Abstract:
Disclosed is a self-closing, soft-close compact hinge comprising of a hinge cup pivotally connected to a hinge body via a hinge arm. A coil spring wrapped around the hinge cup provides the self-closing functionality and biases the hinge to a closed position. A damper is contained within the hinge cup in the path of the swinging hinge arm and guided by a damper cover fixedly attached to the hinge cup. The hinge body is comprised of three separate plates adjustably connected to each other with cam screws. The position of the hinge body with respect to the hinge arm is adjustable in three directions without the need for removal or loosening of mounting hardware used to attach the hinge body to a furniture piece.

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure relates to compact hinges for furniture products. In particular, the present disclosure relates to a compact hinge, adjustable in three directions, providing self-close and soft-close functionality. 
     BACKGROUND OF THE DISCLOSURE 
     In the field of cabinetry and mill work, a recurring problem is the uncontrolled speed at which a cabinet door closes. The typical hinged connection includes a hinge cup mounted to a furniture piece and pivotally connected to a hinge arm mounted to another furniture piece. A metal coil spring biases the metal hinge cup toward the metal hinge arm. Uncontrolled closure can result in damage to cabinetry doors create unwanted noise and premature wear of cabinet faces. 
     Prior art compact hinges have attempted to solve the uncontrolled closure problem unsatisfactorily with a generally combined damper and housing assembly removably fitted to the hinge cup. Such damper assemblies are prone to inadvertent or unwanted removal because they are designed to be removable. Furthermore, the damper assemblies are typically formed of plastic and so are not aesthetically pleasing. Still further, a damper assembly such as found in the prior art is bulky and requires delicate assembly which adds unnecessary expense to the manufacturing process. 
     Hence, there is a need for a damper for a compact hinge that is secured in the hinge cup permanently and yet is aesthetically pleasing, and easy and inexpensive to manufacture. 
     SUMMARY OF THE DISCLOSURE 
     A preferred embodiment is comprised of a hinge cup mounted in a cabinet door, a hinge body mounted to a cabinet carcass, and a hinge arm biased by a coil spring. The hinge arm connects the hinge cup to the hinge body and provides a swinging connection between the cabinet door and the cabinet carcass. A damper, comprised of a fluid filled cylinder and a piston rod extending from the cylinder, is permanently secured within the hinge cup by a metal damper cover. The damper cover is fixedly attached to the hinge cup. The damper is acted upon by an abutment section of the hinge arm. The piston rod abuts the hinge cup. The coil spring is looped around the exterior of the hinge cup while the ends abut and ride on cam surfaces on the hinge arm. The hinge body is comprised of an “L” shaped overlay plate adjustably engaged with an adjustment plate adjustably engaged with a mounting plate. Three separate cam screws provide positional adjustability of the hinge body with respect to the hinge arm in three different directions. The overlay plate and the adjustment plate each include access holes aligned with a mounting hole in the mounting plate. Mounting hardware, such as a wood screw, attaches the mounting plate to the cabinet carcass. 
     In use, the apparatus controls the closing speed of the cabinet door. The damper cover permanently attaches to the hinge cup and secures the cylinder within the hinge cup and adjacent the hinge arm. As the door closes, the abutment section of the hinge arm contacts the cylinder and forces the cylinder towards the back of the hinge cup, positioned and guided by the damper cover, against the bias of the piston moving through the fluid within the cylinder. Rotation of each of the cam screws separately adjusts the position of the cabinet door in a depth direction, a vertical direction, and a horizontal or “overlay” direction without removing the mounting hardware used to mount the hinge body to the cabinet carcass. 
     Those skilled in the art will appreciate the above-mentioned features and advantages of the disclosure together with other important aspects upon reading the detailed description that follows in conjunction with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an isometric view of a preferred embodiment. 
         FIG. 1B  is a partially exploded isometric view of a preferred embodiment. 
         FIG. 1C  is a partially exploded isometric view of a preferred embodiment. 
         FIG. 1D  is an exploded isometric view of a preferred embodiment. 
         FIG. 2  is an isometric view of an overlay plate of a preferred embodiment. 
         FIG. 3  is an isometric view of an adjustment plate of a preferred embodiment. 
