WO2022172001A1

WO2022172001A1 - Hinge

Info

Publication number: WO2022172001A1
Application number: PCT/GB2022/050345
Authority: WO
Inventors: Benjamin Hall
Original assignee: Kingsway Enterprises (Uk) Limited
Priority date: 2021-02-10
Filing date: 2022-02-09
Publication date: 2022-08-18
Also published as: EP4291744A1

Abstract

Disclosed herein is a continuous hinge. The continuous hinge comprises a first hinge portion comprising a first plurality of knuckles; and a second hinge portion opposing the first hinge portion and comprising a second plurality of knuckles. The second plurality of knuckles is interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles. Each knuckle is a separate piece.

Description

Hinge

Field

The present disclosure relates to a continuous hinge, and to a method of manufacturing continuous hinges.

Background

Continuous hinges, for example of the type disclosed in GB2516093, are known. Continuous hinges are elongate, with interdigitated knuckles that run the full length of the hinge. Continuous hinges are robust, and are therefore of particular use in high-security environments. Additionally, because there are no gaps between adjacent knuckles, continuous hinges do not to include anchor points upon which clothing or body parts could become snagged, or around which a rope or cable could be secured to create a ligature. Continuous hinges are therefore also of particular use in environments in which users may be vulnerable.

However, the manufacture of continuous hinges, such as the continuous hinge disclosed in GB2516093, can be expensive, wasteful, and environmentally damaging. This is particularly the case where continuous hinges are constructed from materials that confer robustness, such as metal.

There is demand for a continuous hinge whose construction and manufacture is inexpensive and environmentally considerate, without sacrificing on robustness and safety.

Summary

The inventor of the subject matter disclosed in the present application has found that waste material, and lack of versatility (individual continuous hinges are often designed for specific purposes, and thus cannot be used in a wide variety of applications), are significant factors contributing to the high financial and environmental manufacturing costs discussed in the background section above. The inventor has developed a continuous hinge whose manufacture is simple and reduces material waste, and which is capable of being modified for specific purposes.

At its most general, the present disclosure provides a continuous hinge of modular construction.

In a first aspect, the present disclosure provides a continuous hinge comprising: a first hinge portion comprising a first plurality of knuckles attached to a first spine; and a second hinge portion comprising a second plurality of knuckles attached to a second spine, the second plurality of knuckles being interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles; wherein attachment between the first spine and the first plurality of knuckles comprises a first sliding joint. Attachment between the second spine and the second plurality of knuckles may comprise a second sliding joint. The first sliding joint may comprise: one of a tail and a corresponding socket extending along the spine; and the other of the tail and the corresponding socket extending along each of the knuckles.

The second sliding joint may be similarly configured. For example, the or each sliding joint may be a sliding dovetail joint.

The or each sliding joint may be a joint by which the relevant spine and knuckles can be fitted together by sliding in a first direction (e.g. axial direction) such that they are jointed to resist separation in a second direction (e.g. transverse direction). The second direction may be substantially perpendicular to the first direction. An example of this is a dovetail joint. Other, functionally equivalent or similar joints are also envisaged. The first direction maybe substantially parallel to the rotational axis of the hinge. The rotational axis is the axis about which the first hinge portion and the section hinge portion rotate relative to each other.

In a second aspect, the present disclosure provides a continuous hinge comprising: a first hinge portion comprising a first plurality of knuckles; and a second hinge portion comprising a second plurality of knuckles, the second plurality of knuckles being interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles; wherein each knuckle is a separate piece.

Where each knuckle is a separate piece (i.e. because the knuckles are modular parts), no machining step is required to fabricate the first plurality of knuckles, or the second plurality of knuckles. In contrast, a machining step is required to form the knuckles of GB2516093. In particular, material has to be removed (machined) from a first hinge block to produce a first plurality of knuckles in GB2516093; and material has to be removed (machined) from a second hinge block to produce a second plurality of knuckles in GB2516093. This machining process wastes material. The modular construction of the continuous hinge disclosed herein reduces waste material.

Where attachment between the spine and the knuckles of a hinge portion comprises a sliding joint, the spine(s) can be easily replaced or changed as required for secure attachment to a door leaf or a door frame having a particular configuration. Therefore, the continuous hinge can be easily adapted as required for secure attachment to a variety of door leaves and door frames, without having to replace the continuous hinge altogether. In other words, the hinge can be modified for specific purposes - it is versatile. Because the hinge can be modified for different purposes, rather than having to be replaced entirely, wastage is reduced. Also, robustness of the continuous hinge is still ensured, because the use of a dovetail joint ensures that separation of the spine from the knuckles is prevented.

Each knuckle may comprise a generally cylindrical barrel. Each knuckle may further comprise an attachment portion extending from the generally cylindrical barrel, the attachment portion including an attachment surface for attachment to its respective spine. The attachment surface may be located on a plane that is displaced from a bore of the generally cylindrical barrel. Alternatively, the attachment surface may be located on a plane that passes through or adjacent to the bore of the generally cylindrical barrel. A pin may pass through the knuckles, for example through the bores of the knuckles. The pin may extend from a first end of the continuous hinge, to a second end of the continuous hinge. The pin may be cylindrical. It may be formed of metal, for example steel, for example stainless steel. The continuous hinge may also comprise at least one bushing between at least one pair of, a plurality of pairs of, or each pair of adjacent knuckles.

For example, each knuckle may comprise at least one bushing configured not to rotate relative to the knuckle. For example, a bushing may be inserted into each axial end of each knuckle. Each bushing may comprise a tubular portion extending into the knuckle, and a flange portion in abutment with the respective axial end of the knuckle into which the bushing is inserted. The knuckles and bushings may be configured to prevent rotation relative to one another. For example, the bore of each knuckle may comprise a flat portion. Each bushing may be provided with a corresponding flat portion, such that the flat portion of each bushing engages the flat portion of the bore into which it is inserted. Accordingly, rotation of the bushing relative to the knuckle is prevented. The tubular portion of each bushing may be configured for a snug fit within the bore.

Each bushing may be rotatable relative to the pin. For example, the tubular portion of each bushing may have an inner diameter that substantially matches an outer diameter of the cylindrical pin. The inner surface of the tubular portion may have a circular cross-section, substantially matching the cross-section of the cylindrical pin.

The flange portion of each bushing may sit flush with an outer surface of the knuckle into which it is inserted. For example, the flange portion of each bushing may have an outer diameter that substantially matches the outer diameter of each knuckle (e.g. that substantially matches the outer diameter of the barrel of each knuckle).

The first hinge portion may further comprise a first spine attached to the first plurality of knuckles. And the second hinge portion may further comprise a second spine attached to the second plurality of knuckles. Accordingly, co-alignment of the first plurality of knuckles is maintained by the first spine. And co-alignment of the second plurality of knuckles is maintained by the second spine. The first spine may be for attachment to a door frame, or to a door leaf. The second spine may also be for attachment to a door leaf, or to a door frame.

Attachment between the first spine and each of the first plurality of knuckles may comprise a first sliding joint. The first sliding joint extends along a length of the first hinge portion. The first sliding joint may comprise at least one socket extending along a length of the first spine; and a corresponding at least one tail along the attachment surface of each of the first plurality of knuckles. In an example, the first sliding joint comprises a pair of parallel sockets extending along the length of the first spine; and further comprises a corresponding pair of parallel tails extending along the attachment surface of each of the first plurality of knuckles. But as the skilled person will understand, the first spine may comprise at least one tail, and each of the second plurality of knuckles may comprise a corresponding at least one socket.

