The present invention relates to door stop mechanisms, and more particularly to hinge-integrated adjustable door stops.

A variety of mechanisms are currently used to act as door stops to stop motion of a door at a desired location, with a variety of problems. Some door stops mount to an adjacent wall and are designed to impact a portion of the door or door handle to stop motion of the door. Such door stops have several problems. They are limited in that they are generally only able to stop the door at a single location.

Additionally, they are an additional component to the door system, increasing costs and possible failures. When the door is not engaged to such door stops, they protrude from the wall where they can be in the way (such as for vacuuming or other cleaning) and are visually unappealing. Finally, it is possible for such systems to result in holes and/or dents in the door and/or wall.

Alternatively, similar door stops are attached to the doors and stop the doors by a portion of the door stop striking a wall structure, commonly the base board or other structure on the wall. Such systems have many of the same problems as the wall-mounted stops. If the location of striking the wall is insufficiently reinforced or the door stop is poorly placed, the result may be a hole or holes in the wall. These systems also mar the appearance of the door and provide only minimal or no adjustability of the location of stopping the door. As a separate component, they also add costs to a door system.

Other door stops are floor-mounted. While such stops provide much better adjustability of the location of stopping the door, these stops also have significant problems. Such door stops are commonly located well out from the wall and are therefore a significant trip hazard. Additionally, the stops may require some integration with existing flooring, and once placed are not easy to change the location of stopping the door, as it may be necessary to repair the floor at the original location. These door stops also add costs to a door system.

Still other stops are hinge mounted. One commonly-used hinge-mounted door stop is of the type shown in U.S. Patent No. 3,913,717, and utilizes a pair of arms mounted on top of the hinge pin to impact the door and the casing around the door. While such systems are more-easily adjustable than other systems, they still have significant problems. Such systems are visually unappealing, and commonly result in holes in many doors, such as hollow-core doors. Other door stop systems have similar problems to those discussed above. SUMMARY OF THE INVENTION

Implementation of the invention provides a hinge, such as a hinge for a door, having a hinge-integrated stop. The hinge includes a first hinge leaf with a substantially-planar portion and a knuckle and a second hinge leaf with a

substantially-planar portion and a knuckle. The hinge also includes a hinge pin and a door stop element. When the hinge is assembled with the hinge pin passing through the knuckles of the first hinge leaf and the second hinge leaf, the door stop element is hidden within the knuckles.

Further implementation of the invention provides a hinge, such as a hinge for a door, having a hinge-integrated stop. The hinge includes a first hinge leaf having a substantially-planar portion with a pivot edge and a top edge. The first hinge leaf includes at least a first knuckle extending from the pivot edge of the substantially- planar portion of the first hinge leaf near the top edge. The first knuckle of the first leaf includes an inner splined surface.

The hinge also includes a second hinge leaf having a substantially -planar portion having a pivot edge. The second hinge leaf also includes a first knuckle extending from the pivot edge of the substantially -planar portion of the second hinge leaf, where the first knuckle has an inner surface and a first knuckle stop element on the inner surface.

A hinge pin completes the hinge. The hinge pin has a shaft having a shaft diameter and an upper splined portion having fingers extending beyond the shaft diameter and a hinge pin stop element located on the shaft below the upper splined portion.

One manner by which the hinge is assembled and the stop position chosen is by attaching the first hinge leaf to one of a door and a door frame, attaching the second hinge leaf to the other of the door and the door frame at a position

corresponding to a location of the first hinge leaf, and positioning the door proximate the door frame such that the first knuckle of the first hinge leaf is substantially aligned over the first knuckle of the second hinge leaf. The hinge pin is inserted through the first knuckle of the first hinge leaf and the second knuckle of the second hinge leaf until the upper splined portion of the hinge pin is located just above the inner splined surface of the first knuckle of the first hinge leaf. Then the hinge pin is rotated with respect to the first hinge leaf to a position defining a stop position for the door and is then fully inserted, whereby the upper splined portion of the hinge pin engages the inner splined surface of the first knuckle of the first hinge leaf. This engagement prevents rotation of the hinge pin with respect to the first hinge leaf.

The hinge-integrated stop serves to stop the door at a desired position. As the door is opened or otherwise rotated around the hinge axis, the first knuckle stop element engages the hinge pin stop element, stopping rotational motion of the second hinge leaf with respect to the hinge pin and the first hinge leaf, stopping motion of the door at the desired position.

Improvements to the hinge-integrated stop facilitate methods for

manufacturing the hinge and the integrated stop elements. Other improvements to the hinge-integrated stop improve the ability of the hinge and the hinge-integrated stop to withstand large forces. Other improvements ensure that if a failure mode is encountered, the function of the hinge is maintained and that the part that fails is the hinge pin, which is readily replaceable. Further advantages of the improvements will be discussed in more detail herein or will become apparent from the description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

Figure 1 shows a view of one embodiment of a hinge with a hinge pin removed for illustration purposes;

Figure 2 shows a top and a side view of a first hinge leaf of the embodiment of

Figure 1;

Figure 3 shows a top and a side view of a second hinge leaf of the embodiment of Figure 1;

Figure 4 shows a side view and a cross-sectional view of the hinge pin of the embodiment of Figure 1;

Figure 5 shows a view of an alternate embodiment of a hinge with a hinge pin removed for illustration purposes;

Figure 6 shows a top view and a partial side view of a first hinge leaf of the embodiment of Figure 5; Figure 7 shows a cross-sectional view and a side view of a second hinge leaf of the embodiment of Figure 6;

Figure 8 shows a side view of a hinge pin similar to the hinge pin of the embodiment of Figure 5;

Figure 9 shows top, side, and bottom views of a first hinge leaf having inner splined surfaces on multiple knuckles;

Figure 10 shows an embodiment of a hinge with a hinge pin removed for illustration purposes;

Figure 11 shows an alternate embodiment of a second hinge leaf;

Figure 12 shows an alternate embodiment of a hinge;

Figures 13-23 show various perspective views of another embodiment of a hinge;

Figures 24 and 25 show alternate embodiments of a hinge pin; and

Figures 26-27 show various view of an alternate embodiment of a hinge. DETAILED DESCRIPTION OF THE INVENTION

A description of embodiments of the present invention will now be given with reference to the Figures. It is expected that the present invention may take many other forms and shapes, hence the following disclosure is intended to be illustrative and not limiting, and the scope of the invention should be determined by reference to the appended claims.

