IL162974A - Door hinge system - Google Patents

Description

Tbli o>i3 M tt DOOR HINGES SYSTEM 162974/1 121-02AP.DOC 1.4.2005 DOOR HINGES SYSTEM FIELD OF THE INVENTION The present invention relates to door hinges, in general and, in particular, to door hinges for steel doors, which provide increased ease of hanging the door on a door frame, and increased security.

BACKGROUND OF THE INVENTION At present, door hinges are mounted outside of the door and outside of the door frame on which the door is hung. Steel doors at the entrance to houses, for example, are built this way. This is a distinct disadvantage from a security point of view, as it is relatively easy to break or remove the hinge in order to enter the house or business. In addition, an external hinge cannot support a very heavy weight successfully.

Another disadvantage of conventional hinges is the difficulty of hanging the door on the hinge and onto the door frame. Particularly when dealing with a heavy door, such as a steel door, it is difficult to maneuver the door so as to bring it to the precise location required to hang the door on the door frame.

Yet another problem with conventional hinges is the difficulty of adjusting the position of the door relative to the floor and to the frame, so as to fit into the frame and permit good sealing. The door and the frame are manufactured separately. After the frame is mounted in the wall, it is often difficult to arrange the door so as to fit properly in the frame. In order to adjust the position of the door relative to the frame, the door must be hung, examined, removed from the frame, the hinge must be adjusted, as by screwing further into or out of the frame, and the door re-hung and reexamined. This is a time consuming and tedious procedure, particularly with a heavy steel door.

Accordingly, there is a long felt need for an arrangement whereby doors, particularly heavy doors, can easily be hung and adjusted on a door frame, and it 162974/2 would be very desirable if such an arrangement could provide increased security to reduce the ease of breaking in through the door.

SUMMARY OF THE INVENTION The present invention relates to door hinge assemblies, particularly suitable for heavy steel doors, which permit rapid and easy adjustment of the position of the door relative to the frame. Some embodiments of the invention also provide easy and rapid hanging of the door on the frame. All these advantages are provided by the use of a novel pivot element in the hinge, which is adapted and configured to permit movement of the door relative to the frame while the door is hung on the hinge on the frame. According to one embodiment, he hinge assembly is adapted and configured to seat partially inside the door frame.

There is thus provided, according to one embodiment of the present invention, a pivot element affixable to a door, for use in a hinge assembly for mounting the door on a door frame, the hinge assembly including two pin holding arms mounted on the door frame and a hinge pin for mounting therebetween. The pivot element includes a first bore, preferably a cylindrical bore, for receiving a screw for coupling to the door, and a second cylindrical bore for receiving the hinge pin therethrough, the pivot element being adapted and configured for coupling to the hinge assembly with the second cylindrical bore disposed between the pin holding arms, wherein the longitudinal axis of the second cylindrical bore is perpendicular to the longitudinal axis of the first cylindrical bore, and the second cylindrical bore is spaced apart from the first cylindrical bore. In particular, the pivot element is adapted and configured for adjusting, while the door affixed to the hinge assembly is mounted on the door frame, a position of the door relative to the door frame.

There is also provided, according to another embodiment of the present invention, a hinge assembly for mounting a door on a door frame, the hinge assembly including the pivot element described above. According to one embodiment of the invention, the hinge assembly further includes two pin holding arms mounted on the 162974/3 door frame and a hinge pin, arranged to seat in the second cylindrical bore and the pin holding arms. The pivot element is adapted and configured for adjusting, while the door is hung on the hinge on the door frame, at least one of: the angle of the door relative to the door frame; the distance of the door from the door frame; and the height of the door relative to the door frame. This characteristic of the hinge assembly permits easy and efficient adjustment of the position of the door in two or three directions, and permits more efficient sealing between the door and the frame.

According to an alternative embodiment of the invention, the hinge assembly also includes a frame unit adapted for mounting inside the door frame, the frame unit defining two pin holding arms protruding through the door frame; and a quick connect door element defining pin receiving arms adapted and configured to seat between, and in registration with, the pin holding arms. A hinge pin is arranged to seat in the second cylindrical bore and the pin holding arms and permits rotation of the door from an open orientation to a closed orientation. The frame unit further includes at least one quick connect frame element and the quick connect door element further includes at least one engaging element adapted and configured to engage the connection element when the door having the pivot element is mounted on the door frame.

According to this embodiment, the hinge assembly is mounted largely inside the door and inside the frame, and only a small portion is exposed outside the door and frame. This provides an extremely secure structure, as it is very difficult to take apart or remove the hinge from the door so as to break into the house or business. Furthermore, in certain embodiments, parts of the hinge are reinforced, so the hinge assembly can hold a heavier weight without breaking.