         FIG. 4  is an isometric view of a mounting plate of a preferred embodiment. 
         FIG. 5A  is a sectional view of a hinge body of a preferred embodiment taken along line A-A of  FIG. 1A . 
         FIG. 5B  is a sectional view of a hinge body of a preferred embodiment taken along line B-B of  FIG. 1A . 
         FIG. 6  is an isometric view of a hinge arm of a preferred embodiment. 
         FIG. 7A  is an isometric view of a damper cover of a preferred embodiment. 
         FIG. 7B  is an isometric view of a damper cover of a preferred embodiment. 
         FIG. 8  is an isometric view of a damper of a preferred embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     In the description that follows, like parts are marked throughout the specification and figures with the same numerals, respectively. The figures are not necessarily drawn to scale and may be shown in exaggerated or generalized form in the interest of clarity and conciseness. 
     Referring to  FIGS. 1A-1D , hinge  100  provides a pivotal connection between cabinet door  116  and cabinet frame  118 . Hinge  100  includes hinge cup  102  pivotally connected to hinge arm  104  by hinge pin  106 . Hinge body  108  is adjustably connected to hinge arm  104  by overlay adjustment cam screw  110 . 
     Hinge cup  102  has a semicircular shaped brim  140  opposite ledge  142  encompassing an indention or cup defining interior  144 . Interior  144  includes at least two different horizontal surfaces, cup floor  146  and a pair of cup shelves  148  and  149 . Cup floor  146  forms the base of the cup shape and is positioned between side walls  150  and  151 . Side walls  150  and  151  are connected at one end by generally semicircular shaped rear wall  155 . Cup shelves  148  and  149  are disposed in side walls  150  and  151 , respectively and are positioned beside cup floor  146 . Tab  154  extends from each side wall  150  and  151  at cup shelves  148  and  149  into interior  144 . Each tab  154  is generally triangular shaped and biased in a downward orientation. Side walls  150  and  151  include spring holes  152  and  153  and hinge pin holes  156  and  157 . Tab  160  extends from rear wall  155  underneath ledge  142 . 
     Spring  112  creates a closing bias on the hinge arm. Spring  112  includes loop section  180  connected to coil sections  182  and  183 . Coil sections  182  and  183  lead to spring legs  184  and  185 , respectively. 
     Damper cover  170  is permanently connected to hinge cup  102  via engagement with tabs  154 . As will be discussed in detail below, damper cover  170  secures damper  162  within interior  144  and guides movement of damper  162  along axis of movement  158 . Damper  162  includes a fluid filled and spring loaded cylinder  164 . Piston rod  168  extends from cylinder  164 . Piston head  166  is attached to piston rod  168  within cylinder  164 . The hinge arm acts on damper  162  during a closing movement to control the closing speed of the cabinet door and provide the damping function as the piston head moves through the fluid contained with the cylinder. 
     Typically, hinge cup  102  is affixed to cabinet door  116  with screws through holes  103  and hinge body  108  is affixed to cabinet frame  118  through slot  109 . It should be noted that the orientation of the hinge cup fitted into a bore opening on a door and the hinge arm fitted on to the frame could be reversed. In a preferred embodiment, hinge cup  102 , hinge arm  104 , and hinge body  108  are typically constructed of metal such as cast aluminum or steel alloy plate stock and formed by stamping. 
     Hinge body  108  comprises overlay plate  124 , adjustment plate  126 , and mounting plate  128 . Overlay plate  124  is adjustably connected to adjustment plate  126  by depth adjustment cam screw  130 . Adjustment plate  126  is adjustably connected to mounting plate  128  by vertical adjustment cam screw  132 . Each adjustment cam screw  110 ,  130 , and  132  comprises a typical cam screw shape having a wider, cylindrical camming portion and a narrow, cylindrical offset portion extending therefrom. The separate plates of the hinge body cooperate with the adjustment cam screws to provide positional adjustment of the hinge body relative to the hinge arm in a vertical direction  172 , a depth direction  174 , and an overlay or horizontal direction  176 . 