Embodiments of the invention provide a hinge, such as a hinge for a door, having a hinge-integrated stop. The hinge includes a first hinge leaf with a substantially-planar portion and a knuckle and a second hinge leaf wit a substantially- planar portion and a knuckle. The hinge also includes a hinge pin and a door stop element. When the hinge is assembled with the hinge pin passing through the knuckles of the first hinge leaf and the second hinge leaf, the door stop element is hidden within the knuckles.

Further embodiments of the invention provide a hinge, such as a hinge for a door, having a hinge-integrated stop. The hinge includes a first hinge leaf having a substantially-planar portion with a pivot edge and a top edge. The first hinge leaf includes at least a first knuckle extending from the pivot edge of the substantially- planar portion of the first hinge leaf near the top edge. The first knuckle of the first leaf includes an inner splined surface.

The hinge also includes a second hinge leaf having a substantially -planar portion having a pivot edge. The second hinge leaf also includes a first knuckle extending from the pivot edge of the substantially -planar portion of the second hinge leaf, where the first knuckle has an inner surface and a first knuckle stop element on the inner surface.

A hinge pin completes the hinge. The hinge pin has a shaft having a shaft diameter and an upper splined portion having fingers extending beyond the shaft diameter and a hinge pin stop element located on the shaft below the upper splined portion.

One manner by which the hinge is assembled and the stop position chosen is by attaching the first hinge leaf to one of a door and a door frame, attaching the second hinge leaf to the other of the door and the door frame at a position

corresponding to a location of the first hinge leaf, and positioning the door proximate the door frame such that the first knuckle of the first hinge leaf is substantially aligned over the first knuckle of the second hinge leaf. The hinge pin is inserted through the first knuckle of the first hinge leaf and the second knuckle of the second hinge leaf until the upper splined portion of the hinge pin is located just above the inner splined surface of the first knuckle of the first hinge leaf. Then the hinge pin is rotated with respect to the first hinge leaf to a position defining a stop position for the door and is then fully inserted, whereby the upper splined portion of the hinge pin engages the inner splined surface of the first knuckle of the first hinge leaf. This engagement prevents rotation of the hinge pin with respect to the first hinge leaf.

The hinge-integrated stop serves to stop the door at a desired position. As the door is opened or otherwise rotated around the hinge axis, the first knuckle stop element engages the hinge pin stop element, stopping rotational motion of the second hinge leaf with respect to the hinge pin and the first hinge leaf, stopping motion of the door at the desired position.

In the description, embodiments of hinges are described with respect to a door hinge for providing hinged movement around a substantially-vertical axis to a door. As such, references in the description and in the claims to "vertical" should be understood to refer to refer to a direction substantially parallel to a rotational axis of the hinge, as door hinges are commonly used with axes of rotation that are substantially vertical. Thus, "vertical" as used herein, when referring to hinges where the axis of rotation is horizontal or any other orientation, should be understood as being roughly parallel to the longitudinal axis of the hinge pin.

Figure 1 shows a first embodiment of a hinge. The hinge includes a first hinge leaf 10 and a second hinge leaf 12. The first hinge leaf 10 includes a substantially- planar portion 14 which has a top edge 16, a bottom edge 18, and a pivot edge 20. The pivot edge 20 is the edge of the substantially-planar portion 14 adjacent to or closest to the axis of rotation of the first hinge leaf 10 with respect to the second hinge leaf 12. A first knuckle 22 extends from the pivot edge 20 near the top edge 16 of the substantially-planar portion 14.

In this embodiment, the first knuckle 22 is formed from an extension of the material (commonly metal) forming the substantially -planar portion 14, where the extension has been bent in a curved way to form a roughly-cylindrical shape. A second knuckle 24 extends from the pivot edge 20 near the bottom edge 18 of the substantially-planar portion 14. The second knuckle 24 is also in a roughly-cylindrical shape. A third knuckle 26 extends from the pivot edge 20 near the center of the pivot edge 20, and is also bent or formed into a roughly-cylindrical shape. Figure 2 shows more-detailed top and side views of the first hinge leaf 10 of Figure 1.

As is illustrated in Figure 2, the first knuckle 22 includes an inner splined surface 28. The inner splined surface 28 is provided on at least an upper portion of the first knuckle 22. The inner splined surface 28 may be formed before the first knuckle 22 is rolled up into its roughly-cylindrical final shape, as shown in the side view of Figure 2. When the first knuckle 22 is rolled up, the inner splined surface 28 forms a splined opening 30, as shown in the top view of Figure 3.

The embodiment of the hinge shown in Figure 1 also includes the second hinge leaf 12. The second hinge leaf 12 includes a substantially-planar portion 32 having a pivot edge 34 which is the edge adjacent to or closest to the axis of rotation of the second hinge leaf 12 with respect to the first hinge leaf 10. A first knuckle 36 and a second knuckle 38 extend from the pivot edge 34 of the substantially -planar portion 32. The first knuckle 36 and the second knuckle 38 each have an inner surface when they are rolled into their roughly-cylindrical forms shown in Figure 1.

At least one of the first knuckle 36 and the second knuckle 38 includes a knuckle stop element. In the hinge of Figure 1, the knuckle stop element is a tab 40 extending inward (toward the center of the roughly-cylindrical space defined by the first knuckle 36 and/or the second knuckle 38) from the inner surface of the first knuckle 36 and/or the second knuckle 38. The embodiment of Figure 1 includes a tab 40 on both the first knuckle 36 and the second knuckle 38, which is shown in outline form in Figure 1, but is shown in more detail in the side and top views of the second hinge leaf 12 in Figure 3. The second hinge leaf 12 is shown with the first knuckle 36 and the second knuckle 38 in rolled form in the top view of Figure 3, and with the first knuckle 36 and the second knuckle 38 before being rolled in the side view of Figure 3. Although the views of Figure 3 show the tabs 40 as being roughly centrally located on the pieces of material that are to be rolled or formed into the first knuckle 36 and the second knuckle 38, it should be understood that the tabs 40 may be located at essentially any vertical or rotational location within the inner surface of the first knuckle 36 and the second knuckle 38 that provides the functionality discussed herein.

