide a hinge assembly  20  of the desired length. Alternatively, the length of one or more barrels may be adjusted to achieve a predetermined overall desired length. In this manner the length of the hinge assembly  20  is customizable to a particular application. 
         [0042]    The leaves  22 ,  24  of the hinge assembly  20  are then fastened to the hinged objects, such as an edge of the door and the door frame, using fasteners such as threaded screws or bolts, adhesive, welds, or any other suitable means known to those skilled in the art. The plurality of fasteners is longitudinally spaced along the base flanges  40 ,  42  and extending into the door  28  and the door frame  30 . As shown in  FIG. 1 , the hinge assembly  20  extends the full length of the door  28 , substantially filling the gap between the leaves  22 ,  24  and the door  28  and door frame  30 . The barrels  26  are configured and sized so that there is little or no gap between the barrels  26  or between the barrels  26  and the inner edges of the walls  23  and the leaves  22 ,  24  ( FIGS. 8 and 10 ). 
         [0043]    The hinge assembly  20  allows the door  28  to rotate relative to the door frame  30  in both directions. As the door is opened, the leaves  22 ,  24  of the hinge assembly  20  rotate progressively around the pin  27  to an open position of the door ( FIGS. 9, 11 and 12 ). One surface of each of the leaves  22 ,  24  moves angularly towards the other during door  28  opening thereby functioning to “close” the gap between the leaves  22 ,  24 . Referring to  FIGS. 11 &amp; 12 , the leaves  22 ,  24  are configured so as to provide a stop to limit the angle to which the hinge assembly  20  and the door  28  may be opened. The stop comprises the inner free ends of the walls  23 ,  25  of the leaves  22 ,  24 . The walls  23 ,  25  are in spaced arcuate relation so as to abut one another at a predetermined relative angular position which prevents any further opening of the door  28 . In one embodiment, the angular displacement measured in degrees of angle θ between the leaves  22 ,  24  is about 102 degrees when the door is fully open in either direction from the closed position. It is understood that the leaves  22 ,  24  may be opened to a position greater or less than 102 degrees depending on the design requirements and physical limitations of the intended application. 
         [0044]    The continuous hinge assembly  20  has many advantages, including preventing access to the barrels or the pin for use as a ligature or other unintended use. Moreover, there is little or no gap or crevice existing between the edge of the door and the door frame or door jamb when the door is in an open position. The hinge is continuous along the edge of the door and the components are closely adjacent to each other so there is no gap between the abutting edges of the hinge or between the door and the door frame. This arrangement of the hinge minimizes the risk of crush injury of fingers or limbs caused by conventional hinges since fingers and limbs can no longer be placed within a gap on the hinge side of the door. The hinge can be equipped with a desired number of barrels and a combined length of barrels which are best suited for the service requirements of the application. 
         [0045]    Although the present invention has been shown and described in considerable detail with respect to a few exemplary embodiments thereof, it should be understood by those skilled in the art that we do not intend to limit the continuous to the embodiments since various modifications, omissions and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages, particularly in light of the foregoing description. For example, the continuous hinge assembly shown may be provided for attachment to any pair of hinged objects, including a window, gate, lid and the like. Accordingly, it is understood that the continuous hinge assembly is expressly not limited for use in only door installations, but may be used in any application where at least two hinged objects are to be pivotally connected. Accordingly, we intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope of the continuous hinge assembly as shown and described herein and as defined by the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures.

Summary:
A continuous hinge comprises a first leaf and a second leaf each defining a longitudinal channel, a plurality of barrels defining bores open at each end, each of the barrels including a flange configured to be received in the channels of the first leaf or the second leaf, means for attaching the flanges of the barrels in the channels of the first and second leafs, wherein the barrels may be placed end-to-end for axially aligning the bores of the barrels, and a pivot pin extending through the bores of the barrels. The pivot pin is coextensive with the barrels for joining the barrels and the first and second leaves for relative pivoting movement about the pivot pin. The barrels attached to the first leaf are interspersed between the barrels attached to the second leaf in alternating relationship.