     Referring to  FIG. 2 , overlay plate  124  is generally “L” shaped comprising section  212  generally perpendicularly oriented with section  214 . Section  212  is generally planar having end  219  extending between opposing sides  216  and  217 . Sides  216  and  217  include sections  226  and  227  extending therefrom. Sides  216  and  217  further include slots  232  which extend along each side and which encroach on sections  226  and  227 . Section  212  includes two horizontal planes with a sloping section between. Plane  224  leads to plane  228  along end  219  via slope  230 . Access opening  218  is irregularly shaped and is present in both planes  224  and  228 . Plane  228  includes depth adjustment slot  234 . Depth adjustment slot  234  is sized to receive the camming portion of depth adjustment cam screw  130 . Section  214  is generally planar and includes pocket  220 . Pocket  220  is sized to receive hinge arm  104 . Pocket  220  includes overlay adjustment slot  222 . Overlay adjustment slot  222  is sized to receive the camming portion of overlay adjustment cam screw  110 . 
     Referring to  FIG. 3 , adjustment plate  126  is generally planar having opposing ends  302  and  304  extending between opposing sides  306  and  308 . Side  306  includes block  310  proximate end  304 . Side  308  includes block  316  proximate end  304 . Side  308  further includes tabs  312  and  314  extending towards side  306 . Raised seat  322  extends from adjustment plate  126  proximate end  302 . Raised seat  322  includes depth adjustment hole  328  generally aligned with depth adjustment slot  234 . Depth adjustment hole  328  is sized to receive the offset portion of depth adjustment cam screw  130 . Adjustment plate  126  defines access slot  324 . Access slot  324  is aligned with a portion of access opening  218 . Adjustment plate  126  further defines vertical adjustment slot  326 . Vertical adjustment slot  326  is sized to receive the camming portion of vertical adjustment cam screw  132 . 
     Referring to  FIG. 4 , mounting plate  128  is generally planar having opposing ends  402  and  404  extending between opposing sides  406  and  408 . End  402  includes flange  410 . End  404  includes flange  412 . Guide  414  extends from mounting plate  128  proximate the corner of side  406  and end  402 . Guide  415  extends from mounting plate  128  proximate the corner of side  408  and end  402 . Guides  414  and  415  are generally equidistant from end  404 . Guide  416  extends from mounting plate  128  proximate the corner of side  406  and end  404 . Guide  417  extends from mounting plate  128  proximate the corner of side  408  and end  404 . Guides  416  and  417  are generally equidistant from end  402 . Mounting plate  128  defines access hole  420 . Access hole  420  is generally aligned with depth adjustment hole  328  to allow access to vertical adjustment screw  130  through mounting plate  128 . Mounting plate  128  further defines vertical adjustment hole  422 . Vertical adjustment hole is sized to receive the offset portion of vertical adjustment cam screw  132 . Mounting plate  128  also defines slot  109 . Slot  109  is generally aligned with access slot  324  and access hole  218  to allow access to mounting hardware (for attaching the mounting plate to the cabinet frame) through overlay plate  124  and adjustment plate  126 . 
     Referring to  FIGS. 5A and 5B , cross-sections of an assembled hinge body  108  are shown. Adjustment plate  126  is adjacent mounting plate  128 . Ends  302  and  304  of adjustment plate  126  abut flanges  410  and  412  of mounting plate  128 , respectively. Adjustment plate  126  is slidable with respect to mounting plate  128  in vertical direction  172 . 
     Plane  228  of overlay plate  124  is adjacent raised seat  322  of adjustment plate  126 . Sides  306  and  308  of adjustment plate  126  abut sides  216  and  217  of overlay plate  124 , respectively. Blocks  310  and  316  slidably engage slots  232  in sides  216  and  217 , respectively. Overlay plate  124  is slidable with respect to adjustment plate  126  in depth direction  174 . 
     Referring to  FIG. 6 , hinge arm  104  includes curved cam portions  602  and  603 . Cylindrical sleeve  604  extends between the cam portions. Sleeve  604  is sized to receive hinge pin  106 . Hinge pin  106  passes through hinge pin holes  156  and  157  in hinge cup  102  and sleeve  604  to provide a pivotal connection between hinge arm  104  and hinge cup  102 . Hinge arm  104  includes abutment section  606  extending from sleeve  604 . Attachment section  608  is connected to abutment section  606 . Attachment section  608  defines overlay adjustment hole  610 . Overlay adjustment hole  610  is aligned with overlay adjustment slot  222  and is sized to receive the offset portion of overlay adjustment cam screw  110 . Attachment section  608  is generally planar and sized to slidably engage pocket  220  of overlay plate  124 . Overlay plate  124  is slidable with respect to hinge arm  104  in overlay direction  176 . 