Figure 1 also shows the third component of the hinge, namely a hinge pin 42.

The hinge pin 42 of Figure 1 is shown in more detail in Figure 4. Figure 4 includes a side view of the hinge pin 42, as well as a cross-sectional view of the hinge pin 42 taken along the line 4-4 in the direction shown. The hinge pin 42 includes a shaft 44. The shaft 44 has a shaft diameter 46, which roughly corresponds to the size of the holes passing through the various knuckles, so that when the hinge pin 42 is inserted into the knuckles of the two hinge leaves 10, 12, it forms a snug fit.

In the embodiment of the hinge pin 42 shown in Figure 4, the shaft 42 is not uniformly cylindrical. Instead, the shaft includes a circumferential channel 48 at a longitudinal location corresponding to the first knuckle 36 of the second hinge leaf 12 and another circumferential channel 48 at a longitudinal location corresponding to the second knuckle 38 of the second hinge leaf 12. As may best be seen in the cross- sectional view of Figure 4, the circumferential channels 48 extend circumferentially around the shaft 42 from a longitudinal channel 50 to a longitudinal edge 52. The longitudinal edge 52 of each circumferential channel forms a hinge pin stop element that is configured to engage the first knuckle stop element (e.g. tab 40) and the second knuckle stop element (e.g. tab 40) at a certain rotational position of the hinge pin 42 with respect to the second hinge leaf 12.

The hinge pin 42 also includes an upper splined portion 54. The upper splined portion 54 has a plurality of fingers that extend beyond the shaft diameter 46 so that the effective diameter of the upper splined portion 54 is slightly larger than the shaft diameter 46 of the remainder of the shaft 44. Therefore, although the hinge pin 42 may also have a head 56 similar to the heads of standard hinge pins, some embodiments of the hinge pin 42 need not have a conventional head such as head 56, as the slightly -larger diameter of the upper splined portion 54 serves to prevent the hinge pin 42 from moving too far down or falling out of the hinge. The longitudinal channel 50 serves to permit the hinge pin 42 to enter into the knuckles of the hinge leaves 10, 12 as the hinge is assembled, including entering into the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12, even with the presence of the tabs 40.

Thus, the hinge is assembled such as described in the following manner for use with a door. The first hinge leaf 10 is attached to one of a door and a door frame. The second hinge leaf 12 is attached to the other of the door and the door frame at a position corresponding to the location of the first hinge leaf 10, as with other hinges known in the art. This process may be repeated for any other hinges being used for the door. All of the hinges may have hinge-integrated door stops of the type discussed herein, or only a subset of the hinges (e.g. one hinge or two hinges of a three-hinge door) may have hinge-integrated door stops. Once all hinge leaves for all hinges are attached to the door and frame, the door is positioned proximate the door frame such that the openings of the knuckles of the various hinge leaves of the various hinges are substantially aligned.

The hinge pin 42 of one hinge is then inserted into the first knuckle 22 of the first hinge leaf 10 and partially into the first knuckle 36 of the second hinge leaf 12 until the hinge pin 42 reaches the tab 40 of the first knuckle 36. If the hinge pin 42 is not rotated so that the longitudinal channel 50 aligns with the tab 40, the hinge pin 42 strikes the tab 40 and further insertion is impeded. Therefore, the hinge pin 42 is rotated with respect to the second hinge leaf 12 until the longitudinal channel 50 aligns with the tab 40, and the hinge pin 42 can then be further inserted through the first knuckle 36, through the third knuckle 26 of the first hinge leaf 10, and into the second knuckle 38 of the second hinge leaf 12.

The tab 40 of the second knuckle 38 may also impact the hinge pin 42 if slight rotation of the hinge pin 42 occurs while the tab 40 of the first knuckle 36 is aligned with one of the circumferential channels 48. Alternatively, depending on the spacing of the various knuckles, the tab 40 of the first knuckle 36 may impact on an upper surface of the circumferential channel 48. Regardless, this additional impediment may be cleared by slight rotation of the hinge pin 42 with respect to the second hinge leaf 12 until the hinge pin 42 can be almost fully inserted into the hinge.

In most circumstances, insertion of the hinge pin 42 stops just before the upper splined portion 54 enters into and engages with the inner splined surface 28 of the first knuckle 22 of the first hinge leaf 10. Insertion of the hinge pins 42 of the other hinges occurs similarly until all hinge pins 42 of hinges of the type including hinge- integrated door stops are inserted with the upper splined portions 42 located just above the inner splined surface 28. When the hinge pins 42 are inserted in this way, but not fully inserted, the tabs 40 (or other hinge leaf stop elements) are located within the circumferential channels 50, near the bottom of each circumferential channel 50. This allows the hinge pins 42 to be rotated with respect to both of the first hinge leaf 10 and the second hinge leaf. The hinge pins 42 are therefore rotated to a position defining a stop position for the door (a position where, when the door is opened or otherwise moved to that position, the hinge pin stop element (e.g. the longitudinal edge 52) engages the knuckle stop element (e.g. the tab 40) to stop further rotational motion of the door). Thereafter, the hinge pin 42 is fully inserted into the hinge, whereby the upper splined portion 54 engages the inner splined surface 28, preventing further rotation of the hinge pin 42 with respect to the first hinge leaf 10.

