[0001] The present invention regards concealed door operators. Such door operators are used
for providing an opening or closing force to a door.
[0002] In general, concealed door operators are well-known from the prior art. Concealed
door operators are hidden within a door leaf or a floor or a wall, such that no visible
unit needs to be provided on the door. In case of installation within a cavity of
a door leaf, the width of the cavity is limited by the thickness of the door leaf.
For maximum residual strength, of the door, the width of the cavity should be just
wide enough to accommodate the door closer. This leaves very little clearance between
the outer wall of the concealed door operator and the inner wall of the door cavity.
The installer has to take extra care to align the housing to the cavity. If the clearance
is tight, additional effort is required to press the closer into position within the
cavity.
[0003] It is an object underlying the present invention to provide a low-maintenance concealed
door operator which is simple to manufacture and install.
[0004] The solution of this object is achieved by the features of claim 1. Therefore, the
object is solved by a concealed door operator comprising an operating unit and a housing.
The housing comprises a top face and an opposing bottom face. Further, the housing
comprises at least one side face between the bottom face and the top face. The operating
unit comprises a square pinion protruding from the top face and allowing transmittal
of torque from or to the operation unit. Further, the operating unit is provided within
the housing. In a preferred embodiment, the whole operating unit is provided within
the housing with the square pinion being the only part of the operating unit which
is accessible from outside the housing. At least one side face is inclined such that
the bottom face is smaller than the top face. In particular, said at least one side
face is angulated inward such that an angle between a vertical plate and the side
face remains. The inclination is preferably selected between 0.2 and 1.5 degrees,
in particular between 0.5 and 1.0 degrees. Due to the inclination of said side face,
the maximum dimensions of the bottom face are smaller than the dimensions of the top
face. However, the bottom face could be smaller than caused by the inclination by
providing a step in said side face. Such a design provides the best capability of
installing the concealed door operator. Since the concealed door operator has to be
provided within a cavity of a door leaf, a floor or a wall, the inclination of the
side face provides a lead-in to the cavity.
[0005] The dependent claims comprise advantageous embodiments of the present invention.
[0006] In a preferred embodiment, the concealed door operator comprises at least two opposing
side faces, wherein the two opposing side faces are inclined in an opposite manner.
In particular, the opposing side faces are both inclined inward. As described before,
the dimensions of the bottom face have to be smaller than the dimensions of the top
face due to the inclination. Preferably, the inclined side faces are symmetrically.
[0007] The concealed door operator is preferably characterized in that the housing is a
cast housing. The cast housing can be provided with stiffening means or enhanced wall
sections. Further, any cast housing is simple to manufacture and low in cost. Nevertheless,
the cast housing is designed to provide maximum durability during the lifecycle of
the concealed door operator. Due to the inclination of the side face, there is a draft
angle to facilitate the ejection of the raw housing from the mold during production,
for example by the pressure die casting process.
[0008] In another preferred embodiment, the top face comprises mounting features for mounting
the concealed door operator within a door leaf or a floor or a wall. The mounting
features can be flanges or boreholes for mounting the concealed door operator. In
particular, the mounting features are integrally mounted with the housing.
[0009] In particular, the housing has a prismatic shape, wherein the flanges are provided
on base faces of the prism. Such a design minimizes the room required for mounting
the concealed door operator. The concealed door operator can therefore be installed
into door leafs having a very narrow width.
[0010] The housing preferably has a prismatic shape, while the inclined side face is a face
other than the base faces. With both faces inclined, the above mentioned advantages
regarding lead-in and ejection from the mold are further enhanced.
[0011] The concealed door operator further preferably comprises a cover plate. In order
to save material, the housing preferably comprises a cavity resulting in a cutout
of the top face. The cavity is covered by said cover plate, wherein the cover plate
is fixed only to the housing. In particular, the cover plate is smaller than the top
face such that the top face functions as frame for the cover plate.
[0012] In a preferred embodiment of the concealed door operator, the operating unit is a
door closing unit. Therefore, the door can be opened manually and is closed by the
concealed door operator. Since the door operator is concealed, there is no visible
unit provided on the door such that an esthetic appeal is maintained.
[0013] Preferably, the operating unit comprises an operating piston and a damping piston.
