Patent Description:
Door closers of the type having an anchor assembly for fixing to a door frame and an actuator assembly intended for concealed fitting within the thickness of a door leaf are disclosed in our earlier patent, <CIT>, the content of which is hereby incorporated by reference.

<CIT> discloses a hinge for a door comprising a housing pivotally connected to a fixture by a coupling which includes a linkage and a shuttle located in a bore in the housing, with the shuttle being moveable between first and second positions, corresponding to open and closed positions of the hinge.

A problem with such door closers is that they are not suitable for use in conjunction with door hinges that are vertically adjustable when a door leaf is mounted on a door frame. Door hinges having vertical adjustment when in situ allow for the raising and lowering of a door leaf relative to a door frame, without having to remove the door leaf from the door frame. Attempting to raise or lower a door leaf relative to a door frame when the door system is fitted with a door closer described in <CIT> can cause various components of the door closer and/or door hinge to experience undesirable forces which can, in turn, reduce the lifespan of the door closer and/or door hinge. For example, referring to <FIG> of <CIT>, the linkages and parallel shafts of the door closer can become skewed out of the horizontal plane if the door leaf is raised or lowered relative to the door frame. Skewing the linkages and parallel shafts out of the horizontal plane can induce weaknesses in the door closer, in particular in the components of the operating assembly and/or damper mechanism. Such weaknesses can lead to premature failure of the door closer.

A further problem with such door closers is that they are not suitable for use with hinges that have a variable pivot axis.

A concealed hinge is one example of a hinge having a variable pivot axis. It is known that as the part of a concealed hinge that is connected to a door leaf pivots about the part that is connected to a door frame the axis about which the parts pivot moves in the horizontal plane. This is in contrast to a butt hinge, whereby as the part of the butt hinge that is connected to a door leaf pivots about the part that is connected to a door frame the axis about which the parts pivot remains fixed. Attempting to fit a door closer described in <CIT> to a door system that is fitted with a hinge having a variable pivot axis (such as a concealed hinge) can also cause various components of the door closer and/or door hinge to experience undesirable forces which can, in turn, reduce the lifespan of the door closer and/or door hinge. For example, referring to <FIG> of <CIT>, when fitted to a door system having a variable pivot axis hinge the linkages and parallel shafts can come into contact with the edge mounting member and/or outwardly extending flange parts as the door leaf is pivoted relative to the door frame. Such contact occurs because the pivot axis of the hinge moves in the horizontal plane as the door leaf is pivoted. It is to be appreciated that such contact can induce weaknesses in the door closer which can, in turn, lead to premature failure of the door closer.

There is a need, therefore, to provide door closers that have increased lifespans and/or are more versatile when compared to known door closers.

Embodiments of the invention provide door closers that seek to overcome, or at least substantially reduce, the disadvantages discussed above in relation to lifespan and/or versatility. For instance, embodiments of the invention provide door closers that can be used in door systems that are fitted with hinges having any one or more of the following features: vertical adjustability when in situ; no vertical adjustability when in situ; a variable pivot axis; and a fixed pivot axis.

The invention concerns a door closer according to claim <NUM>.

Thus, when the door closer is in situ, the adjustor plate is moveable relative to the frame mounting plate in either direction along the second axis (B-B), such that a door leaf to which the actuator assembly is mounted can be raised and lowered relative to a door frame to which the frame mounting plate is fixed. The door closer may include more than one link.

The or each link may have a length of less than approximately <NUM>, e.g. between approximately <NUM> and approximately <NUM>, e.g. between approximately <NUM> and approximately <NUM>, e.g. between approximately <NUM> and approximately <NUM>, e.g. approximately <NUM>.

The or each link may be in the form of a rod-like member.

The or each link may be pivotably connected to the adjustor plate.

The adjustor plate may include one or more transverse pin(s), e.g. to which the or each link may be pivotably connected.

The or each transverse pin may pass through a selected one of the slots of the frame mounting plate, such that the or each transverse pin extends through the thickness of the frame mounting plate.

The door closer may include one or more fasteners which pass through respective slots of the frame mounting plate and engage with respective apertures of the adjustor plate.

The or each fastener may include an adjusting screw, whereby the adjusting screw is rotatable in order to vary the distance between the frame mounting plate and the adjustor plate.

The door closer may include a door leaf mounting plate provided with one or more slot(s), wherein the or each slot is elongated along a third axis (C-C), the third axis (C-C) being generally orthogonal to the first axis (A-A) and generally orthogonal to the second axis (B-B).

The actuator assembly may include a damper mechanism operatively connected to the operating member so as to damp movement of the operating member at least as it is driven in a direction towards the fully retracted position.