In some examples, the tail(s) of the first sliding joint may have sloped side- surfaces that each form an acute angle with the attachment surface from which they extend. That is to say, each tail may be narrower at its interface with the attachment surface than it is at a distance from its interface with the attachment surface. For example, they may have a dovetail shape, such that the first sliding joint is a sliding dovetail joint.

The first sliding joint may comprise one of a socket and a corresponding tail extending along the length of the spine, and the other of the socket and the corresponding tail extending along each of the first plurality of knuckles. For example, the socket may extend along the length of the spine, and a corresponding tail may extend along the attachment surface of each of the first plurality of knuckles. Each tail may be curved so as to bend back on itself. For example, each tail may comprise a stem radially extending from the knuckle, and at least one finger which bends back towards the knuckle, such that the finger forms an acute angle with the stem. For example, each tail may comprise a pair of fingers, arranged on opposing sides of the stem from one another. The socket may have a corresponding shape, such that the tail is slidable into the socket. The second sliding joint may be similarly configured.

In the assembled continuous hinge, each knuckle may be secured in place by at least one screw, pin, or rivet extending through the respective spine and into the knuckle. The screw, pin, or rivet may be transversely oriented (e.g. oriented substantially perpendicular to the pin). The screw, pin, or rivet may extend through the spine, and into the tail of the knuckle. The screw, pin or rivet may prevent the knuckle from sliding relative to the spine. Where a threaded screw is used, it may be screwed into a threaded opening formed in the knuckle.

Each knuckle may further be biased away from its respective spine by a transverse-extending grub screw. Each grub screw may similarly be transversely oriented. Each grub screw may be screwed into a threaded hole extending through its respective spine, such that it bears against its respective knuckle to bias the knuckle away from the spine.

Similarly, attachment between the second spine and each of the second plurality of knuckles may comprise a second sliding joint. The second sliding joint extends along a length of the second hinge portion. The second sliding joint may comprise at least one socket extending along a length of the second spine; and a corresponding at least one tail along the attachment surface of each of the second plurality of knuckles. In an example, the second sliding joint comprises a pair of parallel sockets extending along the length of the second spine; and further comprises a corresponding pair of parallel tails extending along the attachment surface of each of the first plurality of knuckles. But as the skilled person will understand, the second spine may comprise the at least one tail, and each of the second plurality of knuckles may comprise a corresponding at least one socket.

In some examples, the tail(s) of the second sliding joint may have sloped side- surfaces that each form an acute angle with the attachment surface from which they extend. That is to say, each tail may be narrower at its interface with the attachment surface than it is at a midpoint displaced from its interface with the attachment surface. For example, they may have a dovetail shape, such that the second sliding joint is a sliding dovetail joint.

The use of a dovetail joint prevents separation of the continuous hinge, thereby ensuring robustness of the continuous hinge.

At least one of the first spine and the second spine may comprise a c-shaped portion for receiving a door leaf. The c-shaped portion may comprise two parallel walls for receiving a door leaf therebetween. A separation distance between the first wall and the second wall may be ¾ inch. In some examples, both the first spine and the second spine may comprise such a c-shaped portion. The use of a c-shaped portion ensures that gaps between the continuous hinge and a door leaf (or door leaves) to which it is attached are eliminated. The or each c-shaped portion may be on an opposite side of the respective spine from the respective dovetail joint.

Alternatively, the spine may comprise a flat plate.

Each spine may comprise a concave abutment surface configured to engage the knuckles of the opposing hinge portion, so as to support rotation of the first hinge portion relative to the second hinge portion while eliminating ligature points. For example, the first spine may comprise a concave abutment surface configured to engage the curved outer surface of each of the second plurality of knuckles (e.g. the curved outer surface of the cylindrical barrel of each of the knuckles); and the second spine may comprise a concave abutment surface configured to engage the curved outer surface of each of the first plurality of knuckles (e.g. the curved outer surface of the cylindrical barrel of each of the knuckles). The concave abutment surface may extend the full length of each spine. The concave abutment surface may have a radius of curvature that substantially matches the radius of curvature of the knuckles. For example, the concave abutment surface may have a radius of curvature that is slightly larger than the radius of curvature of the knuckles, for example less than 5% larger than the radius of curvature of the knuckles. Accordingly, rotation of the first hinge portion relative to the second hinge portion is supported, while at the same time minimising any gap between the spines and the knuckles to which a ligature could otherwise be secured.

The socket of each spine may be located at an apex of the concave abutment surface. The socket may be recessed from the concave abutment surface, for example recessed from the apex of the concave abutment surface. Accordingly, the sliding joint is concealed in the assembled continuous hinge.

The first hinge portion may further comprise a first plurality of bridging members attached to the first spine, each of the first plurality of bridging members positioned adjacent a respective one of the second plurality of knuckles (for example between the first spine and a respective one of the second plurality of knuckles).

The second hinge portion may further comprise a second plurality of bridging members attached to the second spine, each of the second plurality of bridging members may be positioned adjacent a respective one of the first plurality of knuckles (for example between the second spine and a respective one of the first plurality of knuckles).

Thus, each first bridging member may act to bridge a gap between adjacent knuckles of the first hinge portion. Similarly, each second bridging member may act to bridge a gap between adjacent knuckles of the second hinge portion In some examples, each bridging member may further act to bridge a gap between a respective knuckle and the spine opposing the respective knuckle. Therefore, potential snagging or anchor points are further eliminated. Each bridging member may be a separate piece. As with the knuckles, the modular nature of the bridging members ensures that the continuous hinge can be manufactured without wasting material.

Each of the first plurality of bridging members may comprise a concave surface that sits substantially flush with an outer surface of a respective one of the second plurality of knuckles. In particular, where each knuckle comprises a generally cylindrical barrel, each of the first plurality of bridging members may comprise a concave surface having a radius of curvature that substantially matches that of an outer surface of the generally cylindrical barrel of a respective knuckle. Each of the first plurality of bridging members may further comprise an attachment portion extending from the concave surface, the attachment portion comprising an attachment surface for attachment to its respective spine. The attachment surface may be located along a plane that extends through or adjacent a focus of the concave portion. Alternatively, the attachment surface may be located along a plane that is displaced from a focus of the concave portion.

Attachment between the first spine and each of the first plurality of bridging members may comprise the first sliding joint. In other words, the first sliding joint may attach the first spine to the first plurality of knuckles and to the first plurality of members. Thus, at least one tail may extend along the attachment surface of each of the first plurality of bridging members, the at least one tail corresponding to the at least one socket of the first spine. In an example, a pair of parallel tails extend along the attachment surface of each of the first plurality of bridging members. The tail(s) of each of the first plurality of bridging members may have sloped side-surfaces that each form an acute angle with the attachment surface from which they extend. That is to say, each tail may be narrower at its interface with the attachment surface than it is at a midpoint displaced from its interface with the attachment surface. Where the first sliding joint is a sliding dovetail joint, the tails will have a dovetail shape.

Each of the second plurality of bridging members may comprise a concave surface that sits substantially flush with an outer surface of the respective one of the first plurality of knuckles. In particular, where each knuckle comprises a generally cylindrical barrel, each of the second plurality of bridging members may comprise a concave surface having a radius of curvature that substantially matches that of an outer surface of the generally cylindrical barrel of a respective knuckle. Each of the second plurality of bridging members may further comprise an attachment portion extending from the concave surface, the attachment portion comprising an attachment surface for attachment to its respective spine. The attachment surface may be located on a plane that extends through or adjacent a focus of the concave portion. Alternatively, the attachment surface may be located on a plane that is displaced from a focus of the concave portion. Attachment between the second spine and each of the second plurality of bridging members may comprise the second sliding joint. In other words, the second sliding joint may attach the second spine to the second plurality of knuckles and to the second plurality of members. Thus, at least one tail may extend along the attachment surface of each of the second plurality of bridging members, the at least one tail corresponding to the at least one socket of the second spine. In an example, a pair of parallel tails extend along the attachment surface of each of the second plurality of bridging members. The tail(s) of each of the second plurality of bridging members may have sloped side-surfaces that each form an acute angle with the attachment surface from which they extend. That is to say, each tail may be narrower at its interface with the attachment surface than it is at a midpoint displaced from its interface with the attachment surface. Where the second sliding joint is a sliding dovetail joint, the tails will have a dovetail shape.