When the hinge pin 42 is fully inserted into the hinge, the circumferential channels 48 are each wholly or largely contained within one of the first knuckle 36 and the second knuckle 38 of the second leaf 12. Therefore, when the hinge pin 42 is fully inserted, at least a portion of each of the first knuckle 36 and the second knuckle 38 surround a portion of the hinge pin 42 that has the shaft diameter 46 with the exception of at most the longitudinal channel 50. This maintains or improves the stability of the hinge such that the stability of the hinge is not significantly less than that of a standard hinge.

Because of the engagement of the upper splined portion 54 with the inner splined surface 28, the stop position of the hinge is adjustable to a wide variety of positions, as defined by the fingers of the splined portion 54 and the inner splined surface 28. The adjustability is provided during initial installation, and is always available for later adjustment as needed. For later adjustment, the hinge pin 42 is simply tapped upward slightly so that the upper splined portion 54 no longer engages the inner splined surface 28, and then the hinge pin 42 is turned to a new position with respect to the first hinge leaf 10 and tapped back down.

To ensure a desired positioning of the hinge pin 42 with respect to the first hinge leaf 10, a variety of methods may be used. As one example, the head 56 or one of the fingers of the upper splined portion 54 may be marked to show where the second leaf will stop with respect to the hinge pin 42. Therefore, the hinge pin 42 may be rotated until the mark is pointing in the desired direction, and the hinge pin 42 is then fully inserted. Alternatively, while the door is at a position less open than the desired stop position, the hinge pin 42 may be rotated until the hinge pin stop element (e.g. the longitudinal edge 52) engages the knuckle stop element (e.g. the tab 40). Then, the door is opened to the desired stop location. The opening of the door causes the knuckle stop element to push on the pin stop element, thereby rotating the hinge pin 42 with respect to the first hinge leaf 10. While the door is in the desired stop position, the hinge pin 42 is fully inserted into the hinge, locking the stop position.

In still another alternative, the door is opened to the desired stop position, and the hinge pin 42 is rotated until the hinge pin stop element engages the knuckle stop element. Once engagement is reached, the hinge pin 42 is fully inserted into the hinge, the upper splined portion 54 engages the inner splined surface 28, and the stop position is locked. It should be apparent that where multiple hinges with hinge- integrated stops are used, combinations of these procedures could be used with the various hinges. Once all hinge pins 42 of the various hinges are in place and fully inserted, the hinge pin stop element or elements of each hinge pin 42 are substantially aligned with the hinge pin stop elements of the other hinge pin 42 or hinge pins 42.

Figures 5-8 show an embodiment of an alternate hinge, where the hinge pin stop element and the knuckle stop element are a different type of element. Figure 5 shows a complete hinge, Figure 6 shows top and partial side views of the first hinge leaf 10, Figure 7 shows a side view of the second hinge leaf 10 and a cross-sectional view of the second hinge leaf 10 taken along the line and in the direction 7-7 shown, and figure 8 shows an alternative hinge pin 42. Features of this type of embodiment are similar in many ways to the embodiments discussed with respect to Figures 1-4.

Therefore, the first hinge leaf 10 includes the substantially -planar portion 14 having the top edge 16, the bottom edge 18, and the pivot edge 20. In the first hinge leaf 10, the first knuckle 22 extends from the pivot edge 20 near the top edge 16, the second knuckle 24 extends from the pivot edge 20 near the bottom edge 18, and the third knuckle 26 extends from the pivot edge 20 near the center of the pivot edge 20. The second hinge leaf 12 also includes the substantially -planar portion 32 having the pivot edge 34. In the second hinge leaf 12, the first knuckle 36 and the second knuckle 38 extend from the pivot edge 34. The various knuckles form roughly-cylindrical openings sized to snugly receive the hinge pin 42. However, as may be seen in Figures 5 and 8, the hinge pin 42 of this embodiment is configured differently.

The hinge pin 42 includes the shaft 44, upper splined portion 54 and, optionally, the head 56. Additionally, the shaft 44 has the shaft diameter 46 and the upper splined portion 54 includes fingers extending beyond the shaft diameter 46. The hinge pin 42 of this embodiment lacks the circumferential channel 48 and the longitudinal channel. Instead, the hinge pin 42 is provided with a pair of tabs 58 placed to correspond to the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12. In some embodiments, only a single tab 58 is used. In the illustrated embodiment and in other similar embodiments, the tab 58 serves as the hinge pin stop element.

To accommodate the modified hinge pin 42 and to provide the door stopping function, the various knuckles of the first hinge leaf 10 and the second hinge leaf 12 are formed differently from the previously-discussed embodiments. Specifically, with respect to the first hinge leaf, at least the first knuckle 22 is modified as shown in Figure 6. The inner surface of the first knuckle 22 is modified to include a vertical channel 60. The vertical channel 60 allows the hinge pin 42 to pass through the first knuckle 22 with the tab 58 passing through the vertical channel 60. In embodiments where the hinge pin 42 includes two tabs 58, the third knuckle 26 also includes a similarly -placed vertical channel 60.

Similarly, the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12 are provided with corresponding vertical channels 62. The vertical channels allow the hinge pin 42 to pass into the first knuckle 36 and the second knuckle 38 with the tab 58 passing through the vertical channels 62. In this embodiment, for insertion of the hinge pin 52 to occur, the vertical channel 62 or vertical channels 62 of the second hinge leaf 12 must be substantially aligned with the vertical channel 60 or vertical channels 60 of the first hinge leaf 10. When the hinge pin 42 is inserted into the hinge until the upper splined portion is slightly above and not engaging with the inner splined surface 28, the tabs 58 are wholly located within a circumferential channel 64 on an inner surface of the first knuckle 36 and/or the second knuckle 38 of the second hinge leaf 12. Thereafter, the first hinge leaf 10 and second hinge leaf 12 may be rotated with respect to one another, and the location of the stop position of the door set as previously described. In this embodiment, a substantially-vertical edge 66 of the circumferential channel 64 serves as the knuckle stop element that engages the hinge pin stop element (e.g. tab 58) to stop relative movement between the first hinge leaf 10 and the second hinge leaf 12.