In addition, this embodiment permits rapid and easy hanging of the door on the frame by means of the quick connect elements mounted on the door and on the frame. This is a major advantage when working with heavy steel doors, which are difficult to maneuver. In addition, once hung on the frame, the position of the door relative to the frame can be quickly and easily adjusted. 162974/2 BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be further understood and appreciated, and additional advantages will be understood, from the following detailed description taken in conjunction with the drawings in which: Figure 1 is an isometric view of a door arranged to be mounted on a door frame, showing portions of two hinge assemblies according to one embodiment of the invention, for permitting quick connection of the door to the door frame; Figure 2 is a schematic illustration of a door hung on a door frame and illustrating the directions of adjustment made possible by the invention; Figure 3 is a partially cut-away schematic illustration of a door mounted on a door frame, shown in an open orientation, by means of hinge assembly according to one embodiment of the invention; Figure 4 is a schematic illustration of the door and door frame of Figure 3 shown from inside the door frame in a closed orientation; Figure 5 is an exploded view of the hinge assembly assembly of Figure 3; Figure 6 is a schematic illustration of the hinge assembly of Figure 5, showing adjustment of the door along the Z axis; Figures 7a and 7b are isometric illustrations of the pivot element of the hinge assembly of Figure 5, showing adjustment of the door along the Y axis; Figures 8a and 8b are respective side and detail illustrations of the pivot element of Figure 7a, illustrating adjustment of the door along the Y axis; Figure 9 is a schematic illustration of the hinge assembly of Figure 5, viewed from the side of the door; Figure 10 is a plan view of a hinge assembly constructed and operative in accordance with another embodiment of the present invention in an open orientation; Figure 11 is a rear view of the hinge assembly of Figure 10; Figure 12 is an exploded view of the hinge assembly of Figure 10 in use; Figures 13A and 13B are top views of the hinge assembly of Figure 10 during leveling adjustment of a door; and 162974/2 Figure 14 is a top view of the hinge assembly of Figure 10 during adjustment of a door relative to the frame; Figure 15 is an exploded view of a hinge assembly constructed and operative in accordance with a further embodiment of the present invention; Figure 16 is a perspective view of the hinge assembly of Figure 16 as assembled for use; Figure 17 is an exploded view of a hinge assembly constructed and operative in accordance with yet another embodiment of the present invention; and Figure 18 is a perspective view of the hinge assembly of Figure 17 as assembled for use. 162974/4 DETAILED DESCRIPTION OF THE INVENTION The present invention relates to hinge assemblies including a novel pivot element, which permits accurate adjustment of the position of a door relative to the door frame in two or three directions, while the door is hung on the hinge on the frame. The novel pivot element also permits the design of hinge assemblies having a quick connect mechanism, for rapid and easy hanging of the door on the frame.

The invention will now be described by way of example, only, with relation to the Figures. Referring to Figure 1, there is shown an isometric view of a door to be mounted on a door frame, showing portions of two hinge assemblies 10, according to one embodiment of the present invention, mounted in a door 11 for quick connection of the door to a door frame 12 mounted in a wall 13.

A quick connect door element 31, forming part of a door unit of each hinge assembly, is mounted in the door 11. A quick connect frame element 41, here illustrated as a fixed pin, is mounted in, or is an integral part of a frame unit mounted in the door frame 12. As can be seen in Figure 1, door frame 12 includes a cavity 9 in which the quick connect frame element 41 is mounted.

Quick connect door element 31 includes grooves 312 which are complementary to quick connect frame elements 41 mounted in the frame, for rapid hanging of the door. This is accomplished by bringing the door close to the frame in a position such that quick connect frame elements 41 easily enter the complementary grooves 312. Quick connect frame element 41 can have any desired cross section, such as round, square, hexagonal, or any other suitable shape.

The hinge assembly of the present invention may be formed of steel, aluminum, plastic, or other materials. It will be appreciated that for a heavy door, a steel hinge assembly is preferred.

Figure 2 is a schematic illustration of a door 11 with two hinge assemblies 10 according to the present invention as mounted on a door frame in a wall 13. It is a particular feature of the present invention that the hinge assemblies of the invention 162974/4 make it possible to adjust the position of the door 11 relative to the frame and the wall 13, in three directions, while the door is hung on the frame, which is not possible with conventional hinge assemblies. First, the distance between the door and the wall can be adjusted by moving the door in the direction of arrow 14 relative to the wall (in the X axis). Second, the position of the door can be adjusted by moving the door slightly from side to side, as illustrated by arrow 16 (in the Y axis). Third, the height of the door above the floor can be adjusted, as indicated by arrow 15 (the Z axis). A combination of adjusting of two hinge assemblies in the direction of arrow 16 creates rotation of the door relative to the frame, as shown by arrow 17, and the combination of adjusting of two hinge assemblies in the direction of arrow 14 creates rotation of the door about the Y axis. In this fashion, the door can be adjusted in any desired plane relative to the door frame.

