Patent Publication Number: US-2022220785-A1

Title: Split hinge

Description:
CROSS REFERENCE AND PRIORITY CLAIM UNDER 35 U.S.C. § 119 
     This application claims priority to U.S. Provisional Application No. 63/137,397 entitled “Split Hinge” filed on Jan. 14, 2021 and U.S. Provisional Application No. 63/151,432 entitled “Split Hinge” filed on Feb. 19, 2021, both of which are assigned to the assignee hereof and the entirety of both are incorporated by reference herein. 
    
    
     FIELD 
     The present disclosure generally relates to continuous hinges, and in particular a split hinge that allows for improved manufacturing, delivery, and assembly of the continuous hinges. 
     BACKGROUND 
     Conventional door hinges include two mating leaves, with each leaf including a substantially flat web that is fastened to either a door or a door frame, and knuckles that interlock with a pivot pin passing through the knuckles. Another type of conventional hinge is a continuous hinge, which typically runs for the entire length of a door. Continuous hinges typically include two leaves, each with vertical teeth that act like gears, such as spur gear teeth, extending from heads at one edge of the webs, and each webs is attached to either a door or a door frame. The axis of the head is normally vertically aligned when the hinge and door are installed. The vertical teeth of the gear of each head of the two leaves mate with each other. The teeth may extend only around a portion of the head as required to maintain range of motion desired for the door. The teeth may extend only up to where the web and head connect. A cover is typically provided that may be substantially C-shaped to receive the heads of each leaf when the heads of the leaves are put together. The cover typically runs the full length of the hinge and prevents the leaves from separating. 
     SUMMARY 
     The door hinge disclosed in the present application may be a split hinge (otherwise described as a modular hinge) that mimics a continuous hinge (e.g., extending along a portion of, the majority of, or the entire length of the door edge and/or the door frame), and is operatively coupled to the door and the door frame for pivotal movement of the door relative to the frame between a closed position and one or more open positions (e.g., including a fully open position). The split hinge may comprise two or more portions, such as at least a first hinge portion and a second hinge portion. The first hinge portion and the second hinge portion may each comprise two leaves (e.g., two first leaves and two second leaves) having first webs operatively coupled to first heads and second webs operatively coupled to second heads, respectively. A first cover is operatively coupled to the two first leaves (e.g., the first heads of the first leaves) to form the first hinge portion. A second cover is operatively coupled to the two second leaves (e.g., the second heads of the second leaves) to form the second hinge portion. As will be described herein, the first leaves and the second leaves may have the same or different lengths. Moreover, the first cover and the second cover may have the same or different lengths. The two first leaves may have first leaf lengths that are greater than or less than the first cover, while the two second leaves may have second leaf lengths that are greater than or less than the second cover. In particular embodiments, each cover cannot have the same length as the leaf lengths of the leaves to which it is operatively coupled. For example, the first leaf lengths of the two first leaves may not be the same as the first cover length of the first cover. Moreover, the second leaf lengths of the two second leaves may not be the same as the second cover length of the second cover. Consequently, in order to operatively couple the first hinge portion and the second hinge portion, the first cover may extend over the two first leaves, the second cover may extend over the two second leaves, and a portion of the first cover may extend over a portion of the two second leaves or a portion of the second cover may extend over a portion of the two first leaves. Alternatively, a third cover may extend over a portion of the first leaves and a portion of the second leaves. Moreover, one or more extension hinge portions (having extension leaves and an extension cover) may be utilized in order to customize the length of the assembled split hinge and/or further reduces the lengths of the first hinge portion and/or the second hinge portion. 
     One embodiment of the invention comprises a door hinge. The door hinge comprises a first hinge portion and a second hinge portion. The first hinge portion comprises two first leaves, and each of the two first leaves comprises a first web and a first head extending from the first web and having a longitudinal axis. The first hinge portion further comprises a first cover operatively coupled to the two first leaves. The second hinge portion comprises two second leaves, and each of the two second leaves comprises a second web and a second head extending from the second web and having a longitudinal axis. The second hinge portion further comprises a second cover operatively coupled to the two second leaves. The first hinge portion is operatively coupled to the second hinge portion through the first cover or the second cover. 
     In further embodiments, the two first leaves have first leaf lengths that are different than a first cover length of the first cover, and the two second leaves have second leaf lengths that are different than a second cover length of the second cover. 
     In other embodiments, the two first leaves have first leaf lengths and the two second leaves have second leaf lengths. 
     In still other embodiments, the first leaf lengths are greater than the second leaf lengths. 
     In yet other embodiments, the first leaf lengths are less than the second leaf lengths. 
     In other embodiments, the first leaf lengths are equal to the second leaf lengths. 
     In further embodiments, a first web length of the first web is less than a first head length of the first head, and a second web length of the second web is greater than a second head length of the second head. 
     In other embodiments, a first web length of the first web is greater than a first head length of the first head, and a second web length of the second web is less than a second head length of the second head. 
     In still other embodiments, the first cover has a first cover length and the second cover has a second cover length. 
     In yet other embodiments, the first cover length is greater than the second cover length. 
     In other embodiments, the second cover length is greater than the first cover length. 
     In further embodiments, the first cover length is equal to the second cover length. 