Both, the operating piston and the damping piston are engaged with a pinion cam for
transforming the longitudinal movement of the pistons into a rotational movement of
the pinion cam. With such a design, the concealed door operator can be installed in
any door independent from the opening direction of the door. The pinion cam can be
rotated clockwise or counterclockwise while in both cases load is provided to the
operating unit.
[0014] In another preferred embodiment, the operating unit also comprises an operating piston
and a damping piston. The operating piston and the damping piston are connected to
a rack with a pinion engaged with the rack for transforming the longitudinal movement
of the pistons and the rack into a rotational movement of the pinion. This design
allows an installation of the concealed door operator only in doors having a predetermined
opening direction. Therefore, the concealed door operator is preferably provided in
two versions, in the one version the pinion needs to be rotated clockwise for providing
load to the operating unit, in the other version the pinion needs to be rotated counterclockwise
for providing load to the operating unit.
[0015] The housing particularly comprises an opening for removing and/or inserting at least
parts of the operating unit. The opening is preferably covered by an end cap. The
end cap is designed to withstand loads applied by the operating unit when moving the
door. Further, the housing comprises a reinforced wall section around the opening.
This is to enhance the durability of the housing to withstand the pressure loads applied
to the end cap. This optimal design with selective stiffness enhancing integrally
incorporated to the housing minimizes part and material usage while enhancing the
stability and durability of the concealed door operator.
[0016] In the following, preferred exemplary embodiments of the invention are explained
with reference to the drawings. In the drawings:
- Fig. 1
- is a schematic drawing showing an exemplary embodiment of the concealed door operator
according to the invention.
- Fig. 2
- is a schematic drawing showing a first step of installing the concealed door operator
of figure 1 within a door leaf.
- Fig. 3
- is a schematic drawing showing a second step of installing the concealed door operator
of figure 2 within a door leaf.
[0017] Figure 1 shows a concealed door operator according to an exemplary embodiment of
the present invention.
[0018] The concealed door operator 1 comprises a housing 2, in which an operating unit 3
is provided. The operating unit 3 is adapted to operate a door equipped with the concealed
door operator 1. In particular, the concealed door operator 1 can be provided within
a cavity 13 of a door leaf 12.
[0019] For operating the door, i.e. for opening or closing the door, the operating unit
3 comprises a square pinion 4, which is the only part of the operating unit 3 being
accessible from outside the housing 2. The square pinion 4 can be connected to a level
arm which is supported on a wall. When opening or closing the door, the square pinion
4 is rotated and a load is applied to the operating unit 3. This energy is stored
within the operating unit 3 and can be used for operating the door. For example, energy
is stored within the operating unit 3 when opening the door such that the concealed
door closer 1 can use the stored energy for closing the door.
[0020] The housing 2 of the concealed door operator 1 comprises a top face 6, an opposing
bottom face 7, and side faces 8. On the top face 6, mounting features 5 are provided.
The mounting features 5 comprise flanges and through holes for mounting the concealed
door operator 1 on a door leaf 12 or a wall or a floor. In one embodiment, the concealed
door operator 1 is installed within a cavity 13 of the door leaf 12, while the flanges
of the mounting features 5 are disposed on surfaces outside the cavity 13. Mounting
screws can be used for fixing the flanges via the through holes of the mounting features
5. The housing 2 is preferably a single cast piece, which can be made from aluminum
or iron.
[0021] It can be seen from the figures and the above explanation that the housing 2 is very
simple to manufacture. Since the mounting features 5 are integrally formed with the
housing 2, only a single cast piece has to be manufactured.
[0022] The housing 2 according to the exemplary embodiment has a generally prismatic shape.
The mounting features 5, in particular the flanges, are provided on base faces of
the prism. This results in a narrow mounting space required for installation of the
concealed door operator 1.
[0023] Further, the housing comprises an opening for inserting at least parts of the operating
unit 3. The opening is covered by an end cap 9 which also serves as support for the
operating unit 3. The operating unit 3 is adapted to store energy when moving the
door equipped with the concealed door operator 1 in one direction and is adapted to
drive the door in the other direction from the stored energy. At the same time, any
movement of the door is damped. During operation, the operating unit 3 applies pressure
to the end cap 9. Therefore, the end cap is designed to withstand the pressure.
