Abstract:
A door assembly and a door closer arranged and constructed so as to be wholly concealed within the associated door, yet is rendered readily accessible to effect the adjustment thereof to regulate or control the closing speed of the associated door. The door closer is capable of performing all of the functions expected of a door closer such as controlling the closing force, regulating the door closing speed and the arresting of the door in a predetermined opened position.

Description:
FIELD OF THE INVENTION 
   This invention is directed in general to door assembly, and more specifically to a door assembly with a concealed closer within the associated door. 
   BACKGROUND OF THE INVENTION 
   Door closers are commonly used on doors for effecting the closing of a door upon the release of the door on opening. Such door closers are externally connected between the door and the associated door frame. Generally, the door closers are connected to the door and associated frame about midway between the top and bottom of the door. Oftentimes, the closer is connected either adjacent the top or bottom of the door. However, wherever such door closers are externally connected between the door and the associated door frame, their presence is always quite visible and unsightly. It has also been noted that with such door closers, it often happens that one&#39;s clothing may also become entangled with the door closer. While efforts have been made to obviate the problems encountered with the conventional externally and visibly connected door closers, such known efforts entailed excessive costs and installation difficulties. Even with the currently known door closers of the so-called concealed type, a considerable portion of the operating mechanism remains readily noticeable and unsightly. 
   Efforts to conceal door closers included locating the closer in the floor or ceiling adjacent the door, or in the framing around the door. However, with such known floor, ceiling or frame located closers, the actuating levers or connecting mechanism associated with the floor or ceiling mounted piston and cylinder assembly of the door closer would still be visible and unsightly. Further, such floor, ceiling or door frame attempts to hide the closer assembly presented substantial installation difficulties, as is readily evident, and which installation difficulties become greatly aggravated for the after marketed installations of such closers. 
   SUMMARY OF THE INVENTION 
   An object of this invention is to provide a door assembly in which the closer which is virtually concealed within the structure of the associated door so that the closer assembly including the support elements thereof are concealed from view. 
   Another object of this invention is to provide a door closer assembly which can be readily concealed within any of the conventional type door structures or arrangements. 
   Another object is to provide a concealed door closer which is applicable for use with doors of minimum thickness, e.g. for use in storm and/or screen doors. 
   Another object of this invention is to provide a concealed door closer which is relatively simple in construction, positive in operation and relatively inexpensive to fabricate. 
   The foregoing objects, features and other advantages are achieved by a door assembly having concealed within the structure of the door a closer or linear assembly that includes a cylinder and piston unit in which the piston is linearly displaceable within the cylinder. Connected to the piston is a piston rod which extends outwardly through one end of the cylinder. The free end of the piston rod is directly or indirectly anchored to a bracket connected to the inside portion of a door frame adjacent the hinged edge of the door and centered within the thickness of the door edge to project into the hinged edge of the door. This is attained by providing a chamber disposed between the opposed side surfaces of the door in alignment with the bracket to which the linear assembly is connected. The chamber defines the housing for concealing the cylinder and piston unit or linear assembly of the door closer. The arrangement is such that the linear assembly is housed wholly within the thickness of the door so as to be completely out of sight when the door is in the closed or open position. It will be understood that one or more linear assemblies, as described, can be associated with the door depending upon the size and/or weight of the door. The linear assembly concealed within the thickness of the door is capable of performing all of the basic functions of a door closer such as, for example, applying the desired closing force to the door, controlling the closing speed and/or adjustably maintaining the door in a predetermined opened position. 

   
     IN THE DRAWINGS 
       FIG. 1  is a vertical view of a door and associated door frame illustrating one form of the invention of a door closer wholly concealed within the associated door. 
       FIG. 2  is an enlarged sectional view taken along line  2 — 2  on  FIG. 1 . 
       FIG. 3  is a sectional view similar to that of  FIG. 2 , but illustrating the door in an opened position. 