Referring now to Figures 3 and 4, there are shown partially cut-away schematic illustrations of a door mounted on a door frame by means of hinge assembly 2 according to one embodiment of the invention, shown in respective open and closed orientations as shown from inside the door frame 12 and inside the door 11, respectively. A sealing element 118, such as a rubber seal, is preferably provided between the door and the frame.

The hinge assembly 2 includes a door unit 3 and a substantially C-shaped frame unit 4 and is adapted for quick connect hanging of the door on the frame. The structure of these units is seen most clearly in the exploded view of Figure 5. The door unit 3 includes a pivot element 6, configured for attachment to a plate 29 mounted within the door 11, and a quick connect door element 31 . One side of pivot element 6 defines a first portion 34, having a hinge pin receiving bore 342, which is arranged to sit between two pin holding arms 42 on the C-shaped frame unit 4. The other side of pivot element 6 includes a second portion 33 having a threaded bore 332. A screw 35 is seated in threaded bore 332 and protrudes therefrom and through plate 29 in door 11. As can be seen from Figure 5, the longitudinal axis of the threaded bore 332 is perpendicular to the longitudinal axis of the hinge pin receiving 162974/4 bore 342, and the threaded bore 332 is spaced apart from the hinge pin receiving bore 342.

In this embodiment, pivot element 6 is formed of two separate parts, adapted and configured to slide relative to one another. One part includes hinge pin receiving bore 342 and the second part includes the threaded bore 332. An adjustment screw 36 causes movement of first portion 34 a desired distance relative to second portion 33 in the cylindrical of each hinge, as shown by arrow 16 in Figure 2, so as to permit adjustment of the angle of the door relative to the door frame, as shown by arrow 17. Plate 29 defines an elongate aperture 22. A rectangular nut 30 is slidably mounted in plate 29 and engages screw 35. Nut 30 can slide along plate 29 the length of aperture 22, perpendicular to the plane of the door, as long as screw 35 is not tightened. In this way, it is possible to adjust the distance of the door from the door frame or wall, in the direction of arrow 14 (the X axis) in Figure 2. Once this distance has been selected, the screw 35 is tightened in nut 30 to prevent further movement of the door in this direction. Alternatively, a coupling element other than a screw may be provided in threaded bore 332 for coupling to a locking element inside plate 29. In this case, threaded bore 332 need not necessarily be cylindrical.

In this embodiment, door unit 3 includes a substantially C-shaped quick connect door element 31, adapted and configured to fit inside frame unit 4, and which also serves as a reinforcing element. Quick connect door element 31 includes two pin receiving arms 314 adapted to seat between pin holding arms 42 and hold the hinge pin 30 of the door, and at least one engaging element, here shown as two engaging grooves 312. Engaging grooves 312 are adapted and configured to engage a quick connect frame element 41, here a fixed pin, when the door is mounted on the door frame. Preferably, quick connect door element 31 also includes a locking aperture 315 adapted to receive a locking screw 37, as described below.

Door unit 3 is assembled by aligning hinge pin receiving bore 342 between pin receiving bores 313, and sliding hinge pin 32 through bores 342 and 313. According to one embodiment of the invention, hinge pin 32 includes a narrower region 323 162974/4 which is adapted and configured to seat inside pin receiving bore 313, supported on the pin receiving arm 314 of quick connect door element 31. The body 324 of the pin has external threads complementary to the internal threads in hinge pin receiving bore 342. Preferably, the head 321 of hinge pin 32 is shaped to receive an Allen wrench for rotation of the hinge pin.

Frame unit 4 is mounted in a cavity 9 in the door frame 12. Frame unit 4 includes two hinge pin holding arms 42, each having a pin holding bore 421. Hinge pin holding arms 42 are adapted to hold hinge pin 32, about which the door pivots from an open to a closed orientation. As stated above, frame unit 4 also includes quick connect frame element 41, here a fixed pin adapted and configured for engagement by engaging grooves 312. Lugs 43 may also be provided for affixing the frame unit to the frame, as by bolts or rivets. Alternatively, frame unit 4 may be welded to the door frame, or the door frame may be manufactured with a built-in frame unit 4.

In operation, frame unit 4 is mounted inside cavity 9 in the door frame 12 and affixed therein, as by means of lugs 43. The door unit 3 is assembled, by coupling first portion 34 to second portion 33 so as to assemble pivot element 6, seating pivot element 6 in quick connect door element 31, and inserting hinge pin 30 through pin receiving bore 342. Door unit 3 is affixed to the door by inserting screw 35 through the door and through rectangular nut 30 in plate 29 inside the door. The door can now be hung on the door frame by sliding engaging grooves 312 about quick connect frame elements 41, so the quick connect door element engages the quick connect frame element. The door and frame units may now be affixed to one another, as by locking screw 37 through locking aperture 315.

