Abstract:
A hold open arm assembly for a door closer to facilitate access to the holding feature by a resiliently biased plunger on a closer arm that is mounted to a soffit plate. A soffit ramp may extend from the soffit plate to provide a sloped surface for engagement by the plunger, leading to the plunger being gradually depressed as the door continues to open and receiving in a recessed area of its free end a rivet head at the soffit plate to hold the door open. When the first arm member pivots relative to the soffit plate and the plunger approaches the head, the plunger engages the sloped surface of the soffit ramp, slides along the sloped surface toward the head, and receives at least a portion of the head in the opening in the free end.

Description:
BACKGROUND 
     Embodiments of a hold open arm assembly described herein relate generally to a door with apparatus for holding the door open, and more particularly to a hold open arm that facilitates the hold open function. 
     Conventional assemblies include a hold open arm pivotally mounted to a soffit plate that is mounted to the soffit of the door. A spring-biased vertical plunger may be provided that rides on the end of a button head rivet disposed on the soffit plate when the door is in the hold open position. An opening in the end of the plunger ends up resting beneath the head of the rivet. As the plunger approaches the rivet, contact is made between the side of the plunger and the side of the rivet, resulting in lateral force between the two parts, and significant friction as the plunger is forced down the side of the rivet. This may result in excessive wear and/or premature failure of the parts. 
     For the foregoing reasons, there is a need for a new hold open arm assembly that reduces or avoids failures that may be seen with conventionally designed plungers and rivets. 
     SUMMARY 
     In accordance with one embodiment, a soffit ramp for a door hold open assembly including a soffit plate and a plunger is provided. The soffit ramp includes a body distributed around first, second, and third perpendicular, intersecting axes, such that there is a first surface substantially distributed around a plane that includes the first and second axes, and a second surface. The second surface is opposite the first surface, and the distance between the first and second surfaces parallel to the third axis defines a thickness. The second surface defines a channel extending substantially along the first axis, with the channel including a wall on each side and a bottom. The second surface also defines a first sloped surface extending generally in the alignment of the second axis on a first side of the channel from the periphery of the body proximate to the first surface where the thickness is relatively small, to the wall of the channel where the thickness of the body is relatively large. 
     In accordance with another embodiment, a hold open arm assembly is provided for a door mounted to a door frame including a soffit. The door is urged to close by a door closer mounted to the door. The assembly includes a soffit plate substantially distributed about a major plane and adapted to be mounted to the soffit, and a holding feature including a head, with the holding feature mounted to the soffit plate such that the head extends substantially perpendicularly from the major plane. A soffit ramp extends from the soffit plate in a direction away from the major plane. The soffit ramp provides a sloped surface laterally on at least one side of the head, and the distance from the sloped surface to the major plane is greatest proximate to the head. A first arm member has a longitudinal axis, a proximal end, and a distal end, where the proximal end of the first arm member is pivotally mounted to the soffit plate. A housing is mounted to the first arm member, and a resiliently biased plunger having a free end is received in the housing. The plunger extends substantially perpendicularly to the longitudinal axis and defining a recessed area in the free end. A second arm member has a proximal end and a distal end, and the proximal end of the second arm member is pivotally mounted to the distal end of the first arm member and the distal end is adapted to be pivotally mounted to the door closer. When the first arm member pivots relative to the soffit plate and the plunger approaches the head, the plunger engages the sloped surface of the soffit ramp, slides along the sloped surface toward the head, and receives at least a portion of the head in the opening in the free end. 
     In accordance with another embodiment, a method of operating a door is provided. The door is mounted to a door frame including a soffit and is operatively connected to a door closer. A soffit plate is mounted to the soffit, a first arm is pivotally mounted to the soffit plate, a resiliently biased plunger is mounted to the first arm and defines a recessed area in a free end, a second arm is pivotally mounted to the first arm and to the door closer, and a soffit ramp extends downward from the soffit plate. The soffit ramp includes a sloped surface and a holding feature with a head adjacent to the sloped surface. The method includes pushing the door open in a first direction until the plunger engages the sloped surface of the soffit ramp, and continuing to push the door in the first direction. The plunger is caused to be increasingly depressed as the plunger slides along the sloped surface, until the plunger engages the head and receives the head in the recessed area to hold the door open. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding, reference should now be had to the embodiments shown in the accompanying drawings and described below. In the drawings: 
         FIG. 1  is a perspective view of a door closer with an embodiment of a hold open arm assembly installed on a door with the door closed. 
