Abstract:
A cabinet hinge configured to pivotally couple a cabinet door to a frame is disclosed. The frame includes an edge with a first side and a second side. The cabinet hinge includes a door wing configured to be mounted to the cabinet door. The cabinet hinge also includes a frame wing configured to be mounted to the frame and including a wrap portion. The wrap portion includes a first wrap portion configured to wrap around the first side of the frame and the second wrap portion configured to wrap around the second side of the frame. The first wrap portion is configured to extend along the cabinet frame a sufficient distance to prevent splitting of the frame material under normal usage and following normal mounting procedures. The cabinet hinge also includes a hinge arm configured to pivotally couple the door wing and the frame wing. The first wrap portion is configured with a raised surface configured to contact the frame first side.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to a hinge to mount a door to a frame. Specifically, the present invention relates to a hinge to mount a door to a frame, the door and/or frame being made particularly from thin medium density fiber board (MDF) or thin particle board.  
         BACKGROUND  
         [0002]    It is generally known to provide a hinge for mounting a door to a frame. Conventional hinges typically mount to an edge of a frame using screws. Screws are generally inserted into the edge of the frame, parallel to the surface of the frame. However, as a screw is inserted into the frame, there is a tendency for the frame material to fail causing a split in the frame material due to the wedging force of the screw. This problem is magnified when the frame member is made of thin particle board, thin multi-density fiber board, thin plywood, or thin wood. When the screws are tightened into the ends of thin materials, the material can crack, split, or break, thereby damaging the frame, and possibly rendering the frame unusable.  
           [0003]    Hinges are conventionally assembled of two pieces including a frame wing, which is attached to the frame, pivotally coupled to a hinge cup, which is attached to a door. The frame wing commonly includes a set of flanges. The flanges are configured to provide guidance of the frame wing onto the frame during mounting. Because the flanges, which extend along the surfaces of the frame edge are relatively short, they provide little or no holding power during the mounting of the frame wing to the frame, nor do they provide any bend back resistance or resistance to frame material failure.  
           [0004]    Conventionally, during mounting of the frame wing to a frame, a user must hold the frame wing against the frame with one hand while setting a screw with the other hand. Such two hand mounting procedures may be inconvenient as well as difficult.  
           [0005]    Further, during operation, a hinge is used to allow movement of a door from a closed position, through a partially open position, to a fully open position. A user of the door may attempt to “over open” the door by pushing the door in the door opening direction, to a position past “fully open.” Such “over opening” may cause the flange of the frame wing to dig into and damage the frame, may cause the screw to be pulled out of the frame and/or may cause the frame to fail by cracking, breaking, or splitting.  
           [0006]    Because of the relative shortness of conventional frame wing flanges, conventional flanges fail to provide substantial “bend back resistance,” that is, resistance to the door being “over opened,” so as to prevent damage to the frame. Also, because of the relative shortness of the flanges, the frame wing has little or no holding power which may be advantageous during mounting of the frame wing to the frame. Further, because of the relative shortness of the flanges, the flanges do not aid in constraining the frame material to prevent the frame material from cracking, splitting, or breaking.  
           [0007]    Accordingly, there is a need to provide a hinge which is suited to be used on thin particle board, thin MDF, or other thin frame materials and minimizes possible damage to these types of materials. There is also a need to provide a hinge that significantly improves the bend back resistance of the frame/hinge combination. Further, there is a need to provide a hinge which assists a user in installing the cabinet door before screws are inserted. Further still, there is a need to provide a hinge which enhances the holding power of the hinge relative to a surface. Yet further still, there is a need to provide for a hinge having one or more of these or other advantageous features.  
           [0008]    The techniques herein below extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned needs.  
         SUMMARY  
         [0009]    The present invention relates to a cabinet hinge configured to pivotally couple a cabinet door to a frame having an edge with a first side and a second side. The cabinet hinge includes a door wing configured to be mounted to the cabinet door, a frame wing configured to be mounted to the frame. The frame wing includes a wrap portion. A hinge arm is configured to pivotally couple the door wing and the frame wing. The wrap portion includes a first wrap portion that is configured to wrap around the first side of the frame and a second wrap portion that is configured to wrap around the second side of the frame and the first wrap portion is configured to extend along the cabinet frame a sufficient distance to prevent splitting of the frame material under normal usage and following normal mounting procedures and the first wrap portion configured with a raised surface configured to contact the frame first side.  