The knuckles and bridging members of the first hinge portion may alternate along a length of the first hinge portion. They may abut one another along the length of the first hinge portion.

Similarly, the knuckles and bridging members of the second hinge portion may alternate along a length of the second hinge portion. They may abut one another along the length of the second hinge portion.

The continuous hinge is modular in that the first spine, the second spine, each of the knuckles, and each of the bridging members, are separate parts. Each of these parts may have a shape enabling it to be fabricated by extrusion. In particular, each part may have a substantially uniform cross-sectional profile. Furthermore, the first spine and the second spine may be substantially identical to each other. Similarly, the knuckles of the first and second pluralities of knuckles may be substantially identical to one another. And the bridging members of the first and second pluralities of bridging members may be substantially identical to one another. Accordingly, the number of extrusion moulds needed to fabricate the continuous hinge is reduced. Where parts are defined herein as being “substantially identical to each other”, we are referring to a level of similarity between the parts that results from the parts being sections of the same extruded part.

In a third aspect there is provided a method of manufacturing a continuous hinge, the method comprising: forming constituent parts of the continuous hinge by extrusion; and assembling the continuous hinge from the constituent parts. The constituent parts comprise knuckles. Optionally, the constituent parts further comprise a first spine and a second spine. The constituent parts may also comprise bridging members.

For example, the third aspect may be a method of manufacturing a continuous hinge according to the first aspect or the second aspect.

Forming the constituent parts may comprise forming a plurality of constituent parts as a single piece by extrusion; and separating the single piece into the plurality of constituent parts. For example, where the constituent parts comprise knuckles, forming the knuckles may comprise extruding a plurality of the knuckles as a single piece by extrusion; and separating the single piece into the plurality of the knuckles. Where the constituent parts also comprise bridging members, forming the bridging members may comprise extruding a plurality of the bridging members as a further single piece by extrusion; and separating the further single piece into the plurality of bridging members.

The assembling may include assembling a first plurality of the knuckles into a first hinge portion, assembling a second plurality of the knuckles into a second hinge portion; and coupling the first hinge portion to the second hinge portion.

Assembling the first hinge portion may comprise alternately threading a first plurality of the knuckles and a first plurality of the bridging portions along a first spine; and assembling the second hinge portion may comprise alternately threading a second plurality of the knuckles and a second plurality of the bridging portions along the second spine. The threading may comprise assembling the sliding joint(s). Alternatively, assembling the first hinge portion may comprise threading a first plurality of the knuckles along the first spine, arranging the first plurality of knuckles along the first spine so that they are equally spaced from one another, and optionally securing each of the first plurality of knuckles in place by passing a screw (e.g. first screw) through the first spine and into the knuckle. Similarly, assembling the second hinge portion may comprise threading a second plurality of the knuckles along the second spine, arranging the second plurality of knuckles along the second spine so that they are equally spaced from one another, and optionally securing each of the second plurality of knuckles in place by passing a screw through the second spine and into the knuckle.

Assembling the hinge portions may further comprise biasing each knuckle away from its respective spine using a grub screw. In some examples, assembling the hinge portions may comprise adjusting the first screws and the grub screws to position the knuckles. That is, the transverse spacing of each knuckle from its respective spine may be adjusted using the first screw and the grub screw associated with the knuckle. The positioning may be done to achieve smooth operation of the hinge.

Assembling the hinge portions may further comprise affixing a bushing to each axial end of each knuckle. This may be done before threading the knuckles along the spines, or after threading the knuckles along the spines.

Coupling the first hinge portion to the second hinge portion may comprise passing a pin through the knuckles. For example, it may comprise interdigitating the first plurality of knuckles with the second plurality of knuckles (such that the bores of the first and second plurality of knuckles align), and then passing the pin through the interdigitated knuckles.

Forming the constituent parts may comprise extruding a plurality of the knuckles as a single piece, and dividing the single piece into individual knuckles. The forming may further comprise extruding a plurality of the bridging members as a single piece, and dividing the single piece into individual bridging members. The extrusion may be aluminium extrusion.

Brief Description of the Figures

Examples of the present disclosure will now be described, by way of example only, with reference to the accompanying figures, in which:

Figure 1 shows an exploded schematic view of a continuous hinge according to a first embodiment;

Figure 2 shows an assembled schematic view of the continuous hinge of Figure 1 ;

Figure 3 is an end-view of the assembled continuous hinge of Figure 2;

Figure 4 is an end-view of a spine from the continuous hinge of Figure 1 ;

Figure 5 is an end-view of a knuckle from the continuous hinge of Figure 1 ;

Figure 6 shows an exploded schematic view of a continuous hinge according to a second embodiment;

Figures 7A-7C show assembled perspective views of the continuous hinge of Figure 6;

Figure 8 is an end-view of the assembled continuous hinge as shown in Figure 7B;

Figure 9 is a flow chart illustrating a manufacturing method according to the third aspect;

Figure 10 illustrates an alternative to a sliding dovetail joint, for use in examples of the present disclosure; Figures 11 A-11 B respectively illustrate an end-view and a perspective-view of a knuckle belonging to a further alternative to a sliding dovetail joint;

Figure 12 illustrates a bushing for attachment to the knuckle of Figures 11 A-11 B;

Figure 13 illustrates a first spine for attachment to a knuckle according to Figures 11 A-11 B;

Figure 14 illustrates a second spine for attachment to a knuckle according to Figures 11 A-11 B; and

Figures 15A-15B respectively show an end-view and a side-view of an assembled sliding joint, which includes the knuckle of Figures 11 A-11 B, the bushing of Figure 12, the first spine of Figure 13, and the second spine of Figure 14;

Figure 16A shows an end-view of a first spine according to a further embodiment of the present disclosure;

Figure 16B shows a side-view of the first spine from Figure 16A;

Figure 17A shows an end-view of a second spine according to the further embodiment of Figures 16A-16B;

Figure 17B shows a side-view of the second spine from Figure 17A;

Figure 18 shows an end-view of an assembled hinge comprising the first and second spines from Figures 16-17; and

Figure 19 shows a side-view of the assembled hinge from Figure 18.

Like reference numerals are used for like features throughout the description. Detailed Description

Figure 1 shows an exploded, or unassembled, view of a continuous hinge 100 according to a first embodiment. As shown, the constituent parts of the continuous hinge are: spines 102; knuckles 104; bridging members 106; bushings 108; and pin 110. Each of these parts, except for the pin, is an extruded aluminium piece. Pin 110 is a cylindrical steel piece.

The parts to the left of the pin 110 in Figure 1 collectively form a first hinge portion 112. And the parts on the right of the pin 110 in Figure 1 collectively form a second hinge portion 114, which opposes the first hinge portion and is pivotally connected to the first hinge portion when the continuous hinge is assembled as shown in Figure 2.