         FIG. 2  is a perspective view of the door closer and hold open arm assembly of  FIG. 1  with the door open. 
         FIG. 3  a perspective view of the hold open arm assembly of  FIG. 1 . 
         FIG. 4  is a side elevation view of the hold open arm assembly of  FIG. 1 . 
         FIG. 5  is a bottom plan view of the hold open arm assembly of  FIG. 1 . 
         FIG. 6  is a cross-section view of an embodiment of a plunger assembly of the hold open arm assembly of  FIG. 1 . 
         FIG. 7  is an exploded perspective view of the plunger assembly of  FIG. 6 . 
         FIG. 8  is a partial section view of the connection of a soffit plate to an arm of the hold open arm assembly of  FIG. 1 . 
         FIG. 9  is a perspective view of a first embodiment of a soffit ramp of the hold open arm assembly of  FIG. 1 . 
         FIG. 10  is a top plan view of the soffit ramp of  FIG. 9 . 
         FIG. 11  is a section view of the soffit ramp of  FIG. 9  taken along line  11 - 11  of  FIG. 10 . 
         FIG. 12  is a section view of the soffit ramp of  FIG. 9  taken along line  12 - 12  of  FIG. 11 . 
         FIG. 13  is a perspective view of a second embodiment of a soffit ramp of the hold open arm assembly of  FIG. 1 . 
         FIG. 14  is a top plan view of the soffit ramp of  FIG. 13 . 
         FIG. 15  is a section view of the soffit ramp of  FIG. 13  taken along line  15 - 15  of  FIG. 14 . 
         FIG. 16  is a section view of the soffit ramp of  FIG. 13  taken along line  16 - 16  of  FIG. 15 . 
         FIG. 17  is a detailed perspective view of a portion of the hold open arm assembly shown in  FIG. 1 . 
         FIGS. 18-27  are a progression showing an embodiment of a soffit ramp and plunger in operation. 
     
    
    
     DESCRIPTION 
     The embodiments of a hold open arm assembly described herein may be for use with a conventional door closer, including, for example, a spring and a hydraulic cylinder. Moreover, it is understood that the overall construction of the door closer is not critical. Accordingly, although exemplary embodiments will be described in detail herein with respect to a door closer function, detailed explanations of the functioning of the door closer components are deemed unnecessary for understanding by one of ordinary skill in the art. 
     Certain terminology is used herein for convenience only and is not to be taken as a limitation. For example, words such as “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” and “downward” merely describe the configuration shown in the figures. The components may be oriented in any direction and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. 
     Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, an embodiment of a hold open assembly for use with a conventional closing and holding open of a door is shown in  FIGS. 1 and 2  and is generally designated at  50 . The assembly  50  is applied to a door closer  52  that is mounted to a door  54 , the door  54  being pivotally mounted to a frame  56  at an opening  58  in a wall  60  with hinges  61 . The assembly  50 , as shown in  FIGS. 3-5 , includes a soffit plate  62  with mounting holes  63  for attaching the soffit plate  62  to the soffit  64 , a first arm  66  with a proximal end  68  mounted to the soffit plate  62 , and a second arm  72  with a proximal end  74  mounted to the distal end  76  of the first arm  66 . The distal end  80  of the second arm  72  is mounted to the driving shaft  82  of the door closer  52  ( FIG. 1 ). 
     A housing  84  is mounted to the first arm  66  substantially perpendicularly to the longitudinal axis of the first arm  66 . A plunger  86  is disposed in the housing  84 . The assembly  50  further includes a holding feature, shown as a rivet  88 , a stop  89  mountable to the soffit plate  62  on either side of the rivet  88  for preventing movement of the door past a set angle, and a soffit ramp  90 . The soffit ramp  90  is mounted to the bottom side of the soffit plate  90 . 
