The invention relates to appliance hinge assemblies for operatively connecting an appliance door to an appliance body. In particular the invention relates to an improved and efficient appliance hinge assembly. DESCRIPTION OF RELATED ART
Appliance hinge assemblies are employed to facilitate movement of the appliance door to and between a fully closed position and a fully open position. Such hinge assemblies typically comprise of a door mounting lever to which the appliance door is connected and biasing means such as a spring for biasing the door mounting lever into a first position corresponding to the fully closed position of the associated door. The door mounting lever and door connected there to are manually moveable against the biasing force of the spring from the first position to a second position that corresponds to the fully opened position of the door, at which position the weight of the door is sufficient to resist the biasing force of the spring so that the door remains in the fully opened position without continued application of manually opening force to the door. To provide a partially open position of the door, the hinge assemblies are typically provided with a stop member that inhibits movement of a mating glide at a select point which in turn inhibits pivoting movement of the door mounting lever under force of the spring toward its first operative position at a desired intermediate position.
In a typical arrangement, the door mounting lever is pivotally connected to a channel and a glide slides along an inner surface of the channel when the door mounting lever pivots relative to the channel. An example of such a hinge assembly has been described in US 2003/0221285 A1.
Though such hinge assemblies provide a working solution, it has been deemed desirable to enhance such assemblies by providing a smooth operation and increased durability, even when a high force biasing spring is utilized. Conventional designs provide for a stop member that is placed within the channel and accommodates the travel and corresponding stop points of a glide connected to the door lever. While some designs provide a stop with a glide transitioning repeatedly from the channel to the stop member, causing reduced smoothness of operation and wear or damage, other designs provide for a stop member that accommodates the entire travel of the glide. Consequently, the design, manufacture and attachment of the stop to the channel are critical for a smooth and efficient functioning of the hinge assembly. This increases the manufacturing time and processes including the associated inventory cost.
In view of the above, it would be desirable to have a hinge assembly with smooth operation which is cost effective and easy to manufacture and assemble. SUMMARY
The invention relates to a a hinge assembly comprising a channel comprising an inner wall and a pair of side walls projecting outwardly from the inner wall; a door mounting lever that pivots relative to said channel about a pivot axis between a first operative position where said door mounting lever is moved a maximum extent in a first direction and a second operative position where said door mounting lever is moved a maximum extent in a second direction opposite the first direction, at least one roller operatively coupled to the door mounting lever and movable in connection with the channel and in response to movement of the door mounting lever; a spring that biases the roller into continuous engagement with the channel when the door mounting lever is located in both
the first and second operative positions and when said door mounting lever moves between said first and second operative positions, wherein at least one side wall has a profile formed on it, that provides a rolling path for the roller.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The accompanying drawing illustrates the preferred embodiments of the invention and together with the following detailed description serves to explain the principles of the invention. A hinge assembly formed in accordance with the present invention comprises various components and arrangements of components, a preferred embodiment of which is illustrated in the accompanying drawing that form a part hereof and wherein:
Figure 1 illustrates a side view of a hinge assembly in accordance with an embodiment of the invention.
Figure 2 illustrates an elevation view of the hinge assembly of figure 1.
Figure 3 is a schematic illustration of a roller and profile operatively engaged in accordance with an embodiment of the invention.
Figure 4 illustrates a side elevation view of the hinge assembly of figure 1 with the door in the fully open position.
Figure 5 illustrates the hinge assembly at a part open position in accordance with an embodiment of the invention.
Figure 6 illustrates the hinge assembly at a desired intermediate position in accordance with an embodiment of the invention.
Figure 7 illustrates a side view of a channel in accordance with an embodiment of the invention.
Figure 8 illustrates a perspective view of a channel in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
With reference to the accompanying drawings and initially to figure 1, a hinge assembly 10 formed in accordance with the present invention comprises a base or channel 12 adapted for being secured to an appliance frame or chassis. The channel 12 comprises an elongated main channel member 14 having opposite first and second ends 14a, 14b separated from each other along a longitudinal axis. In a preferred embodiment, the main channel member is conformed to include a C-shaped or U-shaped cross section defined by an inner wall 14i, and first and second spaced-apart sidewalls 14f,14s that project outwardly from the inner wall 14i, so that a recess 16 is defined between the first and second sidewalls 14f, 14s.