With continued reference to Figure 1 , the first hinge portion 112 of the specific example shown has three knuckles 104, and three bridging members 106. The knuckles of the first hinge portion 112 are collectively known herein as a first plurality of knuckles. And the bridging members 106 of the first hinge portion 112 are collectively known herein as a first plurality of bridging members. Similarly, the second hinge portion 114 of the specific example shown has three knuckles 104, and three bridging members 106. The knuckles of the second hinge portion 114 are collectively known as a second plurality of knuckles. And the bridging members 106 of the second hinge portion 114 are collectively known as a second plurality of bridging members. The present disclosure is not to be seen as limited to the specific number of components as shown in Figure 1. There may be any number of knuckles, bushings and bridging members. The number of components will depend on the total length of the continuous hinge, among other factors. Flowever, the number of bridging members 106 of the first hinge portion 112 will be equal to the number of knuckles 104 of the second hinge portion 114. And the number of bridging members 106 of the second hinge portion 114 will be equal to the number of knuckles 104 of the first hinge portion 112. Accordingly, each knuckle 104 will abut an opposing bridging member when assembled, and vice versa. Generally, the number of knuckles 104 of the first hinge portion will be equal to the number of knuckles 104 of the second hinge portion 114, as shown. However, the number of knuckles 104 of the first hinge portion 112 may be one more than, or one fewer than, the number of knuckles 104 of the second hinge portion 114. The same applies to the bridging members 106 of the first and second hinge portions.

A bushing 108 is provided between each adjacent pair of knuckles, to enable each adjacent pair of knuckles to rotate relative to one another. In the depicted example, there are five bushings. But as the skilled person will appreciate, the number of bushings will be N-1 (where N is the total number of knuckles in the continuous hinge, and N is also the number of bridging members in the continuous hinge).

Spine 102 of the first hinge portion 112 is identical to spine 102 of the second hinge portion 114. Similarly, the knuckles 104 of the first hinge portion 112 are identical to the knuckles 104 of the second hinge portion 114; and bridge members 106 of the first hinge portion 112 are identical to knuckles 106 of the second hinge portion 114.

As is illustrated with broken lines in Figure 1 , each knuckle has a bore extending therethrough. The inner diameter of this bore is slightly larger than the outer diameter of the pin 110. Accordingly, the pin can extend through the bores in the knuckles when assembled, and rotation of the first hinge portion relative to the second hinge portion is possible.

As can also be seen in Figure 1, the knuckles 104 and bridging members 106 of the first hinge portion 112 alternate along the length of the first hinge portion 112. Similarly, the knuckles 104 and bridge portions 106 of the second hinge portion 114 alternate along the length of the second hinge portion 114.

Figure 2 shows an assembled view of the continuous hinge 100 of Figure 1. As shown, the continuous hinge is elongate, having a longitudinal axis L in the axial direction. When attached to a door leaf, the longitudinal axis is parallel to the edge of the door leaf to which the continuous hinge 100 is attached. As depicted, in this view the components are assembled to form a continuous hinge 100 that comprises a first elongate hinge portion 112 and a second elongate hinge portion 114. When assembled, the first hinge portion 112 abuts the second hinge portion 114. In particular, the first plurality of knuckles are interdigitated with the second plurality of knuckles. That is to say, the first plurality of knuckles interlock with the second plurality of knuckles like the fingers of two clasped hands. When assembled in this way, the respective bores of the individual knuckles co-align to form a single elongate bore 200 that extends the full length of the hinge. The pin extends through this single bore 200, thereby securing the first hinge portion and the second hinge portion together. Moreover, because the single bore 200 and the pin are cylindrical, the first hinge portion and the second hinge portion are able to rotate relative to one another about an axis defined by the pin 110 and the single bore 200. The bushings 108 (not shown in Figure 2) help to enable smooth rotation about this axis.

As is also depicted in Figure 2, each bridging member 106 of the first hinge portion 112 bridges a gap between the spine 102 of the first hinge portion 112 and a respective knuckle 104 of the second hinge portion 114. Similarly, each bridging member 106 of the second hinge portion 114 bridges a gap between the spine 102 of the second hinge portion 114 and a respective knuckle 104 of the first hinge portion 112.

When assembled, the interface between the opposing first and second hinge portions 112, 114 may create a zig-zag pattern 202 that extends from one end of the continuous hinge 100 to the other. No gaps exist between the first hinge portion 112 and the second hinge portion 114. Therefore, there are no anchor points or snag points present between the first and second hinge portions.

The continuous hinge 100 of the first embodiment is a double-action continuous hinge in that, when attached to a door, it supports opening of the door both in the ‘inward’ direction, and the ‘outward’ direction. Figure 3 shows an end-view of the continuous hinge 100 of the first embodiment, as viewed from above in Figure 2. It is the symmetrical shape of the continuous hinge 100 that enables it to open in both directions.

Figure 3 shows how the spine 102, knuckles 104 and bridging members 106 of the first hinge portion 112 are attached together; and how the spine 102, knuckles 104 and bridging members 106 of the second hinge portion 114 are attached together.

It is to be understood that each knuckle 104 in Figure 2 is identical. Therefore, features described herein for the top-most knuckle 104 in Figure 3 apply equally to the other knuckles 104 shown in Figure 2. Similarly, features described herein for the top-most bridging member 106 in Figure 3 apply equally to the other bridging members 106 shown in Figure 2.

Depicted in Figure 3 is the top-most bridging member 106 of the first hinge portion 112 as shown in Figure 2; and the top-most knuckle 104 of the second hinge portion 114 as shown in Figure 2. The top-most bridging portion 106 abuts the top-most knuckle 104. Cylindrical pin 110 extends through top-most knuckle 104 of the second hinge portion 114.

A first sliding joint 300 connects the elongate spine 102 of the first hinge portion 112 to the top-most bridging member 106; and a second sliding joint 302 connects the elongate spine 102 of the second hinge portion 114 to the top-most knuckle 104. The sliding joint has tails and sockets that extend along the longitudinal axis of the continuous hinge. Therefore, the continuous hinge is assembled by sliding the knuckles and the bridging members along the spine. Further, because the tails and sockets are oriented in parallel with the longitudinal axis of the continuous hinge and extend in the same direction as the barrels of the knuckles, the components of the continuous hinge each have a shape that can be formed through extrusion.

As depicted, the first sliding joint 300 comprises a pair of parallel sockets that extend along the spine 102 of the first hinge portion 112 in the axial direction (perpendicular to the page in Figure 3); and a corresponding pair of parallel tails that extend along an attachment surface at an edge of the top-most bridging member 106 (perpendicular to the page in Figure 3). The attachment surface is part of an attachment portion that extends from the concave portion. The tails slot into the sockets.

Similarly, second sliding joint 302 comprises a pair of parallel sockets that extend along the spine 102 of the second hinge portion 114 in the axial direction (perpendicular to the page in Figure 3); and a corresponding pair of parallel tails that extend along an attachment surface at an edge of the top-most knuckle 104 (perpendicular to the page in Figure 3). The attachment surface is part of an attachment portion that extends from the generally cylindrical barrel. Again, the tails slot into the sockets.

Each tail may be of a dovetail shape, having side surfaces which each form an acute angle with the attachment surface from which they extend. In particular, each tail may form an angle of 30 degrees with the attachment surface from which they extend. That is, an internal angle A that adjacent side surfaces make with one another may be 60 degrees (see Figure 4 for illustration). It is this feature that prevents separation of the constituent parts of each hinge portion. As the reader will understand, the tails and sockets are not limited to the dovetail shape illustrated in Figures 3-5. In particular, the tails could be rounded rather than having a dovetail shape. This is illustrated in Figure 10 and Figures 11A-11C, in which the tail is narrower at its interface with the attachment surface than it is at a midpoint displaced from its interface with the attachment surface. Again, the tail in Figure 10 has side surfaces that form an acute angle with the attachment surface from which the tail extends.