     Referring to  FIGS. 7A and 7B , damper cover  170  is shown. Damper cover  170  follows the general shape of the interior of hinge cup  102 . Damper cover  170  has a generally U-shaped cross-section defined by side walls  702  and  703  connected to base  708 . Rear wall  706  extends between side walls  702  and  703  and is connected to base  708  forming interior  704 . Opposite rear wall  706  is opening  710 . Damper cover  170  is typically stamped from 0.8 mm steel. 
     Side wall  702  is comprised of guide portion  730  and engagement portion  732 . Guide ridges  716  are formed in guide portion  730  of side wall  702  and extend toward interior  704 . Engagement portion  732  of side wall  702  includes a rectangular shaped cutout  720  sized to engage tab  154  formed in side wall  150 . Side wall  703  is comprised of guide portion  731  and engagement portion  733 . Guide ridges  717  are formed in guide portion  731  of side wall  703  and extend toward interior  704 . Engagement portion  733  of side wall  703  includes a rectangular shaped cutout  721  sized to engage tab  154  formed in side wall  151 . 
     Guide ridges  712  and  713  extend from base  708  toward interior  704 . Guide ridges  712  and  713  are positioned between guide portions  730  and  731 . Guide ridges  712  and  713  are aligned generally parallel to each other and perpendicularly with opening  710 . Hole  724  is a semicircular shaped opening in rear wall  706 . Hole  724  is sized to allow piston rod  168  to pass through unobstructed. 
     Referring to  FIG. 8 , damper  162  includes piston rod  168  slidable within and extending from cylinder  164 . The cross-section of cylinder  164  shows a generally semicircular shaped curved surface  802  positioned opposite a generally planar surface  804 . Connected between curved surface  802  and planar surface  804  are flanges  808  on one side of cylinder  164  and flanges  809  on the opposing side of cylinder  164 . In between curved surface  802  and planar surface  804  and disposed opposite of piston rod  168  is angled face  810 . An internal spring biases piston rod  168  out of cylinder  164  opposite angled face  810 . In a preferred embodiment, cylinder  164  is typically constructed of injection molded plastic or polyvinyl chloride (PVC). 
     Shown assembled in  FIG. 1A , damper  162  is secured into hinge cup  102  with damper cover  170 . Damper cover  170  is not removable from engagement with hinge cup  102  without damage to damper cover  170  or hinge cup  102 . Engagement portion  732  abuts cup shelf  148  while tab  154  in side wall  150  engages cutout  720 . Engagement portion  733  abuts cup shelf  149  while tab  154  in side wall  151  engages cutout  721 . Planar surface  804  of cylinder  164  rests on cup floor  146 . Piston rod  168  extends through hole  724  and abuts rear wall  155  of hinge cup  102 . Angled face  810  is positioned proximate hinge arm  104 . Spring  112  is positioned around the exterior of rear wall  155  such that loop section  180  rests on tab  160 . Coil sections  182  and  183  are positioned adjacent the exterior of both side walls  150  and  151 . Spring legs  184  and  185  extend from coil sections  182  and  183  into interior  144  through spring holes  152  and  153  and abut cam portions  602  and  603 . 
     As shown in  FIGS. 1B and 1C , guide ridges  712 ,  713 ,  716 , and  717  position and guide cylinder  164  such that linear movement of cylinder  164  follows axis  158 . Curved surface  802  of cylinder  164  abuts guide ridges  712  and  713  and flanges  808  and  809  abut guide ridges  716  and  717 , respectively. 
     In use, hinge  100  provides a pivotal connection between cabinet door  116  and cabinet frame  118 . Hinge cup  102  is mounted in a bore in the cabinet door through holes  103  and hinge body  108  is mounted to the cabinet frame through slot  109  with typical mounting hardware such as wood screws. Hand tools gain access to slot  109  via access opening  218  and access slot  324 . Guides  414 ,  415 ,  416 , and  417  abut the cabinet frame. 