     In other embodiments, the door hinge further comprises one or more couplings for operatively coupling the first cover to one or more of the two first leaves or one or more of the two second leaves. 
     In still other embodiments, the one or more couplings comprise a first coupling for operatively coupling the first cover to the one or more of the two first leaves. The one or more couplings comprise a second coupling for operatively coupling the second cover to the one or more of the two second leaves. The one or more couplings comprise a third coupling for operatively coupling the first cover to the one or more of the two second leaves or the second cover to the one or more of the two first leaves. 
     In yet other embodiments, the third coupling operatively couples the first cover to the one or more of the two second leaves. 
     In other embodiments, the third coupling operatively couples the second cover to the one or more of the two first leaves. 
     In further embodiments, the one or more couplings comprise a set screw. 
     In other embodiments, the door hinge further comprises an extension hinge portion. The extension hinge portion comprises two extension leaves, each of the two extension leaves comprise an extension web and an extension head extending from the extension web and having a longitudinal axis. The extension hinge portion further comprises an extension cover operatively coupled to the two first leaves. The extension hinge portion is operatively coupled to the first hinge portion or the second hinge portion. 
     Other embodiments of the invention comprise a door assembly comprising a door, a door frame, and a door hinge. The door hinge comprises a first hinge portion and a second hinge portion. The first hinge portion comprises two first leaves, and each of the two first leaves comprises a first web and a first head extending from the first web and having a longitudinal axis. The first hinge portion further comprises a first cover operatively coupled to the two first leaves. The second hinge portion comprises two second leaves, and each of the two second leaves comprises a second web and a second head extending from the second web and having a longitudinal axis. The second hinge portion further comprises a second cover operatively coupled to the two second leaves. The first hinge portion is operatively coupled to the second hinge portion through the first cover or the second cover. One of the two first leaves and one of the two second leaves are operatively coupled to a door, and another of the two first leaves and the two second leaves are operatively coupled to the door frame. 
     Other embodiments of the invention comprise a method of installing a door hinge to a door system. The method comprises assembling a first hinge portion to a second hinge portion. The first hinge portion comprises two first leaves, and each of the two first leaves comprises a first web and a first head extending from the first web and having a longitudinal axis. The first hinge portion further comprises a first cover operatively coupled to the two first leaves. The second hinge portion comprises two second leaves, and each of the two second leaves comprises a second web and a second head extending from the second web and having a longitudinal axis. The second hinge portion further comprises a second cover operatively coupled to the two second leaves. The first hinge portion is operatively coupled to the second hinge portion through the first cover or the second cover. The method further comprises assembling one of the two first leaves and one of the two second leaves to a door frame, and assembling another of the two first leaves and another of the two second leaves to a door. 
     To the accomplishment the foregoing and the related ends, the one or more embodiments comprise the features hereinafter described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings. 
         FIG. 1  is a front view of a split hinge having a first hinge portion and a second hinge portion, in accordance with embodiments of the present disclosure. 
         FIG. 2  is a side front view of a split hinge having first leaves, second leaves, a first cover, and a second cover, in accordance with embodiments of the present disclosure. 
         FIG. 3  is a side view of a portion of split hinge having two first leaves assembled to a first cover and two second leaves assembled to a second cover, in accordance with embodiments of the present disclosure. 
         FIG. 4  is a cross-sectional view of a first hinge portion, in accordance with embodiments of the present disclosure. 
         FIG. 5  is a side front view of a split hinge having first leaves, second leaves, a first cover, a second cover, and a third cover, in accordance with embodiments of the present disclosure. 
         FIG. 6A  is a side view of a portion of a split hinge having a first hinge portion before assembly with a second hinge portion, in accordance with embodiments of the present disclosure. 
         FIG. 6B  is a perspective view of the second hinge portion of  FIG. 6A , in accordance with embodiments of the present disclosure. 
         FIG. 7  is a side view of a portion of a split hinge in which a first cover of a first hinge portion is being assembled to two second leaves of a second hinge portion, in accordance with embodiments of the present disclosure. 
         FIG. 8  is a side view of a portion of a split hinge in which a first cover of a first hinge portion is being further assembled to two second leaves of a second hinge portion, in accordance with embodiments of the present disclosure 
         FIG. 9  is a side view of a portion of a split hinge before completion of the assembly of a first cover of a first hinge portion to two second leaves of a second hinge portion, in accordance with embodiments of the present disclosure 
         FIG. 10  is a side view of a split hinge having a first hinge portion assembled to a second hinge portion in which a first cover is assembled with two second leaves, in accordance with embodiments of the present disclosure. 
         FIG. 11  is a front view of an assembled split hinge having a first hinge portion that is open and second hinge portion that is closed, in accordance with embodiments of the present disclosure. 
         FIG. 12  is a front view of an assembled split hinge having a first hinge portion that is open and second hinge portion that is open, in accordance with embodiments of the present disclosure. 
         FIG. 13A  is a perspective view of a full mortise hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13B  is a perspective view of a full surface hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13C  is a perspective view of a half mortise hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13D  is a perspective view of a half surface hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13E  is a perspective view of a double swing hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13F  is a perspective view of an emergency release stop hinge, in accordance with embodiments of the present disclosure. 
