Abstract:
A hinge, comprising a cup having a rim and an arm pivotably connected to the cup, wherein the arm is permitted to pivot between a closed position and an open position, the open position defining a opening angle between the cup and arm. An adjustable stopper coupled to the arm is engagable with the rim whereby the opening angle is controlled by adjustment of the stopper.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a divisional of U.S. patent application Ser. No. 12/388,410, filed Feb. 18, 2009. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to an adjustable hinge and, more particularly, to a hinge with an adjustment mechanism for controlling the opening angle of the hinge. 
       BACKGROUND 
       [0003]    Most hinges designed for use in entry way doors or cabinet frames permit an opening angle 90 degrees or greater in order to permit sufficient access to the storage area for the user. Yet, there are some situations where it is desirable to use a hinge that restricts the angle to 90 degrees or less. For example, some households are equipped with a “sink” or “tip-out” tray mounted in an opening on the front panel of a kitchen sink cabinet, directly in-front of the sink tub. These types of tray mechanisms and their corresponding hinges are specially designed to permit the tray to pivot in and out of the tight space formed between the frame of the sink cabinet, counter top and sink tub. 
         [0004]    While hinges for sink trays are known in the art, such prior art hinges are in the form of scissor-type hinges, such as the first and second prior art hinges  100 ,  101  shown in  FIGS. 1 and 2 , respectively. The first and second prior art hinges  100 ,  101  incorporate a complex system of levers, panels, pins and coil springs and are relatively expensive because of their complexity and the amount of material they use. These prior art hinges are also designed to be mounted to the side walls of the sink cabinet, which reduces the space available for the sink tray. 
         [0005]    Accordingly, it is desirable to have a hinge with a simple, compact and economical design that includes an adjustment mechanism for controlling the opening angle so it can be used in conjunction with cabinet or door systems—such as sink tray system or the like—where it is desirable to be able to adjust the permitted opening angle. 
       SUMMARY 
       [0006]    In an embodiment, the hinge of the present application comprises a recessed cup and arm, the arm being pivotably connected to the cup. One end of the cup includes securing flanges adapted to engage a panel. At the opposite end of the cup a slanted rim is formed atop the recessed portion of the cup. 
         [0007]    In one form, a mounting plate is formed on one portion of the arm and is adapted to be fastened to a cabinet frame or other mounting structure. At the other portion of the arm, referred to herein as the second portion, the arm is bent in order to form a curl that winds around a hinge pin secured in the cup, thereby permitting the arm to pivot relative to the cup. As the arm pivots from a closed position to an open position, an opening angle A is formed between the outer surface of the cabinet frame and inner surface of the panel. 
         [0008]    An adjustable stopper disposed along a first axis X-X is threaded through a passage formed in the second portion of the arm. A second end of the stopper extends into the cup, and may be beveled in order to form a shoulder disposed at an angle relative to the first axis X-X. As the arm pivots to the closed position, the shoulder contacts the rim, whereby the rim operates as a abutment for the stopper. 
         [0009]    The hinge may be incorporated in a sink tray system where a sink tray or tip-out tray is mounted to the inner surface of the cabinet panel using fastening screws or the like. It will be appreciated that the hinge and its corresponding adjustment mechanism permits the tray to pivot in and out of the tight space formed between the fame of the sink cabinet, counter top and sink tub. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    For the purpose of facilitating an understanding of the subject matter sought to be protected, there is illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages, should be readily understood and appreciated. 
           [0011]      FIG. 1  is a partial cross-sectional view of a first prior art sink tray hinge. 
           [0012]      FIG. 2  is a partial cross-sectional view of a second prior art sink tray hinge. 
           [0013]      FIG. 3  is a partial cross-sectional view of an embodiment of the hinge of the present application where the hinge is shown in the closed position. 
           [0014]      FIG. 4  is a partial cross-sectional view of the hinge of  FIG. 3 , but showing the hinge in the open position. 
           [0015]      FIG. 5  is an enlarged partial cross-sectional view of the hinge of  FIG. 4 , but showing the components of the self-closing/self opening functions in more detail. 
           [0016]      FIG. 6  is a partial plan view of the hinge of  FIG. 4 . 
           [0017]      FIG. 7  is a partial cross-sectional view of the hinge of  FIG. 3  incorporated with a typical sink tray system having a tray, frame and panel. 
           [0018]      FIG. 8  is a partial cross-sectional view similar to  FIG. 7 , but showing the hinge in the open position. 
           [0019]      FIG. 9  is an enlarged front view of an embodiment of a multi-adjustable hinge. 
           [0020]      FIG. 10  is an enlarged front view of an embodiment of a safety bracket. 
           [0021]      FIG. 11  is a perspective view of the safety bracket of  FIG. 10  incorporated with a typical sink tray system. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    While the present invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. 