       FIG. 4  is a sectional view similar to that of  FIG. 2 , but illustrating a slightly modified embodiment of the invention. 
       FIG. 5  is a sectional view similar to that of  FIG. 2 , but illustrating a modified embodiment of the invention. 
       FIG. 6  is a sectional view similar to  FIG. 2 , but illustrating a modified embodiment of the door closer assembly. 
       FIG. 7  is a sectional view similar to that of  FIG. 2 , but illustrating still another modified embodiment of the door closer assembly. 
       FIG. 8  is a sectional view similar to that of  FIG. 2  illustrating another modified embodiment of the door closer assembly. 
       FIG. 9  is a sectional view similar to that of  FIG. 2  illustrating a further modified embodiment of the door closer assembly. 
       FIG. 10  is a sectional view similar to that of  FIG. 2  illustrating a further modified embodiment of a door closer assembly. 
   

   DETAILED DESCRIPTION 
   Referring to the drawings, there is illustrated in  FIG. 1  a door  20 , a door frame  21  and linear assembly  22  wholly concealed within the associated door  20 . As used herein, a linear assembly is defined as a door closer or a door closing speed controlling device that includes a cylinder having a reciprocally mounted piston and a piston rod connected thereto which extends through one end of the cylinder. It will be understood that the structure of the door  20  may take any suitable form. Such doors  20  may comprise opposed longitudinal support frame  20 A,  20 B to which the side door panels  20 C and  20 D are secured to define a hollow type door. In the event of a solid door (not shown), the instant invention would require that such solid door have formed therein a chamber such as shown at  23 , sized to receive the linear assembly  22 . In the illustrated embodiment of  FIG. 1 , two such linear assemblies are illustrated, one being concealed adjacent the top of the door  20  and the other concealed adjacent the bottom of the door. The construction of the respective linear assemblies  22  is similar. However, it will be understood that depending on the size and/or weight of the door, one or more linear assemblies may be associated with any given door  20 . 
   In accordance with this invention, the linear assembly  22  may take several different forms. The simplest form is illustrated in  FIG. 2 . As shown, the linear assembly  22  includes a cylinder  24  having a piston  25  reciprocally disposed within the cylinder  24 . Connected to the piston  25  is a piston rod  26  having its free end  26 A pivotally connected to a support bracket  27  by means of a pivot pin  28 . 
   The bracket  27  is connected to the inside portion or jam  21 A of the door frame  21  adjacent the door hinge  29 . To accommodate the support bracket  27 , the support frame or edge  20 B of the door  20  is drilled or formed to define a chamber or hole  30 . The other end of the cylinder  24  is provided with a mounting plate  31  which is pivotally connected by a pivot  31 A to an end support bracket  32 , suitably secured to the inside surface of the door panel  20 C. 
   In the illustrated embodiment of  FIGS. 1 to 3 , a compression spring  33  is interposed between the piston  25  and one end of the cylinder  24 . The arrangement is such that upon the opening of the door  20 , the compression spring  33  is compressed as noted in  FIG. 3  so that upon the releasing of the door, the compression spring  33  will normally bias the door  20  toward its closed position as shown in  FIG. 2 . The cylinder may contain fluid, e.g. a liquid medium or air arranged to flow from one side of the piston  25  to the other side of the piston  25  to control the speed at which the door  20  is returned from its open position to a closed position upon release of the door. In the event air is the fluid to be controlled, a means is provided to meter the flow of air on one side of the piston to atmosphere. In the event the speed controlling fluid is a liquid, means are provided to meter the flow of liquid from one side of the piston to the other side of the piston. This can be accomplished either by an external metered circuit that bypasses the piston in directing the liquid medium from one side of the piston to the other side of the piston or providing the piston with a metered orifice through which the liquid can flow from one side of the piston to the other side thereof in a controlled manner, or the speed control can be achieved by rotating the piston rod relative to the cylinder or vice versa, or by adjusting the piston rod relative to the piston as disclosed in my co-pending patent application Ser. No. 10/446,893 filed May 28, 2003, which is incorporated by reference herein in its entirety. 