With continued reference to Figure 3, each knuckle 104 includes the same shape and size of tail(s); and each bridging member 106 has the same shape and size of tail(s). Furthermore, each of the spines 102 has the same shape and size of sockets. Therefore, the first sliding joint 300 attaches all of the knuckles 104 and bridging members 106 of the first hinge portion 112 to the first spine 102.

Similarly, the second sliding joint 300 attaches all of the knuckles 104 and bridging members 106 of the second hinge portion 112 to the second spine 102. Accordingly the hinge portions 112 and 114 are very robust. The sliding joints prevent them from separating into their constituent parts during use.

Other features shown in Figure 3 include the cylindrical barrel of the knuckle 104, and the corresponding concave surface of the bridging member 106. The radius of curvature of the outer surface of the cylindrical barrel matches the radius of curvature of the concave surface. Therefore, the bridging member 106 can maintain contact with the knuckle 104 as the hinge rotates about the pin 110. Accordingly, no gaps exist between the first hinge portion 112 and the second portion 114, even as the two hinge portions are rotated relative to one another.

Referring to Figure 5, a base portion 502 of each knuckle 104, which extends from the cylindrical barrel 500 of each knuckle 104, includes the second sliding pattern. Further, the base portion 502 includes planar sidewall surfaces that form an acute internal angle B with each other. Each bridging member 106 similarly includes planar sidewall surfaces that form an acute internal angle with each other. Accordingly, the continuous hinge 100 allows opening of a door in both pivotal directions (i.e. in the ‘inwards’ and ‘outwards’ direction).

As shown in Figures 3 and 4, each spine is generally C-shaped. That is to say, each of them includes two parallel longitudinal walls that extend along the spine.

In use, the parallel walls of each spine may receive a door leaf or the like therebetween. The walls of each spine may have an inner spacing of ¾ inch (19.05mm). Thus, they may be for use with door leaves having a thickness of ¾ inch.

Typically, the continuous hinge disclosed herein will have a length in the axial direction (shown with arrow L in Figure 2) that is equal to the height of a door leaf to which it is to be attached. For example, the continuous hinge can have a length of 2m, such that it is suitable for attachment to a door leaf having a height of 2m.

Alternatively, the spine may be generally L-shaped (not shown), e.g. for attachment to an inner edge or an outer edge of a door frame. Any number of spine shapes could be used, provided that the spine includes the required tails or sockets for attachment to the knuckles and bridging portions.

Figures 6-8 show a single-action continuous hinge 100’ according to a second embodiment, so-called because when fitted to a door, it supports opening of the door in only one direction (the ‘inwards’ direction, or the ‘outwards’ direction).

Figure 6 shows an exploded, or unassembled, view of the continuous hinge 100’ according to the second embodiment. As shown, the constituent parts of the continuous hinge 100’ are: spines 102’; knuckles 104’; bridging members 106’; bushings 108’; and pin 110’. The constituent parts are split into a first hinge portion 112’, and a second hinge portion 114’. As the reader will understand, the continuous hinge 100’ of the second embodiment is conceptually similar to the continuous hinge 100 of the first embodiment, but with a number of structural differences as are discussed below.

Cross-hatched regions in Figure 6 show the location of tails or sockets on the knuckles 104’ and the bridging members 106’, for engaging (when assembled) corresponding sockets or tails which extend along the reverse-side of each of the spines 102’ as shown in Figure 6. Thus, when assembled, the spine 102’ of the first hinge portion 112’ attaches to the knuckles 104’ and the bridging members 106’ of the first hinge portion 112’ so as to form a planar attachment surface (for attachment to a door leaf or to a door frame). The same is true of the spine 102’, knuckles 104’ and bridging members 106’ of the second hinge portion 114’.

Figures 7A-7C respectively show the single-action continuous hinge 100’ in an open position, an ajar (partially open) position, and a closed position. When in the closed position, the spine 102’ of the first hinge portion 112’ abuts the spine 102’ of the second hinge portion. In other words, the continuous hinge 100’ can fully close. A wireway 700 for electrical wiring are shown in Figure 7C. The wireway may, for example, convey wires for operating an electrical door lock system.

As can be seen from Figures 7A-7C, the continuous hinge 100’ of the second embodiment dispenses with the C-shaped portion from the continuous hinge 100 of the first embodiment. Instead, the continuous hinge 100’ of the second embodiment includes planar attachment surfaces for attachment to one of a door leaf and a door frame.

Figure 8 is an end-view of the continuous hinge 100’ of the second embodiment, as viewed from above in Figure 7B.

As shown in Figure 8, the spines 102’ of the single-action continuous hinge 100’ are each a flat plate carrying sliding sockets/tails. Each of the spines 102’ is for attachment to one of a door leaf and a door frame.

Figure 8 shows how the spine 102’, knuckles 104’ and bridging members 106’ of the first hinge portion 112’ are attached together; and how the spine 102’, knuckles 104’ and bridging members 106’ of the second hinge portion 114’ are attached together.

It is to be understood that each knuckle 104’ in Figures 6 and 7 is identical. Therefore, features described herein for the top-most knuckle 104’ in Figure 8 apply equally to the other knuckles 104’ shown in Figures 6 and 7. Similarly, features described herein for the top-most bridging member 106’ in Figure 8 apply equally to the other bridging members 106’ shown in Figures 6 and 7.

Depicted in Figure 8 is the top-most bridging member 106’ of the first hinge portion 112’ as shown in Figures 6 and 7; and the top-most knuckle 104’ of the second hinge portion 114’ as shown in Figures 6 and 7. The top-most bridging portion 106’ abuts the top-most knuckle 104’. Cylindrical pin 110’ extends through top most knuckle 104’ of the second hinge portion 114’.

A first sliding joint 600 connects the elongate spine 102’ of the first hinge portion 112’ to the top-most bridging member 106’; and a second sliding joint 602 connects the elongate spine 102’ of the second hinge portion 114’ to the top-most knuckle 104’. As depicted, the first sliding joint 600 comprises a pair of parallel sockets that extend along the spine 102’ of the first hinge portion 112’ in the axial direction (perpendicular to the page in Figure 8); and a corresponding pair of parallel tails that extend along an attachment surface at an edge of the top-most bridging member 106’ (perpendicular to the page in Figure 8). The attachment surface is part of an attachment portion that extends from the concave portion. The tails slot into the sockets.

Similarly, second sliding joint 602 comprises a pair of parallel sockets that extend along the spine 102’ of the second hinge portion 114’ in the axial direction (perpendicular to the page in Figure 8); and a corresponding pair of parallel tails that extend along an attachment surface at an edge of the top-most knuckle 104’ (perpendicular to the page in Figure 8). The attachment surface is part of an attachment portion that extends from the generally cylindrical barrel. Again, the tails slot into the sockets.

Each tail may be of a dovetail shape, having side surfaces which each form an acute angle with the attachment surface from which they extend. In particular, each tail may form an angle of 30 degrees with the attachment surface from which they extend. That is, an internal angle A that adjacent protrusions make with one another may be 60 degrees. It is this feature that prevents separation of the constituent parts of each hinge portion. Again, the tails and sockets could alternatively be shaped as shown in Figure 10, for example.