The first part of the adjustor plate may include the aperture for receiving the adjustment member, and the second part of the adjustor plate may include the formation enabling adjustment of the door leaf relative to the door frame in a direction parallel to the second axis (B-B).

The formation enabling adjustment of the door leaf relative to the door frame in a direction parallel to the second axis (B-B) may include at least one elongate slot with which a fastener is engageable.

Embodiments of the various aspects of the invention will now be described by way of example only and with reference to the accompanying drawings, of which:.

With reference in particular to <FIG>, in some embodiments a door closer <NUM> may include an anchor assembly <NUM> which is, in use, mounted in or on an edge of a door frame facing an edge of a door leaf that is hinged to the door frame, and an actuator assembly <NUM> which is mounted, in use, within the thickness of the door leaf.

The anchor assembly <NUM> may include a frame mounting plate <NUM> which is fixable relative to the door frame, and an adjustor plate, indicated generally at <NUM>, which is located adjacent the frame mounting plate <NUM> on the side thereof remote from the door leaf.

The actuator assembly <NUM> is so dimensioned as to be suitable for fitting within the thickness of a door leaf and for this purpose is provided with a housing <NUM> and a door leaf mounting plate <NUM>. The door leaf mounting plate <NUM> is fixable relative to the door leaf so as to hold the housing <NUM> in place.

Within the housing <NUM> of the actuator assembly <NUM> there is provided an operating member which operates in a manner known in the art. In some embodiments, the operating member may include a pair of parallel shafts <NUM>. An example of such a shaft <NUM> is shown in <FIG>.

In some embodiments, the operating member may include one shaft <NUM>, or more than two (e.g. three, four, five, etc.) shafts <NUM>.

The operating member is coupled by a link <NUM> to the adjustor plate <NUM> and mounted for a range of movements between a fully retracted position, in which the anchor assembly <NUM> is held adjacent the actuator assembly <NUM> when the door leaf is in the closed configuration, and an extended position, in which the anchor assembly <NUM> is in spaced relation to the actuator assembly <NUM> when the door leaf is in the open configuration.

The link <NUM> extends along an axis A-A and the operating member moves in the housing <NUM> along the axis A-A as the door leaf is opened and closed. It is to be appreciated, therefore, that the direction of the axis A-A changes as the door leaf is pivoted; the direction of the axis A-A moves in a horizontal plane as the door leaf is opened and closed.

The operating member is biased inwardly of the housing <NUM> towards the retracted or "door closed" configuration, e.g. as described in <CIT>.

In some embodiments, the actuator assembly <NUM> may include a damper mechanism (not shown) to regulate the rate of closure of the door leaf relative to the door frame.

In some embodiments, for example in embodiments where the door closer <NUM> has vertical adjustability, the adjustor plate <NUM> may include a first part 12a (shown in <FIG>) and a second part 12b (shown in <FIG>). In some embodiments, for example in embodiments where the door closer <NUM> need not have vertical adjustability, the adjustor plate <NUM> may be formed as a single part or the adjustor plate <NUM>. In some embodiments (not shown) the adjustor plate <NUM> may include more than two separable parts.

With reference to <FIG>, the first part 12a of the adjustor plate <NUM> may include a first pair of facing edges 120a, 122a and a second pair of facing edges 124a, 126a, which connect the first pair of facing edges 120a, 122a to one another. The first pair of facing edges 120a, 122a may be longer than the second pair of facing edges 124a, 126a. When the door closer <NUM> is in situ, the first pair of facing edges 120a, 122a lies substantially in or parallel to an axis B-B which is at <NUM>° relative to the axis A-A. The first part 12a may also be provided with one or more aperture(s) 128a, 129a, e.g. one aperture 128a may be located adjacent each of the second pair of facing edges 124a, 126a. One or more of the aperture(s) 128a, 129a may be threaded.

With reference to <FIG>, the second part 12b of the adjustor plate <NUM> may include a first pair of facing edges 120b, 122b and a second pair of facing edges 124b, 126b, which connect the first pair of facing edges 120b, 122b to one another. The first pair of facing edges 120b, 122b may be longer than the second pair of facing edges 124b, 126b. In use, the second part 12b is orientated relative to the first part 12a such that the first pair of facing edges 120b, 122b lies substantially in or parallel to the axis B-B. The second part 12b may be provided with one or more aperture(s) 128b, which align with the aperture(s) 128a of the first part 12a. The second part 12b may be provided with aperture 129b, which may be threaded.

