US3571989A

US3571989A - Plastic cement case

Info

Publication number: US3571989A
Application number: US618447A
Authority: US
Inventors: Joseph J Gaysowski
Original assignee: Rixson Inc
Current assignee: Rixson Inc
Priority date: 1967-02-24
Filing date: 1967-02-24
Publication date: 1971-03-23
Anticipated expiration: 1988-03-23

Abstract

An improved cement case for effecting the floor mounting of a door control unit, such as a door closer or door check, for controlling a swinging door. The case is made of impact resistant plastic material and supports metal anchors which, with the case, are embedded in cement. The door control unit which is disposed in the case is directly connectable with the metal anchors.

Description

United States Patent [72] Inventor Joseph J. Gaysowski Westchester, Ill.

[21] Appl. No. 618,447

[22] Filed Feb. 24, 1967 [45] Patented Mar. 23,1971

[73] Assignee Rixson Inc.

Franklin Park, Ill.

[54] PLASTIC CEMENT CASE 13 Claims, 11 Drawing Figs.

[52] U.S. Cl. 52/27, 52/127, 52/707 [51] Int. Cl E05f 7/00, E04b 1/41 [50] Field of Search 220/38, 3.4, 55 (A); l6/49, 55; 52/27, 221, 704, 707,127

[56] References Cited UNITED STATES PATENTS 1,023,294 4/1912 Bennett 52/27 1,599,745 9/1926 Cinnamond 52/704X 2,687,788 8/1954 Rapp 52/704X 2,867,349 1/1959 Parker, Jr. 220/33 2,933,755 4/1960 Carlson 16/55 FOREIGN PATENTS 559,458 l/l958 Belgium 52/221 919,494 2/1963 Great Britain 52/127 Primary Examiner-Alfred C. Perham AttorneyJohnson, Dienner, Emrich, Verbeck & Wagner ABSTRACT: An improved cement case for effecting the floor mounting of a door control unit, such as a door closer or door check, for controlling a swinging door. The case is made of impact resistant plastic material and supports metal anchors which, with the case, are embedded in cement. The door control unit which is disposed in the case is directly connectable with the metal anchors.

PLASTIC CEMENT CASE BACKGROUND AND BRIEF SUMMARY OF THE INVENTION Heretofore door control units have generally been mounted in-a cast iron cement case which is recessed into the floor at the pivot axis of the door, such cast iron case being usually embedded in a surrounding filling of cement, withthe door control unit connected to the metal case and transmitting forces to the cement through the metal case.

There are several objections to such cast iron cement cases and it is the fundamental purpose of the present invention to avoidthese objections by providing a new and improved construction of case which is composed of a plasticmaterial, associated with a unique form and arrangement of metal anchors. One of the objections to a cast iron case is that it is quite susceptible to fracture if it is allowed to drop upon a hard surface, which is always a possibility in the transportation of these cases and in their handling at the job site. In making comparative tests between cast iron constructions and plastic constructions I discovered that, when assemblies composed of a cast iron case and a cast iron cover were subjectedto drop tests of one foot, two feet and three. feet down upon a cement floor the cast iron case frequently cracked or sustained other damage such that the case was rendered no longer usable. On the other hand, when the plastic case of the present invention underwent similar drop tests, only av slight deformation results, at most, so that the case was still capable of use.

Another disadvantage of a cast iron case is that it is much heavier than a plastic case. For example, in one representative size of case, the cast iron construction weighed approximately 7 pounds, whereas the plastic construction of thesame size and formation weighed approximately 1 pound. This substantial weight differential makes the plastic construction cheaper to ship and easier to handle.

With regard to corrosion, the plastic case has much better corrosion resistance compared to the cast iron case, under similar environmental conditions.

The plastic construction is much more economical to make, affording approximately a 45 percent cost reduction per unit.

However, thedirect substitution of a plastic material for cast iron in the cement case is not feasible because high loads andstresses resulting from use of the door control unit would have to be transmitted through the plastic. to the cement. A plastic case does not have the capability of transmitting or supporting as high a load as an iron case does. However, it is entirely adequate to act as a form for cement when cement is poured around the case on installation, since a cement case formed of plastic material such as A.B.S. can effectively keep wet cement, water and dirt out of the case.