A door mounting lever 20 is pivotally connected to the channel member 14. As shown the channel 12 preferably comprises a tab 18 connected to or formed as an integral part. The tab provides a location to which a door mounting lever 20 is pivotally connected to the channel member 14 by a fastener Rl such as a rivet, pin or the like. The door mounting lever 20 is adapted for being secured to an associated appliance door by a fastener or any other suitable means. The door mounting lever 20 and door connected thereto pivot about the fastener Rl relative to the channel 12 to and between a first operative position as illustrated in figure 1, and a second operative position as illustrated in figure 4 where the door is fully pivoted away from the appliance to allow free access to the space enclosed by the appliance and the door. In the preferred embodiment as illustrated, the door mounting lever 20 is at least approximately parallel to the main channel member 14 when in the first operative position and lies transverse relative to the main channel member 14 when in the second operative position.
The main channel member 14 defines a slot 14d in the inner wall 14i, and the door mounting lever 20 comprises a tail portion 22 that projects through the slot into the recess 16. The hinge assembly 10 further comprises a spring cam member 30 that is pivotally connected to the tail portion 22 of the door mounting lever 20 by a fastener R2 such as a rivet, pin or the like. As such, pivoting movement of the door mounting lever 20 relative to the channel 12 about the fastener Rl results in movement of the spring cam member 30 axially toward and away from the first and second ends 14 a, 14b of the main channel member 14. These movements are readily apparent upon comparing Figures 1 and 4 with each other. The spring cam 30 comprises first and second opposite ends 30a, 30b, and the tail 22 of the door mounting lever 20 is preferably connected to the spring cam member
30 at a location generally axially between these ends 30a, 30b. Furthermore, its is preferred that the first end 30a be located adjacent the channel member 14 while the second end 30b projects outwardly away from the channel member 14.
The hinge assembly 10 comprises at least one roller 40 operatively coupled to the door mounting lever 20. In the illustrated embodiment, the roller 40 preferable comprises a plastic member, such as a molded plastic member, that is secured to the first end 30a of the spring cam member 30 so as to be operatively coupled to the door mounting lever 20 via spring cam member 30. Alternatively, the roller 40 can be defined integrally or as a sub-assembly construction with the first end 30a of the spring cam member 30.
In accordance with the teachings of the document, the channel has a profile 50 formed on its side walls 14f, 14s and is positioned to be engaged with the rollers 40 for all operative positions of the door mounting lever 20. The profile 50 is cut on the channel or the channel may be formed with the profile. The profile 50 is preferably located on the sidewal Is of the channel 14s and 14f.
With reference to Figures 7 and 8, profile 50 comprises an elongate tail portion 52, a curved cramming portion 50b, a first dwell point or recess 50c, and a second dwell point or recess 50d (the profile 50 comprises at least one of these dwell points 50c,50d). The first and second dwell points 50c, 50d are separated from each other by a peak portion 50e. Preferably, the elongated tail portion 52 defines a planar tail surface. The cramming portion 50b defines a curved rolling surface 54 that smoothly blends into the planar tail surface 52 by way of a curved transition surface 56. The curved surface 54 also connects with the first dwell point 50c. The surfaces 52, 54 and 56 of the profile cooperate to define a rolling surface 58 for the roller 40 along the sides of the channel.
As shown in Figure 3 of a pair of rollers 40, are connected to the first end 30a of the spring cam member 30 by adhesive, molding, mechanical fit or the like. The roller 40 comprises a curved outer surface 42 that is conformed and dimensioned to rotatively engage the profileSO, in particular the tail portion 50a, curved cramming portion 50b, first dwell point 50c, second dwell point 50d and peak 50e thereof. The roller also preferably has a slot formed on its outer surface 42 that is dimensioned to receive a side wall.
Furthermore, the rollers 40 is conformed and dimensioned so that it is at least partially received into the dwell points 50c, 50d.
The hinge assembly 10 further comprises biasing means for urging the door mounting lever 20 to its first operative position, as shown in Figure 1 and for maintaining the rollers 40 engaged with the profile 50 for all operative positions of the door mounting lever 20. In the illustrated preferred embodiment, the biasing means comprises a tension coil spring 60 including a first end secured to the channel 12 or another fixed anchor point and a second end secured to the spring cam member 30. Most preferably, as illustrated, the first end of the spring is secured to the main channel member 14 adjacent the first end 14a, and the second end of spring 60 is secured to the spring cam member 30 adjacent its second end 30b. This arrangement in combination with the location where the tail 22 of door mounting lever 20 is pivotally secured to the spring cam member 30 via fastener R2 results in the spring 60 urging (i.e., pulling) the second end 30b of the spring cam member 30 toward the first end 14a of the main channel member 14 which, in turn, result in the first end 30a of spring cam member 30 and rollers 40 being biased into engagement with the profile 50 at all times and for all operative hinge positions.