   In the event that the linear element  22  is used only for performing the closing force function, it is not necessary to provide any sealing between the piston and the cylinder. It will be apparent that the door closing functions, such as providing the closing force, the speed at which the door closes and/or to hold the door open or in a door arresting position, may be incorporated within the linear assembly or accomplished by different combinations of linear assemblies, which has the capability of providing one or more of the door closing functions. For example, the linear assembly for effecting a door arresting or holding position may be of the type disclosed in my co-pending patent application Ser. No. 10/627,261 filed Jul. 25, 2003, for Door Closure With Door Arresting Mechanism, which is also incorporated herein by reference in its entirety. 
   It will be noted that the support bracket  27  is arranged to be received within the hole  30  formed in the hinge edge of the door so that the entire linear assembly  22  and its supports  27  and  32  are wholly concealed within the door when closed. 
     FIG. 4  illustrates a slightly modified form of the invention. In this form of the invention, the construction of the linear assembly  22  is similar to that hereinbefore described with respect to  FIGS. 1 to 3 . However, in the embodiment of  FIG. 4 , the linear assembly  22  is concealed within the door by pivotally connecting the mounting plate  31  of the cylinder to the support bracket  27  mounted to the door jamb  21 A, and pivotally connecting the piston rod to the end support  32 . In all other respects, the structure and function of the linear assembly  22  is similar to that described with respect to  FIGS. 1 to 3 . 
     FIG. 5  illustrates a modified form of the invention wherein the speed control function of the linear assembly  40  is effected by rotation of the cylinder  41  relative to the piston rod  42  and its connected piston. In this form of the invention, the free end  42 A of the piston rod  42  is pivotally connected to the support bracket  27  by pivot pin  28 . Connected to the other end of the cylinder  41  is a cylinder extension bar  43  supported by a mounting bracket  44  secured to door panel  20 C. The mounting bracket includes a grommet or bearing  45  through which the cylinder extension  43  extends. Connected to the free end of the cylinder extension  43  is an extension rod  43 A that extends to an opening  46  formed in the opposite edge of the door  20 . It will be noted that the extension rod  43 A is coupled to the cylinder extension  43  by any suitable means, e.g. a pin  47 . Formed in the end of the extension rod  43 A is a slot  43 B adapted to receive a tool, e.g. a screwdriver, so as to facilitate the rotation of the cylinder  41  relative to piston rod to effect the adjustment of the speed control of the linear assembly  40 . In all other respects, the operation and the structure is as hereinbefore described. 
     FIG. 6  illustrates a modified embodiment of the invention wherein the speed control function of the linear assembly  50  is effected by the adjustment of a rotatable piston rod  51  relative to the stationary cylinder  52 . In this form of the invention, the mounting plate  31  on the end of the cylinder  52  is pivotally connected to the support bracket  27  by a pivot pin  28 . The piston rod  51  is rotatably attached to a support means  53 , which is illustrated as a tube or sleeve  54 , projecting inwardly of the door  20  from a hole  54 A formed in the opposite edge of the door  20 . At the inner end of the sleeve  54  is a bushing  56  that supports the piston rod  51  within the sleeve  54 . The arrangement is such that the piston rod  51  is essentially secured against linear movement along its center line, but rotatable about its center line while allowing slight perpendicular movement relative to its support means  54 . The end of the piston rod  51  is provided with a slot  57  to facilitate the rotation of the piston rod  51  by a suitable tool, e.g. a screwdriver, for effecting the adjustment of the speed control of the linear assembly  50 . In all other respects, the structure and operation is similar to that hereinbefore described. 
