Abstract:
An adjustable door hinge includes a receptor base and a panel leaf adjustably secured to the receptor base and at least partially defining a vertical adjustment opening and a horizontal adjustment opening. An adjustment transfer element is at least partially contained within the vertical adjustment opening and a vertical adjustment element is rotatably connected to the adjustment transfer element. Rotation of the vertical adjustment element adjusts a position of the panel leaf to any position between a first position and a second position. A horizontal adjustment element is rotatably connected to the horizontal adjustment opening. Rotation of the horizontal adjustment element adjusts a position of the panel leaf to any position between a third position and a fourth position. Vertical and horizontal adjustment of the hinge may be performed independently.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 61/163,234, entitled “Adjustable Door Hinge,” filed on Mar. 25, 2009, the disclosure of which is hereby incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to door hinges, more specifically, to door hinges that may be adjusted in both the vertical and horizontal directions. 
       BACKGROUND 
       [0003]    Hinges secure door panels to door jambs and provide for quiet opening and closing of pivoting doors. Typical hinges include two leaves, one secured to the door panel, the other secured to the door jamb. The leaves each include mating structures or barrels that extend outward from the leaf secured to the door and the leaf secured to the jamb. These mating structures are shaped to receive a pin, bolt, or other elongate element to join the two leaves together to form a hinged connection. Due to the close tolerances required, these pins are often difficult to install. Also since pins typically include an enlarged head to prevent fall out, they must be installed from the top of the hinge. Notwithstanding this direction of installation, however, over time, the pins may back out of the hinge connection, even when the pins are installed from the top of the hinge. 
         [0004]    Additional problems arise with hinges as building walls and floors settle. When first installed, clearances between the door panel and door jamb may be ideal, allowing the door to open and close with ease. As structures settle and shift, however, the clearances between the door panel and door jamb may be reduced, often causing friction. Alternatively or additionally, door panels and frames may contract or expand due to changes in humidity. A door installed during the winter (when humidity is generally lower) may display ideal clearances, but may expand during the humid summer, reducing clearance between the door panel and door jamb. Also, if a door hinge is inadvertently misaligned during installation, problems with operation may ensue. Whether due to settling, humidity, or misalignment, reduced clearance may cause frictional contact between the door panel and door jamb, making the door difficult to open and close. 
       SUMMARY OF THE INVENTION 
       [0005]    In one aspect, the invention relates to an adjustable door hinge having a base, a panel leaf adjustably secured to the base and at least partially defining a vertical adjustment opening, an adjustment transfer element at least partially contained within the vertical adjustment opening, and substantially fixed against rotation relative to the panel leaf, and a vertical adjustment element rotatably connected to the adjustment transfer element, wherein a rotation of the vertical adjustment element adjusts a position of the adjustment transfer element and the panel leaf between a first position and a second position. In an embodiment, the adjustable hinge further includes a plate for adjustably securing the panel leaf to the base. In another embodiment, the panel leaf defines a plurality of slots, the plate has a plurality of posts, and the slots are adapted to slidably receive the posts. In yet another embodiment, the panel leaf at least partially defines a horizontal adjustment opening, and the adjustable hinge further includes a horizontal adjustment element rotatably connected to the horizontal adjustment opening, wherein a rotation of the horizontal adjustment element adjusts a position of an edge portion of the panel leaf between a third position and a fourth position. In still another embodiment, the horizontal adjustment element defines a recess for receiving an adjustment tool. 
         [0006]    In another embodiment of the above aspect, the adjustable hinge further includes an adjustment interface rotatably connected to the vertical adjustment element, where the adjustment interface is substantially orthogonal to the vertical adjustment element. In an embodiment, the adjustment interface defines a recess for receiving an adjustment device. In another embodiment, the panel leaf includes a panel barrel. In yet another embodiment, the adjustable hinge further includes a jamb leaf including a jamb barrel, wherein the jamb barrel and the panel barrel are substantially aligned. In still another embodiment, the adjustable hinge further includes a pivot pin of a substantially uniform dimension along at least a portion thereof, wherein the pivot pin is located within the jamb barrel and the panel barrel. 
         [0007]    In another embodiment of the above aspect, the adjustable hinge further includes a cap inserted into at least one of the jamb barrel and the panel barrel. In an embodiment, the adjustment transfer element is a nut and the vertical adjustment element is a screw. In another embodiment, the adjustable hinge further includes a plurality of bushings located substantially within the jamb barrel and the panel barrel. In certain embodiments, the bushings each include at least one rib to prevent a rotation within the jamb barrel and the panel barrel. In yet another embodiment, the adjustable hinge further includes a plate fixed to the base, wherein the panel leaf is pivotally mounted to a portion of the plate opposite the edge portion. In still another embodiment, the edge portion of the panel leaf rotates relative to the plate. 