         FIG. 13G  is a perspective view of a hinge having offset webs, in accordance with embodiments of the present disclosure. 
         FIG. 13H  is a perspective view of a hinge having webs of different lengths, in accordance with embodiments of the present disclosure. 
         FIG. 14  is a perspective view of an unassembled hinge having a first hinge portion, a second hinge portion, and a third hinge portion, in accordance with embodiments of the present disclosure. 
         FIG. 15  is a method of manufacturing, delivering, and installing a split hinge, in accordance with embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description teaches specific example embodiments of the invention; however, other embodiments of the invention do not depart from the scope of the present invention. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. 
     Referring now to the drawings, wherein like reference numerals designate corresponding or similar elements throughout the several views, embodiments of a door hinge are shown in  FIGS. 1-5 . The door hinge disclosed in the present application may be a split hinge  20  that mimics a continuous hinge (e.g., extending along a portion of, the majority of, or the entire length of the door edge and/or the door frame), and is operatively coupled to the door and the door frame for pivotal movement of the door relative to the frame between a closed position and one or more open positions (e.g., including a fully open position). As illustrated in  FIGS. 1-4  the split hinge  20  may comprise a first hinge portion  30  and a second hinge portion  50 . The first hinge portion  30  and the second hinge portion  50  may each comprise two leaves (e.g., two first leaves  32 ,  42  and two second leaves  52 ,  62 ) having first webs  34 ,  44  operatively coupled to first heads  38 ,  48  and second webs  54 ,  64  operatively coupled to second heads  58 ,  68 , respectively. A first cover  80  is operatively coupled to the two first leaves  32 ,  42  (e.g., the first heads  38 ,  48  of the first leaves  32 ,  42 ) to form the first hinge portion  30 . A second cover  90  is operatively coupled to the two second leaves  52 ,  62  (e.g., the second heads  58 ,  68  of the second leaves  52 ,  62 ) to form the second hinge portion  30 . As will be described herein, the first leaves  32 ,  42  and the second leaves  52 ,  62  may have the same or different lengths. Moreover, the first cover  80  and the second cover  90  may have the same or different lengths. The two first leaves  32 ,  42  may have first leaf lengths that are greater than or less than the first cover  80 , while the two second leaves  52 ,  62  may have second leaf lengths that are greater than or less than the second cover  90 . In particular embodiments, each cover cannot have the same length as the leaf lengths of the leaves to which it is operatively coupled. For example, the first leaf lengths of the two first leaves  32 ,  42  cannot be the same as the first cover length of the first cover  80 . Moreover, the second leaf lengths of the two second leaves  52 ,  62  cannot be the same as the second cover length of the second cover  90 . Consequently, in order to operatively couple the first hinge portion  30  and the second hinge portion  50 , the first cover  80  may extend over the two first leaves  32 ,  42 , the second cover  90  may extend over the two second leaves  52 ,  62 , and a portion of the first cover  80  may extend over a portion of the two second leaves  52 ,  62  or a portion of the second cover  90  may extend over a portion of the two first leaves  32 ,  44 . 
     Returning to  FIGS. 1-4 , the first hinge portion  30  and the second hinge portion  50  are described in further detail herein. The first hinge portion  30  may comprise two first leaves  32 ,  42 . Each first leaf  32 ,  42  may include a first web  34 ,  44  (e.g., plates of any shape, orientation, length, or the like) and a first head  36 ,  46  extending at least partially along the edges of the first web  34 ,  44  (e.g., along a portion of, along an entirety of, and/or extending past an end of the first web  34 ,  44 ). The two first leaves  32 ,  42  may be described as a proximal first leaf  32  and a distal first leaf  42 , and moreover, the features thereof may also be described as proximal and distal (e.g., a proximal first head  38 , a distal first head  48 , a proximal first web  34 , and a distal first web  44 ). The second hinge portion  50  may comprise two second leaves  52 ,  62 . Each second leaf  52 ,  62  may include a second web  54 ,  64  (e.g., plates of any shape, orientation, length, or the like) and a second head  56 ,  66  extending along the edges of the web  54 ,  64  (e.g., along a portion of, along an entirety of, and/or extending past an end of the first web  34 ,  44 ). The two second leaves  52 ,  62  may be described as a proximal second leaf  52  and a distal second leaf  62 , and moreover, the features thereof may also be described as proximal and distal (e.g., a proximal second head  58 , a distal second head  68 , a proximal second web  54 , and a distal second web  64 ). 
     The first webs  34 ,  44  and second webs  54 ,  64  may be integrally operatively coupled (e.g., formed integrally with) to the first heads  38 ,  48  and second heads  58 ,  68 , respectively. Alternatively, the first webs  34 ,  44  and second webs  54 ,  64  may be formed separately from the first heads  38 ,  48  and second head  58 ,  68 , and thereafter, operatively coupled to the first heads  38 ,  48  and second heads  58 ,  68 , respectively (e.g., connected through fasteners, welds, or the like). The first webs  34 ,  44  and the second webs  56 ,  66  may be adapted to be mounted to a door or a door frame, as applicable, through the use of fasteners (e.g., screws, rivets, bolts, or the like) through apertures in the webs  36 ,  46 ,  56 ,  64 . 