In this position, quick connect door element 31 sits inside frame unit 4. As can be seen in Figure 4, only a small portion of the hinge assembly 2 protrudes from the door 11 and the door frame 12. This arrangement, together with the double layer of metal provided by quick connect door element 31 and frame unit 4, makes cutting off 162974/4 the hinge to remove the door extremely difficult, if not impossible, particularly if the hinge assembly is made of steel.

The position of the door 11 relative to door frame 12 can now be adjusted, while the door is hanging on the door frame. Rotation of hinge pin 32 within hinge pin receiving bore 342 causes raising or lowering of the door relative to the door frame (indicated as the Z axis 15 in Figure 2). If desired, a locking screw (not shown) may be added to hinge pin 30 to lock the door in the desired orientation and prevent inadvertent release of hinge pin 32 and movement of the door in the Z axis. Preferably, this adjustment is carried out on all hinges on the door to substantially the same degree. The distance of the door from the frame (reference 14 in Figure 2) is adjusted by sliding screw 35 along elongate aperture 22 in door plate 29 until the door seals against the door frame at the desired position. The angle of the door in the Y axis (references 16 and 17 in Figure 2) is adjusted by separately adjusting the location of first portion 34 of the pivot element relative to the second portion 33 in each hinge assembly, by rotating the adjustment screw 36.

Figures 7a and 7b are isometric illustrations of the pivot element 6 of the hinge assembly of Figure 5, illustrating the elements which permit adjustment of the door along the Y axis. In the illustrated embodiment, first portion 34 and second portion 33 move relative to one another along a track 331 between them. Adjustment screw 36 is used to move second portion 33 towards or away from the door.

Figures 8a and 8b are respective side and detail illustrations of the pivot element 6 of Figure 7a, also illustrating the elements which permit adjustment of the door along the Y axis. In Figure 8b, one embodiment of an adjustment screw 36 is shown in detail. In this embodiment, adjustment screw 36 includes a threaded portion 361 arrange for screwing into a threaded aperture 364 in first portion 34, a disc 362 affixed to second portion 33, and a head of adjustment screw 363 adapted to receive an Allen wrench.

It will be appreciated that, unlike prior art methods of adjusting the door position which require the door to be removed and re-hung each time an adjustment 162974/3 is made, the present invention permits adjustment of the location of the door relative to the frame in three dimensions while the door is hanging on the frame.

Figures 6 and 9 are schematic illustrations of an alternative embodiment of the hinge assembly of the present invention, shown respectively from the frame side and from the door side. In this embodiment, the pivot element is formed as a single unit, and a threaded bushing 61 is rotatably mounted in threaded bore 332. Screw 35 is freely mounted in threaded bushing 61. Rotation of threaded bushing 61, by means of a suitable wrench, causes the portion of the door at that hinge assembly to move in the Y axis relative to the frame. As can be seen, the longitudinal axis of the threaded bore 332 is perpendicular to the longitudinal axis of the hinge pin receiving bore 342, and the threaded bore 332 is spaced apart from the first bore.

Also illustrated is adjustment of the height of the door (in the Z axis), by means of an Allen wrench 5 in adjustment aperture 320. Hinge pin receiving bore 342 of the pivot element in the door unit is slightly shorter than the distance between the pin receiving arms of quick connect door element 31. Rotation of hinge pin 32 causes the pivot element, and the door attached thereto, to move up or down in spaces 52 relative to the pin holding arms 42 of the frame unit 4. Spaces 52 may be relatively small, for example between about 0.1mm and about 10 mm, or of any other desired size.

It will be appreciated that the novel adjustment mechanism of the present invention, which permits adjustment of the door relative to the door frame while the door is hanging on the frame, can also be utilized with hinges of other designs. In particular, the pin holding arms need not be inside the door or door frame, but can be external. In addition, hinges without a quick connect mechanism can also be produced using this adjustment mechanism.

One example of an alternative embodiment of the present invention is shown in Figures 10, 11 and 12, which are respective plan, rear and exploded views of a hinge assembly 100 in an open orientation. Hinge assembly 100 includes a threaded hinge pin 102 mounted on a door frame 104 between two pin retaining elements 106, 162974/3 108. Pin retaining elements 106 and 108 are affixed to a door frame plate 110 disposed inside door frame 104, for example, by nuts 112, and are disposed outside the frame. Pin retaining elements 106 and 108 define threaded bores in which the threaded hinge pin 102 is screwed by means of complementary screw threads along its length (not shown).

Hinge assembly 100 also includes a pivot element 120 configured for attachment to a plate 122 mounted within a door 114. Door 114 preferably includes a sealing portion 116 adapted and configured to receive a rubber seal (not shown) for sealing against the door frame. One side of pivot element 120 defines a first bore, a hinge pin receiving bore 124 which is a threaded pin receiving bore, arranged to sit between pin retaining arms 106 and 108 for rotation about threaded hinge pin 102 during opening and closing of the door.