Each knuckle 104’ includes the same shape and size of tails; and each bridging member 106’ has the same shape and size of tail. Furthermore, each of the spines 102’ has the same shape and size of sockets. Therefore, the first sliding joint 600 attaches all of the knuckles 104’ and bridging members 106’ of the first hinge portion 112’ to the first spine 102’. Similarly, the second sliding joint 300 attaches all of the knuckles 104’ and bridging members 106’ of the second hinge portion 112’ to the second spine 102’. Accordingly the hinge portions 112’ and 114’ are very robust. The sliding joints prevent them from separating into their constituent parts during use. Other features shown in Figure 8 include the cylindrical barrel of the knuckle 104’, and the corresponding concave surface of the bridging member 106’. The radius of curvature of the outer surface of the cylindrical barrel matches the radius of curvature of the concave surface. Therefore, the bridging member 106’ can maintain contact with the knuckle 104’ as the hinge rotates about the pin 110’. Accordingly, no gaps exist between the first hinge portion 112’ and the second portion 114’, even as the two hinge portions are rotated relative to one another.

Figures 11-15 show another alternative sliding joint configuration, for use as an alternative to the dovetail configuration shown above. Figures 11 A-11 B show a knuckle 104” forming part of the alternative sliding joint configuration; Figure 12 shows a bushing 108” for attachment to the knuckle 104”; Figure 13 shows a first spine 102a forming part of the alternative sliding joint configuration; Figure 14 shows a second spine 102b forming part of the alternative sliding joint configuration; and Figures 15A-15B show a continuous hinge 100” incorporating the components from Figures 11-14.

As shown in Figures 11A-11 B, knuckle 104” comprises a tail 1100. The tail 1100 comprises a stem 1102 which extends radially from a cylindrical outer surface 1103 of the knuckle, and a pair of opposing fingers 1104a, 1104b which each extend from a distal end of the stem 1102 (distal from the barrel), and curve back towards the knuckle 104”, such that each finger 1104a, 1104b forms an acute angle with the stem 1102 from which it extends. In the depicted example, each of the fingers 1104a, 1104b forms an acute angle of approximately 45 degrees with the stem 1102. As will be described below, each of the first spine 102a and the second spine 102b comprises an axial socket 1300, 1400 having a shape corresponding to that of the tail 1100, so that the knuckle 104” can be securely attached to either one of the spines 102a, 102b by sliding the tail 1100 along one of the socket 1300 and the socket 1400 in the axial direction.

With continued reference to Figures 11A-11 B, the bore of the knuckle 104” comprises a flat portion 1110. The flat portion 1110 is positioned adjacent the stem 1102. Flat portion 1100 is provided to engage a corresponding flat portion 1204 of the bushing 108” (described below) when assembled, to thereby prevent rotation of the bushing 108” relative to the knuckle 104”.

Referring now to Figure 12, the bushing 108” includes a tubular portion 1200 and a flange portion 1202. The tubular portion 1200 is shaped for a snug fit within the bore of the knuckle 104”, such that rotation of the bushing 108” relative to the knuckle 104” is prevented. In particular, bushing 108” includes a flat portion 1204 corresponding to the flat portion 1110 of the knuckle 104”. When assembled, such that the tubular portion 1200 of the bushing 108” is inserted into the bore of the knuckle 104”, the flat portion 1204 of the bushing 108” will engage the flat portion 1110 of the knuckle 104” to thereby prevent rotation of the bushing 108” within the knuckle 104”.

Unlike the outer surface of the tubular portion 1200, the inner surface of the tubular portion 1200 has a circular cross-section, with no flat portions.

Accordingly, when the pin 110 is passed through the bushing 108”, the bushing 108” will be rotatable relative to the pin 110.

In some examples, one bushing 108” may be inserted into each axial end of each knuckle 104”. Accordingly, smooth rotation of the pin 110 within the knuckles 104” is supported. Smooth operation of the continuous hinge 100” is thereby ensured.

The outer diameter of the flange portion 1202 may be substantially equal to the diameter of the outer surface 1103 of the knuckle 104”, such that the outer surface of the flange portion 1202 sits substantially flush with the outer surface 1103 of the knuckle 104” when assembled. Rotation of the interdigitated knuckles relative to one another is thereby aided.

We turn now to Figures 13-14. Each of the first spine 102a and the second spine 102b comprises a respective socket 1300, 1400 having a shape corresponding to that of the tail 1100. That is, each of the sockets 1300, 1400 is configured to receive the tail 1100 of a respective knuckle 104” (or indeed of a respective plurality of knuckles 108”). As depicted in Figures 13 and 14, the parallel walls forming the receiving portion from earlier examples are dispensed with. As the reader will understand, the parallel walls are optional in this example (and every example), and may be included as required. Typically, the first spine 102a is for attachment to a door leaf; while second spine 102b is for attachment to a door frame. A protrusion 1305 extends along the length of the first spine 102a. A channel 1405 extends along the length of the second spine 102b.

The sockets 1300, 1400 have a shape that generally corresponds to that of the tail 1100. That is to say, the tail 1100 comprises the male part of the sliding joint, and the sockets 1300, 1400 comprise the female part of the sliding joint.

Sockets 1300, 1400 each also comprise fingers 1118a, 1118b which are configured to extend between the fingers 1104a, 1104b and the stem 1102 when assembled. The fingers 1118a, 1118b curve inwards to securely engage the fingers 1104a, 1104b. The joint is robust as a result.

Once a knuckle 104” has been threaded along one of the first spine 102a or the second spine 102b using the sliding joint, it can then be secured in place, so as to stop it from sliding relative to the spine. This is achieved by passing a screw, pin or rivet (not shown) through the spine and into the knuckle. The screw, pin or rivet extends through a hole 1302, 1402 formed through the spine, and into an opening 1140 formed in the knuckle. Because the screw, pin or rivet extends in the transverse direction (i.e. perpendicular to the axis of the sliding joint), it acts to prevent sliding of the knuckle 108” relative to the spine. Where a threaded screw is used, the opening 1140 may be threaded for engagement with the threaded screw. In the depicted example, the knuckle 108” has three openings 1140, for receiving three screws, pins or rivets. As the reader will understand, a different number of screws, pins or rivets could be used as required. For example, the knuckle 108” could include a single opening, or two openings, or more than three openings.

As also shown in Figures 13-14, each of the first spine 102a and the second spine 102b includes a concave curved abutment surface 1304, 1404. The concave abutment surface 1304, 1404 extends the full length of each spine 102a, 102b, and has a radius of curvature that is generally equal to, or slightly larger than, a radius of curvature of an external surface 1103 of the knuckle 104”. For example, the outer surface 1103 of the knuckle 104” may have a radius of curvature of 13.5mm, while the curved abutment surface 1304, 1404 has a radius of curvature of 14mm.

Turning now to Figure 15A, we see an end-view of an assembled continuous hinge 100” comprising the knuckle 104” of Figures 11A-11B; the bushing 108” of Figure 12; the first spine 102a of Figure 13; and the second spine 102b of Figure 14. As can be seen, the bushing 108” is inserted into the knuckle 104”, and pin 110” is inserted through the bore of the bushing 108”. Additionally, the tail 1102 of the knuckle 104” is inserted into the second spine 102b, while the outer surface 1103 of the knuckle 104” abuts the concave abutment surface 1304 of the first spine 102a. Accordingly, gaps and ligature points are avoided, but the first spine 102a is nonetheless capable of pivoting relative to the knuckle 104”. As shown in the view of Figure 15A, the second spine 102b and the knuckle 104” shown comprise a first hinge member 112”, while the first spine 102a comprises a second hinge member 114”. The first and second hinge members 112”, 114” are pivotally coupled to each other the tail 1100 of the knuckle 104” is received within the socket 1114 of the second spine 102b; and the outer curved surface of the knuckle 104” abuts the concave curved surface 1304 of the first spine 102a.