           [0010]    The present invention also relates to a hinge for pivotally coupling a door to a frame being constructed of a thin medium density fiberboard (MDF) or thin particle board. The hinge includes a door portion configured to be mounted to the door and a base portion pivotally coupled to the door portion, where the base portion configured to be mounted on an edge of the frame with a fastener. The hinge further includes a first wrap portion extending from the base portion along a front surface of the frame and a second wrap portion extending from the base portion along a rear surface of the frame. The first wrap portion extends along the surface of the frame a distance in the range of approximately 0.15 to 0.75 inches. The second wrap portion extends along the surface of the frame a distance in the range of approximately 0.4 to 1.0 inches.  
           [0011]    The present invention further relates to a cabinet hinge configured to pivotally couple a cabinet door to a frame having an edge with a first side and a second side. The cabinet hinge includes a door wing configured to be mounted to the cabinet door, an insert having a hinge arm configured to pivotally couple the door wing and the insert, and a wrap portion configured to be coupled to the frame. The wrap portion being interchangeable with the insert, the wrap portion including an apperture configured to accept the insert, the wrap portion selectively sized to fit around the frame edge. 
       
    
    
     DESCRIPTION OF THE FIGURES  
       [0012]    The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, in which:  
         [0013]    [0013]FIG. 1 is a front perspective view of a cabinet hinge having a mounting cup and a frame wing coupled thereto according to an exemplary embodiment.  
         [0014]    [0014]FIG. 2 is a rear perspective view of the cabinet hinge shown in FIG. 1.  
         [0015]    [0015]FIG. 3 is a front perspective view of a cabinet hinge having a mounting cup and a frame wing coupled thereto according to an alternative embodiment.  
         [0016]    [0016]FIG. 4 is a top view of the cabinet hinge shown in FIG. 3.  
         [0017]    [0017]FIG. 5 is a front perspective view of a frame wing according to an alternative embodiment.  
         [0018]    [0018]FIG. 6 is a front perspective view of an interchangeable wrap of the frame wing shown in FIG. 5.  
         [0019]    [0019]FIG. 7 is a top view of the frame wing shown in FIG. 5.  
         [0020]    [0020]FIG. 8 is a cross sectional view of the frame wing shown taken across the line  8 - 8  in FIG. 5. 
     
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS  
       [0021]    Referring to FIGS.  1 - 8 , exemplary embodiments of a hinge for mounting a cabinet door to a cabinet frame are shown. It should be noted at the outset that the hinge can be used in any of a wide variety of cabinet doors and other doors, including concealed and unconcealed hinge arrangements known to those skilled in the art who may review the disclosure. Referring to FIG. 1, an exemplary embodiment of a hinge  10  is shown. Hinge  10  is used to mount a cabinet door or door stile for selective pivotal movement between an open position (depicted in FIG. 1) and a closed position with respect to a frame  40 .  
         [0022]    Hinge  10  includes a door wing  20  pivotally coupled to a frame wing  30 . Door wing  20  is shown as a hinge cup type door wing, and is adapted to be mounted into and within a substantially cylindrical bore or recess in a door. Hinge cup  22  may be adapted to fit into other bore geometries, not limited to substantially cylindrical. Frame wing  30  is adapted to be mounted to an edge  42  of frame  40  as depicted in FIG. 1. According to an exemplary embodiment, the hinge arrangement shown, having hinge cup  22  substantially embedded in a door, and having frame wing  30  mounted to edge  42  of frame  40 , is an arrangement designed to conceal the hinge from view when viewed from the front of a cabinet. This arrangement is commonly known in the art as a “concealed” hinge.  
         [0023]    Frame wing  30  includes base  32 , front wrap  34 , and rear wrap  36 . As depicted in FIG. 1, base  32  is a substantially flat, rectangular plate having a width, along horizontal axis X-X, substantially corresponding to a width of frame  40 . In an exemplary embodiment, base  32  has a width of approximately 0.6 inches, however, any base width may be used depending on the thickness of the frame material to be used. Furthermore, base  32  is oriented substantially perpendicular to rear frame surface  43  and front frame surface  44 .  
         [0024]    As shown in FIG. 1, base  32  includes mounting slots  38 , shown as oblong apertures in base  32 . Mounting slots  38  are configured to receive fasteners, such as but not limited to wood screw  56  (FIG. 4). Wood screw  56  is inserted through mounting slot  38  and screwed into frame  40 , rigidly coupling frame wing  30  to frame  40 . Once attached to frame  40 , frame wing  30  may be adjusted in a vertical direction (shown as vertical axis Y-Y) by loosening wood screws  56  and sliding frame wing  30  along axis Y-Y. The limit of vertical adjustment is bounded by the length of mounting slot  38 .  
         [0025]    Frame wing  30  further includes rear wraps  36  and front wraps  34 . Rear wraps  36  and front wraps  34  extend substantially perpendicular to base  32 , and are substantially parallel with frame surface  43 . In an exemplary embodiment, front wrap  34  has a width, along vertical axis Y-Y, of approximately 1.6 inches. Alternatively, front wrap  34  may have any appropriate width. In an exemplary embodiment, front wrap  34  has a depth, along depth axis Z-Z, of approximately 0.3 inches or anywhere in the range of approximately 0.15 to 0.75 inches. Alternatively, front wrap  34  may have any appropriate depth depending on the frame material. In an exemplary embodiment, rear wrap  36  has a depth, along depth axis Z-Z, of approximately 0.6 inches or anywhere in the range of approximately 0.4 to 1.0 inches. Alternatively, rear wrap  36  may have an appropriate depth to support the frame material.  
         [0026]    Shown in FIGS.  1 - 2 , rear wrap  36  and front wrap  34  further include ribs  44 . In an exemplary embodiment rib  44  is a raised surface on inner surfaces  46  of rear wraps  36  and inner surfaces  48  of front wraps  34 . Raised surface  50  of rib  44  may be in the shape of a portion of a cone. Alternatively, rib  44  may be any of a variety of textured surfaces, including, but not limited to slotted, knurled, and/or other raised surfaces.  
         [0027]    As discussed above, hinge  10  is used to mount a cabinet door or door sitle for selective pivotal movement between an open position and a closed position. In attaching hinge  10  to frame  40 , frame wing  30  is slid over edge  42 , located in a desired mounting position. As frame wing  30  is slid over edge  42 , ribs  44  wedge into the front and rear of frame surface  43  of cabinet frame  40 . As ribs  44  wedge into frame surface  43 , they operate to grab frame  40 , thereby assisting to hold hinge  10  in place prior to wood screws  56  being inserted. Accordingly, an installer mounting frame wing  30  to edge  42  of frame  40  could slide frame wing  30  onto edge  42 . Frame wing  30  would be substantially held in position by ribs  44  even if the installer does not hold frame wing  30 . Therefore, the installer may concentrate on positioning and inserting screws  56 .  
         [0028]    As shown in FIGS. 3 and 4, but equally applicable to alternative embodiments such as, but not limited to, those embodiments depicted in FIGS.  1 - 2 , and  5 - 8 , to attach a frame wing  230  to a frame  240 , wood screw  256  is screwed into frame  240 . As wood screw  256  is further tightened into frame  240 , the frame material tends to separate or be wedged apart by wood screw  256 . Because rear wrap  236  and front wrap  234  are elongated and extend along surfaces  243  and  244  a significant distance, rear wrap  236  and front wrap  234  serve to constrain the material of frame  240  from expanding due to the wedging force of wood screw  256 . Hinge  200  includes a single flange rear wrap  236 , as depicted in FIG. 3 having ribs  237  formed on rear wrap  236 . It should be noted that FIGS. 3 and 4 are representative of the many and varied configurations of both rear wraps  236  and front wraps  234 .  
         [0029]    In an exemplary embodiment, frame wing  30  may be configured to fit on a frame having a thickness in a range of ¼ inch to 1 inch, however, other frame material sizes may be used as well. Such materials include, but are not limited to medium-density fiberboard (MDF), other fiberboard, particle board, plywood, wood, etc.  
         [0030]    Referring again to FIGS. 1 and 2, the oversized front and rear wraps  36  and  34  offer several advantages. One such advantage is front wrap  34  and rear wrap  36  help to prevent frame  40 , which, in an exemplary embodiment, is made from thin MDF or thin particle board, from cracking, splitting, or breaking. Front wrap  34  and rear wrap  36  prevent damage by applying a holding force to frame surface  43  when wood screws  56  are inserted into frame  40 , thereby preventing frame  40  from expanding due to the wedging force exerted by wood screws  56 .  
         [0031]    Furthermore, in addition to ribs  44 , the oversized front and rear wraps  34  and  36  increase the holding power of hinge  10  during mounting. Because wraps  34  and  36  are elongated, more contact occurs between wraps  34  and  36  than conventional devices. Such increased contact area provides additional frictional interference adding to the holding power of frame wing  30 .  
         [0032]    Because of the oversized front and rear wraps  34  and  36  and ribs  44 , the bend-back resistance of frame wing  30  and frame  40  combination is improved. As a door coupled to frame wing  30  is “over opened” past a nominal point, wrap  34  will distribute the opening force over surface  43 , helping to resist breakage, failure, cracking, or splitting of the material of frame  40 . Further, ribs  44  help to prevent movement of wing  30  relative to frame  40 , such that less pull out force is exerted on screw  56 . Accordingly, because of the unique design of frame wing  30 , screw  56  is less likely to be pulled out from edge  42  and the material of frame  40  is less likely to be damaged.  
         [0033]    According to an alternative embodiment, depicted in FIGS.  5 - 8 , frame wing  130  may be a two piece design. Frame wing  130  includes insert  160  and interchangeable wrap  180 .  
         [0034]    Interchangeable wrap  180  includes base  132 , front wrap  134 , and rear wrap  136 . As shown in FIG. 6, base  132  is a substantially flat, rectangular portion having a width, along horizontal axis X-X, substantially corresponding to a width of frame. Base  132  is oriented substantially perpendicular to frame surface  142 .  
         [0035]    Base  132  further includes aperture  182  located within base  132 . Aperture  182  is sized to receive insert  160  as will be discussed below. Aperture  182  is substantially centered within base  132  but may be alternatively located at any location along base  132 . As shown in FIG. 6, interchangeable wrap  180  further includes wrap slots  138 . Wrap slots  138  are exemplary disposed substantially along a center-line axis of base  132 , on an outer edge of aperture  182 .  
         [0036]    Interchangeable wrap  180  further includes front wraps  134  and rear wraps  136 . Rear wraps  136  and front wraps  134  extend substantially perpendicular to base  132 , and are substantially parallel with frame surface  143 . In an exemplary embodiment, rear wrap  136  may be configured with surface textures, such as, but not limited to ribs, which serve the same function as ribs  44 , depicted in FIG. 2.  
         [0037]    Frame wing  130  further includes insert  160 . Insert  160  includes plate  184 , hinge arm  186 , and pivots  188 . Plate  184  is a substantially flat, rectangular portion having a size substantially corresponding to the size of aperture  182 . Plate  184  further includes insert slots  190  disposed substantially along a center-line axis of plate  184 , on an outer edge of plate  184 . Plate  184  further includes wraps  192  which are substantially perpendicular to plate  184 , and are configured to correspond to the width of interchangeable wrap  180 . Alternatively, wraps  192  may be omitted.  
         [0038]    Insert  160  and interchangeable wrap  180  are assembled to form frame wing  130  which may be attached to frame  140 . Interchangeable wrap  180  is slid over edge  142 , located in a desired mounting position. As frame wing  130  is slid over edge  142 , optional ribs wedge into the front and rear of frame surface  143  of frame  140 , thereby assisting to hold frame wing  130  in place prior to assembly. Insert  160  is then fitted into aperture  182 . Alternatively, because wraps  134  and  136  are oversized and elongated, wraps  134  and  136  grip frame edge  142  by a frictional interference fit and help to align plate  184  in place prior to assembly. When insert  160  is placed in aperture  182 , insert slots  190  and wrap slots  138  are aligned to form fastener hole  194  (FIG. 8). Fasteners, shown as wood screws  156 , are then attached to frame  140 . Head  196  of wood screws  156  applies a force to both base  132  and plate  184 , thereby preventing both interchangeable wrap  180  and insert  160  from moving. Wood screws  156  may be used with an optional washer or may be washer head screws having a large flange  197  which acts as a washer but is integrated into screw  156 . Frame wing  130  may be adjusted by loosening wood screws  156  and sliding frame wing along axis Y-Y. The limit of adjustment is bounded by the length of fastener hole  194 .  
         [0039]    The two piece design of frame wing  130  offers several advantages. One such advantage is reducing the number of sized parts required to assemble frame wing  130 . In other words, plate  184  may be used in conjunction with a variety of bases  132  which may be sized for different frame widths. For example, the same insert  160  may be used for cabinet frames utilizing frame material of a variety of different thicknesses. If, for example, a cabinet frame is built using ¾ inch MDF and another is built using ½ inch MDF, the same insert  160  may be used for both cabinets, thereby requiring only different frame wings  130 . Also the frame wing dimensions may be varied to optimize performance characteristics depending on the frame material being used. Also, plate  184  may be easily interchanged with a plate having a different hinge arm  186  configuration or hinge arm type.  
         [0040]    It is also important to note that the construction and arrangement of the elements of the hinge shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the scope of the present inventions as expressed in the appended claims.