Therefore, according to my invention the plastic case serves primarily as a housing for the door control unit to keep out liquids, cement and dirt, while also serving to carry metal anchors which become embedded in cement when the case itself is embedded in cement. The torsional and shock loads are transmitted'from the door control unit directly through the metal anchors to the cement, and thus the loads bypass the plastic case completely.

The anchors are associated with the plastic case by integral plastic protrusions or projections in the form of posts, lugs or nibs on the case and by recesses and openings in the case which prevent the metal anchors from becoming disassociated from the plastic case during handling of the case before the case and anchors are installed in the cement. Alternately, or in a supplementary manner, the anchors may be associated with the case by a temporary locating plate which also serves to close off the open top of the case and prevents cement, etc., from entering the case during installation in the floor.

BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWINGS Referring now to the accompanying drawings illustrating a preferred embodiment of the invention:

FIG. 1 is a plan view of my improved plastic cement case;

FIG. 2 is a side elevational view of the case of FIG. 1;

FIG. 3 is a fragmentary, vertical, sectional enlarged view taken approximately on the plane of the line 3-3'of FIG. 1 illustrating one of the anchor sockets of the cement case prior to the insertion of the anchor therein;

FIG. 4 is a view similar to FIG. 3 showing a vertical section through one of the metal anchors and an associated fragmentary portion of the cement case embedded in cement;

FIG. 5 is a detail, sectional, enlarged view taken on the plane of the line 5-5 of FIG. 1;

FIG. 6 is a detail plan view looking down upon the top end of one of the metallic anchors;

FIG. 7 is a side elevational view of the anchor of FIG. 6;

FIG. 8 is a top plan view. of the cement case of F IG.1 with a door control unit disposed in the case;

FIG. 9 is a side elevation of the case of FIG. 8 and illustrates extensions for the anchors and shows the door control unit indicated in dotted outline;

FIG. 10 is a fragmentary, sectional, enlarged view on the line 10-10 of FIG. 8and includes a modification in the form of an added fastener; and

FIG. 11 is a fragmentary view similar to FIG. 10 but showing a temporary locating plate disposedin the upper portion of the case in place of the door control unit.

DETAILED DESCRIPTION Referring first to FIGS. 1 and'2, my improved plastic case 10 comprises a lower portion 15 of a somewhat oval outline. The case is defined by a bottom wall 16 having substantially vertical

curved end walls

17 and 18 formed'integral therewith. The right-hand curved end wall 17 of FIG. 1 is formed concentrically around the center C, and the left-hand curved end wall 18 is formed concentrically around the center C, the righthand end wall 17 preferably being of larger radius than the left-hand end wall 1-8. These curved end walls are joined together by substantially vertical diagonally extending straight sidewalls 19 integral therewith. Such sidewalls 19 preferably have formed on the outside thereof integral upwardly extending reinforcing ribs 20. The

curved end walls

17, 18 and the straight sidewalls 19 have a slight outward flare (see FIG. 3) for molding purposes and the sidewalls, end walls and bottom wall are integral.

Formed as an integral upward extension of the lower part 15 of the plastic case is an upper portion 25. This is preferably of rectangular traylike outline, in plan view, having an open top area, as viewed in FIG. 1, but may be of any other shape desired. Such traylike outline comprises the two

end flanges

26, 27 and the two

side flanges

28, 29 integrally joined together at the four comers and also integrally joined with adjacent walls of the lower portion 15 by certain horizontal wall means or webs now to be described.

At the two corners of the case, at the right side of FIG. 1, are formed horizontal walls or

web portions

30 and 30. These web portions are formed integral with the right-hand end wall or flange 26 and with the

adjacent sidewall

28 or 29, and merge integrally into the curved end wall 17. These two web portions 30 and 30' have

circular holes

31 and 31 respectively, passing therethrough which constitute the upper ends of plastic mounting sockets S for anchors A which will be presently described.