         [0023]    Referring to  FIGS. 3-8 , there is illustrated a hinge  10  comprising a recessed cup  13  and an arm  30  extending into the cup  13 . The cup  13  is inserted into a bore  19  formed in a cabinet panel  200  or the like. In one form, one end of the cup  13  includes securing flanges  17  extending outwardly from opposing sides of the cup  13 . Each flange  17  may include an aperture for receiving fastening screws  18  or the like for sercurment to cabinet panel  200 . At the opposite end of the cup  13  a slanted rim  15  is formed atop a recessed portion  14  of the cup  13 . It will be appreciated that the cup  13  can be formed in many ways, such as, for example, from a single pressed piece of sheet metal or casting. 
         [0024]    In an embodiment, arm  30  has a first portion  31  and second portion  34 . The first portion  31  includes a mounting plate  32  adapted to be secured over a frame  250  or other mounting structure, such as those found in typical sink cabinets or the like. The second portion  34  of the arm  30  extends into the cup  13 . In one form, the second portion  34  terminates in a curl  35  that winds around a hinge pin  40  secured in the cup  13 , thereby permitting the arm  30  to pivot relative to the cup  13 . As the arm  30  pivots from a closed position to an open position, an opening angle A is formed between the outer surface of the cabinet frame  250  and inner surface of the panel  200 . It will be appreciated that the arm  30 , including the first and second portions  31 ,  34  may be pressed or cast from a single piece of sheet metal having multiple bends. 
         [0025]    The end of the curl  35  is notched in order to define opposing projections  36 . A coil spring  60  winds around a second pin  70  secured in the cup  13  and includes two legs  62  that extend toward and engage projections  36 . It will be appreciated that the interaction between the legs  62  of the coil spring  60  and projections  36  effectuate a self-opening and self-closing function. In particular, as the arm  30  pivots from the closed position toward the open position the free ends of the legs  62  pass over corners  37  of the projections  36  generating a moment force which biases the arm  30  towards the open position. Likewise, as the arm  30  pivots from the open position toward the closed position, the free ends of the legs  62  pass over corners  37  of the projections  36  generating a moment force which biases the arm  30  towards the closed position. 
         [0026]    Referring to the embodiments shown in  FIGS. 3-8 , an adjustable stopper  50  extending along a first axis X-X is threaded through a passage  38  formed in an intermediate portion of the arm  30 . The stopper  50  may be in the form of a machine screw with a first end  52  in the form of a Phillips drive head or the like, although other structures for stopper  50  may be used as well. The passage  38  penetrates and extends slightly beyond the thickness of the arm  13  in order to permit a sufficient number of threads  39  to be engaged by the stopper  50 . Preferably, at least 3 or 4 thread  39  rotations should formed in the passage  38  to ensure the stopper  50  doesn&#39;t slip or otherwise disengage during normal operation. 
         [0027]    In an embodiment, a second end  55  of the stopper extends toward the cup  13 . The termination of the second end  55  may be beveled or chamfered in order to form an angled cross section having a shoulder  58  disposed at an angle relative to the first axis X-X. As the arm  30  pivots to the closed position, the shoulder  58  contacts the rim  15 , whereby the rim operates as an abutment surface for the stopper  50 . In one form, the cup  13  and stopper  50  are shaped such that the contacting surfaces of the shoulder  58  and rim  15  are disposed substantially parallel to each other to provide increased reliability by decreasing component wear. In that regard, such an arrangement maximizes the area of contact between the shoulder  58  and rim  15 , which prevents excess pressure and denting of the rim  15 . 
         [0028]    As shown in  FIGS. 7-8 , the hinge  10  may be incorporated in a typical sink tray system  100  where a sink tray or tip-out tray  210  is mounted to the inner surface of the cabinet panel  200  using fastening screws or the like. The fact that the stopper  50  acts to restrict opening angle A permits the tray  210  to pivot inwardly and outwardly of the generally tight space formed between the frame  250  of the sink cabinet, counter top (not shown) and sink tub (not shown). 
         [0029]    In a method for installing the hinge  10  in a sink tray system  100 , the user begins by inserting the cup  13  into a bore  19  formed in an inner surface of a cabinet panel  200  and securing the flanges  17  to the panel  200  using fastening screws. In a sink tray system  100  incorporating two hinges  5 , one hinge  10  is installed on each end of the inner surface of the panel  200 , and each of the steps below are repeated for each hinge  10 . 