As the reader will understand, because the knuckle 108” directly abuts the first spine 102a as described above, the bridging members 106 from Figure 2 above can be dispensed with. As shown in Figure 15B, three knuckles 108” are attached to the second spine 102b to form the first hinge member 112”; and three knuckles 108” are attached to the first spine 102a to form the second hinge member 114”. No bridging members are present or required. The three knuckles 108” of the first hinge portion 112” are interdigitated with the three knuckles 108” of the second hinge portion 114”. As shown in Figure 15b, the use of interdigitating knuckles 104” with a common pin 110” pivotally secures the first and second hinge members 112”, 114” together. Beneficially, the sliding joint is also entirely concealed in the assembled joint as shown in Figure 15A. Accordingly, ligature points are avoided.

Figures 16-19 show a further embodiment of a double-action hinge according to the present disclosure. The further embodiment of Figures 16-19 is similar to the embodiment of Figures 11-15. Flowever, there are a number of differences, as described below.

Figures 16A and 16B respectively show an end-view, and a side-view, of a first spine 102a’ according to the further embodiment. The first spine 102a’ is similar to the first spine 102, as illustrated by the like reference numerals. An abutment surface 1604 is labelled on the first spine 102a’. The abutment surface 1604 includes the protrusion 1305 extending along the length of the first spine 102a’.

The abutment surface 1604 is for attachment to a door leaf or door frame.

The first spine 102a’ includes a plurality of first holes 1302, a plurality of second holes 1600, and a plurality of third holes 1602, formed therethrough.

Each of the first holes 1302 extends transversely through the first spine 102a’, from the abutment surface 1604 to the socket 1300. Each of the first holes 1302 is countersunk or counterbored into the abutment surface 1604. The first holes 1302 are thereby configured for receiving threaded screws, such that the heads of the threaded screws sit flush with, or recessed from, the abutment surface 1604.

Each of the second holes 1600 is threaded, for receiving a threaded grub screw, and also extends transversely through the spine from the abutment surface 1604 to the socket 1300. The first holes and the second holes are arranged along a centreline of the abutment surface 1600, as shown in Figure 16B. Accordingly, they are positioned such that each of the first and second holes opens into the socket 1300 so as to engage a respective knuckle 104”. On the other hand, the third holes 1602 are arranged along the opposing lateral edges of the spine. The third holes are provided for securing the hinge to a door leaf or door frame.

Figures 17A and 17B respectively show an end-view, and a side-view, of a second spine 102b’ according to the further embodiment. The second spine 102b’ is similar to the second spine 102b, as illustrated by the like reference numerals. However, the second spine 102b’ has a flat abutment surface 1704 for abutment with a door leaf or door frame. The abutment surface 1704 does not have a channel extending along its length. Additionally, the second spine 102b’ has a plurality of first holes 1402, a plurality of second holes 1700, and a plurality of third holes 1702. The arrangement and configuration of the holes is the same as described above for Figures 16A and 16B.

Figure 18 shows an assembled end-view of a continuous double-action hinge 100”’ according to the further embodiment. As shown, the continuous double action hinge 100”’ comprises the first spine 102a’ of Figures 16A-16B, the second spine 102b’ of Figures 17A-17B, knuckles 104” from Figures 11A-11B, bushings 108” from Figure 12, and a pin 110”. The assembled hinge has a first hinge portion 112”’, and a second hinge portion 114”’. Also shown in Figure 18 are threaded screws 1800. The screws 1800 extend through the first holes 1302, 1402, and are screwed into the threaded openings 1140 formed in the knuckles 104”. Accordingly, the screws 1800 are attached to the knuckles, and prevent movement of the knuckles 104” along the spines 102a’, 102b’.

Figure 19 shows a side-view of the assembled continuous double-action hinge 100”’ from Figure 18. Shown in Figure 19 are the threaded screws 1800, which are screwed into the knuckles 104” to prevent movement of the knuckles 104” along the spines 102a’, 102b’. Also shown are threaded grub screws 1802, which are screwed into the threaded second holes 1600, 1700, so as to bear against the knuckles 104”. Accordingly, the threaded grub screws 1802 bias the knuckles 104” away from the spines 102a’, 102b’, while the threaded screws 1800 bias the knuckles 104” towards the spines 102a’, 102b’. Because the screws 1800, 1802 work in opposite directions from one another, they enable the exact positions of the knuckles 104” relative to the spines 102a’, 102b’ (in particular, the transverse separations of the knuckles 104” from the spines 102a’, 102b’) to be minutely and accurately controlled, so as to achieve smooth operation of the hinge. For example, if one knuckle is located slightly too close to its respective spine, such that smooth operation of the hinge is prevented, then the grub screw 1802 bearing against that knuckle can be tightened (i.e. screwed further into the spine) so as to bias the knuckle further from the spine, and thereby correct the position of the knuckle. Similarly, if a knuckle is located slightly too far away from its respective spine, then the threaded screw 1800 attached to that knuckle can be tightened, so as to more the knuckle closer to the spine and thereby correct the position of the knuckle.

In the further embodiment, one bushing 108” may be inserted into each end of each knuckle.

Fabrication

A method of fabricating a continuous hinge (such as the continuous hinge 100, or the continuous hinge 100’, or the continuous hinge 100”) will now be described, with reference to Figure 9.

At step 900, the spines 102/1027102a/102b are formed by aluminium extrusion.

At step 902, the aluminium spines are then cut to size. In some examples, both spines 102/102’ are cut from a single extruded piece.

At step 904, the knuckles 104/1047104” are formed by aluminium extrusion. At step 906, the aluminium knuckles are then cut to size. Multiple of the aluminium knuckles are cut from a single extruded piece. In some examples, all of the knuckles are cut from a single extruded piece.

At step 908, the bridging members 106/106’ are formed by aluminium extrusion.

At step 910, the bridging members are then cut to size. Multiple of the bridging members are cut from a single extruded piece. In some examples, all of the bridging members are cute from a single extruded piece. This step is omitted for the continuous hinge 100”.

At step 912, the first hinge portion 112/112’ is assembled by ‘threading’ hinge portions and bridging members alternately along the first sliding joint profile one of the spines. Regarding the first hinge portion 112”, step 912 comprises threading knuckles 104” along the second spine 102b, arranging the knuckles 104” along the second spine 102b so that they’re equally spaced from one another; and securing them in place using screws, pins or rivets.

At step 914, the second hinge portion 114/114’ is assembled by similarly ‘threading’ hinge portions and bridging members alternately along the first sliding joint profile of the other of the spines. Regarding the second hinge portion 114”, step 912 comprises threading knuckles 104” along the first spine 102a, arranging the knuckles 104” along the first spine 102a so that they’re equally spaced from one another; and securing them in place using screws, pins or rivets.

At step 916, the continuous hinge 100/1007100” is assembled by arranging the first and second hinge portions such that their knuckles interdigitate; and passing a pin 110/1107110” through a single channel formed through the knuckles (i.e. defined by the aligned bores of the knuckles). Bushings (where used) are placed between adjacent knuckles. In the case of the continuous hinge 100”, one bushing 108” is affixed to each end of each knuckle 104”.

In Figure 9, fabrication of the spines, knuckles and bridging members are shown as being performed in parallel. This leads to manufacturing efficiencies when performed on a large scale. However, in smaller manufacturing plants, these steps may be performed sequentially.