     The heads  38 ,  48 ,  58 ,  68  may be continuous and extend along the entire length of the related webs  34 ,  44 ,  54 ,  64 , or the heads  38 ,  48 ,  58 ,  68  may be discontinuous (e.g., have one or more slots between separate head portions) and be located only over a portion of the related webs  34 ,  44 ,  54 ,  64 . For example, hinge slots  22  may be formed (e.g., milled, or the like) in the leaves  32 ,  42 ,  52 ,  62  and one or more bearings  10  (e.g., plastic, metal, composite, or other like bearings  10 ) may be operatively coupled to the leaves  32 ,  42 ,  52 ,  62  at the locations of the hinge slots  22  (e.g., the slots receive the bearings  10 ). The bearings  10  bear the weight of the door and keep adjacent leaves from sliding past each other. The heads  38 ,  48 ,  58 ,  68  may comprise gear teeth  70 , extending therefrom (e.g., from substantially arcuate portion of each head  38 ,  48 ,  58 ,  68 ). The gear teeth  70  may be radial, helical, or other shaped gear teeth, and may extend around at least a portion of the heads  38 ,  48 ,  58 ,  68  (e.g., the arcuate portion for a distance adequate for the gear teeth to mesh throughout the full range of motion of the hinge  20 , or the like). 
       FIG. 4  illustrates a cover (e.g., a first cover  80 ) operatively coupling one first leaf  32  to another first leaf  42 . The covers  80 ,  90  may be substantially C-shaped with returns at each end. At the end of each return, a portion may be provided that is substantially circular in cross-section to act as a pivot feature  82 ,  92  received by the head  38 ,  48 ,  58 ,  68  of a leaf  32 ,  42 ,  52 ,  62 , which may be considered a hook portion  39 ,  49 ,  59 ,  69 . Each leaf  38 ,  48 ,  58 ,  68  pivots around the pivot feature  82 ,  92  while the gear teeth  70  mesh centrally between the pivot features  82 ,  92 . The hook portions  39 ,  49 ,  59 ,  69  truncate abruptly at hook ends  39 A,  49 A,  59 A,  69 A, which in this embodiment are flat surfaces (however, the hook ends  39 A,  49 A,  59 A,  69 A may have any surface of any shape). The hook ends  39 A,  49 A,  59 A,  69 A, in some embodiments are truncated in order to permit the closing of the hinge  20 , when they are received in pockets  86 ,  96  in the covers  80 ,  90  as shown in  FIG. 4 . While the pivot features  82 ,  92  are illustrated a substantially circular in cross-section, the pivot features can be any shape around which a portion of the leaves (e.g., the hooks or other feature may pivot). As will be described in further detail with respect to  FIG. 15 , the split hinge  30  may be assembled by meshing the gear teeth  70  together in proper alignment, which may be most easily done in the position of  FIG. 4 . This corresponds to the position of a closed door with the webs  34 ,  44 ,  54 ,  64  in or near contact with each other, and then the first cover  80  may be slid over the first heads  38 ,  48  of the first leaves  32 ,  42 , while the second cover  90  may be slid over the second heads  58 ,  68  of the second leaves  52 ,  62 . It should be understood that the second cover  90  of the second portion  50  and/or an extension cover  150  of an extension hinge portion  100  (described in further detail below) have the same or similar components and may be assembled in the same or similar way. 
     As previously discussed, it should be understood that the door hinge  20  may be formed such that the first leaves  32 ,  42  and the first cover  80  have different lengths and the second leaves  52 ,  62  and the second cover  90  have different lengths. As such, the first leaves  32 ,  42  have first leaf lengths and the second leaves  52 ,  62  have second leaf lengths. In some embodiments, the first leaf lengths of the first hinge portion  30  is equal to the second leaf lengths of the second hinge portion  50 . Moreover, the first cover length of the first cover  80  may be greater than the second cover length of the second cover  90 . As such, in this embodiment, the first cover  80  may be operatively coupled to the first heads  38 ,  48  of the first hinge portion  30 , and extend over and be operatively coupled to the second heads  58 ,  68  of the second hinge portion  50 . As such, the second cover  90  may only be operatively coupled to the second heads  58 ,  68  of the second hinge portion  50 . 
     In other embodiments, the first leaf lengths of the first leaves  32 ,  42  may be greater than the second leaf lengths of the second leaves  32 ,  42 . Moreover, the first cover length of the first cover  80  may be less than or equal to the second cover length of the second cover  90 . As such, in this embodiment, the first cover  80  may be operatively coupled to only the first heads  38 ,  48  of the first hinge portion  30 . As such, the second cover  90  may be operatively coupled to the second heads  58 ,  68  of the second hinge portion, and extend over and be operatively coupled to the first heads  38 ,  48  of the first hinge portion  30 . 
     In other embodiments, the first leaf lengths of the first leaves  32 ,  42  may be less than the second leaf lengths of the second leaves  52 ,  62 . Moreover, the first cover length of the first cover  80  may be greater than or equal to the second cover length of the second cover  90 . As such, in this embodiment, the first cover  80  may be operatively coupled to the first heads  38 ,  48  of the first hinge portion  30  and extend over and be operatively coupled to the second heads  38 ,  48  of the second hinge portion  50 . As such, the second cover  90  may be operatively coupled to only the second heads  58 ,  68  of the second hinge portion  50 . 