         [0030]    The user may then secure the mounting plate  32  to a surface of the frame  250 , also using fastener screws or the like. The opening angle A, (i.e. range of opening) can be controlled by manually rotating the stopper  50  using a screw driver or the like, which, depending on the direction of rotation, causes the stopper  50  to thread towards the cup  13  along the first axis X-X, or away from the cup  13 , also along the first axis X-X. It will be appreciated that the permitted opening angle A is minimized when the stopper  50  is fully inserted. In an embodiment, the desired opening angle A-A, may be between 20 and 70 degrees, depending on how far the user desires the tray  210  to tip outwardly toward the user. For example, a opening angle A-A too large (generally greater than 90 degrees) may permit the contents of the tray  210  to spill out, while a opening angle A-A too small may fail to permit the user sufficient access to the contents within the tray  210 . 
         [0031]    Securement of the tray  210  to the inner surface of the panel  200  is achieved by applying fasteners, such as a screw, to mounting slots (not shown) formed on the opposing surface of the tray  210 . It will be appreciated that the cup  13  is substantially recessed in the bore  19  and may be arranged to lay substantially flush with an inner surface of the panel  200 , thereby permitting additional space for the tray  210  along the inner surface of the panel  200 . It will also be appreciated that in a fully assembled sink tray system  100 , hinge  10  is substantially concealed behind the panel  200  for aesthetic purposes. Also, in one form, the hinge  10  of the current application permits the tray  210  to be sized in a manner that takes full advantage of the space available in the sink cabinet. In that regard, the tray  210  can be sized to extend substantially the full distance between the side walls  103 . 
         [0032]    In one form, the sink tray system  100  may further comprise a safety bracket  410  mounted at either end of the panel  200  to protect against safety hazards associated with excess force being applied to the panel  200  or tray  210 . For example, an unattended child who grasps the panel  200  or tray  210  in an attempt to swing or climb may cause forces to be applied to the hinge  10  beyond its weight capacity, which could result in breakage of the hinge  10  at the hinge pin  40  or the like, thereby creating a potential safety hazard. Accordingly, referring to  FIGS. 10 ,  11  safety brackets  410  may be mounted at either end of the panel  200 . In one form, the safety bracket  410  comprises an extension  440  with a foot  420  at one end and a catch  450  at the other end. The foot  420  may be provided with two apertures  425  that receive wood screws  430  for fastening the safety bracket  410  to the panel  200 . The catch  450  may be in the form of a dowel or the like and can be secured to the extension  440  by means of a machine screw that engages an aperture, as shown in  FIG. 11 . The safety bracket  410  should be positioned on the panel  200  in a manner that causes the catch  450  to overlap with a vertical member  255  of the cabinet frame  255 . In this form, as the hinge  10  and panel  200  pivot toward the open position, the catch  450  is positioned to abut the inner surface of the vertical member  255  of the cabinet frame, thereby preventing the panel  200  from pivoting too wide relative to the vertical member  255 . 
         [0033]    In an alternative embodiment shown in  FIG. 9 , a multi-adjustable hinge  310  may incorporate a two-piece adjustable arm  330  having a mounting plate  332  and jacket  331  having sleeves  333  folded from a single piece of sheet metal. The sleeves  333  are adapted to slideably engage a lower portion  334  that extends into the cup  13 . An elongated opening  339  centered in the lower portion  334  is sized to receive an adjustment screw  341  adapted to pass through the elongated opening  339  towards an aperture (not shown) in the rear portion of the jacket  331 . In one form, threads formed in this aperture are sized to threadably engage the threads of the adjustment screw  341  in a well known manner. The adjustable stopper  50  is threadably engaged through the passage  38 , which is substantially centered in the lower portion  334  of the arm below the elongated opening  339 . It will be appreciated that the cup  13 , spring loaded self-opening and self-closing and angle adjustment features of the alternative embodiment shown in  FIG. 9  operate with a design and structure substantially the same to those shown in the embodiment of  FIGS. 3-8 . 
         [0034]    In operation of the alternative embodiment shown in  FIG. 9 , loosing of the adjustment screw  341  enables the jacket  331  and mounting plate  332  to shift vertically relative to lower portion  334 , thereby permitting vertical adjustment of the surfaces relative to each other to which the mounting plate  332  and cup  13  are attached. For example, the additional adjustment feature of the multi-adjustable hinge  310  may permit vertical adjustment of the cabinet frame  250  relative to the panel  200 , should the multi-adjustable hinge  310  be used with the a typical sink tray system  100 , such as those shown in  FIGS. 7-8 . The adjustment screw  334  can be turned for tightening purposes in order to prevent movement of the mounting plate  332  relative to the lower portion  334  when they have reached their desired relative positions. 
         [0035]    It will be appreciated that while the components of the adjustable and multi-adjustable hinges  10 ,  310  are made of cold rolled steel in one form, other sufficiently rigid materials may also be used, such as plastics or metals. 
         [0036]    The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be appreciated that changes and modifications may be made without departing from the broader aspects of applicants&#39; contribution.