The other side of pivot element 120 includes a second bore 126, in this embodiment a cylindrical threaded bore, seen most clearly in Figure 11. The second bore is formed 126 such that its longitudinal axis is at an angle of 90° to the longitudinal axis of first cylindrical bore 124. A hollow bushing 128, having external screw threads, is mounted in threaded bore 126. An inner screw 130 seats freely in hollow bushing 128 and protrudes therefrom so as to pass through plate 122.

Plate 122 defines a substantially U-shaped recess 132, with an elongate aperture 134. A rectangular nut 136 having a threaded aperture 138 is slidably mounted in recess 132 of plate 122 and threadedly engages inner screw 130.

Operation of this embodiment of the invention is as follows. Pivot element 120, with hollow bushing 128 and inner screw 130 therein, is seated between pin retaining elements 106 and 108 and the hinge pin 102 is screwed between them. The hinge assembly is affixed to door frame plate 110 which is inside the door frame 104. Door frame 104 may include a cut-away portion 105 into which pivot element 120 turns when the door is closed. The door 114 is hung on pivot element 120, with inner screw 130 protruding through door 114 into bore 138 in nut 136 and through elongate aperture 134 of plate 122 in the door. Thus, this hinge assembly has no quick connect 162974/2 mechanism. The door is now adjusted in substantially the same manner as that described above with relation to Figures 1 to 9.

First, the height of the door relative to the frame (or the floor) is adjusted by rotating threaded hinge pin 102. Rotation of threaded hinge pin 102, as by means of an Allen wrench, serves to raise or lower pivot element 120 relative to each of pin retaining elements 106 and 108. Each hinge assembly 100 on the door may be adjusted to about the same degree.

Once the height is fixed, without removing the door from the door frame, the door is leveled relative to the floor (i.e., rotated in a vertical plane). This is accomplished using the hollow bushing 128, as illustrated in Figures 13 A and 13B, which are top views of the hinge assembly of Figure 10 during leveling adjustment of a door. As can be seen, rotation of hollow bushing 128, by means of an appropriate wrench, causes bushing 128 to protrude more or less from second bore 126 in pivot element 120. This, in turn, causes a change in the size of the gap 140 between the sealing portion 116 of the door and the pivot element 120 (see 140 and 140' on Figures 13A and 13B, respectively.) In order to ensure that the door is substantially horizontal, each of the hinge assemblies 100 on the door may be adjusted to a different degree, thereby pivoting the door relative to the door frame in a vertical plane, for example, the upper hinge closer to the frame while the lower hinge is farther from the frame, or vice versa.

Finally, the position of the door 114 is adjusted relative to the door frame 104, as shown in Figure 14. This is accomplished when the door is in the closed orientation. As can be seen in Figure 14, a door/frame gap 142 in the vertical plane remains between the door 114 and the door frame 104. Inner screw 130 is loosened inside rectangular nut 136, and the door is pushed towards the frame, in the direction of arrow 144, until substantially no gap remains between the sealing portion 116 of the door and the door frame 104. It will be appreciated that pushing the door in the direction of arrow 144 causes inner screw 130 to slide along elongate aperture 134 in the U-shaped portion 132 of plate 122. When the door reaches the desired position, 162974/2 inner screw 130 is tightened against rectangular nut 136, thereby preventing inadvertent motion of the door relative to the door frame in an open orientation.

Referring now to Figure 15, there is shown an exploded view of a hinge assembly 150 constructed and operative in accordance with a further embodiment of the present invention. Hinge assembly 150 includes a frame unit 152 and a mating door unit 170. Hinge assembly 150 is constructed and adapted to provide both a quick connection for rapid and easy mounting of a door onto a door frame, and increased security against break- ins. This is accomplished by mounting a substantial portion of hinge assembly 150 inside the door frame, where there is no access from the outside, and by providing a locking mechanism which holds the door to part of the hinge assembly inside the frame, even if the hinge pin is removed.

Frame unit 152 is substantially C-shaped and includes a central portion 154 integrally formed with two mounting members 156. Preferably central portion 154 is substantially planar. Frame unit 152 is designed to seat inside the door frame, and mounting members 156 are configured and adapted to be affixed to the frame, as by bolts. A threaded bore 158 is preferably provided in central portion 154 to receive a retaining screw (not shown). Frame unit 152 further includes two pin holding arms 160, 162 at each end of central portion 154 for holding the hinge pin of the door, described in detail below.