     It should be understood that the first leaves  32 ,  42  and the second leaves  52 ,  62 , as well as the first cover  80  and the second cover  90  may have any lengths, and as such be operatively coupled together in various configurations. Moreover, while the split hinge  20  is only described herein as being split into a first hinge portion  30  and a second hinge portion  50 , it should be understood that the split hinge  20  and/or components thereof may be split into any number of portions (e.g., three or more portions, or the like). As illustrated in  FIG. 5 , in one example, the split hinge  20  may have two first leaves  32 ,  42  and two second leaves  52 ,  62 , but the cover may be split into three covers. As such, the first cover  80  may be operatively coupled to the two first leaves  32 ,  42 , the second cover may be operatively coupled to the two second leaves  52 ,  62 , and a third cover  98  may be operatively coupled to a portion of the two first leaves  32 ,  42  and a portion of the two second leaves  52 ,  62  (e.g., located in the middle of the split hinge  20 ). 
     By splitting the hinge  20  into two portions it should be understood that the first leaves  32 ,  42 , the second leaves  52 ,  62 , the first cover  80 , and the second cover  90  (or other leaves and/or covers) may be manufactured, packaged, and/or shipped more easily when compared to a single unsplit continuous hinge, as will be described in further detail with respect to  FIG. 15 . Moreover, by utilizing a split hinge  20  having first leaves  32 ,  42  and second leaves  52 ,  62 , a first cover  80 , and a second cover  90  having different lengths allows for an installer to pre-assemble the split hinge  20  before operatively coupling the hinge to the door and/or the door frame. As will be described in further detail with respect to  FIG. 15 , by pre-assembling the split hinge  20 , the installer can avoid potential alignment issues that could occur by assembling different hinge portions on the door and/or the door frame separately. 
       FIGS. 6A-10  illustrate the assembly of the first hinge portion  30  to the second hinge portion  50 . In the illustrated embodiments, the first cover  80  has a cover length that is greater than first leaf lengths  32 ,  42  of the first hinge portion  30 , while the second cover  90  has a cover length that is less than second leaf lengths  52 ,  62  of the second hinge portion  50 . As illustrated in  FIGS. 6A and 6B , the first cover  80  is operatively coupled to the first leaves  32 ,  42 , as previously described herein (e.g., sliding the cover  80  over the first heads  38 ,  48  of the first leaves  32 ,  42 ). Moreover, the second cover  90  is operatively coupled to the second leaves  52 ,  62 , as previously described herein (e.g., sliding the cover  90  over the second heads  58 ,  68  of the second leaves  52 ,  62 ). 
     As illustrated in  FIG. 7  the first hinge portion  30  is operatively coupled to the second hinge portion  50  by sliding the first cover  80  over the second heads  58 ,  68  of the second leaves  52 ,  62 . As further illustrated in  FIGS. 8-10 , the first cover  80  continues to slide over the second heads  58 ,  68  of the second leaves  52 ,  62  until an end of the first hinge portion  30  butts against an end of the second hinge portion  50  and/or an end of the first cover  80  butts against an end of the second cover  90 . 
     In some embodiments of the invention, one or more couplings may be utilized to aid in preventing the first cover  80  and the second cover  90  from further movement with the first leaves  32 ,  42  and/or the second leaves  52 ,  62 . For example, one or more first couplings may be utilized for operatively coupling the first cover  80  to the first leaves  32 ,  42  and/or the second leaves  52 ,  62 ; one or more second couplings may be utilized for operatively coupling the second cover  90  to the second leaves  52 ,  62  and/or the first leaves  32 ,  42  (e.g., depending on the lengths of the first leaves  32 ,  42 , the second leaves  52 ,  62 , the first cover  80 , and/or the second cover  90 ). In some embodiments the couplings may comprise any type of fastener (e.g., set screw, nut, bolt, or the like), clamp, clip, pin, or any other coupling may be utilized to operatively couple the covers  80 ,  90  to the leaves  32 ,  42 ,  52 ,  62 . 
       FIGS. 11 and 12  illustrate that the first leaves  32 ,  42  and the second leaves  52 ,  62  operate independently of each other to open and close as the teeth  70  of the first heads  38 ,  48  and second heads  58 ,  68  operate independently of each other. While the first hinge portion  30  and the second hinge portion  50  may operate independently when the split hinge  20  is pre-assembled, when the split hinge  20  is assembled to a door and/or a door frame, the first hinge portion  30  and the second hinge portion  50  will operate together to allow a door to open and close. 
     It should be further understood that in some embodiments the heads  38 ,  48 ,  58 ,  68  may be longer or shorter than the webs  34 ,  44 ,  54 ,  64  of the first hinge portion  30  and/or the second hinge portion  50 . Additionally, or alternatively, one first head  38  (e.g., a proximal first head  38 ) may be longer or shorter than another first head  48  (e.g., a distal second head  48 ), while one second head  58  (e.g., a proximal second head  58 ) may be longer or shorter than another second head  68  (e.g., a distal second head  68 ). In this way, a first head  38  of the first hinge portion  30  may interact with a second head  68  of a second hinge portion  50 , such that even though the first hinge portion  30  may be split from a second hinge portion  50 , the hinge portions operate together when assembled. For example, teeth  70  of one of the first heads  38  moves with the teeth  70  of the other first head  48  and with the teeth  70  of one of the second heads  68 . In these configurations, the heads  38 ,  48 ,  58 ,  68  and/or webs  34 ,  44 ,  54 ,  64 , in addition to the covers  80 ,  90  may also aid in operative coupling of the first hinge portion  30  to the second hinge portion  50  (e.g., to aid in the stability of the hinge  20 , or the like). 