     Hinge  100  provides adjustment in three directions after mounting without removing or loosening the mounting hardware. One direction of adjustment is the depth movement of the cabinet door. This adjustment is required when the inside face of the door does not lay flush with the cabinet frame thus impeding the opening and closing action. To effect the depth adjustment, depth adjustment cam screw  130  is rotated. As depth adjustment cam screw  130  is rotated, the camming portion of depth adjustment cam screw  130  abuts, rotates within, and slides along depth adjustment slot  234  while the offset portion of depth adjustment cam screw  130  rotates within depth adjustment hole  328 . During manufacture, the offset portion of depth adjustment cam screw  130  is inserted through access hole  420  and shot peened or deformed so as to prevent depth adjustment cam screw  130  from escaping depth adjustment hole  328 . Rotation of depth adjustment cam screw  130  causes hinge arm  104  and overlay plate  124  to move together in direction  174  relative to adjustment plate  126  and mounting plate  128  and the cabinet frame. Once the desired position is achieved, rotation of depth adjustment cam screw  130  is ceased. 
     Another direction of adjustment is the horizontal or “overlay” adjustment of the cabinet door. This adjustment is required when the vertical edges of the cabinet door do not align with the vertical edges of the cabinet frame or the vertical edges of an adjacent cabinet door or drawer. To effect the overlay adjustment, overlay adjustment cam screw  110  is rotated. As overlay adjustment cam screw  110  is rotated, the camming portion of overlay adjustment cam screw  110  abuts, rotates within, and slides along overlay adjustment slot  222  while the offset portion of overlay adjustment cam screw  110  rotates within overlay adjustment hole  610 . During manufacture, the offset portion of overlay adjustment cam screw  110  is inserted into overlay adjustment hole  610  and shot peened or deformed so as to prevent removal. Rotation of overlay adjustment cam screw  110  causes hinge arm  104  to move in direction  176  relative to hinge body  108  and the cabinet frame. Once the desired position is achieved, rotation of overlay adjustment cam screw  110  is ceased. 
     Another direction of adjustment is the vertical adjustment of the cabinet door. This adjustment is required when the horizontal edges of the cabinet door do not align with the horizontal edges of the cabinet frame or the horizontal edges of an adjacent cabinet door or drawer. To effect the vertical adjustment, vertical adjustment cam screw  132  is rotated. As vertical adjustment cam screw  132  is rotated, the camming portion of vertical adjustment cam screw  132  abuts, rotates within, and slides along vertical adjustment slot  326  while the offset portion of vertical adjustment cam screw  132  rotates within vertical adjustment hole  422 . During manufacture, the offset portion of vertical adjustment cam screw  132  is shot peened or deformed to prevent removal of vertical adjustment cam screw  132  from vertical adjustment hole  422 . Rotation of vertical adjustment cam screw  132  causes hinge arm  104 , overlay plate  124 , and adjustment plate  126  to move together in direction  172  relative to mounting plate  128  and the cabinet frame. Once the desired position is achieved, rotation of vertical adjustment cam screw  132  is ceased. 
     During a closing motion, spring  112  provides a closing bias. The closing bias provided by spring  112  is a result of spring legs  184  and  185  biasing hinge arm  104  via cam portions  602  and  603 . Damper  162  opposes the closing bias and mitigates the closing speed of the cabinet door so as to lessen the impact of the cabinet door on the cabinet frame. Damper  162  is secured within hinge cup  102  by damper cover  170 . As the cabinet door closes, abutment section  606  abuts face  810  and forces cylinder  164  towards rear wall  155  while piston rod  168  and damper cover  170  remain stationary relative to hinge cup  102 . Since piston rod  168  abuts rear wall  155 , as cylinder  164  moves through opening  710 , piston head  166  moves through the fluid in cylinder  164  to provide the soft-close functionality. The guide portion of damper cover  170  directs the cylinder  164  so that it may slide longitudinally along axis  158  between sides  702  and  703  guided by guide ridges  712 ,  713 ,  716 , and  717  through opening  710 . 
     It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this disclosure is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present disclosure as defined by the appended claims.