At the other end of the upper tray formation 25 there are also formed horizontal wall or web portions 34,. 34'. These web portions are formed integrally with the end wall 27 and with the

sidewalls

28,29 and merge integrally with the lower diagonal sidewalls 19. These web portions 34, 34' have

circular holes

35, 35, respectively, passing therethrough which constitute the upper ends of mounting sockets S for the two left-hand anchors A.

At the lefthand end of the plastic case a downwardly sloping wall, or cover, portion 38 inclines from the end wall 27 of the tray formation 25 to the curved end wall 18 of the lower portion 15 of the case, this cover 38 being formed integral with both portions of the case. A portion of a door control unit (see FIG. 8) is disposed in this covered end of the case. The particular formation of the case which has been shown will serve to mount different shapes or sizes of door control units, but it will be understood that the plastic case could be formed in other sizes or shapes to receive other types and shapes of door control units.

The case 10 is fonned of moldable or castable lightweight nonmetallic, nonceramic material which is impact resistant. I prefer a thermoplastic material of the A.B.S. type (acrylonitrile-butadiene-styrene) available, for example, under brand names such as Cycolac G.S.M. (Borg Warner Corporation) or Kralastic (U.S. Rubber Company).

Referring now to the four sockets S of the case 10, a circular holes, such as

holes

31, 31', 35 or 35', forms the uppermost element of each of these sockets. Below and adjacent the

holes

31 and 31 is another element of plastic sockets S at the right end of the case consisting of a vertical rib 60 formed integral with the plastic case and projecting outwardly to bear against the back or inner side of the anchors shank 50. As shown in FIGS. 3 and 4, the lower end of this projecting rib 60 is formed with an integral protrusion or nib 61, which forms a limiting stop holding the anchor against downward movement once it has been inserted into the socket S. The plastic composition of the case affords sufficient flexibility to permit the anchor A to be pressed past this nib 61 when the anchor is being pushed upwardly into the hole 31 or 31' where it has a light press fit.

The socket S consists of still another element in the form of a cylindrical post 70 formed integral with the upper portion 25 of the case. This plastic post extends downwardly from web 30, for example, and fits in the right angle space between the two

metallic wings

51 and 52 of each anchor (See FIG. 8). This post holds the anchor against rotary movement, which is helpful particularly when one is threading the screw 42 down into the threaded bore 44 within the shank portion 50 before the anchor is set in the cement. The post 70 is properly positioned for engaging between the

wings

51 and 52 by locating the axis of the post on an extension of the radial line r extending from the center C through the center of the hole 31. The post 70 may terminate short of the bottom ends of the

wings

51 and 52, to expose more area of the wings for engagement with the surrounding cement.

The formation of the anchor-holding sockets S at the lefthand end of the unit, as viewed in FIGS. 1 and 2, is substantially the same as at the right-hand end, except that the outwardly projecting rib 80 is made substantially as wide as the shank of the anchor, and is formed with a relatively wide depression or groove 82 extending downwardly therealong in which the surface of the shank 50 will seat when the anchor is associated with the case, A nib or protrusion 81 projects outwardly from the lower end of the rib 80, to perform the same stop function as does the nib 61 in FIGS. 3 and 4.

The two

web portions

30, 30 at the right-hand end and the two web portions 34, 34' adjacent to the left-hand end of the case, as viewed in FIGS. 1 and 2, serve to support the four corners of top wall 40 of a door control unit (See FIGS. 8, 9 and 11). Screws 42 pass down through holes 43 in connecting portions, in the form of flanges, of this wall 40, and screw into tapped holes 44 in each of the four anchor units A mounted in the sockets S of the plastic case 10.