       FIGS. 13A through 13H  illustrate different types of hinges that may utilize the split hinge configuration described herein. As illustrated in  FIG. 13A  the split hinge  20  may be a full mortise hinge. As illustrated in  FIG. 13B  the split hinge  20  may be a full surface hinge. As illustrated in  FIG. 13C  the split hinge  20  may be a half mortise hinge. As illustrated in  FIG. 13D  the split hinge  20  may be a half surface hinge. As illustrated in  FIG. 13E  the split hinge  20  may be a double swing hinge. As illustrated in  FIG. 13F  the split hinge  20  may be an emergency release hinge. As illustrated in  FIG. 13G  the split hinge  20  may be an offset leaf hinge. As illustrated in  FIG. 13H  the split hinge  20  may be a short leaf hinge. It should be understood that disclosure provided herein may be incorporated into any type of continuous hinge or other type of hinge not explicitly discussed herein. 
     As previously discussed, in some embodiments the hinge  20  (including the covers  80 ,  90 ) may be split into more than two portions  30 ,  50 , such as, but not limited to three, four, five, or any number of portions. Regardless of the number of portions into which the hinge  20  may be split, the lengths of the portions and/or the covers may be the same and/or different in order to allow for pre-assembly as previously described herein with respect to the first hinge portion  30  and the second hinge portion  50 . 
     It should be understood that continuous hinges may range in length from 79 inches to 110 inches (or range within, outside, or overlap these values), and typically be about 1 inch shorter than the door height. For example, for a 7 foot door, the hinge may be 83 inches. In some embodiments, the split hinge  20  (including the covers  80 ,  90 ) may be standard sizes, such as to create a hinge that is 83 inches in length. However, one or more third hinge portions  100  (e.g., otherwise described as extension portions  100 , extension hinge portion  100 , or the like) may be utilized to provide additional flexibility in customizing the length of the split hinge  20 , while keeping the length of any split hinges  20  below desired lengths for manufacturing, moving, packaging, shipping, installing, or the like. 
     As illustrated in  FIG. 14 , an extension hinge portion  100  may comprise two leaves (e.g., two extension leaves  112 ,  122 ) having extension webs  114 ,  124  operatively coupled to extension heads  118 ,  128 . An extension cover  150  is operatively coupled to the two extension leaves  112 ,  122  (e.g., the extension heads  118 ,  128  of the extension leaves  112 ,  122 ) to form the extension hinge portion  100 . The two extension leaves  112 ,  122  may have extension leaf lengths that are greater than, less than, or equal to the extension cover  150 . In the illustrated embodiment in  FIG. 14 , the extension cover  150  and the two extension leaves  112 ,  122  have the same length, but are offset from each other to allow for operative coupling with the first hinge portion  30  and/or the second hinge portion  50 . As previously discussed with respect to the covers  80 ,  90  of the first hinge portion  20  and the second hinge portion  90 , the extension cover  150  may be substantially C-shaped with returns at each end and the extension heads  118 ,  128  may comprise gear teeth  70 , extending therefrom, as was previously discussed with respect to  FIG. 4 . As such, at the end of each return, a portion may be provided that is substantially circular in cross-section to act as a pivot feature  82 ,  92  received by the head  118 ,  128  of a leaf  112 ,  122 , which may be considered a hook portion  119 ,  129 . Each leaf  112 ,  122  pivots around the pivot feature  82 ,  92  while the gear teeth  70  mesh centrally between the pivot features  82 ,  92 . The hook portions  119 ,  129  truncate abruptly at hook ends  119 A,  129 A, which in this embodiment are flat surfaces (however, the hook ends  119 A,  129 A may have any surface of any shape). The hook ends  119 A,  129 A, in some embodiments are truncated in order to permit the closing of the hinge  20 , when they are received in pockets  86 ,  96  in the cover  150 , as previously described with respect to  FIG. 4 . As will be described in further detail with respect to  FIG. 15 , the split hinge  20  may be assembled by meshing the gear teeth  70  together in proper alignment, which may be most easily done in the position of  FIG. 4 . Like the first hinge portion  30  and the second hinge portion  50 , the extension hinge portion  100  may also have couplings to aid in preventing the extension cover  150  moving with respect to the extension leaves  112 ,  122 . Moreover, bearings  10  may also be used in the extension portion  100  as previously discussed with respect to the first hinge portion  30  and the second hinge portion  50 . 
     It should be understood that the extension hinge portion may be operatively coupled to the first hinge portion  30  and/or the second hinge portion  50 , or any other hinge portion (e.g., third, fourth, fifth, or the like portion) in the same or similar way as previously described herein with respect to the operative coupling between the first hinge portion  30  and the second hinge portion  50 . Moreover, while the extension hinge portion  100  may be located between the first hinge portion  30  and the section hinge portion  50 , it should be understood that the extension hinge portion  100  may be located on either end of the split hinge  20  (e.g., on the outer end of the first hinge portion  30  or the second hinge portion  50 ). 