       FIGS. 6 and 7  detail the embodiments of the plunger  86  and housing  84 . The housing  84  is mounted in an opening  91  in the first arm  66 . The housing  84  may be substantially cylindrical and hollow, with an end cap  92  closing the free end, at which there is an end wall  94  through which the plunger  86  may slide. A roll pin  96  may be provided to prevent turning of the plunger  86  relative to the housing  84 , with the roll pin  96  passing through an opening  98  in the plunger  86  and being disposed in a notch  100  on each side of the housing  84 . The plunger  86  has a shaft  102  with an enlarged end  104  distal from the end cap  92 . A recessed area  106  is provided at the end of the enlarged end  104 . A spring  108  may be provided to resiliently bias the plunger  86  outwardly from the housing  84 . The spring  108  urges the plunger  86  outward by applying force to the end wall  94  of the housing and the inner surface of the enlarged end  104  of the plunger  86 . 
     The pivotal connection of the first arm  66  to the soffit plate  62  is shown in  FIG. 8 . Openings in each part  66 ,  62  are aligned and a stud  110  is riveted in place. A sleeve bearing  112  is provided in the opening in the first arm  66 . The pivotal connection between the first arm  66  to the second arm  72  is made similarly. 
     In the embodiment shown, the rivet  88  ( FIGS. 3 and 4 ) secures the soffit ramp  90  in place on the bottom surface of the soffit plate  62 .  FIGS. 9 and 10  show a first embodiment of a soffit ramp  90   a . The soffit ramp  90   a  includes a central channel  120  along its minor longitudinal axis X-X with a bottom  122  and two walls  124 . Opposing sloped surfaces  126   a ,  128   a  are provided along the major longitudinal axis Y-Y, where the soffit ramp  90   a  is thinner at its periphery. The thickness of the soffit ramp  90   a  increases as the minor axis is approached, until the channel  120  is reached. Ridges  130   a ,  132   a  provide a boundary and additional material strength at the sides of the sloped surfaces  126   a ,  128   a  and are shaped symmetrically about the major axis Y-Y such that the soffit ramp  90   a  may be mounted to the soffit plate  62  in either of two directions in which the minor axis is coincident with the longitudinal axis of the soffit plate  62 . A central opening  134  is provided to receive the holding feature, or rivet  88 , which serves to fasten the soffit ramp  90   a  to the soffit plate  62  and to provide a head that is received in the opening in the free end of the plunger  86 . 
       FIG. 11  shows a section view of the soffit ramp  90   a . The walls  124  of the channel  120  are outwardly sloped such that their extended surfaces form an angle α, in this case approximately 90 degrees. The outward slope of the channel walls  124  impacts the points of contact of the plunger  86  with the rivet  88  and the end of the sloped surfaces  126   a ,  128   a  proximate to the rivet  88 . The slope β of the sloped surfaces  126   a ,  128   a  may be, for example, between approximately 10 and 30 degrees, and is in this case approximately 20 degrees, relative to the bottom  122  of the channel or the bottom surface (in this view) of the soffit ramp  90   a . Corners and intersections of surfaces may be rounded or chamfered as known by one of ordinary skill in the art. 
       FIG. 12  shows a section view of the sloped surface  126   a  of the first embodiment of a soffit ramp  90   a  described above; a section view of the other sloped surface  128   a  would be similar. As may be seen, the ridges  130   a ,  132   a  are symmetrical and the same size. 
       FIGS. 13 and 14  show a second embodiment of a soffit ramp  90   b . This soffit ramp  90   b  is similar to the soffit ramp  90   a  of  FIGS. 9 and 10 , except that the sloped surfaces  126   b ,  128   b  and ridges  130   b ,  132   b  are not symmetrical about the major axis Y-Y, and are shaped to accommodate the sweep path of the plunger  86 , with the arcs concave in the same direction. 