Although not present in all embodiments, the cross-sectional view of the second hinge leaf 12 shown in Figure 7 illustrates one feature that may be incorporated into some embodiments of the invention, including types similar to the embodiment of Figure 1 and types similar to the embodiment of Figure 5. This feature is that at least one of the circumferential channels 64 has a varying depth that is shallower proximate the substantially-vertical edge 66. The shallower depth of the circumferential channel 64 may cause frictional engagement with the tab 58, causing the door to be more likely to slow at least slightly or even stop before the hinge pin stop element and the knuckle stop element fully engage to stop the door. This may serve to reduce or prevent sudden stops of the door and may also serve to lessen rebound of the door after hitting the stop. A similar feature incorporated in the embodiment of Figure 1 utilizes a circumferential channel 48 having a similarly- varying depth.

The hinge pin 42 illustrated in Figure 8 illustrates an additional feature that may be provided for some embodiments. To increase the strength and the security of the positioning of the hinge pin 42 with respect to the first hinge leaf 10, a lower end of the shaft 44 may be provided with a lower splined portion 68. The lower splined portion 68 has fingers that extend no farther than the shaft diameter 46, so that the lower splined portion 68 is able to pass thorugh the various knuckles. The lower splined portion is configured to engage with an inner splined surface 70 of the second knuckle 24 of the first hinge leaf 10 (this inner splined surface 70 is not shown, but may be similar to the inner splined surface 28), as illustrated in the embodiment of the first hinge leaf 10 shown in Figure 9. The inner splined surface 70 of the second knuckle 24 in such embodiments defines a splined opening 72 (when the second knuckle is in a rolled configuration) that is narrower than the splined opening 30 defined by the inner splined surface 28 of the first knuckle 22. Figure 9 shows an embodiment of the first hinge leaf 10 in accordance with such embodiments.

Figure 10 shows another embodiment of a hinge, with the hinge pin 42 removed from the hinge for illustration purposes. The tabs 58 of the hinge pin 42 of this embodiment include a sloped lower edge, the purpose of which will be discussed with respect to the accompanying embodiment of the second hinge leaf 12 shown in Figure 11. This embodiment includes the circumferential channel 64, in which a lower portion includes the varying depth as discussed above, and an upper un-sloped portion 74 is also provided. This un-sloped portion 74 may make it easier to set the hinge pin stop location during use of the hinge, as the tabs 58 on the hinge pin 42 do not encounter resistance when they are located in the un-sloped portion 74 and the hinge pin 42 is rotated with respect to the second hinge leaf 12. Then, when the desired set location is reached, the hinge pin 42 is to be pushed downward. The sloped lower edge of the tabs 58 assists the user in overcoming any resistance encountered as the lower edge of the tabs 58 engages the varying-depth portion of the circumferential channel 64, making final insertion of the hinge pin 42 easier.

Figure 12 shows an embodiment of a hinge and illustrates features that may be incorporated into the hinge to improve strength of the hinge. Improving strength of the hinge may be desirable in some embodiments as greater forces may be encountered at the hinge than are encountered at the hinge with other types of door stops, due to the greater leverage at the hinge. The embodiment of Figure 12 shows four mounting holes 76 on each of the first hinge leaf 10 and the second hinge leaf 12 (rather than the three mounting holes shows in some other illustrated embodiments). The additional mounting hole 76 may ensure more secure connection to a door and door frame, preventing or reducing the likelihood of stripping out screws from the door and/or frame. Additionally, a crease 78 has been added to each of the various knuckles proximate the joint of the knuckles to the respective substantially-planar portions. The crease 78 increases the resistance of that portion of the knuckle to unwanted bending from the original location. Although not shown in Figure 12, similar (or further) strengthening of the various knuckles may be achieved by spot welding each knuckle once it is rolled into its final configuration.

Even with strengthening features such as those illustrated in Figure 12, it is envisioned that forces larger than desired may occasionally be applied to a hinge. While Figure 12 illustrates features that improve strength of the hinge, other features may be provided to deal with exceptional large forces. For example, with respect to embodiments incorporating tabs 58 on the hinge pin 42, the tabs 58 may be designed to break from the shaft 44 at a desired force level. For example, the tabs 58 may be initially formed so as to break away from the shaft 44 at a certain force level.

Alternatively, the tabs 58 may be notched or scored so as to break away from the shaft 44 at a certain force level.

Additionally, even if the tabs 58 are not so designed, the design of such embodiments of the hinge is such that it is anticipated that the most common mode of failure of the hinge-integrated stop will be breakage of the tabs 58. When the tabs 58 are broken, they remain contained within the first knuckle 36 and the second knuckle 38, and the hinge then functions as a normal hinge. Thus, even when failure (designed or otherwise) occurs, the hinge continues to function as a normal hinge. Repair of the hinge to full door-stop functionality is easily achieved by simply purchasing a new matching hinge pin 42. The old, broken, hinge pin 42 is removed, whereupon the broken tabs 58 simply fall out the bottom of the hinge. The new hinge pin 42 is inserted and set as discussed above, and full functionality of the hinge-integrated stop is restored. Hinges and hinge pins 42 in accordance with embodiments of the invention can therefore be made and/or sold that incorporate specific known breaking points of the tabs 58 so as to prevent unwanted damage to a door or frame attached to the hinge.

As still another example, the tabs 58 of the hinge pin 42 may be manufactured or formed such that upon application of sufficient force, the tabs 58 fold away from their normal position rather than breaking off as discussed above. Such folding may be permanent or may be reversible or partially reversible. If the folding is reversible or partially reversible, the tabs 58 may fully or partially return to a normal functioning position to return at least modest stopping ability to the hinge-integrated door stop. Thus, the hinge-integrated door stop may at least partially retain its functionality after an over-force failure until the hinge pin 42 can be replaced. Where a folding capability of the tabs 58 is provided, the hinge pin 42 may optionally be modified so as to contain cavities into which the tabs 58 may fold on occurrence of the over-force event.