[0024] The side faces 8 of the housing 2 are inclined. In particularly, the side faces 8
are inclined inward such that the bottom face 7 needs to be smaller than the top face
6. Therefore, a draft angle A is present between a vertical plane and the side faces
8. The draft angle A is selected between 0.5 and 1.0 degree.
[0025] The side faces 8 are inclined for two reasons: First, the draft angle A facilitates
the ejection of the raw housing from the mold during production, especially in case
the housing2 is produced by the pressure die casting process. Second, the inclined
side faces 8 of the housing 2 function as lead-in to the cavity during installation
of the concealed door operator 1. With this feature, the installer need not align
accurately to insert the concealed door operator 1 into the cavity 13. The lead-in
also caters for a snug fit at the top face when the concealed door operator 1 is completely
installed to the door leaf 12.
[0026] Figures 2 and 3 show two steps of installing the concealed door operator 1 into the
cavity 13 of the door leaf 12. A first step is shown in figure 2. It is apparent that
the draft angle A functions as lead-in to the cavity 13, since the narrower dimension
at the bottom face 7 provides clearance 10 for the initial engagement. After initial
engagement, the concealed door closer 1 slides into the cavity 13, preferably guided
by the draft.
[0027] Figure 3 shows a second step of installing the concealed door operator 1. The state
shown in figure 3 is when the concealed door operator 1 is completely inserted into
the cavity 13. The dimension of the top face 6 is substantially equal to the dimension
of the cavity such that an appearance of tight fit 11 is given. Hence, the inclined
side faces 8 of the housing 2 provide both, a clearance 10 at the beginning of the
installation process and a tight fit 11 at the end of the installation process.
[0028] It can be seen from the above that the exemplary embodiments of the concealed door
operator 1 that the invention provides several advantages during installation. Therefore,
the concealed door operator 1 is low in cost and simple to install.
Reference numerals
[0029]
- 1
- concealed door operator
- 2
- housing
- 3
- operating unit
- 4
- square pinion
- 5
- mounting feature
- 6
- top face
- 7
- bottom face
- 8
- side face
- 9
- end cap
- 10
- clearance
- 11
- snug fit
- 12
- door leaf
- 13
- cavity
- A
- draft angle
1. Concealed door operator (1), comprising
- an operating unit (3) having a square pinion (4) allowing transmittal of forces
to or from the operating unit (3), and
- a housing (2), having a top face (6), an opposing bottom face (7), and at least
one side face (8) between the top face (6) and the bottom face (7),
- wherein operating unit (3) is provided within the housing (2),
- wherein said square pinion (4) protrudes from the top face (6), and
- wherein at least one side face (8) is inclined such that the bottom face (7) is
smaller than the top face (6).
2. Concealed door operator (1) according to claim 1, characterized by at least two opposing side faces (8), wherein the two opposing side faces (8) are
inclined in an opposite manner.
3. Concealed door operator (1) according to claim 1 or 2, characterized in that the housing (2) is a cast housing.
4. Concealed door operator (1) according to one of claims 1 to 3, characterized in that the top face (6) comprises mounting features (5) for mounting the concealed door
operator (1) within a door leaf (12) or a floor or a wall.
5. Concealed door operator (1) according to claim 4, characterized in that the housing (2) has a prismatic shape and the mounting features (5) are provided
on base faces of the prism.
6. Concealed door operator (1) according to one of claims 1 to 5, characterized in that the housing (2) has a prismatic shape and the inclined side face (8) is a face other
than the base faces.
7. Concealed door operator (1) according to one of the claims 1 to 6, characterized by a cover plate, wherein the cover plate is fixed only to the housing (2).
8. Concealed door operator (1) according to one of the claims 1 to 7, characterized in that the operating unit (3) is a door closing unit.
9. Concealed door operator (1) according to one of the claims 1 to 8, characterized in that the operating unit (3) comprises an operating piston and a damping piston, wherein
the operating piston and the damping piston are engaged with a pinion cam for transforming
the longitudinal movement of the pistons into a rotational movement of the pinion
cam.
10. Concealed door operator (1) according to one of the claims 1 to 9, characterized in that the operating unit (3) comprises an operating piston and a damping piston, wherein
the operating piston and the damping piston are connected to a rack with a pinion
engaged with the rack for transforming the longitudinal movement of the pistons and
the rack into a rotational movement of the pinion.