         [0008]    The present invention displays advantages over existing adjustable hinges that utilize, for example, a head of a threaded bolt or other elongate component to adjust the vertical position of a door hinge. The present invention reduces friction in the vertical adjustment mechanism by eliminating this head/hinge leaf interface to improve operation. Additionally, existing hinges utilize an adjusting screw located between the hinge barrels and a leaf pivot axis. By locating the leaf pivot axis between the adjustment mechanism and the hinge barrels, as in the present invention, operation is improved. Additionally, the ability to insert the hinge pin from either above or below the door increases versatility of the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0009]    Other features and advantages of the present invention, as well as the invention itself, can be more fully understood from the following description of the various embodiments, when read together with the accompanying drawings, in which: 
           [0010]      FIG. 1  is a schematic perspective view of an adjustable door hinge in accordance with one embodiment of the present invention; 
           [0011]      FIG. 2  is an exploded schematic perspective view of the adjustable door hinge of  FIG. 1 ; 
           [0012]      FIG. 3  is a schematic perspective view of an adjustable panel portion of the adjustable door hinge of  FIG. 1  with a cover plate removed; 
           [0013]      FIG. 4  is another schematic perspective view of the adjustable panel portion of the adjustable door hinge of  FIG. 1  with the cover plate removed; 
           [0014]      FIG. 5  is a schematic perspective view of a panel leaf, an upper fixed plate, and a lower fixed plate of the adjustable door hinge of  FIG. 1 ; 
           [0015]      FIG. 6  is a schematic perspective view of the upper fixed plate and the lower fixed plate of  FIG. 5 ; and 
           [0016]      FIG. 7  is a schematic perspective view of the panel leaf of  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0017]      FIG. 1  depicts a schematic perspective view of an adjustable door hinge  100  in accordance with one embodiment of the invention. The hinge  100  includes a jamb leaf  102  and a panel leaf  104 , the former of which is secured directly to a door jamb with screws through a plurality of openings. The panel leaf  104  is received within a receptor base  106  of an adjustable panel portion  108 , which is covered by a cover plate  110 . Further, the cover plate  110  is secured with screws or other connectors to the receptor base  106  and prevents dirt and other contaminants from entering the receptor base  106  and, along with the receptor base  106 , contains the various moving parts of the hinge  100  (as described below). The cover plate  110  also adds a decorative or other finish to the hinge  100 . Openings  112  and  114  in the cover plate  110  allow access to a horizontal adjustment mechanism and a vertical adjustment mechanism, which may be actuated by a screwdriver or other instrument. The cover plate  110  may also include adjustment indicators or other symbols to depict adjustment or positional location of the hinge  100 . During adjustment (described in more detail below), the vertical and horizontal positions of the panel leaf  104  within the receptor base  106  change. An oversized slot  116  in the cover plate  110  prevents contact between the cover plate  110  and the panel leaf  104 , regardless of the position of the panel leaf  104 . 
         [0018]    One or more barrels are formed on each of the leaves  102  and  104 , and are located and aligned to mate with each other. In the depicted embodiment, two jamb barrels  118  are formed on an end of the jamb leaf  102 , and a panel barrel  120  is formed on an end of the panel leaf  104 . When installed, the two jamb barrels  118  are located above and below the panel barrel  120 . When substantially aligned, the barrels  118  and  120  form a channel in which a pivot pin is inserted. Bushings  122  allow for reduced-friction movement between the barrels  118  and  120 . Also, caps  124  are located on either end of the barrels  118  to prevent the pivot pin from falling from, or backing out of, the aligned barrels  118  and  120 . 
         [0019]      FIG. 2  depicts an exploded schematic perspective view of one embodiment of the adjustable door hinge  100  of  FIG. 1 . Unlike headed pivot pins that have an enlarged head to prevent the pivot pin from falling from the aligned barrels of a hinge, the depicted pivot pin  202  is of a substantially uniform diameter. This allows the pivot pin  202  to be inserted from the top or bottom of the aligned barrels  118  and  120 , which is advantageous for hinge installations which have limited clearance above or below the hinge  100 . Caps  124  may be screwed on, or press fit, into the top and bottom jamb barrels  118  to secure the pivot pin  202  in place, preventing fall-out or back-out of the pivot pin  202 . 