In some embodiments, the second part 12b may have formed therein one or more aperture(s) 121b, which may be threaded. The embodiment shown in <FIG> has four apertures 121b, although it is to be appreciated that other embodiments (not shown) may have fewer or more than four apertures 121b without departing from the scope of the invention.

Referring to <FIG>, in some embodiments the frame mounting plate <NUM> may include a first pair of facing edges <NUM>, <NUM> and a second pair of facing edges <NUM>, <NUM>, which connect the first pair of facing edges <NUM>, <NUM> to one another. The first pair of facing edges <NUM>, <NUM> may be longer than the second pair of facing edges <NUM>, <NUM>. In use, the frame mounting plate <NUM> is orientated relative to the adjustor plate <NUM> such that the first pair of facing edges <NUM>, <NUM> lies substantially in or parallel to the axis B-B.

In some embodiments, the frame mounting plate <NUM> may be provided with one or more slot(s) <NUM>, which align with the apertures 128a, 128b of the respective first and second parts 12a, 12b.

Referring to <FIG>, in some embodiments, the frame mounting plate <NUM> may be provided with apertures to receive fixing screws <NUM> for fixing the anchor assembly <NUM> to the frame. In some embodiments, the frame mounting plate <NUM> may be provided with apertures to receive fixing screws <NUM> for fixing a cover plate <NUM> thereto. The purpose of the cover plate <NUM> is primarily to improve the aesthetic appearance of the door closer <NUM>.

Referring back to <FIG>, in some embodiments, the frame mounting plate <NUM> may include one or more slot(s) <NUM> which, in use, align substantially with the aperture(s) 121b of the second part 12b. The frame mounting plate <NUM> may include a slot <NUM> which, in use, aligns with aperture 129b of the second part 12b.

In some embodiments, the slot(s) <NUM>, <NUM>, <NUM> may be elongated and extend in the direction of the axis B-B.

With reference to <FIG>, the door leaf mounting plate <NUM> may include a first pair of facing edges <NUM>, <NUM> and a second pair of facing edges <NUM>, <NUM>, which connect the first pair of facing edges <NUM>, <NUM> to one another. The first pair of facing edges <NUM>, <NUM> may be longer than the second pair of facing edges <NUM>, <NUM>.

Referring to <FIG>, in some embodiments, the door leaf mounting plate <NUM> may be provided with apertures to receive fixing screws <NUM> for fixing the housing <NUM> within the door leaf. When fixed to the door leaf the first pair of facing edges <NUM>, <NUM> of the door leaf mounting plate <NUM> lies substantially in or parallel to the axis B-B. In some embodiments, the door leaf mounting plate <NUM> may be provided with apertures to receive fixing screws <NUM> for fixing a cover plate <NUM> thereto. The purpose of the cover plate <NUM> is primarily to improve the aesthetic appearance of the door closer <NUM>.

Referring back to <FIG>, the door leaf mounting plate <NUM> may be provided with one or more slot(s) <NUM>, which, when the frame mounting plate <NUM> and the door leaf mounting plate <NUM> are fitted to the respective door frame and door leaf, align substantially with the slot(s) <NUM> of the frame mounting plate <NUM>. In some embodiments, the or each slot <NUM> may be elongated along an axis C-C, the axis C-C being at <NUM>° relative to the axis B-B. It is to be appreciated that the axis C-C is also at <NUM>° relative to the axis A-A. In other words, the or each slot <NUM> may extend between the facing edges <NUM>, <NUM> of the door leaf mounting plate <NUM>.

Referring to <FIG> there is shown a shaft <NUM> having a first end <NUM> and a second end <NUM>. In some embodiments, the shaft <NUM> may include a first linking member <NUM>, e.g. in the form of a drilled hole, at or adjacent the first end <NUM> thereof. The first linking member <NUM> is for connecting the shaft <NUM> to components of the operating member located within the housing <NUM>. In some embodiments, the shaft <NUM> may include a second linking member <NUM>, e.g. in the form of a drilled hole, at or adjacent the second end <NUM> thereof. The second linking member <NUM> is for pivotably connecting the shaft <NUM> to a link <NUM>.

Referring to <FIG>, there is shown a link <NUM> having a body <NUM> provided at each end with respective linking members <NUM>, <NUM>, e.g. in the form of drilled holes.

The link <NUM> may be in the form of a rod-like member (as shown in the figures).

In some embodiments, the link <NUM> may take other forms such as that of a plate-like member or a chain.

In some embodiments, there may be more than one link <NUM>. For instance, the embodiments shown in the figures have two links <NUM> but in other embodiments fewer (e.g. one) or more (e.g. three, four, five, etc.) links <NUM> may be provided.