Central portion 154 further includes at least one protruding element 164, here shown as two protrusions. Protruding elements 164 serve to engage a complementary groove or grooves 166 in a quick connect door element 168 in door unit 170. Quick connect door element 168 further includes a countersink 169 for housing a screw head, adapted to seat in registration with threaded bore 158 when quick connect door element 168 is seated on frame unit 152, as explained in detail below. Quick connect door element 168 also includes two pin receiving arms 172 adapted to seat within pin holding arms 160 and 162 and hold the hinge pin 190 of the door.

Door unit 170 further includes a pivot element 180 configured for attachment to a door (not shown). Pivot element 180 includes first threaded cylindrical bore 182. 162974/2 A hollow bushing 184, having external screw threads, is mounted in the threaded bore 182. An inner screw (not shown) passes through hollow bushing 184 and protrudes therefrom so as to engage a nut inside the door, substantially as described with regard to Figure 10.

One side of pivot element 180 defines at least one depending tooth 186 arranged to extend beyond and engage a far edge 155 of central portion 154 of frame unit 152. The other side of pivot element 180 defines a pin receiving cylindrical bore 188, whose longitudinal axis is perpendicular to the longitudinal axis of threaded bore 182. Pin receiving cylindrical bore 188 is arranged to sit between pin holding arms 172 for rotation about a hinge pin 190 during opening and closing of the door. Hinge pin 190 has a smooth outer surface and seats freely within pin receiving cylindrical bore 188 and pin receiving arms 172. A bearing 192 is mounted in pin holding arm 162 for receiving one end of hinge pin 190. A screw 194 is rotatably mounted in pin holding arm 160. The other end of hinge pin 190 may define a portion 196 of wider diameter which seats on screw 194. Thus, rotation of screw 194 causes hinge pin 190, and pivot element 180 thereon, to move up and down between pin holding arms 160 and 162.

The operation of hinge assembly 150 is similar to that described above with regard to Figure 5 and will be described with reference to Figures 15 and 16. Pivot element 180, with hollow bushing 184 and an inner screw (not shown) therein, is affixed to the door, substantially as described above, and frame unit 152 is affixed inside the door frame. Screw 194 is screwed into pin holding arm 160 and bearing 192 is mounted in pin holding arm 162. Pin holding cylindrical bore 188 is seated between, and in registration with, pin receiving arms 172 and the hinge pin 190 is mounted between them, so as to seat on screw 194.

The door is mounted quickly and easily by bringing the quick connect door element 168 into engagement with frame unit 152. This is accomplished by sliding quick connect door element 168 over central portion 154 until grooves 166 can engage protruding element 164. Quick connect door element 168 is now seated on 162974/2 central portion 154, with protruding element 164 firmly engaged by grooves 166, and pin receiving arms 172 seated between, and in registration with pin holding arms 160 and 162. It will be appreciated that this arrangement provides reinforcement for the pin holding arms and help in supporting the door. This is particularly important when the door is a heavy door, such as a steel door. Quick connect door element 168 is firmly affixed to frame unit 152, as by a bolt 159 passing through countersink 169 and threaded bore 158.

The height, angle and distance of the door from the frame are now adjusted in substantially the same manner as that described above with relation to Figures 13 to 14. When the door is closed, further protection is provided against unauthorized removal of the door by depending teeth 186 which extend beyond central portion 154 and engage its far edge 155 opposite the pin holding arms.

It will be appreciated that the provision of pin receiving arms within the pin holding arms provides two additional layers which must be cut and removed should anyone unauthorized wish to remove the door from the frame. In fact, even if the pin holding arms are cut, the door cannot be removed due to the teeth protruding from the quick connect door element, which engage the planar portion in the frame unit inside the frame. Thus, this embodiment provides a quick connect mechanism together with added security features against vandalism or unauthorized entry.

Referring now to Figure 17, there is shown an exploded view of a hinge assembly 200 constructed and operative in accordance with a further embodiment of the present invention. Hinge assembly 200 includes a frame unit 202 and a mating door unit 220. Hinge assembly 200 is also constructed and adapted to provide both a quick connection for rapid and easy mounting of a door onto a door frame, and increased security against break-ins. This is accomplished by mounting a substantial portion of hinge assembly 200 in a cavity in the door frame, where there is no access from the outside, and by providing a locking mechanism which holds the door to part of the hinge assembly inside the frame, even if the hinge pin is removed. 162974/2 Frame unit 202 includes a central, preferably planar portion 204 integrally formed with two mounting members 206. Central portion 204 is designed to seat inside the door frame, and mounting members 206 are configured and adapted to be affixed to the frame, as by bolts. A countersink 208 is preferably provided in central portion 204 to receive a retaining screw (not shown). Frame unit 202 further includes two pin holding arms 210 and 212 for holding the hinge pin of the door.