Another embodiment of the hinge pin 42 may include a different type of tab 58 providing additional or different features from the embodiments discussed above. In this embodiment, the hinge pin 42 may have an outward appearance essentially identical to the appearance of any hinge pin 42 shown in Figures 5, 8, 10, or 23-25, however, the tabs 58 may be made retractable such that the tabs 58 may be pushed inward until they are substantially flush with the surrounding surface of the hinge pin 42. Sloped portions of the tabs 58 on the bottom and/or top of the retractable tabs 58 (See Figures 23-25) may facilitate inward displacement of the tabs 58 as the hinge pin 42 is inserted into or removed from the hinge. In this embodiment, the vertical channels 60, 62 may not be necessary for insertion of the hinge pin 42, as the tabs 58 are displaced during insertion, and then spring out (e.g. by a spring force) into their stop-engaging functional position when the hinge pin 42 is fully inserted in the hinge.

Figures 13-23 illustrate various views of another embodiment of the invention. Figure 13 shows a perspective view of the assembled hinge. Figures 14-17 show various perspective views of the first hinge leaf 10 of this embodiment. Figure 18 shows a perspective view of a splined insert 80 for insertion into the second knuckle 24 of the first hinge leaf, as is shown inserted in Figure 17. Figures 19-22 show various perspective views of the second hinge leaf 12 of this embodiment. Figure 23 shows a perspective view of the hinge pin 42 of this embodiment. As is illustrated in Figure 13, when the hinge of this embodiment is assembled, it substantially resembles the hinges discussed and shown previously in most regards. Significantly, the integrated door stop features are hidden from view within the various knuckles of the hinge. The most significant difference in appearance is that the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12 have an enlarged diameter or bulge compared with the hinges of previous Figures. There are multiple purposes for this enlargement. First, the bulge serves to preserve the life of a progressive die used to manufacture the second hinge leaf 12, as during manufacture the metal forming the second hinge leaf 12 need not be smashed thinner (or at least not nearly as much), but is instead deformed into a cavity. The deformation forming the buckle also makes the respective knuckles stronger. This change is most visible in Figures 19-22.

Another change that is not visible in the assembled hinge may be seen with reference to Figures 14-17 and 23. The first knuckle 22 of the first hinge leaf 10 is provided with an upper protrusion 82 that extends upward of the upper edge of the first knuckle 22 but inward of an outermost surface of the first knuckle 22. As may be seen in Figure 14, the first knuckle 22 is the one that has the inner splined surface 28. As such, the first knuckle 22 is subject to additional forces each time the door stop features of the hinge are used, which forces may tend to cause the first knuckle 22 to tend to open over time, which could allow the hinge pin 42 to eventually slip and not provide the desired door stop features. As may be seen in Figure 23, the head 56 of the hinge pin 23 in this embodiment is mushroom shaped and has a lower cavity 84 that accepts the upper protrusion 82 when the hinge pin 23 is fully inserted into the hinge. The engagement of the upper protrusion 82 with the lower cavity 84 provides additional security to the first knuckle 22 against unwanted opening of the first knuckle 22.

Figures 15-17 show perspective views of the first hinge leaf 10 looking approximately down and up through the hinge pin channel. The view of Figure 15 shows the upper protrusion and the vertical channel 60 of the first knuckle 22. The view of Figure 17 shows an optional feature that may be included in certain embodiments of the hinge for further security of engagement between the first hinge leaf 10 and the hinge pin 42, specifically the splined insert 80. The view of Figure 16 shows the first hinge leaf 10 with the splined insert 80 removed from the second knuckle 24, illustrating a splined insert opening 86 configured to receive the splined insert 80. The splined insert 80 has a notch 88 and the splined insert opening 86 has a notch tab 90 to ensure proper alignment of the splined insert 80 within the splined insert opening 86 such that the fingers of the splined insert 80 align properly relative to the fingers of the splined opening 30 so that the hinge pin 42 can be properly inserted therein.

As may be appreciated from Figures 17 and 18, the splined insert 80 is a continuous element and is not a rolled element like the various knuckles. As such, the splined insert 80 is extremely resistant to undesired opening that could allow the fingers of the splined insert 80 to disengage from corresponding fingers on the lower splined portion 68 of the hinge pin 42. The splined insert 80 may be fixedly attached inside the splined insert opening 86 such as by welding, bonding, and the like. While the embodiment illustrated in Figures 13-23 includes the splined insert 80, other embodiments do not have the splined insert 80 but just the splined interaction between the first knuckle 22 and the hinge pin 42.

As may be seen in Figure 18, the splined insert 80 has twenty-four fingers 92 that are equally spaced around the opening of the splined insert 80. This is intended to be exemplary only, but it will be readily appreciated that having this number of fingers 92 means that the door stop features of the hinge with respect to a single hinge pin 42 may be adjusted in increments of fifteen degrees (three hundred sixty degrees divided by twenty-four). Corresponding numbers of similar fingers are provided on the hinge pin 42 and the splined opening 30 (of course the total number of fingers in the splined opening 30 will be fewer, as there is a gap from the curling of the first knuckle 22 as well as an additional gap for the vertical channel 60). This may be sufficient adjustability in some instances. In other instances, it may be desired to have a finer adjustment capability than fifteen degrees. This finer adjustment may be achieved in one of several fashions. In one exemplary manner, finer adjustment may be achieved by increasing the number of fingers 92 (and decreasing their angular spacing). Thus, if thirty fingers 92 are provided, the door stop angle may be adjusted in twelve-degree increments. If thirty-six fingers 92 are provided, the door stop angle may be adjusted in ten-degree increments.

Depending on the materials used for the various components and any desired strength characteristics, there may be a practical limit on the number of fingers 92 that may be provided, and thus the minimum adjustment angle that can be achieved using a method relying on increasing the number of fingers 92. Instead, a different method may be used that relies on having multiple hinge pins 42, each with the relative rotational location of the fingers 92 rotated a certain amount with respect to the hinge pin stop element (e.g. the tabs 58). For example, returning to the example of Figure 18, a single hinge pin 42 will allow stop adjustment in fifteen-degree increments. If two hinge pins 42 are provided, each having their respective fingers rotated at seven and one-half degrees differently compared to their respective tabs 58, then the stop of the hinge can be adjusted at seven and one-half degree increments by, in part, selecting which of the two hinge pins 42 to use. Similarly, adjustment in five-degree increments can be achieved in the system of Figure 18 using three different hinge pins 42. In this fashion, any adjustment increment for the door stop features can be provided with multiple hinge pins 42. A system with multiple hinge pins 42 may be sold together, or individual hinge pins 42 may be sold separately.