In some embodiments, the or each link <NUM> may have a length of less than approximately <NUM>. For instance, the or each link <NUM> may have a length of approximately <NUM> ± <NUM>.

In some embodiments, the link <NUM> may have a length of approximately <NUM> or greater, e.g. <NUM> ± <NUM>.

The or each link <NUM> may be pivotably connected to the adjustor plate <NUM> through the slots <NUM> of the frame mounting plate <NUM>. In some embodiments, the adjustor plate <NUM> may include one or more transvers pin(s) <NUM>, to which the or each link <NUM> may be pivotably connected.

Referring to <FIG>, there is shown a transverse pin <NUM> having a body <NUM> provided at each end with respective linking members <NUM>, <NUM>, e.g. in the form of drilled holes.

Referring to <FIG>, each shaft <NUM> (not visible since they are accommodated within the housing <NUM>) is pivotably connected to one end <NUM> of a respective link <NUM>, e.g. by a pin, so that each shaft <NUM> can pivot relative to its respective link <NUM>. The end <NUM> of each link <NUM> is connected to the adjustor plate <NUM>. In some embodiments, the end <NUM> of each link <NUM> may be connected to the adjustor plate <NUM> by the respective transverse pin <NUM>.

In some embodiments, the or each transverse pin <NUM> may be fixed to the first part 12a of the adjustor plate <NUM> and pass through apertures 128b and slots <NUM> of the respective second part 12b and frame mounting plate <NUM>, such that the or each transverse pin <NUM> extends through the thickness of the second part 12b and frame mounting plate <NUM>.

In some embodiments, the or each transverse pin <NUM> may be formed integrally with the first part 12a and/or the second part 12b.

In some embodiments, an adjustment member, for example an adjusting screw <NUM> extends through the aperture 129b of the second part 12b and is engaged in the aperture 129a of the first part 12a of the adjustor plate <NUM>. It is to be appreciated that the adjusting screw <NUM> passes through the slot <NUM> of the frame mounting plate <NUM>. Rotation of the adjusting screw <NUM> varies the distance between the frame mounting plate <NUM> and the adjustor plate <NUM> in a manner known in the art.

In some embodiments, fasteners <NUM> may be provided which engage with the respective apertures 121b of the second part 12b. It is to be appreciated that the fasteners <NUM> pass through the slots <NUM> of the frame mounting plate <NUM>.

Advantageously, in some embodiments the door closer <NUM> is such that a door leaf to which the actuator assembly <NUM> is mounted can be raised and lowered relative to a door frame to which the frame mounting plate <NUM> is fixed when the door leaf is hinged to the door frame.

Referring to <FIG>, it will now be explained how a door leaf may be raised or lowered whilst being hinged to a door frame and fitted with a door closer <NUM> according to an embodiment of the invention. In this situation the hinge(s) connecting the door leaf and door frame must be vertically adjustable when in situ, but may have a variable pivot axis (e.g. a concealed hinge) or a fixed pivot axis (e.g. a butt hinge).

<FIG> shows a door closer <NUM> in a first configuration which corresponds to a door leaf to which the actuator assembly <NUM> is mounted being set at its maximum raised position relative to a door frame to which the frame mounting plate <NUM> is fixed. <FIG> shows the door closer <NUM> in a second configuration which corresponds to the door leaf being set at its maximum lowered position relative to the door frame.

To move between the first and second configurations the fasteners <NUM> are loosened, so that the adjustor plate <NUM> can be moved relative to the frame mounting plate <NUM> along the axis B-B. This means that the actuator assembly <NUM> (and door leaf to which it is mounted) can be moved along the axis B-B relative to the frame mounting plate <NUM> (and door frame to which it is fixed).

The fact that the slots <NUM>, <NUM>, <NUM> are elongated along the axis B-B means that the adjustor plate <NUM> and the parts coupled thereto (such as links <NUM> and actuator assembly <NUM>) can be moved without hindrance in either direction along the axis B-B.

An advantage of this aspect of the invention is that the links <NUM> and shafts <NUM> do not become skewed out of the horizontal plane as the door leaf is raised or lowered relative to the door frame. Instead, as can be seen from <FIG>, the links <NUM> (and hence respective shafts <NUM>) remain in the horizontal plane when the actuator assembly <NUM> is set at its maximum raised position (<FIG>) and maximum lowered position (<FIG>) relative to the frame mounting plate <NUM>, or any position in between the maximum raised and maximum lowered positions. Consequently, door closers <NUM> according to this aspect of the invention can be used with door systems fitted with hinges that are vertically adjustable when the door leaf and door frame are fixed to one another. The provision of the slots <NUM>, <NUM>, <NUM> means that the adjustor plate <NUM> (and hence actuator assembly <NUM> to which it is connected) can be moved relative to the frame mounting plate <NUM> which, in turn, can prolong the lifespan of the door closer <NUM> and also the hinges themselves.