It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other implementations will be apparent to those of skill in the art upon reading and understanding the above description. For example, the constituent parts could be manufactured by 3D printing, such as additive manufacturing, rather than by aluminium extrusion. Although the present disclosure has been described with reference to a specific example implementation, it will be recognized that the disclosure is not limited to the implementations described, but can be practiced with modification and alteration insofar as such modification(s) and alteration(s) remain within the scope of the appended claims. Further, features of the continuous hinge 100, the double-action continuous hinge 100’, and the continuous hinge 100” can be combined, insofar as such a combination is technically possible. Accordingly, the specification and drawings are to be regarded in an illustrative sense rather than a restrictive sense. The scope of the disclosure should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

The present disclosure also includes a number of examples according to the following numbered clauses.

1. A continuous hinge comprising: a first hinge portion comprising a first plurality of knuckles attached to a first spine; and a second hinge portion comprising a second plurality of knuckles attached to a second spine, the second plurality of knuckles being interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles; wherein attachment between the first spine and the first plurality of knuckles comprises a first sliding joint.

2. The continuous hinge of clause 1 , wherein attachment between the second spine and the second plurality of knuckles comprises a second sliding joint.

3. A continuous hinge comprising: a first hinge portion comprising a first plurality of knuckles; and a second hinge portion comprising a second plurality of knuckles, the second plurality of knuckles being interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles; wherein each knuckle is a separate piece.

4. The continuous hinge of any preceding clause, wherein each knuckle comprises a generally cylindrical barrel.

5. The continuous hinge of any preceding clause, wherein the knuckles are substantially identical to one another. 6. The continuous hinge of any preceding clause, wherein each knuckle has a substantially uniform cross-sectional profile.

7. The continuous hinge of any preceding clause, further comprising a pin passing through the knuckles.

8. The continuous hinge of any of clauses 3 to 7, wherein: the first hinge portion further comprises a first spine attached to the first plurality of knuckles; and the second hinge portion further comprises a second spine attached to the second plurality of knuckles.

9. The continuous hinge of clause 1 , 2 or clause 8, wherein each of the first spine and the second spine has a uniform cross-sectional profile.

10. The continuous hinge of clause 8, wherein: attachment between the first spine and each of the first plurality of knuckles comprises a first sliding joint; and attachment between the second spine and each of the second plurality of knuckles comprises a second sliding joint.

11. The continuous hinge of any of clause 8-10, wherein at least one of the first spine and the second spine comprises a c-shaped portion for receiving a door leaf.

12. The continuous hinge of clause 11 , wherein the or each c-shaped portion comprises two parallel walls for receiving a door leaf therebetween.

13. The continuous hinge of any of clause 8-12, wherein: the first hinge portion further comprises a first plurality of bridging members attached to the first spine, each of the first plurality of bridging members positioned adjacent a respective one of the second plurality of knuckles; and the second hinge portion further comprises a second plurality of bridging members attached to the second spine, each of the second plurality of bridging members positioned adjacent a respective one of the first plurality of knuckles; wherein each bridging member is a separate piece.

14. The continuous hinge of clause 13, wherein the bridging members are substantially identical to one another.

15. The continuous hinge of any of clause 13-14, wherein each bridging member has a substantially uniform cross-sectional profile.

16. The continuous hinge of any of clause 13-15, wherein: attachment between the first spine and each of the first plurality of bridging members comprises the first sliding joint; and attachment between the second spine and each of the second plurality of bridging members comprises the second sliding joint.

17. The continuous hinge of any of clause 13-16, wherein: each of the first plurality of bridging members comprises a concave surface that sits substantially flush with an outer surface of a respective one of the second plurality of knuckles; and each of the second plurality of bridging members comprises a concave surface that sits substantially flush with an outer surface of a respective one of the first plurality of knuckles.

18. The continuous hinge of clause 1 , wherein each knuckle comprises at least one bushing configured such that relative rotation of the knuckle and the at least one bushing is prevented.

19. The continuous hinge of clause 1 , wherein each of the first plurality of knuckles is secured to the spine by a transverse-extending screw, pin or rivet.

20. The continuous hinge of clause 1 , wherein the second spine comprises a concave abutment surface configured to abut a curved outer surface of each of the first plurality of knuckles. 21. A method of manufacturing a continuous hinge according to any preceding clause, the method comprising: forming the constituent parts by extrusion; and assembling the continuous hinge from the constituent parts.

22. The method of clause 21 , wherein the constituent parts comprise the knuckles, and wherein forming the knuckles by extrusion comprises: extruding a plurality of the knuckles as a single piece by extrusion; and separating the single piece into the plurality of the knuckles.

Claims

1. A continuous hinge comprising: a first hinge portion comprising a first plurality of knuckles attached to a first spine; and a second hinge portion comprising a second plurality of knuckles attached to a second spine, the second plurality of knuckles being interdigitated with the first plurality of knuckles and pivotally coupled to the first plurality of knuckles; wherein attachment between the first spine and the first plurality of knuckles comprises a first sliding joint; wherein each knuckle of the first plurality of knuckles is secured in place by at least one screw, pin, or rivet extending through the first spine and into the knuckle.

2. The continuous hinge of claim 1 , wherein attachment between the second spine and the second plurality of knuckles comprises a second sliding joint.

3. The continuous hinge of claim 1 or claim 2, wherein each knuckle comprises a generally cylindrical barrel.

4. The continuous hinge of any preceding claim, wherein the knuckles are substantially identical to one another.

5. The continuous hinge of any preceding claim, wherein each knuckle has a substantially uniform cross-sectional profile.

6. The continuous hinge of any preceding claim, further comprising a pin passing through the knuckles.

7. The continuous hinge of any preceding claim, wherein each of the first spine and the second spine has a uniform cross-sectional profile.

8. The continuous hinge of any preceding claim, wherein at least one of the first spine and the second spine comprises a c-shaped portion for receiving a door leaf.

9. The continuous hinge of claim 8, wherein the or each c-shaped portion comprises two parallel walls for receiving a door leaf therebetween.

10. The continuous hinge of claim 2, wherein: the first hinge portion further comprises a first plurality of bridging members attached to the first spine, each of the first plurality of bridging members positioned adjacent a respective one of the second plurality of knuckles; and the second hinge portion further comprises a second plurality of bridging members attached to the second spine, each of the second plurality of bridging members positioned adjacent a respective one of the first plurality of knuckles; wherein each bridging member is a separate piece.

11. The continuous hinge of claim 10, wherein the bridging members are substantially identical to one another.

12. The continuous hinge of any of claims 10-11, wherein each bridging member has a substantially uniform cross-sectional profile.

13. The continuous hinge of any of claims 10-12, wherein: attachment between the first spine and each of the first plurality of bridging members comprises the first sliding joint; and attachment between the second spine and each of the second plurality of bridging members comprises the second sliding joint.

14. The continuous hinge of any of claims 10-12, wherein: each of the first plurality of bridging members comprises a concave surface that sits substantially flush with an outer surface of a respective one of the second plurality of knuckles; and each of the second plurality of bridging members comprises a concave surface that sits substantially flush with an outer surface of a respective one of the first plurality of knuckles.

15. The continuous hinge of any preceding claim, wherein each knuckle comprises at least one bushing configured such that relative rotation of the knuckle and the at least one bushing is prevented.

16. The continuous hinge of any preceding claim, wherein the second spine comprises a concave abutment surface configured to abut a curved outer surface of each of the first plurality of knuckles.

17. The continuous hinge according to any preceding claim, wherein each knuckle is biased away from its respective spine by a transverse-extending grub screw.

18. A method of manufacturing a continuous hinge according to any preceding claim, the method comprising: forming the constituent parts by extrusion; and assembling the continuous hinge from the constituent parts.

19. The method of claim 18, wherein the constituent parts comprise the knuckles, and wherein forming the knuckles by extrusion comprises: extruding a plurality of the knuckles as a single piece by extrusion; and separating the single piece into the plurality of the knuckles.