Referring now in detail to these anchor units A, which are all identical, each is preferably composed of metal and l find that powdered iron sintered into the form of the anchor to be a very satisfactory material both because of its adequate strength and savings in cost. Referring particularly to FIGS. 6 and 7, the anchor comprises a cylindrical shank or body portion 50 from which laterally projects a structure in the form of two longitudinally extending projections, such as

wing portions

51 and 52, which are at right angles to each other (FIG. 6). These two integral wings extend from the bottom end of the cylindrical shank 50 up to a level below the upper end of the anchor whereby a shoulder 54 is provided on each wing. The cylindrical upper end 55 of the anchor extending from the shoulder 54 to the top end, has a light press fit in any one of the

holes

31, 31', 35 and 35' formed in the

web portions

30, 30', 34 and 34'. The upper extremity of the shank is beveled or chamfered as indicated at 57, to facilitate the insertion of the shank in an upward direction into the bottom end of a hole, such as

holes

31, 31, 35 and 35. When the anchors are positioned in their sockets the shoulders 54 at the upper ends of the

wings

51 and 52 abut against the undersides of the

armate web portions

30, 30', 34 and 34' of the case and prevent the anchors from being moved upwardly through the

holes

31, 31', 35 and 35'. It will be obvious that the projecting

wing portions

51 and 52 preclude the insertion of the anchor downwardly into the top ends of the

holes

31, 35. Preferably the upper ends of the shanks 50 of the anchors A extend slightly above the plane of the

webs

30, 30, 34 and 34' of the case 10.

The outer surface of each of the two

wings

51 and 52 of each anchor is inclined upwardly and inwardly as at 58. This increases the cement anchorage when the overlying cement sets but also more easily permits the anchors to be forced out of the cement if it is ever necessary to remove them.

A finishing cover plate or threshold (FIG. 4) may be fastened to the top 40 of the door control unit 39 by screws which thread into threaded apertures 45 in the top wall 40.

Referring now to the installation of the improved plastic case 10 and its anchors A, the anchors A are first inserted upwardly into the four sockets S from the under sides thereof, by having the upper ends of the metal shank portions 50 pressed into the

holes

31, 31+, 35 and 35' in the

plastic web portions

30, 30, 34 and 34 and past the

nibs

61 and 81 until the lower ends of the anchors can snap past the nibs and rest on them. During this procedure the anchors are directed so that their

wings

51 and 52 straddle the downwardly extending plastic posts 70.

The anchors are thereby associated with and supportable by the cement case since they are restrained from separation from the case by axial movement by reason of their shoulders 54 bearing on the under side of the

webs

30, 30', 34 and 34' and because of the

nibs

61 or 81. They are restrained against lateral separation from the case by reason of the

ribs

61, or 81, integral with the walls of the case, the vertical posts 70, and the walls of the

holes

30, 30', 34 and 34 which bear against the outer upper surface 55 of the shank portion 50. Furthermore, the anchors are restrained against rotation relative to the cement case because the

wings

51 and 52 straddle a post 70.

The assembly of the plastic case 10 and its anchors A is then located in a recess in the floor at the proper place for aligning the door control unit with the axis of the door. Wet cement is then poured around the case 10 and around the

wings

51, 52 of each of the anchors A. The door control unit 39 can then be secured to the anchors A, preferably after the cement is set, by passing the screws 42 through the holes 43 and threading them down into the tapped holes 44 in the anchor shanks. Alternatively, after the anchors have been associated with the case 10, the door control unit 39 can be placed in the case 10 and can be secured to the anchors A so that the plastic case, door closer unit, and anchors A can be positioned as a unit in the floor before pouring the concrete.

It will be seen from the foregoing that at each of the anchors A the direct metal-to-metal contact between the flanges on the top wall 40 of the door control unit 39 and the tops of the anchor shanks 50 results in a complete bypassing of the door loads past the plastic material directly to the cement. Also, the unique mounting of the anchors in the plastic sockets prevents the anchors from falling out of the plastic case during the preliminary handling of the assembly in the act of locating the assembly with respect to the floor and embedding it in cement.

I68. 8 and 9 are views similar to those of FIGS. 1 and 2 but showing the door control unit 39 disposed in the case 10 and secured to the anchors A. Adjacent each corner of the top 40 of unit 39 there is a slightly raised, plane horizontal surface 43. At each such surface there is a hole 43 aligned with the in the event it is desired to increase the anchoring effect of 5 an anchor A, I provide an extension 87 which can be a threaded bolt, threaded into the lower end of the threaded opening 44 of the anchor. Obviously bolts of different length may be used if desired.