Central portion 204 defines three cut-away areas on the edge 215 thereof opposite pin holding arms 210 and 212: a central cut-away area 214, and two shallower cut-away areas 216 on either side of the central cut-away area. Central cut-away area 214 serves to engage a complementary protruding tooth 216 in a quick connect door element 218 in door unit 220. Quick connect door element 218 further includes a threaded bore 219 adapted to seat in register with countersink 208 when quick connect door element 218 is seated on frame unit 202, as explained in detail below. Quick connect door element 218 also includes two pin receiving arms 222 adapted to seat between pin holding arms 210 and 212 and hold the hinge pin (not shown) of the door.

Door unit 220 further includes a pivot element 230 configured for attachment to a door, substantially as described with regard to Figure 15. One side of pivot element 230 defines two depending teeth 236 arranged to extend beyond central portion 204 of frame unit 202 and engage cut-away portions 217. The other side of pivot element 230 defines a pin receiving cylindrical bore 238, and is arranged to seat between pin receiving arms 222 for rotation about a hinge pin during opening and closing of the door. The hinge pin in this embodiment may be a conventional threaded hinge pin, or a hinge pin like hinge pin 180 and seat between a bearing and a screw. In any event, rotation of the hinge pin itself or of a screw associated with the hinge pin causes the pivot element 230 to move up and down between pin holding arms 210 and 212.

The operation of hinge assembly 200 is substantially similar to that described above with regard to Figure 16 and only the novel quick connect operation will be 162974/2 described, with reference to Figure 18. Once the pivot element 230 has been affixed to the door and coupled to quick connect door element 218, the door is mounted quickly and easily by bringing quick connect door element 218 into engagement with frame unit 202, which has previously been affixed to the door frame. This is accomplished by inserting pin receiving arms 222 between, and substantially in registration with, pin holding arms 210 and 212. Quick connect door element 218 is now pivoted until it lies flat on central portion 204 and protruding tooth 216 firmly engages central cut-away area 214. Only by pivoting quick connect door element 218 to release tooth 216 from central cut-away area 214 is it possible to remove the door from the frame. Quick connect door element 218 is additionally affixed to frame unit 202, as by a bolt 209 passing through threaded bore 219 and countersink 208. The height, angle and distance of the door from the frame are now adjusted in substantially the same manner as that described above with relation to Figures 13a to 14.

When the door is closed, further protection is provided against unauthorized removal of the door by depending teeth 236 which extend beyond central portion 204 and engage shallow cut-away areas 217.

While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. It will further be appreciated that the invention is not limited to what has been described hereinabove merely by way of example. Rather, the invention is limited solely by the claims which follow. 162974/1

Claims (17)

1. A pivot element affixable to a door, for use in a hinge assembly for mounting the door on a door frame, the hinge assembly including two hinge pin holding arms for mounting on the door frame and a hinge pin for mounting therebetween, the pivot element comprising: a first cylindrical bore for receiving a screw for coupling to the door; and a second cylindrical bore for receiving the hinge pin therethrough, the pivot element being adapted and configured for coupling to the hinge assembly with said second cylindrical bore disposed between the pin holding arms; wherein a longitudinal axis of said second cylindrical bore is perpendicular to a longitudinal axis of said first cylindrical bore, and said second cylindrical bore is spaced apart from said first cylindrical bore; and wherein said pivot element is adapted and configured for adjusting, while the door affixed to the hinge assembly is mounted on the door frame, a position of the door relative to the door frame.

2. The pivot element accoding to claim 1, wherein said pivot element is formed of a first portion having said first cylindrical bore and a second portion having said second cylindrical bore, said first portion and said second portion being coupled for slideable movement relative to one another for adjustment of a position of the door relative to the door frame.

3. The pivot element according to claim 1, wherein said first cylindrical bore includes internal screw threads, and further comprising a threaded bushing seated in said first cylindrical bore, wherein said screw is seated in said threaded bushing, said threaded bushing and said screw being adapted and configured for adjustment of positions of the door relative to the door frame. 162974/1

4. A hinge assembly for mounting a door on a door frame, the hinge assembly comprising: two hinge pin holding arms for mounting on the door frame; a pivot element for affixing to the door, the pivot element comprising: a first cylindrical bore for receiving a screw for coupling to the door; and a second cylindrical bore for receiving the hinge pin therethrough, wherein a longitudinal axis of said second cylindrical bore is perpendicular to a longitudinal axis of said first cylindrical bore, and said second cylindrical bore is spaced apart from said first cylindrical bore; and the pivot element being adapted and configured for coupling to the hinge assembly with said second cylindrical bore disposed between the pin holding arms; a hinge pin arranged to seat in said second cylindrical bore and said pin holding arms; wherein said pivot element is adapted and configured for adjusting a position of the door relative to the door frame, while the door affixed to the hinge assembly is mounted on the door frame.

5. The hinge assembly according to claim 4, wherein said pivot element is formed of a first portion having said first cylindrical bore and a second portion having said second cylindrical bore, said first portion and said second portion being coupled for slideable movement relative to one another for adjustment of a position of the door relative to the door frame.