     FIG. 7  illustrates a further modification of the invention. In this form of the invention, the linear assembly  60 , concealed within the door  20 , has one end of the cylinder  61  connected to the inner surface of the door panel  20 C by means of an L-shaped bracket  62 . The front or free end of the piston rod  65  is pivotally attached by pivot pin  64 A to one end of a linking bar  63 . The other end of the linking bar  63  is pivotally connected to the support bracket  27  by pivot pin  64 . In all other respects, the structure and function is the same as hereinbefore described. 
     FIG. 8  illustrates a slightly modified form of the invention. In this form of the invention, the linear assembly  70 , concealed within the door  20 , has its cylinder  71  slidably disposed within the door chamber  23 . This is attained by pivotally connecting the mounting plate  31  on one end of the cylinder  71  to the support bracket  27  by means of an interconnecting link  72 , one end of the link being pivotally connected to the mounting plate  31  by a pivot pin  73  and the other end of the link  72  pivotally connected to the support bracket  27  by a pivot pin  73 A. The free end of the piston rod  74  is fixed to the panel  20 C of the door  20  by a suitable fastener  75 . 
     FIG. 9  is directed to a further embodiment of the invention. In this embodiment, the linear assembly  80  is supported within the chamber  23  of the door  20  so that the cylinder  81  can be rotated relative to piston rod  82  for effecting any adjustment in the rate of closing of the door, and whereby the linear assembly is restrained against any relative movement along its center line. As shown in  FIG. 9 , one end of the cylinder  81  is provided with a grooved collar  83  which is journalled to a support bracket  84  secured to the door panel  20 C. The front end of the piston rod  82  is attached to the support bracket  27  by means of an interconnected link  85  similar to that described with respect to  FIG. 8 . The respective ends of the link  85  are pivotally connected to the associated piston rod by pin  73  and to the support bracket  27  by pivot pin  73 A. The other end of the cylinder  81  is provided with a slotted boss  86  disposed in alignment with the opening  87  through which a tool, e.g. a screwdriver, can be inserted to effect the speed adjustment of the linear assembly  80 . 
     FIG. 10  is directed to still a further modification of the invention. In this form of the invention, the cylinder  91  of the linear assembly  90  is slidably mounted within the chamber  23  of the door  20 . In this form of the invention, the mounting plate  92  of the cylinder  91  is attached to the support bracket  27  by means of an interconnecting link  93 . As shown, the link  93  is pivotally connected at one end to the mounting plate  92  by a pivot pin  94  and the other end of the link  93  is pivotally connected to the support bracket  27  by pivot pin  95 . 
   The piston rod  96  is supported within the chamber  23  in a manner whereby the piston rod is longitudinally fixed, but rendered rotatable about its center line. This is attained by means of a bearing  97  connected to the piston rod  96  at an intermediate point as shown in  FIG. 10 . The bearing  97  in turn is rotatably supported by a bracket  98  which is suitably secured to the door panel  20 C by a fastener  99 . In the illustrated embodiment, the bearing  97  is provided with an external annular groove  100  which compliments a mounting hole  101  formed in bracket  98 . The arrangement is such that the piston rod  96  is prohibited from encountering any linear movement, but free to rotate about its centerline for adjusting the closing speed of the door as hereinbefore stated. To facilitate the adjusting of the closing speed, the edge of the door opposite the hinged edge is provided with an access opening  102  which is disposed in alignment with the free end of the piston rod  96 . As hereinbefore described, the free end of the piston rod  96  is provided with a slot  103  adapted to receive a tool, e.g. a screwdriver, to effect the rotation of the piston rod  96  in one direction or the other to regulate the flow of actuating medium to control the door closing speed as hereinbefore described. 
   From the foregoing, it will be noted that the variously described embodiments of the linear assembly enables the same to be wholly concealed within a door chamber or cavity so as to substantially enhance the aesthetic appearance of the door assembly, and the arrangement being such that the described linear assembly can perform all of the usual functions of a conventional door closer, while being wholly concealed within a relatively small door cavity or chamber  23 . 
   While the present invention has been described with respect to various embodiments, it will be understood that variations and modifications thereof may be made without departing from the spirit and scope of this invention.