       FIG. 15  shows a section view of the soffit ramp  90   b , similarly configured in this view to the soffit ramp  90   a  shown in  FIG. 11 .  FIG. 16  shows a section view of the sloped surface  126   b  of the second embodiment of a soffit ramp  90   b  described above; a section view of the other sloped surface  128   b  would be a mirror image. The sloped surface  126   b  is offset from the major axis X-X, resulting in ridge  130   b  being wider at this location than ridge  132   b.    
     While many dimensions are possible, the soffit ramps  90   a ,  90   b  may be, for example, about 1.3 inches along the major axis X-X and about 0.75 inches along the minor axis Y-Y. The thickness of the ridges  130   a ,  132   a ,  130   b ,  132   b  in top plan view may be, for example, 0.11 inches at their intersection with the minor axis Y-Y. 
       FIG. 17  shows the plunger  86  in the housing  84  approaching the soffit ramp  90 . The head  140  of the rivet  88  may be seen in the channel  120  of the soffit ramp  90 . The head  140  may be a domed or rounded, as in the button-head shape shown to facilitate sliding engagement with the plunger  86 . A cylindrical stop is provided on the distal side of the soffit ramp  90  to prevent further opening of the door (not shown). The soffit ramp  90  is shown in operation in  FIGS. 18-27 , with the plunger  86  moving from left to right in the figures. In  FIG. 18 , the plunger  86  engages the sloped surface  126  of the ramp  90  and is moving toward the rivet  88 . The plunger  86  travels along the sloped surface  126 , with the plunger  86  being pressed downward. The right side of the enlarged end  104  of the plunger  86  has moved to the lower end of the sloped surface  126  in  FIG. 19 .  FIG. 20  shows the right side of the enlarged end  104  engaging the head  140  of the rivet  88 . Because of the vertical displacement of the plunger  86  caused by the sloped surface  126 , the plunger  86  engages the rivet  88  at a position on the head  140  of the rivet  88  where the rivet&#39;s surface is angled more towards horizontal than at a higher point on the rivet&#39;s head  140 . This has the effect of reducing the horizontal force exerted by the plunger  86  on the rivet  88 , which may help reduce or avoid premature failure of the parts, and serve to prolong their lives. 
     In  FIG. 21 , the right side of the enlarged end  104  of the plunger  86  is approaching the lowest point on the head  140  of the rivet  88 , and the plunger  86  has separated from the sloped surface  126 .  FIG. 22  shows the plunger  86  immediately before reaching the lowest point on the rivet&#39;s head  140 , and  FIG. 23  shows the plunger  86  in that lowest position.  FIGS. 24 ,  25 ,  26 , and  27  progressively show the plunger  86  moving into position directly beneath the rivet  88 , with the recessed area  106  in the enlarged end  104  of the plunger  86  receiving the head  140  of the rivet  88  as the plunger  86  moves to the right and upward. The shape of the recessed area  106  is sloped at the opening, like a funnel, to facilitate movement of the plunger  86  off of the head  140  when the door is to be closed and to provide a relatively tight fit with the head  140  as shown in  FIG. 27 . 
     The hold open arm assembly  50  in general may be made of conventional materials for such components, such as steel alloy. The soffit ramp  90  may be made of case hardened steel, such as, for example, AISI 8620 steel. Preferably, the soffit ramp  90  will have a carbon nitride surface hardness of Rc 55 to 60 equivalent, with 0.035 to 0.040 inches total effected depth. Also preferably, the grain in the steel will run along the length of the sloped surfaces  126   a ,  128   a ,  126   b ,  128   b  and have a surface finish of approximately 63 micro inches. Further preferably, no tool marks should be left on the soffit ramp&#39;s finished surface. As an alternative to being a separate component, the soffit ramp may be cast or forged as part of the soffit plate as a unitary construction, and preferably would be heat treated for hardening. 
     Although a rivet  88  is shown as the holding feature, other hardware could be used. For example, the holding feature could be a screw with a rounded head, or could be a staked-in ball bearing, with the ramp  90  configured to capture the ball bearing. 
     Although only a few exemplary embodiments have been shown and described in considerable detail herein, it should be understood by those skilled in the art that we do not intend to be limited to such 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 teachings. Accordingly, we intend to cover all such modifications, omission, additions and equivalents as may be included within the spirit and scope 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.