6. The hinge assembly according to claim 4, wherein said first cylindrical bore includes internal screw threads, a threaded bushing is seated in said first cylindrical bore, and 162974/1 said screw is seated in said threaded bushing, wherein rotation of said threaded bushing causes movement of the door relative to the hinge assembly, for pivoting in a vertical plane.

7. The hinge assembly according to any of claims 4 to 6, further comprising: a mounting plate, defining a nut retaining recess, adapted for mounting in the door, said nut retaining recess including an elongate aperture; and a locking nut slideably mounted in said nut receiving recess; said nut receiving recess being adapted to permit slideable motion of said locking nut along the nut receiving recess and to prevent rotational movement of said nut in said recess; wherein said screw threadably engages said locking nut and passes through said elongate aperture, said screw and nut being movable along the length of said elongate aperture to adjust a position of the door relative to the door frame.

8. A hinge assembly for mounting a door on a door frame, the hinge assembly comprising: a substantially C-shaped frame unit adapted for mounting inside the door frame, said frame unit including two pin holding arms adapted to seat in a cavity in the door frame; a door unit comprising: a substantially C-shaped quick connect door element defining pin receiving arms adapted and configured to seat in said frame unit between and in registration with said pin holding arms, and a pivot element comprising: a first cylindrical bore for receiving a screw for coupling to the door; and 162974/1 a second cylindrical bore for receiving the hinge pin therethrough, wherein a longitudinal axis of said second cylindrical bore is perpendicular to a longitudinal axis of said first cylindrical bore, and said second cylindrical bore is spaced apart from said first cylindrical bore; and the pivot element being adapted and configured for coupling to the hinge assembly with said second cylindrical bore disposed between the pin holding arms; and a hinge pin arranged to seat in said second cylindrical bore and said pin holding arms; wherein said quick connect door element further comprises at least one engagement element; and said frame unit further comprises a quick connect frame element including at least one complementary engagement element, wherein said at least one engagement element is adapted to engage said at least one complementary engagement element when the door is mounted on the frame.

9. The hinge assembly according to claim 8, wherein: said complementary engagement element includes a pin; and said engagement element includes at least one groove adapted and configured to engage said pin.

10. The hinge assembly according to claim 8, wherein: said complementary engagement element includes at least one protrusion; and said engagement element includes at least one groove adapted and configured to engage said protrusion.

11. The hinge assembly according to claim 8, wherein: 162974/1 said complementary engagement element includes a cut-away portion on said planar portion; and said engagement element includes at least one protruding tooth adapted and configured to extend beyond said plate and engage said cut-away portion.

12. The hinge assembly according to any of claims 9 to 1 1, further comprising a locking mechanism for preventing unauthorized removal of the door from the door frame when the door is closed.

13. The hinge assembly according to claim 12, wherein said frame unit includes a central portion; and said locking mechanism comprises at least one tooth protruding from said pivot element and adapted and configured to lockingly engage an edge of said central portion opposite said pin holding arms.

14. The hinge assembly according to claim 13, wherein said central portion is a substantially planar portion.

15. A method for mounting a door on a door frame, the method comprising: providing a hinge assembly according to claim 4; mounting said pivot element on the door; mounting two hinge pin holding arms on the door frame; hanging the door on the door frame; and while the door is hung on the door frame, adjusting at least one of: the angle of the door relative to the door frame; the distance of the door from the door frame; and the height of the door relative to the door frame.

16. A method for mounting a door on a door frame, the method comprising: 162974/1 providing a hinge assembly comprising: a substantially C-shaped frame unit adapted for mounting inside the door frame, said frame unit including two pin holding arms adapted to seat in a cavity in the door frame, and a quick connect frame element; a door unit comprising: a substantially C-shaped quick connect door element defining pin receiving arms, said quick connect door element being adapted and configured to sit in said frame unit between and in registration with said pin holding arms, and a pivot element comprising: a first cylindrical bore for receiving a screw for coupling to the door; and a second cylindrical bore for receiving the hinge pin therethrough, wherein a longitudinal axis of said second cylindrical bore is perpendicular to a longitudinal axis of said first cylindrical bore, and said second cylindrical bore is spaced apart from said first cylindrical bore; and the pivot element being adapted and configured for coupling to the hinge assembly with said second cylindrical bore disposed between the pin holding arms; inserting a hinge pin in said second cylindrical bore, said pin receiving arms, and said pin holding arms; and engaging said quick connect frame element with said quick connect door element. 162974/1

17. The method according to claim 16, wherein said quick connect door element comprises at least one engagement element; said quick connect frame element includes at least one complementary engagement element; and said step of engaging includes engaging said at least one complementary engagement element with said at least one engagement element when mounting the door on the frame. AGENT FOR APPLICANT