In FIG. there is shown a modification of the plastic post 10 70 which fits between the

wings

51 and 52 of the anchor A. It is made with a hollow center 88 and is adapted to receive a self-threading fastener in the form of a screw 89 with an enlarged head which can engage the lower end of the anchor A.

Such fastening means 89 may be used if exceptionally rough l5 handling of the case and its associated anchors is expected prior to placement in the floor, otherwise they are not needed.

FIG. 11 illustrates the manner in which a temporary plate 90, having a configuration similar to that of the open upper rectangular portion (25) of case 10, may be secured in the case to the anchors A to keep the interior of the case from having dirt or cement get in it prior to use or during its embedment in cement. The plate has four holes such as hole 91, disposed to exactly overlie the anchors A. The plate may be removed after the case is in place and then the door control unit 39 may be placed in the case and secured to the anchors. An additional advantage which arises from the use of the temporary locating plate 90 is that it assists in aligning the anchors within their sockets S so that the anchors will be held in the cement, when it is set, in proper alignment for reception of the same screws which will be used to secure the door control unit 39 to the anchors after the temporary plate 90 has been removed. v

If a temporary plate 90 is used, it would be possible to dispense with protrusions such as 61 and 81 of the sockets S, 3

provided the plate 90 is left in the case and still secured to the anchors A until after the case has been disposed in the floor and the cement has been poured. Preferably the plate 90 is left in the case until after the cement has set around and over the anchors. It is possible to eliminate

protrusions

61 and 81 in 40 such instance because the plate 90 and screws 42 will assure that the anchors are associated with the case 10. The screws 42 have their heads bearing on the top of plate 90, and plate 90 rests on the

horizontal webs

30, 30', 34 and 34, while the lower ends of screws 42 are threaded into the anchors A and hold the anchors with their abutment surfaces, or shoulders, 54 against the under side of the

webs

30, 30', 34 and 34'. However, it is preferred to use the

protrusions

61 and 81, since the case 10 is then adapted to be used in a greater variety of ways.

While I have described a preferred form of my invention I do not intend to be limited to that specific form, except insofar as the claims are so limited, since modifications will readily suggest themselves to one skilled in the art who has my disclosure before him.

Iclaim:

1. In combination, a door control unit adapted to have anchorage to a body of cement in a floor and said door control unit having a rigid, metal, stressdransmitting, connecting portion; fastening means and rigid, metal, stress-transmitting anchoring means for connecting said door control unit by means of said unit's rigid metal, stress-transmitting, connecting portion to said body of cement in which the anchoring means is adapted to be rigidly embedded; and a plastic cement case for substantially separating said door control, unit from said cement; said anchoring means being adapted to be carried by said cement case prior to embedment in the cement and being carried by and supported in the cement after said anchoring means and case are embedded in cement and the cement has hardened, and said rigid, metal, stress-transmitting, connecting portion of the door control unit being connected to said rigid, metal, stress-transmitting anchoring means in metal-to-metal contact without the plastic cement case intervening in the connection, and thereby being connected to the hardened cement,. whereby substantially all stresses originating from operation of the door control unit will be transmitted directly to the cement instead of being transmitted to the cement by means of the walls of the plastic cement case.

2. The invention of claim 1 wherein portions of the anchoring means extend from outside the cement case through an opening in the cement case and those extending portions are engaged by, and serveto support, said rigid, metal, stresstransmitting, connecting portion of the door control unit.

3. For use with a door control unit having a rigid, metal, stress-transmitting, connecting portion and being adapted to have anchorageto a body of cement in a floor, a plastic cement case to separate from the cement the door control unit which is adapted to be seated within the case, and rigid, metal, stress-transmitting anchor means adapted to anchor the door control unit to the body of cement, said anchor means being adapted to be carried by said cement case prior to embedment in cement and being carried by and supported in the cement after said anchor means and case are'embedded in cement and the cement is hardened, and said rigid, metal, stress-transmitting, connecting portion of the door control unit being adapted to be connected to said rigid, metal, stress-transmitting anchor means in metal-tometal contact, without the plastic cement case intervening in the connection, and thereby being connected to the hardened cement, whereby substan-- tially all stresses originating from operation of the door control unit will be transmitted directly to the cement instead of being transmitted to the cement by means of the walls of the 5 plastic cement case.