The provision of the slot <NUM>, in particular, has the further advantage that, if desired, it is possible to retain the feature of the adjusting screw <NUM> for varying the distance between the frame mounting plate <NUM> and the adjustor plate <NUM>. It is to be appreciated that without the slot <NUM> it would not be possible to move the adjustor plate <NUM> along the axis B-B relative to the frame mounting plate <NUM> and have the ability to vary the distance between the frame mounting plate <NUM> and adjustor plate <NUM>. It is also to be appreciated that in order for the door closer <NUM> to exhibit adjustability along the axis B-B and the ability to vary the distance between the frame mounting plate <NUM> and adjustor plate <NUM> the adjustor plate <NUM> must be formed into at least two separate parts 12a, 12b. The adjusting screw <NUM> is engaged with the first part 12a to permit variation in the distance between the frame mounting plate <NUM> and adjustor plate <NUM> and the fasteners <NUM> are engaged with the second part 12b to permit adjustability along or parallel to the axis B-B. This is adjustability enables the door leaf to be adjusted relative to the door frame vertically, i.e. in a direction parallel to the second axis (B-B).

The applicant has surprisingly found that by ensuring that the length of the or each link <NUM> is less than approximately <NUM> (e.g. approximately <NUM> ± <NUM>) the life of the door closer <NUM> and/or the door hinges can be prolonged. This is due to the fact that the pivoting connection between the or each link <NUM> and its respective shaft <NUM> exits the housing <NUM> via respective slots <NUM> in the door leaf mounting plate <NUM> as the door leaf pivots about the door frame towards its open configuration but before the pivot axis of the variable pivot axis hinge starts to move in the horizontal plane. Consequently, neither the link <NUM> nor its respective shaft <NUM> come into contact with the door leaf mounting plate <NUM> when the door closer <NUM> according to this aspect of the invention is fitted to a door system having a variable pivot axis hinge. In this situation the hinge(s) connecting the door leaf and door frame may or may not be vertically adjustable when in situ.

A further beneficial feature of the invention is the fact that the slots <NUM> extend along the axis C-C. Since the axis C-C is at <NUM>° relative to the axis A-A there is an additional effect that neither the link <NUM> nor its respective shaft <NUM> come into contact with the door leaf mounting plate <NUM> as the door leaf pivots about the door frame towards its open configuration. Consequently, the life of the door closer <NUM> may be further prolonged.

It is to be appreciated that whilst the figures show embodiments in which the adjustor plate <NUM> includes separate first and second parts 12a, 12b, in some embodiments (for example embodiments where vertical adjustability is not essential) either one of the first and second parts 12a, 12b may be omitted. Therefore, features described in relation to the first part 12a may be provided on the second part 12b, and vice versa.

Claim 1:
A door closer (<NUM>), including:
an anchor assembly (<NUM>), including:
a frame mounting plate (<NUM>) which is fixable relative to a door frame; and
an adjustor plate (<NUM>); and
an actuator assembly (<NUM>) for mounting within the thickness of a door leaf to move the door leaf between open and closed configurations relative to the door frame, the actuator assembly (<NUM>) including an operating member coupled by a link (<NUM>) to the adjustor plate (<NUM>) and mounted for a range of movements between a fully retracted position, in which the anchor assembly (<NUM>) is held adjacent the actuator assembly (<NUM>) when the door leaf is in the closed configuration, and an extended position, in which the anchor assembly (<NUM>) is in spaced relation to the actuator assembly (<NUM>) when the door leaf is in the open configuration, the link (<NUM>) being configured to extend from the adjustor plate (<NUM>) along a first axis, the frame mounting plate (<NUM>) is provided with one or more slot(s) (<NUM>, <NUM>, <NUM>), the or each slot (<NUM>, <NUM>, <NUM>) being elongated in a vertical direction along a second axis (B-B), the second axis being generally orthogonal to the first axis, wherein the adjustor plate (<NUM>) includes a first part (12a) and a second part (12b), the first part (12a) being attachable to a door frame and the second part (12b) being attachable to the frame mounting plate (<NUM>), one of the first part (12a) and the second part (12b) including an aperture (129a, 129b) for receiving an adjustment member which enables the distance between the frame mounting plate (<NUM>) and the adjustor plate (<NUM>) to be varied, and one of the first (12a) and the second part (12b) including a formation which enables adjustment of the position of the door leaf relative to the door frame in a direction parallel to the second axis (B-B).