Figures 19-22 show the second hinge leaf 12 of this embodiment, showing how the first knuckle 36 and second knuckle 38 are bulged compared with previously- discussed embodiments. This provides certain potential advantages as discussed previously. The functionality of the hinge remains essentially unchanged when compared with the embodiments discussed previously. The view of Figure 21 shows the un-sloped portion 74, which, as discussed above, may assist in placement of the stop position. The hinge pin 42, as shown in Figure 23 may then be tapped into final place, with sloped bottom portions 94 of the tabs 58 serving to facilitate movement of the tabs 58 over the portion having a varying depth 96 shown in Figure 21.

Although not every element discussed with respect to Figures 1-12 has been discussed with respect to or specifically numbered in Figures 13-23, it is believed that the applicability of such features will be readily apparent from the study of this description and the accompanying Figures.

In situations where opening of one or more of the knuckles occurs and allows slipping of the hinge pin 42 relative to the first hinge leaf 10, one or more of the inner splined surface 28 and the upper splined portion 54 may be subject to unwanted wear that reduces the ability of the hinge-integrated door stop to provide its stopping function against elevated motions. Thus, even though the user will typically be able to simply remove the hinge pin 42 and reset the stop position one or more times after one or more failure events, the wearing that occurs during over- force failure events may eventually reduce the stop functionality of the hinge-integrated door stop to the point where replacement of the hinge pin 42 or the first hinge leaf 10 will be necessary. Embodiments of the invention provide features designed to minimize the possibility of failure. Some of the features of the hinges and hinge-integrated door stops discussed above with respect to Figures 13-23 include features to reduce failure of the hinge- integrated door stop. For example, the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12 incorporate a bulge which makes the respective knuckles stronger and less prone to opening forces that may be encountered as the hinge- integrated stop features are engaged. Additionally, the upper protrusion 82 that extends upward of the upper edge of the first knuckle 22 is configured to engage the lower cavity 84 of the mushroom-shaped head 56 of the hinge pin 42 to effectively make the knuckle a "closed" system resistant to unwanted opening of the first knuckle 22, which unwanted opening could allow the hinge pin 42 to slip. Finally, the splined insert 80 provides similar functionality and "closed" nature to the second knuckle 24.

Additional options may provide the benefits of a "closed" knuckle to minimize or prevent unwanted opening of the respective knuckle. For example, while Figures 13 and 23 show a hinge pin 42 having a mushroom-shaped head 56 with a lower cavity 84, similar functionality may be provided using a separately provided ring or washer. The ring or washer engages or covers the upper protrusion 82 that extends upward of the upper edge of the first knuckle 22 best seen in Figure 14 and serves to prevent or minimize unwanted opening of the first knuckle 22. Use of the ring or washer may reduce the difficulty and cost of manufacturing the hinge pin 42, as the mushroom-shaped head 56 would no longer be needed. The ring or washer may be essentially permanently affixed to the first knuckle 22 at the time of manufacture, and may essentially match the first knuckle 22 and/or the hinge pin 42 in outward appearance.

Another feature that may be used to prevent or reduce the tendency of the first knuckle 22 to open as force is applied to the hinge-integrated door stop at the stop position is to modify the shape of the splines of the upper splined portion 54 and the inner splined surface 28. For example, Figures 2, 6, 9, 15, 17, 18, and 23 show splines that are each individually symmetrical, with both sides of each spline extending at approximately the same angle from the underlying surface, as is also illustrated in Figure 24. In some embodiments, the splines could be modified as shown in Figure 25 so that an engaging surface of each spline extends approximately perpendicular from or normal to the underlying surface. In this way, the engaging surface of the splines of the splined portion 54 and the splines of the inner splined surface 28 would cause less opening force to be applied to the first knuckle 22 (and/or second knuckle 24). This feature could be combined with other features tending to reduce opening of the first knuckle 22 and/or second knuckle 24 discussed herein.

Still another feature that may be used to prevent or reduce the tendency of the first knuckle 22 and/or second knuckle 24 to open as force is applied to the hinge- integrated door stop at the stop position is illustrated with respect to Figures 26-27. The feature shown in these Figures is a reversal of the orientation or direction of forming the knuckles 22, 24, 26 of the first hinge leaf 10. In effect, the first hinge leaf 10 is formed such that the first hinge leaf 10 is flipped over end-for-end before being used as part of the hinge, such that any force applied to the first knuckle 22 and/or the second knuckle 24 by engagement of the door stop features is applied to the first knuckle 22 and/or the second knuckle 24 in a direction that tends to tighten or close the first knuckle 22 and/or the second knuckle 24.

Figure 26 shows a perspective view of a complete hinge of such an embodiment. As the hinge is opened in the direction shown by the arrow in Figure 26, the tabs 58 of the hinge pin 42 engage the substantially vertical edges 66 of the circumferential channels 64 of the first knuckle 36 and the second knuckle 38 of the second hinge leaf 12. This applies a rotational force to the hinge pin 42, which is then applied through the upper splined portion 54 to the inner splined surface 28 of the first knuckle 22 (and correspondingly through the lower splined portion 68 and inner splined surface 70, if present, to the second knuckle 24). In the embodiments discussed prior to Figure 26, such a force would tend to open the first knuckle 22 and/or the second knuckle 24, but in this embodiment, the rotational direction of the force shown by the arrow in Figure 26 tends instead to tighten the first knuckle 22 and/or the second knuckle 24, improving the engagement between the respective splined portions of the hinge pin 42 and the first hinge leaf 10. This modification has been shown in testing to greatly improve the ability of the hinge-integrated door stop to absorb individual and repetitive forces without failing.

