Integrally hinged stile
View Patent ↗A hinge for a bi-fold door is integrated with a pair of stiles. Each stile has a hinge flange integrated to the stile. Opposing stiles with opposing and aligned hinge flanges collectively create an integral hinge assembly that may be useful in thermal doors employing one or more thermal breaks.
1. A thermal folding door comprising:
first, second, and third door panels;
a first integral hinge assembly interposing the first and second door panels and including:
a first stile coupled to the first door panel and integral with a first flange and a first gear;
a second stile coupled to the second door panel and integral with a second flange and a second gear;
a first thermal break coupled to the first stile; and
a second thermal break coupled to the second stile and aligned with the first thermal break in a single plane; and
a second integral hinge assembly interposing the second and third door panels and including:
a third stile coupled to the second door panel and integral with a third flange and a third gear;
a fourth stile coupled to the third door panel and integral with a fourth flange and a fourth gear;
a third thermal break coupled to the third stile; and
a fourth thermal break coupled to the fourth stile,
wherein the third and fourth thermal breaks are aligned with the first and second thermal breaks in the single plane, and wherein the first and second integral hinge assemblies alternate between an interior side and an exterior side.
2. The thermal folding door of claim 1 , wherein each gear includes a gear portion having a cog, and wherein the first and second gears are oriented such that the cog of the first gear interlaces with the cog of the second gear.
3. The thermal folding door of claim 2 , wherein the first and second flanges are oriented such that arcs of the first and second gears, respectively, oppose each other.
4. The thermal folding door of claim 1 , wherein at least one of the first and second integral hinge assemblies is manufactured by extrusion or pultrusion.
5. The thermal folding door of claim 1 , wherein the first and second integral hinge assemblies are made of a material selected from the group consisting of aluminum, titanium, steel, PVC, and fiberglass.
6. The thermal folding door of claim 1 , further comprising:
a first recess defined in the first flange and the first gear;
a second recess defined in the second flange and the second gear, wherein the first and second recesses are aligned to form an opening; and
a knuckle arranged within the opening.
7. The thermal folding door of claim 6 , further comprising a gear cap that secures the first and second gears and covers the knuckle, wherein the first and second gears are oriented to interlace with each other.
8. The thermal folding door of claim 7 , wherein the knuckle is secured to the gear cap with a set screw.
9. The thermal folding door of claim 1 , wherein the first integral hinge assembly is continuous along an entire height of the first and second door panels, and wherein the second integral hinge assembly is continuous along an entire height of the second and third door panels.
10. The thermal folding door of claim 1 , wherein the first thermal break comprises two first thermal breaks coupled to the first stile, and wherein the second thermal break comprises two second thermal breaks coupled to the second stile and aligned with the two first thermal breaks in the single plane.
11. A thermal folding door, comprising:
first, second, and third door panels;
a first integral hinge assembly interposing the first and second door panels and including:
a first stile coupled to the first door panel and integral with a first flange and a first gear that define a first recess;
a second stile coupled to the second door panel and integral with a second flange and a second gear that define a second recess, wherein the first and second recesses are aligned to form a first opening;
a first knuckle arranged within the opening;
a first gear cap that secures the first and second gears and covers the first knuckle;
a first thermal break coupled to the first stile; and
a second thermal break coupled to the second stile and aligned with the first thermal break in a single plane; and
a second integral hinge assembly interposing the second and third door panels and including:
a third stile coupled to the second door panel and integral with a third flange and a third gear that define a third recess;
a fourth stile coupled to the third door panel and integral with a fourth flange and a fourth gear that define a fourth recess, wherein the third and fourth recesses are aligned to form a second opening;
a second knuckle arranged within the second opening; and
a second gear cap that secures the third and fourth gears and covers the second knuckle;
a third thermal break coupled to the third stile; and
a fourth thermal break coupled to the fourth stile, wherein the third and fourth thermal breaks are aligned with the first and second thermal breaks in the single plane,
wherein the first and second integral hinge assemblies alternate between an interior side and an exterior side.
12. The thermal folding door of claim 11 , wherein at least one of the first and second knuckles is secured to the first and second gear caps, respectively, cap with a set screw.
13. The thermal folding door of claim 11 , wherein at least one of the first and second integral hinge assemblies is manufactured by extrusion or pultrusion.
14. The thermal folding door of claim 11 , wherein at least one of the first and second integral hinge assemblies is made of a material selected from the group consisting of aluminum, titanium, steel, PVC, and fiberglass.
15. The thermal folding door of claim 11 , wherein the first integral hinge assembly is continuous along an entire height of the first and second door panels, and wherein the second integral hinge assembly is continuous along an entire height of the second and third door panels.