     The extension hinge portion  100  may be made to be any length, such as 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 30, 36, or the like inches (or range between, outside, or overlap any of these values). However, in particular embodiments it should be understood that the extension hinge portion  100  may be approximately 12 inches. As such, in one example embodiment, a hinge may be provided in a two part split hinge  20  (e.g., a first hinge portion  30  and a second hinge portion  50 ) that when assembled would form a hinge  20  having of length of approximately 83 inches. Moreover, one or more extension portions  100  having an extension length of approximately 12 inches could be provided to a user to create an assembled hinge  20  having a length of approximately 95 inches (e.g., with a first extension portion  100 ) or approximately 107 inches (e.g., with an additional second extension portion  100 ). As such, any number of extension portions  100  may be used to change the length of the assembled hinge. As such, regardless of the ultimate length of the assembled split hinge  20 , the components may be manufactured, moved, packaged, shipped, delivered to the installation site, installed by a user (e.g., installer), or the like in a smaller configuration than a single continuous hinge (e.g., two or more portions, three or more portions, four or more portions, or the like have different or the same lengths in order to reduce the length of the package). For example, the packaging of the split hinge may be packaged in a package length that is less than approximately 48 inches (or any packaging that is less than or greater than 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, 25, 30, or the like percent of 48 inches). 
       FIG. 15  illustrates a method of manufacturing, packaging, shipping, and installing the hinges  20  described herein. As illustrated in block  202  of  FIG. 15 , the hinge leaves may be manufactured to create the desired lengths of the leaves  32 ,  42 ,  52 ,  62 ,  112 ,  122 . It should be understood that leaves of a continuous hinge may be formed, and thereafter, cut into the desired number of first leaves  32 ,  42 , second leaves  52 ,  62 , and/or extension leaves  112 ,  122 , having the desired lengths. Alternatively, the first leaves  32 ,  42 , second leaves  52 ,  62 , and/or extension leaves  112 ,  114  may be manufactured to the desired length without cutting a larger continuous leaf. Regardless of how the leaves are formed, a variety of manufacturing methods may be used. The leaves  32 ,  42 ,  52 ,  62 ,  112 ,  122  including the webs  34 ,  44 ,  54 ,  64 ,  114 ,  124  and the heads  38 ,  48 ,  58 ,  68 ,  118 ,  128  and the teeth  70  therefor, may be formed by methods that include, for example, die casting, injection molding, machining, extruding a blank, embossing/coining the gear teeth, or the like. The teeth  70  may also be lubricated by being impregnated with a lubricant coating such as polytetrafluoroethylene. Materials used for the hinge leaves  32 ,  42 ,  52 ,  62 ,  112 ,  122  may include, for example, various materials such as aluminum, steel, stainless steel, plastic resin, composite (e.g., plastic resin over-molded onto a substrate of different material), or the like. 
     Block  204  of  FIG. 15  further illustrates that the covers  80 ,  90 ,  150  may be manufactured to create the desired lengths of the covers  80 ,  90 ,  150 . It should be understood that a continuous cover may be formed, and thereafter, cut into the desired number of first covers  80 , second covers  90 , extension covers  150  (if needed), or the like having the desired lengths. Alternatively, the first covers  80 , second covers  90 , extension covers  150  (if needed), or the like may be manufactured to the desired length without cutting a longer continuous cover. Regardless of how the covers  80 ,  90 ,  150  are formed, a variety of manufacturing methods may be used. The covers  80 ,  90 ,  150  may be formed by methods that include, for example, die casting, injection molding, machining, extruding a blank, embossing, and/or the like. Materials used for the covers  80 ,  90 ,  150  may include, for example, various materials such as aluminum, steel, stainless steel, plastic resin, composite (e.g., plastic resin over-molded onto a substrate of different material), or the like. 
     It should be understood that the leaves  32 ,  42 ,  52 ,  62 ,  112 ,  114  and covers  80 ,  90 ,  150  may be manufactured to the desired lengths to improve the packaging and shipping of the split hinge  20 . For example, the first leaves  32 ,  42  may be formed to a first length that is equal to the second cover length of the second cover  90 . Moreover, the second leaves  52 ,  62  may be formed to a second length that is equal to the first cover length of the first cover  80 . As such, the length of the packaging may be created such that the length of the packaging may be sized base on the longer of the first leaves  32 ,  42  and the second cover  90  or the second leaves  52 ,  62  and the first cover  80 . In other embodiments of the invention, the first leaves  32 ,  42  and second leaves  52 ,  62  may be the same length, and three covers may be utilized such that the length of the packaging is based on the length of the leaves  32 ,  42 ,  52 ,  62 . Furthermore, the extension portion(s)  150  may have extension leaves  112 ,  122  and a cover  150  that are the same length (and offset) or having lengths that are greater or less than each other depending on the configurations and lengths of the first leaves  32 ,  42 , second leaves  52 ,  62 , first cover  80 , and/or second cover  90 . 