Operation of the hinge assembly 10 is best described with reference to Figures 1,4, 5 and 6. Figure 1 shows the door mounting lever 20 in its first operative position corresponding to the "closed" position of a door connected thereto, where the door mounting lever is moved a maximum extent in a first direction. When the door mounting lever 20 is located in its first operative position, the rollers 40 are seated in the second dwell point 50d of profile 50. Engagement of rollers40 with surface 50el under biasing force of spring 60 urges the spring cam member 30 toward first end 14a of main channel member 14 so that door mounting lever 20 is held firmly in is first operative position. In order words, the peak 50e is conformed so that when the roller 40 is urged inward towards inner wall 14i the roller 40 is urged by surface 50el of peak 50e toward the first end I4a of the main channel member 14 to pull the lever 20 into its first operative position as shown. In the case where the hinge assembly 10 is used in an oven environment, this ensures that the door D connected to lever 20 will tightly mate with the opening of the cooking chamber defined by the oven chassis.
In FIG.4, the door mounting lever 20 is pivoted against the biasing force of spring 60 a maximum distance away from the channel 12 in a second direction opposite the first direction to a second operative position corresponding to the fully opened position for the appliance door connected thereto. In the illustrated embodiment, the second operative position is defined by the position of the door mounting lever 20 in which the tail 22 engages the main channel member 14 which acts as a stop to prevent further pivoting movement of the lever 20 about the fastener Rl. When the door mounting lever 20 is pivoted from the first operative position of, Figure 1 to the second operative position of Figure 4, tail 22 of the lever 20 moves the spring cam member 30 toward the second end
14b of the main channel member 14 which results in the roller 40 rolling out of the second dwell point 50d, over the peak 50e end first dwell point 50c, over the surface 52 of the tail portion of the profile cut in the channel 50. As previously noted, at all the times, the biasing force of spring 60 on second end 30b of spring cam member 30 results in the rollers 40 being continuously urged into abutment with the profile 50 as it rolls there on. The weight of the door connected to the lever 20 is sufficient to overcome the biasing force of spring 60when the mounting lever 20 is in the second operative (fully opened) position as shown in Figure 4.
Pivoting movement of the door mounting lever 20 from the second operative (fully opened) position toward the first operative (fully closed) position results in the roller 40 rolling on the profile surface of tail 52 toward the transition surface 56 and surface 54 as shown in Figure 5. It should be noted that the rollers 40 maintains in contact with profile 50 at all times.
Continued movement of the door mounting lever 20 from the (intermediate) position shown in Figure 5 toward the first operative (fully closed) position result in rolling of rollers 40 over curved cam surface 56. As roller 40 rolls over cam surface 56, it is moved away from the inner wall 14i of the main channel member 14 which counteracts natural shortening of the spring 60 (because the second end of the spring cam member 30 is pivoted away from the first end of spring. This section improves counterbalance and feel of the hinge assembly 10.
Upon sufficient pivoting of the door mounting lever 20 toward the first operative position the rollers 40 will eventually roll over the surface 56 and seat in the first dwell point 50c which defines an intermediate operative position corresponding to a broil
position for the door connected to the door mounting lever 20.When the roller 40 is located in the first dwell point 50c, the biasing force of the spring 60 causes the rollers 40 to bear against the sloped outer surface 50e2 of the peak 50e which maintains rollers 40 in the dwell point 50c. As shown in FIG.6 the biasing force of the spring 60 is fully counterbalanced by the weight of the door connected to lever 20 and by engagement of rollers 40 with first dwell point 50c so that manual force need not be applied to the door D to hold same in position. Of course, the door and lever 20 can be moved to the first operative (fully closed) position by simple application of manual force in that direction so that the roller 40 rolls over peak 50e of profile 50 and into the second dwell point 50d as shown in FIG.l.