         [0020]    Two fixed plate screws  204  pass through a lower fixed plate  206  via the openings  204   a . The lower fixed plate  206  may define threaded passages for the screws  204  (allowing the screws  204  to secure the lower fixed plate  206  to the receptor base  106 ) or the passages may be unthreaded. In an alternative embodiment, the lower fixed plate  206  may be otherwise fixed to the receptor base  106  or cast as a single piece integral with the receptor base  106 . The screws  204  pass through posts  208  extending from the lower fixed plate  206  and are secured in threaded recesses  210  located in an upper fixed plate  212 . The posts  208  extend through slots  214  in the panel leaf  104  and thus allowing the panel leaf  104  to be adjustably secured to the receptor base  106 . The dimensions of the posts  208  and the slots  214  allow for vertical adjustment of the panel leaf  104  without interference from the posts  208 . Additionally, the posts  208  prevent the panel leaf  104  from being pulled out from the receptor base  106 . The receptor base  106  also defines a recess  216  for receiving a bevel gear  218 , which is used to adjust the vertical position of the hinge  100 , as described below. A slot  116  is oversized to allow vertical movement of the panel leaf  104  within the receptor base  106 . 
         [0021]      FIG. 3  depicts a schematic perspective view of the adjustable panel portion  108  of the adjustable door hinge  100  of  FIG. 1  with the cover plate  110  removed. To adjust the vertical position of the panel leaf  104  within the receptor base  106 , a user may insert a screwdriver, hex key wrench, or other adjustment tool into a recess  302 , located within the bevel gear  218 , to rotate the bevel gear  218 . The bevel gear  218  acts as an adjustment interface, allowing rotation of a vertical adjustment element  304 , even though the axis of rotation of the bevel gear  218  is located substantially orthogonal to the vertical adjustment element  304 . In an alternative embodiment, the bevel gear  218  may be eliminated and the vertical adjustment element  304  may be accessed from the bottom of the receptor base  106  and adjusted directly with an adjustment tool. As the vertical adjustment element  304  rotates, an adjustment transfer element  306  transfers the rotational movement of the vertical adjustment element  304  into vertical movement of the panel leaf  104 . 
         [0022]    The slots  214  of the panel leaf  104  slide along the posts  208  during adjustment. The panel leaf  104  at least partially defines a vertical adjustment opening  304   a  that receives the vertical adjustment element  304  and the adjustment transfer element  306 , and thus allows for the panel leaf  104  to be adjusted substantially along the vertical axis V as the adjustment transfer element  306  moves. In the depicted embodiment, the vertical adjustment element  304  and the adjustment transfer element  306  are a threaded screw and a nut respectively. However, it is contemplated that the vertical adjustment element  304  and the adjustment transfer element  306  may be of any configuration that can transfer a rotation of the vertical adjustment element  304  to a linear movement of the panel leaf  104  substantially along the vertical axis V. 
         [0023]    To adjust the horizontal position of the panel leaf  104  within the receptor base  106 , a user may insert a similar or differently configured adjustment tool into a recess  308  located within a horizontal adjustment element  310  to rotate the horizontal adjustment element  310 . In the depicted embodiment, the panel leaf  104  at least partially defines a horizontal adjustment opening to receive the horizontal adjustment element  310 . In the depicted embodiment, the horizontal adjustment element  310  is a threaded screw and the horizontal adjustment opening is threaded. As the horizontal adjustment element  310  is rotated, the position of the panel leaf  104  along the depth of the screw changes, so as to adjust the horizontal position of the panel barrel  120  by changing the angle of the panel leaf  104  relative to the receptor base  106 . The lower fixed plate  206  and the upper fixed plate  212  act as a pivot axis A about which the panel leaf  104  may be rotated. In general, an edge portion  312  of the panel leaf  104  moves within the receptor base  106 , while a portion of the panel leaf  104  proximate the pivot axis and opposite to the edge portion  312  remains relatively fixed. The extent of this rotational movement of the edge portion  312  of the panel leaf  104  is limited at least in part by the total depth of the receptor base  106  and the length of the horizontal adjustment element  310 . To facilitate this rotation, the surfaces of both the lower fixed plate  206  and the upper fixed plate  212  that interface with the panel leaf  104  are curved, as shown in more detail in subsequent figures. 
         [0024]      FIG. 4  is another schematic perspective view of the adjustable panel portion  108  of the adjustable door hinge  100  of  FIG. 1 , with the cover plate  110  removed. In this figure, curved surfaces  402  of the lower fixed plate  206  and the upper fixed plate  212  are more clearly depicted. Additionally, an alternative location  404  for the vertical adjustment mechanism (on the bottom of the receptor base  106 ) is identified. Having both of the vertical adjustment mechanism and the horizontal adjustment mechanism accessible from the face of the cover plate  110  may be desirable, however, since the cover plate  110  is easily accessible regardless of the orientation of the hinge  100  on a door panel. 
         [0025]      FIG. 5  depicts a schematic perspective view of the panel leaf  104 , the lower fixed plate  206  and the upper fixed plate  212  of the adjustable door hinge  100  of  FIG. 1 . In this figure, the horizontal adjustment opening  502  and the vertical adjustment opening  304   a  in the panel leaf  104  are depicted.  FIG. 6  depicts a schematic perspective view of the lower fixed plate  206  and the upper fixed plate  212  of  FIG. 5 . The posts  208  are sized to extend through the slots  214  defined by the panel leaf  104  to allow for movement substantially along the vertical axis V. Additionally, as noted above, the curved surfaces  402  of the lower fixed plate  206  and the upper fixed plate  212  allow for horizontal adjustment of the panel leaf  104 , as described above. 
         [0026]      FIG. 7  is a schematic perspective view of the panel leaf  104  of  FIG. 5 . As depicted in this figure, the panel leaf  104  defines a plurality of slots  214  for receipt of the posts  208  described above, as well as the horizontal adjustment opening  502  and the vertical adjustment opening  304   a . The vertical adjustment opening  304   a  is sized to receive both the adjustment transfer element  306  and the vertical adjustment element  304  in a first opening portion  702  and a second opening portion  704  respectively, as depicted in the figure. The staggered profile of the first opening  702  allows the adjustment transfer element  306  to transfer both upward and downward vertical movement to the panel leaf  104 .  FIG. 7  also depicts one of the bushings  122  inserted into the panel barrel  120 . The bushings  122  are designed with a rib  706  that is trapped between a curl of the barrels  118  or  120  and a face of the leaves  102  or  104 . The rib  706  prevents the bushings  122  from spinning inside the barrels  118  and  120 , and ensures that the bushings  122  located on the mating jamb barrel  118  and panel barrel  120  are sliding against each other instead of rotating against the barrels  118  and  120 . The rib  706  need not be used, but it helps prevent the bushings  122  from spinning and wearing prematurely, if the bushings  122  were to rub against the barrels  118  and  120  which may be metallic. 
         [0027]    The materials utilized in the manufacture of the hinge  100  may be those typically utilized for hinge manufacture, e.g., zinc, steel, brass, stainless steel, etc. Material selection for most of the components may be based on the proposed use of the hinge  100 . Appropriate materials may be selected for hinges used on particularly heavy door panels, as well as on hinges subject to certain environmental conditions (e.g., moisture, corrosive atmospheres, etc.). For particularly light-weight door panels (for example, cabinet door panels), molded plastic, such as PVC, polyethylene, etc., may be utilized for the receptor base, cover plate, leaves and other components. Nylon, acetal, Teflon®, or combinations thereof may be utilized for the bushings  122  to reduce friction, although other low-friction materials are contemplated. Threaded or press fit metal or nylon caps also may be used. 
         [0028]    The terms upper, lower, top, bottom, panel, jamb, etc., as used herein, are relative terms used for convenience of the reader and to differentiate various elements of the adjustable hinge  100  from each other. In general, unless otherwise noted, the terms are not meant to define or otherwise restrict location of any particular element. For example, the adjustable hinge  100 , as disclosed therein, may be installed on a door panel with the vertical adjustment mechanism located near the top or bottom of the hinge  100 , depending on the orientation of the hinge  100  during installation. Additionally, the jamb leaf  102  may be secured to the door panel and the receptor base  106  may be secured to the door jamb. Alternatively, the hinge  100  could be used with the barrels  118  and  120 , and pivot pin  202  oriented in a horizontal manner. Additionally, the jamb leaf may form a single jamb barrel, while the panel leaf may form two jamb barrels. Either leaf may also form multiple barrels, as desired for a particular application. 
         [0029]    While there have been described herein what are to be considered exemplary and preferred embodiments of the present invention, other modifications of the invention will become apparent to those skilled in the art from the teachings herein. The particular methods of manufacture and geometries disclosed herein are exemplary in nature and are not to be considered limiting. It is therefore desired to be secured in the appended claims all such modifications as fall within the spirit and scope of the invention. Accordingly, what is desired to be secured by Letters Patent is the invention as defined and differentiated in the following claims, and all equivalents.