     As illustrated by block  206  of  FIG. 15 , the leaves  32 ,  42 ,  52 ,  62 ,  112 ,  122  and the covers  80 ,  90 ,  150  are packaged for shipping to a client, either as separate components, or pre-assembled into a first hinge portion  30 , second hinge portion  50 , and extension(s)  100 . Because of the reduced length of the hinge leaves  32 ,  42 ,  52 ,  62 ,  112 ,  122  and the covers  80 ,  90 ,  150  the split hinge(s)  20  may be packaged (e.g., individually, or in multiple groups) in a size with lengths that are smaller than the packaging for typical continuous hinges. Due to the reduced size of the components (e.g., the reduced length) the product is easier to package (e.g., both in the packaging and the process for packaging), handle (e.g., movement before and/or after packaging to the required locations either manually or using standard automated processing machinery), transport (e.g., ground, air, and/or manual carrying), and deliver (e.g., to a job site, commercial, residential, or the like location). 
     Block  208  of  FIG. 15 , further illustrates that during installation an installer may operatively couple the first leaves  32 ,  42  to the first cover  80 , operatively couple the second leaves  52 ,  62  to the second cover  90 , and/or operatively couple the extension leaves  112 ,  122  to the extension cover  150 . Alternatively, this may occur during the manufacturing process and/or during packaging. During assembly, as previously described herein, two heads  38 ,  48  or  58 ,  68  are located adjacent each other, such that the teeth  70  of the heads  38 ,  48 ,  58 ,  68 ,  118 ,  128  engage each other. Thereafter, a cover  80 ,  90 ,  150  slides over the heads  38 ,  48 ,  58 ,  68 ,  118 ,  128  of two adjacent heads  38 ,  48 ,  58 ,  68 ,  118 ,  128  in order to form the first hinge portion  30 , the second hinge portion  50 , and/or the extension hinge portion  100 . Before installation of the first hinge portion  30 , the second hinge portion  50 , and/or the extension hinge portion  100  to a door or door frame, the installer may operatively couple the first hinge portion  30  and the second hinge portion  50 . As previously discussed herein, the first hinge portion  30  may be operatively coupled to the second hinge portion  50  by sliding the first cover  80  over the second leaves  52 ,  62  of the second hinge portion  50 . Alternatively, the second cover  90  may be slid over the first leaves  32 ,  42  of the first hinge portion  30 . In sill other embodiments, a third cover may be slid over the first leaves  32 ,  42  of the first hinge portion  30  and over the second leaves  52 ,  62  of the second hinge portion. Alternatively, the installer may operatively couple the extension hinge portion  100  between the first hinge portion  30  and the second hinge portion  50 . As such, the first hinge portion  30  may be operatively coupled to the extension hinge portion  100  by sliding the first cover  80  over the extension leaves  112 ,  122  of the extension portion  100 , and sliding the extension cover  150  over the second leaves  52 ,  62  of the second hinge portion  50  (or vise versa). Alternatively the first hinge portion  30  and the second hinge portion  50  may be operatively coupled together as described above, and the extension portion  100  may be operatively coupled to an end of the first hinge portion  30  or the second hinge portion  50  by sliding the extension cover  150  over the first leaves  32 ,  42  or the second leaves  52 .  62 . 
     As illustrated by block  210  in  FIG. 15 , the installer operatively couples the assembled split hinge  20  to the door frame and/or a door through the use of one or more connectors (e.g., fasteners, such as screws, bolts, or the like, or any other type of connectors). By pre-assembling the first hinge portion  30  to the second hinge portion  50  (and in some cases the extension hinge portion  100 ) the assembled split hinge  20  is more easily assembled to a door and/or a door frame. That is, by first assembling the first hinge portion  30  to the second hinge portion  50  the split hinge  20  is aligned properly to allow the door to swing property when installed. Alternatively, if the separate portions of the split hinge were first assembled to the door and/or frame it may be difficult to properly align the first hinge portion  30  with the second hinge portion  50 . By installing the hinge portions separately to the door and/or door frame the hinges may bind, become damaged, have increased friction, or the like, and thus, the door may not open smoothly. However, it should be understood that the present disclosure allows for the installation of the first hinge portion  30 , the second hinge portion  50 , and/or one or more extension portions  100  before pre-assembling the split hinge  20  (e.g., assembling each portion directly on a door and/or wall, with or without the use of an alignment tool). 
     It should be understood that while the present invention is described with respect to geared hinges, the present invention may also be used in accordance with continuous pin and barrel hinges. In these embodiments, two or more pins (e.g., first pin, second pin, or the like), like the covers previous described herein, may be used that have different pin lengths than the leaves lengths described herein. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “top,” “bottom,” “side,” “distal,” “proximal,” “upper,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upward,” “downward”, “first”, “second”, or other like terminology merely describe the configuration shown in the figures. The referenced components may be oriented in an orientation other than that shown in the drawings and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise. 
     It will be understood that when an element is referred to as “operatively coupled” to another element, the elements can be formed integrally with each other, or may be formed separately and put together. Furthermore, “operatively coupled” can mean the element is directly coupled to the other element, or intervening elements may be present between the elements. Furthermore, “operatively coupled” may mean that the elements are detachable from each other, or that they are permanently operatively coupled together. 
     Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.