Owing to the design described herein, the performance characteristics of the hinge assembly 10 can be altered by simply altering the profile 50 and or the materials from which the profile and or rollers are defined for example use of a low friction material for the rollers and or profile will result in a hinge assembly 10 that exhibits quicker, lighter travel and feel. Conversely, use of higher friction materials for the rollers and or profile will result in a hinge assembly 10 that exhibits slower, heavier travel and feel.
It is preferred that the channel 12 including main channel member 14 and tab 18, door mounting lever 20 and spring cam member 30 each be defined from one or more metal stampings, although other materials can be used. The spring 60 is preferably a metallic coil spring, although other types of springs and spring materials can be used without departing form the overall scope and intent of the present development, as noted, the profile 50 is preferably defined as a one-piece construction along with the channel from a metal stamping. The rollers 40 is also preferably defined from molded plastic
material nylon or filled nylon or another suitable material that is affixed to the first end 30a of the spring cam member 30 as shown by fastening with welding, or simply by means of a friction fit or otherwise. In an alternative embodiment the rollers 40 can be formed from metal and or can be formed as one piece construction with the spring cam member 30 itself as part of the metal stamping form which the spring cam defined. In such a roller, a tyre may be added to the integrally formed roller. The tyre can be of any suitable material such as rubber or plastic. It is not intended that the invention be limited to these or any other particular materials also unless stated otherwise, all components, members and the like, regardless of name can be defined as one-piece construction or can be assembled or fabricated from multiple parts. While one spring 60 is shown, the hinge assembly can comprise multiple springs for biasing the door mounting lever and rollers although references are made herein to use of the hinge assembly 10 for connecting an oven door to an oven body or chassis, it is not intended that the hinge assembly 10 be limited to use in such environment, and the hinge assembly 10 is suitable for use alone or in a set to secure a door pivotally to a support structure in any other appliance or other environment.
The provision of a profile accommodating the end and intermediate positions of the door eliminates the requirement of an additional step member and the associates manufacturing process. The invention has been described with reference to preferred embodiments. Modifications will occur to those of ordinary skill in the art to which the invention pertains upon reading this specification. It is intended that the claims be construed to encompass all such modifications and alternations to the fullest extent permitted by law.

Since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or the general characteristics thereof, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims rather than the foregoing description all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.

We claim:
1. A hinge assembly comprising:
a channel comprising an inner wall and a pair of side walls projecting outwardly from the inner wall;
a door mounting lever that pivots relative to said channel about a pivot axis between a first operative position where said door mounting lever is moved a maximum extent in a first direction and a second operative position where said door mounting lever is moved a maximum extent in a second direction opposite the first direction,
at least one roller operatively coupled to the door mounting lever and movable in connection with the channel and in response to movement of the door mounting lever;
a spring that biases the roller into continuous engagement with the channel when the door mounting lever is located in both the first and second operative positions and when said door mounting lever moves between said first and second operative positions, wherein at least one side wall has a profile formed on it, that provides a rolling path for the roller.
2. A hinge assembly as claimed in claim 1 comprising a spring cam member
pivotally connected to the door mounting lever and including at least one roller,
wherein the spring extends between an anchor point on the channel and said
spring cam member.
3. A hinge assembly as claimed in claim 2 wherein said spring cam member is
pivotally connected to the door mounting lever at a pivot point located between
first and second ends of said spring cam member and wherein the at least one
roller is located substantially at the first end of the spring cam member and said
spring is connected to a second end of the spring cam member.
4. A hinge assembly as claimed in any of the preceding claims wherein the roller is
integrally formed with the spring cam member.
5. A hinge assembly as claimed in claim 1, 2, 3, or 4 wherein the roller is separately
formed and connected to the spring cam member.
6. A hinge assembly as claimed in any of the preceding claims wherein the roller is
formed of a plastic material.
7. A hinge assembly as claimed in any of the preceding claims wherein the roller is
provided with a tyre.
8. A hinge assembly as claimed in claim 1 wherein the roller comprises a slot on its
outer surface.
9. A hinge assembly as claimed in claim 1 wherein the profile has at least one dwell
point in which the roller selectively seats.
10. A hinge assembly as claimed in claim 1 wherein the profile has at least two dwell
points separated from each other by a peak portion, the peak portion comprising
first and second sloped surfaces that converge with each other to define the peak.

11. A hinge assembly as claimed in claim 11 comprising two rollers connected to the
spring cam member such that each roller rolls on the first and second side wall.
12. A hinge assembly substantially as herein described with reference to and as
illustrated by the accompanying drawings.