4. The case of claim 3 wherein the anchor means may be disassociated from said case and are constructed of a rigid metallic material.

5. The invention of claim 3 together with a locating plate and wherein the anchor means are supportable from the case through the intermediary of said locating plate which is disposed in the open upper side of the case and temporarily connected with the anchor means.

6. The invention of claim 3 wherein the anchor means are carried by the case and have an anchoring portion embeddable in the body of cement and a connecting portion exposed so as to be operatively and rigidly connectable with the rigid, metal, stress-transmitting, connecting portion of the door control unit, whereby support for the door control unit is derived directly from the hardened cement through the anchor means and not through the walls of the cement case.

7. The invention of claim 3 wherein the case has socket means, including openings through the case, for carrying the anchor means with the case.

8. The invention of claim 7 wherein a socket means includes protrusions connected with the case and adapted to hold an associated anchor means against axial, lateral and rotational displacement relative to the case with a portion of the anchor means extending through an opening in the case.

9. The invention of claim 8 together with fastening means connectable with one of the protrusions to restrain said anchor means from becoming disassociated from said case.

10. The invention of claim 7 wherein an anchor means comprises a shank portion fittable within the socket means and having a portion extending through an opening in the case and adapted for connection with the connecting portion of the door control unit, and at least one portion projecting from the shank portion for embedded anchorage in the cement.

11. The invention of claim 10 wherein said one portion of said anchor means is a laterally extending wing member which has an upwardly and inwardly inclined surface.

12. The invention of claim 3 wherein said anchor means is internally threaded and thereby adaptable for connection with a door control unit.

13. The invention of claim 12 together with extension means for said anchor means.

Claims

1. In combination, a door control unit adapted to have anchorage to a body of cement in a floor and said door control unit having a rigid, metal, stress-transmitting, connecting portion; fastening means and rigid, metal, stress-transmitting anchoring means for connecting said door control unit by means of said unit''s rigid metal, stress-transmitting, connecting portion to said body of cement in which the anchoring means is adapted to be rigidly embedded; and a plastic cement case for substantially separating said door control unit from said cement; said anchoring means being adapted to be carried by said cement case prior to embedment in the cement and being carried by and supported in the cement after said anchoring means and case are embedded in cement and the cement has hardened, and said rigid, metal, stress-transmitting, connecting portion of the door control unit being connected to said rigid, metal, stresstransmitting anchoring means in metal-to-metal contact without the plastic cement case intervening in the connection, and thereby being connected to the hardened cement, whereby substantially all stresses originating from operation of the door control unit will be transmitted directly to the cement instead of being transmitted to the cement by means of the walls of the plastic cement case.

2. The invention of claim 1 wherein portions of the anchoring means extend from outside the cement case through an opening in the cement case and those extending portions are engaged by, and serve to support, said rigid, metal, stress-transmitting, connecting portion of the door control unit.

3. For use with a door control unit having a rigid, metal, stress-transmitting, connecting portion and being adapted to have anchorage to a body of cement in a floor, a plastic cement case to separate from the cement the door control unit which is adapted to be seated within the case, and rigid, metal, stress-transmitting anchor means adapted to anchor the door control unit to the body of cement, said anchor means being adapted to be carried by said cement case prior to embedment in cement and being carried by and supported in the cement after said anchor means and case are embedded in cement and the cement is hardened, and said rigid, metal, stress-transmitting, connecting portion of the door control unit being adapted to be connected to said rigid, metal, stress-transmitting anchor means in metal-to-metal contact, without the plastic cement case intervening in the connection, and thereby being connected to the hardened cement, whereby substantially all stresses originating from operation of the door control unit will be transmitted directly to the cement instead of being transmitted to the cement by means of the walls of the plastic cement case.