Figure 27 shows top-down views of the first hinge leaf 10, shown individually (at top), the second hinge leaf 12, shown individually (in the middle), and the first hinge leaf 10 and the second hinge leaf 12 shown together prior to inserting the hinge pin 42 (at bottom). As can be seen from these views, the knuckles of the first hinge leaf 10 are bent differently than is normal for hinges so as to allow the first hinge leaf 10 and the second hinge leaf 12 to mate properly and allow an attached door to completely close. Additionally, it may be seen that the respective knuckles of the first hinge leaf 10 and the second hinge leaf 12 curl in the same direction when assembled into a finished hinge, which is contrary to most normal hinges where the knuckles normally curl in opposite directions. While this places the gap at the end of the curl of the knuckles of the first hinge leaf 10 outward of the finished and closed hinge, the difference in appearance will be minimal and typically barely noticeable.

In some instances, the forces applied to the hinge-integrated stop of such an embodiment may result in over-tightening of either the first knuckle 22 or the second knuckle 24. Such over-tightening may make it more difficult to remove the hinge pin 42. To make it easier to remove the hinge pin 42 in the event of over-tightening, the ends of the first knuckle 22 and the third knuckle 26 may be chamfered, and a slight indentation may be coined in the location where the hinge pin 42 is inserted so that in the event of an over- force event where the first knuckle 22 is forced into the other side of the metal, the hinge pin 42 can still be removed.

The inner splined surface 28 of the first knuckle 22 has been shown and discussed with respect to Figures 2-17 as occupying an uppermost portion of the first knuckle 22. Manufacture of the inner splined surface 28 has been discussed with respect to use of a progressive die. A similar effect may be achieved using a broaching process, such as subsequent to the point in time when the first knuckle 22 has been formed into its final curved shape. Where broaching is used to form the inner splined surface 28, the inner splined surface 28 may extend for any desired length of the first knuckle 22, including the entire length of the first knuckle 22. Similar considerations may apply for forming the inner splined surface 70, if present, in the second knuckle 24.

Through testing of various manufacturing processes, it has been found that a medial placement of the inner splined portion around the center of the first knuckle 22 facilitates manufacture of the first hinge leaf 10 in certain instances. Specifically, where manufacture of the inner splined surface 28 has been achieved using a progressive die, the first knuckle 22 is then formed into its curled or curved shape using another die. It can be difficult to achieve a proper curved/cylindrical shape without the die causing deformation of the splines of the inner splined surface 28 when the inner splined surface 28 is located at the top of the first knuckle 22 as shown and discussed with respect to Figures 2-17. Therefore, embodiments of the invention embrace medial placement of the inner splined surface 28 within the first knuckle 22, such that upper and lower portions of the first knuckle 22 can receive cams during the process of bending the knuckles into shape. The first knuckle 22 is then formed around the cams without damaging the splines inside the first knuckle 22. The smooth inner portions of the first knuckle 22 both above and below the inner splined surface 28 thus facilitate forming of the first knuckle 22 into its final shape without causing unwanted deformation of the inner splined surface 28. Similar considerations may apply for forming the inner splined surface 70, if present, in the second knuckle 24.

Regardless of the location of the upper splined surface 28 in the first knuckle

22 or the location of the inner splined surface 70 in the second knuckle 24, the manner for forming the respective splined surface may be any appropriate mechanism now known in the art or later adopted. For example, upset forging may be used to form the various splined surfaces. Similarly, coining may be used to form the respective splined surfaces. As discussed above, broaching is another option for forming the splined surfaces. In many instances, the method of manufacture may result in strengthening of the splines and of the respective knuckles. As may be appreciated, as the overall inner diameter of the second knuckle 24 may be somewhat smaller when the inner splined surface 70 is present (so as to engage the lower splined portion 68 as discussed above), the manufacturing method chosen may result in a slightly-reduced outer diameter of the second knuckle 24. Alternatively, the method of manufacture may be selected and/or modified to result in a slightly greater overall thickness of the finished metal of the second knuckle 24.

While not illustrated in the Figures, embodiments of the invention may be used with bearing type hinges. The bearings in such hinges may be modified from standard bearings so as to allow passage of any stop elements contained on the hinge pin 42 (e.g. the tabs 58). Another feature that may be incorporated into embodiments of the hinge pin 42 may include a feature to permit a tool (e.g. a Phillips-head or slot- head screwdriver, a star drive, a hex wrench, or the like) to be inserted into the hinge pin 42 from below (e.g. the end away from the head 56) while the hinge pin 42 is in the knuckles but above its position securing a set position so that the hinge pin 42 may be rotated to its set position using the tool.

One contemplated benefit of the various embodiments of the present invention is the ease with which the embodiments of the invention may be manufactured and used. Essentially, the manufacturing processes currently used for manufacturing hinges need only be slightly modified to accommodate the invention. The stamping and knuckle-forming processes currently used to form hinges are acceptable to manufacture first hinge leaves 10 and second hinge leaves 12 in accordance with embodiments of the invention. A minor addition of steps may be used in some instances to incorporate the inner splined surface 28, to add the tabs 40, the circumferential channels 64, the vertical channels 60, the vertical channels 62, or any other knuckle stop elements or similar elements to those discussed herein. Hinge pins 42 in accordance with embodiments of the invention may be forged as are current hinge pins, with modified forging to incorporate the features discussed herein.

Another contemplated benefit is the fact that the hinge-integrated door stop is readily adjustable. Additionally, the adjustability is achieved without any need for modification or repair of an attachment point such as with prior door-, wall-, or floor- mounted door stops.

Another contemplated benefit is the fact that the door stop is entirely contained within the hinge, and is therefore essentially undifferentiated from prior hinges. The embodiments of the invention may therefore be used in a wide variety of situations, including situations where aesthetics of the hinge are of high importance. As the hinge-integrated door stop is located within the hinge, it also prevents any need to have external elements that are potential hazards and/or annoyances with respect to cleaning.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

What is claimed and desired to be secured by Letters Patent is: