throbber
US009879471B2
`
`(12) United States Patent
`US 9,879,471 B2
`(10) Patent No.:
`Lewis et al.
`(45) Date of Patent:
`Jan. 30, 2018
`
`(54) REINFORCED FOLDING DOOR AND HINGE
`ASSEMBLY
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`(71) Applicant: Woodfold Mfg., Inc., Forest Grove, OR
`(US)
`
`(72)
`
`Inventors: Mark F. Lewis, Portland, OR (US);
`Rick Scott Alvarado, Gaston, OR (US)
`
`(73) Assignee: WOODFOLD MFG., INC., Forest
`Grove, OR (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. No.: 15/171,478
`
`(22)
`
`Filed:
`
`Jun. 2, 2016
`
`(65)
`
`Prior Publication Data
`
`US 2017/0089122 A1
`
`Mar. 30, 2017
`
`Related US. Application Data
`
`(60) Provisional application No. 62/235,455, filed on Sep.
`30, 2015.
`
`(51)
`
`Int. Cl.
`E05D 3/02
`E06B 3/48
`E05D 15/26
`(52) us. Cl.
`CPC ................ E06B 3/481 (2013.01); E05D 3/02
`(2013.01); E05D 15/26 (2013.01); E05Y
`2900/]32 (2013.01)
`
`(2006.01)
`(2006.01)
`(2006.01)
`
`(58) Field of Classification Search
`CPC .. E06B 3/481; E04D 3/02; E04D 3/04; E04D
`15/26; E04D 11/06
`See application file for complete search history.
`
`1,463,346 A *
`
`3,131,753 A *
`
`7/1923 Walker .................... E06B 3/481
`16/DIG. 31
`5/1964 Dixon ..................... E06B 3/481
`16/225
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`Lewis, “Hinge Knuckle for Folding Door Assembly”, U.S. Appl.
`No. 29/568,458, filed Jun. 17, 2016.
`
`(Continued)
`
`Primary Examiner 7 Katherine W Mitchell
`Assistant Examiner 7 Abe Massad
`
`(74) Attorney, Agent, or Firm 7 Stoel Rives LLP
`
`(57)
`
`ABSTRACT
`
`An accordion type folding door system having a plurality of
`elongated panels hinged together along their longitudinal
`side edges into a pleated or zig zag arrangement, the folding
`panels being interconnected by a hinge assembly. The hinge
`assembly is disposed between and interconnects a pair of
`adjacent panels, each of the pair of interconnected adjacent
`panels including a side edge having longitudinal groove and
`an extension flange, wherein the hinge assembly includes a
`hinge pin and a plurality of hinge knuckles disposed verti-
`cally end-to-end in alternating arrangement on the hinge pin,
`the hinge knuckle having a tubular central opening for
`accepting the hinge pin, an outwardly extending tongue for
`connecting to a corresponding longitudinal groove in an
`adjacent panel in a tongue and groove connection, and an
`outwardly flared wedge that extends beyond the extension
`flanges of the panels, whereby the wedge cooperates with
`the extension flanges to limit angular folding extension to a
`maximum desired angle.
`
`7 Claims, 11 Drawing Sheets
`
`
`
`EMI Exhibit 1001
`
`Page 1 of 18
`
`EMI Exhibit 1001
`Page 1 of 18
`
`

`

`8/1975 Dagenais .................. E05D 3/02
`3,901,302 A *
`16/263
`-
`3913171 A * 10/1975 R d ......................... E05F 5/06
`’
`’
`e1
`16/342
`432“” A
`9/1980 SCherer """"""""""" 1310632???
`'
`4’387’760 A
`“983 GreSChbaCh """"""" mfg/1:3:
`4,922,987 A
`5/1990 Mamntate et 31.
`4,998,941 A *
`3/1991 Smith ..................... E05D 11/06
`16/374
`
`,,
`
`,,
`
`9/1992 Pasternak
`5,150,501 A
`12/1995 Hoffman
`5,472,037 A
`6/1996 Harris
`D370,839 s
`8/1996 Figueiredo et al.
`5,549,148 A
`12/1998 Cousins
`D402,536 S
`6/1999 Russell
`D411,434 s
`6,669,272 132* 12/2003 Ayabe .................... B60] 5/0487
`ISO/89.12
`
`US 9,879,471 B2
`
`Page 2
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`D496,248 S
`D520,862 s
`7,290,581 B2
`D562,108 s
`8,191,603 Bl
`D680,419 s
`8960 257 B2
`,
`,
`D729,605 s
`D731,296 s
`D732,703 s
`2005/0063058 A1
`2011/0155145 A1
`2012/0124776 A1*
`
`2014/0367056 A1
`
`9/2004 Liebendorfer
`5/2006 Munson
`11/2007 Lee
`2/2008 Pester
`6/2012 Motosko
`4/2013 Green
`2/2015 Goodman
`5/2015 Ramey
`6/2015 Nelson
`6/2015 Kreutzman
`3/2005 Langley
`6/2011 Chua
`5/2012 McDonnell
`_
`12/2014 Mlller
`
`............. E05D11/06
`16/375
`
`OTHER PUBLICATIONS
`
`-
`-
`Notlce ofAllowance from Lew1s et al. U.S.App1. No. 29/568,458,
`dated APE 14, 2017, 11 Pages
`
`* cited by examiner
`
`EMI Exhibit 1001
`
`Page 2 of 18
`
`EMI Exhibit 1001
`Page 2 of 18
`
`

`

`U.S. Patent
`
`Jan. 30, 2018
`
`Sheet 1 of 11
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`US 9,879,471 B2
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`EMI Exhibit 1001
`
`Page 3 of 18
`
`EMI Exhibit 1001
`Page 3 of 18
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`

`

`U.S. Patent
`
`Jan. 30, 2018
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`Sheet 2 of 11
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`US 9,879,471 B2
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`EMI Exhibit 1001
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`Page 4 of 18
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`EMI Exhibit 1001
`Page 4 of 18
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`

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`U.S. Patent
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`Jan. 30, 2018
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`Sheet 3 of 11
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`US 9,879,471 B2
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`EMI Exhibit 1001
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`Page 5 of 18
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`EMI Exhibit 1001
`Page 5 of 18
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`

`

`U.S. Patent
`
`Jan. 30 2018
`
`Sheet 4 of 11
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`
`
`g.
`
`sfin
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`EMI Exhibit 1001
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`Page 6 of 18
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`EMI Exhibit 1001
`Page 6 of 18
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`

`

`U.S. Patent
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`Jan.30,2018
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`Sheet5 ofll
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`US 9,879,471 B2
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`35a
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`EMI Exhibit 1001
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`Page 7 of 18
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`EMI Exhibit 1001
`Page 7 of 18
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`U.S. Patent
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`Jan. 30, 2018
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`Sheet 6 of 11
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`US 9,879,471 B2
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`42a
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`4211
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`EMI Exhibit 1001
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`Page 8 of 18
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`EMI Exhibit 1001
`Page 8 of 18
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`U.S. Patent
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`Jan. 30, 2018
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`Sheet 7 of 11
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`EMI Exhibit 1001
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`Page 9 of 18
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`EMI Exhibit 1001
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`U.S. Patent
`
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`
`EMI Exhibit 1001
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`Page 10 of 18
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`EMI Exhibit 1001
`Page 10 of 18
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`

`

`U.S. Patent
`
`Jan. 30, 2018
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`Sheet 9 of 11
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`US 9,879,471 B2
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`“a
`
`ma
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`
`
`42a
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`66 ,~
`
`
`
`
`
`11a
`
`EMI Exhibit 1001
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`Page 11 of 18
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`EMI Exhibit 1001
`Page 11 of 18
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`

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`U.S. Patent
`
`Jan. 30, 2018
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`Sheet 10 of 11
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`US 9,879,471 B2
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`EMI Exhibit 1001
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`Page 12 of 18
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`EMI Exhibit 1001
`Page 12 of 18
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`

`

`U.S. Patent
`
`Jan. 30, 2018
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`Sheet 11 of 11
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`US 9,879,471 B2
`
`100
`
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`
`30a
`
`3013
`
`3%
`
`331:.
`
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`
`30f
`
`‘ 39h
`
`EMI Exhibit 1001
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`Page 13 of 18
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`EMI Exhibit 1001
`Page 13 of 18
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`

`

`US 9,879,471 B2
`
`1
`REINFORCED FOLDING DOOR AND HINGE
`ASSEMBLY
`
`RELATED APPLICATION DATA
`
`This application claims priority under 35 U.S.C. § 119(e)
`to US. Provisional Application No. 62/235,455 filed on Sep.
`30, 2015, hereby incorporated by reference.
`
`BACKGROUND
`
`The field of the present invention is directed to folding
`doors such as used for closets, elevators and room entrances.
`An accordion type folding door comprises an assembly of
`vertically arranged panels placed side-by-side and sus-
`pended from a suitable track. The adjacent side edges of the
`panels are interconnected by sheet vinyl plastic hinges.
`Altemately, the vinyl plastic hinges may be replaced as
`described in US. Pat. No. 4,922,987 with hinging assem-
`blies that interconnect the panels, the hinging assemblies
`comprising a plurality of knuckles made of hard durable
`material (plastic or metal) and tongue and groove means for
`attachment of the knuckles to the side margins of the
`adjacent panels in an alternating arrangement,
`i.e., with
`alternate knuckles attached to the same panel, with a hinge
`pin made of steel or other stout material received in the
`knuckles. Though this design with the interconnection
`exhibits higher strength over the prior vinyl plastic hinge,
`the present inventor(s) have recognized potential for addi-
`tional improvement.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is an isometric view of a top portion of a folding
`door assembly in an extended or closed position.
`FIG. 2 is a cross-sectional view of the folding door
`assembly of FIG. 1 taken along line 2-2.
`FIG. 3 is a partial cross-sectional view of a portion of the
`folding door assembly of FIG. 1 taken along line 3-3, on an
`enlarged scale.
`FIG. 4 is a partial cross-sectional view, similar to FIG. 3,
`but with the door in a folded or open position.
`FIG. 5 is a perspective view of a hinge knuckle unit of the
`folding door assembly of FIG. 1.
`FIG. 6 is a top end plan view of the hinge knuckle unit of
`FIG. 5 showing example dimensions.
`FIG. 7 is an isometric view of the bottom connection of
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`the folding door assembly of FIG. 1.
`FIG. 8 is an isometric view of the retainer screw shown
`in FIG. 7.
`
`50
`
`FIG. 9 is a full length isometric view of a four panel
`folding door assembly.
`FIG. 10 is a top diagrammatic view of the four panel
`folding door assembly of FIG. 9 in the closed, un-folded,
`extended position.
`FIG. 10A is a top diagrammatic view of the four panel
`folding door assembly of FIG. 10 in the open, folded,
`contracted position
`FIG. 11 is a front side perspective view of the slide plate
`section of the folding door assembly of FIG. 9, on an
`enlarged scale.
`FIG. 12 is a left side perspective view of the slide plate
`section of FIG. 11.
`
`FIG. 13 is a front side perspective view of the slide post
`section of the folding door assembly of FIG. 9, on an
`enlarged scale.
`
`55
`
`60
`
`65
`
`2
`
`FIG. 14 is a partial cross-sectional view ofa portion ofthe
`folding door assembly of FIG. 1, on an enlarged scale, with
`an alternate hinge knuckle unit.
`FIG. 15 is a top end plan view of the hinge knuckle unit
`of FIG. 14
`
`FIG. 16 is a top diagrammatic view of an eight panel
`folding door assembly.
`FIG. 17 is a top diagrammatic view of a nine panel folding
`door assembly.
`FIG. 18 is a diagrammatic view of a hinge knuckle
`arrangement for a folding door assembly according to an
`embodiment.
`
`Additional aspects and advantages will be apparent from
`the following detailed description of preferred embodi-
`ments, which proceeds with reference to the accompanying
`drawings.
`
`DETAILED DESCRIPTION OF PREFERRED
`EMBODIMENTS
`
`Preferred embodiments will now be described with ref-
`
`erence to the drawings. To facilitate description, any element
`numeral representing an element in one figure will represent
`the same element in any other figure. The preferred embodi-
`ments will describe a particular folding door, but it will be
`appreciated that details ofthe system may be applied in other
`forms such as folding wall sections or the like.
`FIGS. 1-3 illustrate an accordion type folding door system
`5 according to a first embodiment. Certain features of the
`folding door system 5 are similar to those described in US.
`Pat. No. 4,922,987 hereby incorporated by reference. The
`folding door system 5 comprises a plurality of elongated
`panels 10 hinged together along their longitudinal side edges
`into the illustrated pleated or zig zag arrangement. Four
`panels 10, 10a, 10b, 100 are illustrated in FIG. 1, but there
`may be any suitable plurality of panels, two or more. The
`panels 10, 10a, 10b, 100 may comprise any suitable struc-
`tural material, such as wood, particle board, clear or opaque
`plastic, or metal.
`Panels 10, 10a, 10b, 100 are suitably framed, in part by
`cap pieces 12, 12a, 12b, 120 mounted on the top and bottom
`edges of each panel. The cap pieces 12, 12a, 12b, 120 may
`be channel-shaped (in cross-section) and receive the top and
`bottom margins ofthe respective panels 10, 10a, 10b, 100 In
`the first embodiment, the cap pieces 12, 12a, 12b, 120 are
`hinged together, hinges 13a, 13b, 13c connecting an adja-
`cent pair of cap pieces. For example, the hinge 13a connects
`the cap piece 12a to the cap piece 12, the hinge 13b connects
`the cap piece 12 to the cap piece 12b, and the hinge 13c
`connects the cap piece 12b to the cap piece 120. The hinges
`13a, 13b, 130 are capped at the bottom and do not extend
`into the central hinge mechanisms described below. Such a
`construction may help prevent binding of adjacent cap
`pieces when folding.
`The central segments of cap pieces 12, 12a, 12b, 120 are
`provided with openings 16. These openings provide means
`for mounting roller assemblies 18a, 18b, on selected panels
`(in the panel 10 and the panel 100), by which the folding
`door system 5 is suspended on a ceiling track, not illustrated
`but of conventional construction. The ceiling track is
`mounted across the entrance of the space to be closed off by
`the folding door system 5.
`The panels 10, 10a, 10b, 100 each includes longitudinal
`side framing members along panel side edges. Specifically,
`the panel 10 includes longitudinal side framing members
`20a, 2019; the panel 1011 includes longitudinal side framing
`member 200 (the other side framing member not shown); the
`
`EMI Exhibit 1001
`
`Page 14 of 18
`
`EMI Exhibit 1001
`Page 14 of 18
`
`

`

`US 9,879,471 B2
`
`3
`panel 10b includes longitudinal side framing members 20d,
`206; and the panel 100 includes longitudinal side framing
`member 20f (the other side framing member not shown).
`FIG. 2 is a cross section of FIG. 1 illustrating a portion of
`the hinge connections,
`three of the panels 10, 10a, 10b
`showing example construction. Each side framing member
`20a-d may comprise a metal strip having the cross section as
`illustrated in FIG. 2. Each side framing member is shaped
`with an inner side margin provided with a respective lon-
`gitudinal recess or groove 22a-d. The outer side margin of
`each panel 10, 1011 or 10b may be dimensioned to fit into
`respective groove 22a-d, along with a quantity of adhesive
`for securing the panel into the groove.
`Each side framing member 20a-d is also provided along
`its outer margin with a respective longitudinally extending
`groove 24a, 24b, 24c, 24d. Each of the side framing mem-
`bers 20a-d is also provided, along its sides, with a respective
`pair of longitudinally extending flanges. Framing member
`20a has extending flanges 26a, 28a, framing member 20b
`has extending flanges 26b, 28b, framing member 200 has
`extending flanges 260, 280, and framing member 20d has
`extending flanges 26d, 28d. These flanges serve to shield the
`mechanism of the central hinge system by means of which
`two adjacent panels are coupled together in hinging relation.
`Top hinges 13a, 13b, 13c provide the structural support
`for the door structure, by means of which the panels are
`hinged to each other in the desired configuration. A second
`hinging connection is provided by the central hinge system
`that may extend about the full length of the panels, from top
`to bottom.
`
`In addition to providing a hinging function, the central
`hinging system may serve a barrier function, sealing oif the
`space between adjacent panels in such a manner as to
`prevent access to the area behind the door. The central
`hinging system between adjacent framing members 2011, 200
`of panels 10, 1011 includes a plurality of hinge knuckles 30a,
`30b, etc. and the central hinging system between adjacent
`framing members of panels 10, 10b includes a plurality of
`hinge knuckles 31a, 31b, etc. The hinge knuckle 3011
`includes an outwardly flared wedge section 3511 and the
`hinge knuckle 30b disposed below the hinge knuckle 3011
`also includes an outwardly flared wedge section (not vis-
`ible). A similar plurality of hinge knuckles 31a, 31b are
`shown in FIG. 2 between adjacent framing members 20b,
`20d of panels 10, 10b. The hinge knuckle 31a includes an
`outwardly flared wedge section 35b and the hinge knuckle
`31b disposed below the hinge knuckle 31b also includes an
`outwardly flared wedge section (not visible) Further details
`of the central hinging systems will now be described with
`respect to just one of the connections with reference to
`FIGS. 3-7 and 18 but the description equally applies to the
`other connections and panels in the folding door system 5.
`As shown particularly in FIGS. 2-5, the central hinge
`assembly comprises a plurality of hinge knuckles 30a, 30b
`disposed end to end between each pair of adjacent framing
`members 2011, 200, and a hinge pin 33a received within the
`central tubular openings of the knuckles (an opening 32a in
`hinge knuckle 30a is shown). Similarly as shown in FIG. 2,
`another central hinge assembly comprises a plurality of
`hinge knuckles 31a, 31b disposed end to end between a pair
`of adjacent framing members 20b, 20d, and a hinge pin 33b
`received within the central tubular openings of the knuckles
`(an opening 32b in hinge knuckle 31a is shown).
`FIG. 5 illustrates an example hinge knuckle 30a. The
`hinge knuckle 30a may be made of PVC plastic having
`desired properties of strength,
`rigidity, and temperature
`insensitivity. The element may be formed out of other
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`
`suitable plastics, metals, or combinations. The PVC plastic
`may be formed in a desired color to match the panels
`sections for enhancing aesthetics. The hinge knuckle 30a is
`provided with a cylindrical central section 3711 forming a
`central opening 32a and a longitudinally extending tongue
`34a terminating in a bead 3611 that nests within the longi-
`tudinally extending groove 24a. The hinge knuckle 3011 also
`has an outwardly flared wedge section 3511 that extends
`beyond the flanges 26a, 260.
`The tongue 34a of the hinge knuckle 3011 with the
`associated bead 36a cooperates with the longitudinally
`extending groove 24a on the framing member 20a and a
`tongue 34b of the hinge knuckle 30b with an associated bead
`36b cooperates with the longitudinal extending groove 24c,
`thereby collectively forming tongue and groove connections
`by means of which the hinge knuckles 30a, 30b, etc. are
`coupled to framing members 20a, 200, in alternating posi-
`tions/orientations. In other words, direction and connection
`of the beads will be arranged in an alternating fashion with
`one hinge knuckle connecting to a panel on one side and the
`next/adjacent hinge knuckle (above and below) connecting
`to the panel on the other side, thus forming the central hinge
`assembly of the hinge system. The beads 36a, 36b may be
`round rod shape (as illustrated) seating within the respective
`longitudinally extending grooves 2411, 240 that may be
`round, cylindrical shape, or the beads 36a, 36b may be other
`suitable shape such as T-shaped, disposed in a suitably-
`shaped groove.
`Though any number of hinge knuckle units, two or more,
`may serve the central hinge assembly function, multiple
`hinge knuckle units may provide advantages of strength and
`visibility blockage. As an example, for a typical height door
`of 78%; inches, seven full length (e.g., 10 inch long) hinge
`knuckles (arranged in alternating directions) may be stacked
`with a first partial length (e.g., 4 inch long) hinge knuckle on
`the top and a second partial
`length (4 inch long) hinge
`knuckle (e.g. hinge knuckle 30x) on the bottom. FIG. 18
`illustrates an example hinge knuckle assembly 100 arrange-
`ment with eight full length (10 inch long) hinge knuckles
`30a, 30b, 300, 30d, 306, 30], 30g, 30h) arranged in alter-
`nating directions stacked with a first partial length (4 inch
`long) hinge knuckle 30x on the bottom and a second partial
`length (4 inch long) hinge knuckle 30y on the top, aligned
`and secured together by pin/post 3311. Other sizes (and
`numbers) of hinge knuckle units may be employed.
`As previously mentioned, the hinge knuckle 30a may
`include an outwardly flared wedge section 35a that extends
`beyond the flanges 2611, 260. The wedge section 3511 coop-
`erates with the flanges 2611, 260 (the flanges 2611, 26c
`contacting respective outer surfaces of the wedge section
`3511) thereby limiting the minimum size of gap G1 and
`limiting the maximum angle B1 (see FIG. 3) that the folding
`door sections may extend to an angle B1 of about 110°. By
`limiting the angular un-folding extension to a desired maxi-
`mum angle, and providing limiting resistance along the
`entire length of the door via operation of the wedge sections,
`the strength of the folding door assembly to resist horizontal
`pressure is enhanced. The wedge section 35a (of the hinge
`knuckle 3011) may be flared or pie-shaped as illustrated, or
`may alternately be square, rectangular, with curved sides or
`other suitable shape.
`While FIG. 3 illustrates folding door sections in a maxi-
`mum closed or un-folded position, FIG. 4 illustrates the door
`panels 10, 10a of folding door sections in the maximum
`open position, the door panels in a folded, parallel position
`next the wall.
`
`EMI Exhibit 1001
`
`Page 15 of 18
`
`EMI Exhibit 1001
`Page 15 of 18
`
`

`

`US 9,879,471 B2
`
`5
`FIG. 6 illustrates the hinge knuckle 30a of FIGS. 3-5 and
`further provides an example size dimensions: radius R1 (of
`the central openings 32a):0.065 inches; radius R2 (of the
`cylindrical
`central
`section 37a):0.133 inches;
`radius
`R3:0.176 inches; radius R4:0.343 inches; radius R5:0.050
`inches; length D1:0.210 inches; length D2:0.165 inches;
`angle A1 (of the wedge section 35a):63.5°; and angle A2
`(from the wedge section 35a to the bead 36a):57.5°.
`FIGS. 7-8 illustrate an example bottom connection of the
`folding door assembly of FIG. 1 according to an embodi-
`ment. The door panels have bottom cap pieces 42a, 42b
`(similar to the top cap pieces 12, 12a, 12b) that are hinged
`together Via hinge 40 connecting the bottom cap pieces of an
`adjacent pair of panels. The hinge 40 is capped and does not
`extend into the central hinge mechanism. The hinge pin 33a
`“floats” in an installed relation through the central openings
`32a in the hinge knuckles and thus is not secured directly to
`a structural member. A screw 50 (only the head of the screw
`is Visible in FIG. 7, and further details of the screw 50 are
`shown in FIG. 8) is secured into the central opening of the
`bottom-most hinge knuckle 30x thus trapping the hinge pin
`33a in place in operative position. In the event the screw 50
`becomes dislodged from the knuckle unit 30x, the screw 50
`is provided with a suflicient length shaft that the screw
`would slide down with its head into contact with the hinge
`40 wherein a portion of the screw shaft still extending into
`the central opening of the hinge knuckle 30x and thus
`continue to retain the hinge pin 33a in place.
`FIGS. 9-13 illustrate details and operation of a four panel
`door assembly 511. The same elements in these figures are
`shown by common numerals from the previously described
`figures. The door assembly 5a includes four full size door
`panels 10, 10b, 100, 10d, two half door panels 10a, 10x, a
`slide panel section 11a and a wall panel section 11b secured
`to the wall 7. The slide panel section 11a is supported and
`guided at the top on the ceiling track by mounting roller
`assemblies 19a, 19b, and at the bottom by slide tab 60 that
`is disposed in and slides along floor channel 110. Alternating
`panel sections also include a top mounting roller assembly
`(the panel section 10 includes a mounting roller assembly
`1811 and the panel section 100 includes mounting roller
`assembly 18b) and alternating panel sections also include a
`bottom slide post that engages the floor channel 110 (the
`panel section 10 includes slide post 7011 and the panel
`section 100 includes slide post 70b). The panel sections are
`interconnected by hinge systems, as previously described,
`both at the top cap pieces (hinges 13a-e, 13x, 13y), at the
`bottom rails, and by central hinge assemblies (100a-e, 100x,
`100y (each central hinge assembly comprising a central
`hinge pin and a plurality of stacked hinge knuckles such as
`assembly 100 of FIG. 18). Specifically, slide panel 11a is
`connected to half panel 1011 by hinge knuckle assembly
`100y, half panel 10a is connected to panel 10 by hinge
`knuckle assembly 100a, panel 10 is connected to panel 10b
`by hinge knuckle assembly 100b, panel 10b is connected to
`panel 100 by hinge knuckle assembly 1000, panel 100 is
`connected to panel 10d by hinge knuckle assembly 100d,
`panel 10d is connected to half panel 10x by hinge knuckle
`assembly 100e, and half panel 10x is connected to wall panel
`11b by hinge knuckle assembly 100x.
`Both elements of the central hinge assembly (the hinge
`knuckle and the hinge pin) are fabricated from hard, durable,
`strong material so that they resist forcible entry through the
`central hinge structure. Thus hinge pin 33a may be made of
`a suitable metal such as steel. The hinge knuckles 30a, 30b
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`etc. may be fabricated from a strong, hard, plastic such as
`rigid vinyl (PVC) plastic or other suitable material such as
`metal (e.g., brass).
`
`Thus, when the door is in its extended (un-folded) posi-
`tion of FIGS. 1, 2, 9 and 10, the joints on one side are
`protected by means of flanges 2611, 26c engaging the wedge
`3511. On the other side of the door, the space between the
`panels is protected by the continuous barrier presented by
`hinge knuckles 30a, 30b, etc. mounted on (e.g., made of
`steel) hinge pin 33a. The door accordingly is protected
`against vandalism and entry by the application of force other
`than a force of door-destructive caliber.
`
`FIGS. 14-15 illustrate an alternate hinge knuckle 13111 as
`described in US. Pat. No. 4,922,987. The alternate hinge
`knuckle 131a includes a cylindrical central section 13711
`forming a central opening 132a and a longitudinally extend-
`ing tongue 134a terminating in a bead 13611 that nests within
`the longitudinal extending groove 24b. Multiple hinge
`knuckles are stacked to a desired (as previously described)
`and secured by central pin 13311. The alternate hinge knuckle
`131a (hereinafter referred to as the “old hinge knuckle
`design” or the “old hinge knuckle configuration”) does not
`include the outwardly extending wedge 35a of the hinge
`knuckle 30a of FIG. 5 and thus permits the adjacent door
`panels 10a, 10b to open to a larger angle B2 as shown in
`FIG. 14, and a smaller gap G2 between adjacent extending
`flanges 26b, 26d (the extending flanges 26b, 26d contacting
`each other to limit opening of the panels).
`
`Each of the hinge knuckle assembles 100a-e, 100x, 100y
`may comprise the new design of the hinge knuckle 30a of
`FIG. 5, but a door assembly may comprise a combination of
`the hinge knuckle assemblies of different designs. The new
`hinge knuckle design 30a of FIG. 5 with the wedge 3511
`provides for stronger force resistance but permits a smaller
`extension angle B1 (see FIG. 3) than the extension angle B2
`permitted by the old hinge knuckle design 131a (see FIG.
`14). It has been determined that only smaller number of
`hinge assemblies are needed to be constructed with the new
`hinge knuckle design to achieve superior resistance perfor-
`mance, and thus most of the hinge assemblies may be
`constructed with the old hinge knuckle design to permit
`larger extension angles. For example, the door assembly 5a
`of FIG. 10 may be configured as set forth in the following
`Table A with the new hinge knuckle configuration arranged
`only on the inside hinge sections:
`
`TABLE A
`
`Four Panel Door Assembly 53
`
`Hinge Assembly
`
`Hinge Knuckle
`Configuration
`
`100y
`1003
`100b
`100c
`100d
`100e
`100x
`
`old
`new
`old
`new
`old
`new
`old
`
`Altemately, for a door assembly 5a as in FIG. 10, the new
`hinge knuckle configuration may be disposed only on out-
`side hinge sections as set forth in Table B:
`
`EMI Exhibit 1001
`
`Page 16 of 18
`
`EMI Exhibit 1001
`Page 16 of 18
`
`

`

`7
`TABLE B
`
`Four Panel Door Assembly 5a alternate
`
`Hinge Assembly
`
`Hinge Knuckle
`Configuration
`
`100y
`100a
`100b
`100c
`100d
`100e
`100x
`
`old
`old
`new
`old
`new
`old
`old
`
`FIGS. 16 and 17 illustrate larger size panel door assem-
`blies. The eight panel door assembly 5b in FIG. 16 includes
`eight full size panels 10, 10b, 106, 10d, 106, 10], 10g, 10h,
`half panel 10a, half panel 10x, slide panel 11a, and wall
`panel 11b. The panel sections are pivotally connected by
`hinge assemblies 100a-1', 100x, 100y. Alternating panel
`sections include a top mounting roller assembly (the panel
`section 10 includes a mounting roller assembly 18a, the
`panel section 106 includes mounting roller assembly 18b,
`the panel section 106 includes a mounting roller assembly
`186, the panel section 10g includes mounting roller assem-
`bly 18d) and each alternating panel sections (10, 106, 106,
`10g) also includes a bottom slide post (such as slide post 70a
`in FIG. 13) that engages the floor channel 110.
`The door assembly 5b of FIG. 16 may be configured
`entirely with the new style hinge knuckle 30a, but may
`alternately be configured with the new hinge knuckle con-
`figuration arranged on most of the inside ones of hinge
`assemblies, as set forth in the following Table C, or only on
`the outside (100b, 100d, 100], 100k):
`
`TABLE C
`
`Eigl_1t Panel Door Assembly 5b
`
`Hinge Assembly
`
`Hinge Knuckle
`Configuration
`
`100y
`100a
`100b
`100c
`100d
`100e
`100f
`100g
`100h
`100i
`100x
`
`old
`old
`old
`new
`old
`new
`old
`new
`old
`old
`old
`
`The nine panel door assembly Sc in FIG. 17 includes nine
`full size panels 10, 10b, 106, 10d, 106, 10f, 10g, 10k, 101',
`half panel 10a, half panel 10x, slide panel 11a, and wall
`panel 11b. The panel sections are pivotally connected by
`hinge assemblies 100a-j, 100x, 100y. Alternating panel
`sections include a top mounting roller assembly (the panel
`section 10 includes a mounting roller assembly 18a, the
`panel section 106 includes mounting roller assembly 18b,
`the panel section 106 includes a mounting roller assembly
`186, the panel section 10g includes mounting roller assem-
`bly 18d,
`the panel section 101'
`includes mounting roller
`assembly 186) and each alternating panel sections (10, 106,
`106, 10g, 101') also includes a bottom slide post that engages
`the floor channel 110.
`
`The door assembly Sc of FIG. 17 may be configured with
`the new style hinge knuckle 3011, but may also include may
`be configured with the new hinge knuckle configuration
`
`US 9,879,471 B2
`
`8
`arranged only on most of the inside hinge sections 100c,
`1006, 100g as set forth in the following Table D:
`
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`TABLE D
`
`Nine Panel Door Assembly 5c
`
`Hinge Assembly
`
`Hinge Knuckle
`Configuration
`
`100y
`100a
`100b
`100c
`100d
`100e
`100f
`100g
`100h
`100i
`100j
`100x
`
`old
`old
`old
`new
`old
`new
`old
`new
`old
`old
`old
`old
`
`Other combinations of old and new style hinge knuckles
`may be employed to provide a desired strength property
`(provided by the new design) or larger extension angle
`(provided by the old design).
`Though the present invention has been set forth in the
`form of its preferred embodiments,
`it
`is nevertheless
`intended that modifications to the disclosed systems and
`methods may be made without departing from inventive
`concepts set forth herein.
`
`The invention claimed is:
`
`1. An accordion type folding door system comprising
`a plurality of adjacent panels arranged vertically and
`side-by-side, each panel including a top end having an
`upper margin, and a bottom end having a lower margin;
`a hinge assembly disposed between and interconnecting a
`pair of adjacent panels, each of the pair of adjacent
`panels including a side edge having longitudinal
`groove and an extension flange,
`wherein the hinge assembly comprises
`a hinge pin,
`a plurality of hinge knuckles disposed vertically end-
`to-end in an alternating arrangement on the hinge
`pin, at least one of the hinge knuckles comprising a
`tubular central opening for accepting the hinge pin,
`an outwardly extending tongue for connecting to a
`corresponding longitudinal groove in an adjacent
`panel in a tongue and groove connection, and an
`outwardly flared wedge that extends between and
`beyond the extension flanges of the panels, whereby
`the wedge cooperates with, and respective outer
`surfaces of the wedge directly contact, the extension
`flanges to limit angular un-folding extension of the
`pair of adjacent panels to a maximum desired angle.
`2. A system according to claim 1 wherein the plurality
`hinge knuckles comprise a first partial length hinge knuckle
`disposed at a bottom of the hinge pin, a second partial length
`hinge knuckle disposed at a top of the hinge pin, and seven
`or eight full length hinge knuckles disposed on the hinge pin
`between the first and second partial length hinge knuckles.
`3. A system according to claim 1 further comprising
`a track positioned across a space to be secured;
`mounting roller assemblies disposed on upper margins of
`selected panels for mounting the panels on the track.
`4. A system according to claim 1 further comprising upper
`and lower hinges mounted at top and bottom margins of each
`panel for hinging the adjacent panels together.
`
`EMI Exhibit 1001
`
`Page 17 of 18
`
`EMI Exhibit 1001
`Page 17 of 18
`
`

`

`US 9,879,471 B2
`
`10
`a plurality of first hinge knuckles disposed vertically
`end-to-end in an alternating arrangement on the
`hinge P111:
`wherein each of the first hinge knuckles comprises a
`first hinge knuckle configuration comprising a tubu-
`lar central opening for accepting the first hinge pin,
`an outwardly extending tongue for connecting to a
`corresponding longitudinal groove in an adjacent
`panel in a tongue and groove connection, and an
`outwardly flared wedge that extends between and
`beyond the extension flanges of the panels, whereby
`the wedge cooperates with, and respective outer
`surfaces of the wedge directly contact the extension
`flanges to limit angular un-folding extension of the
`first pair of adjacent panels to a maximum desired
`angle,
`wherein the second hinge assembly comprises
`a second hinge pin,
`a plurality of second hinge knuckles disposed vertically
`end-to-end in an alternating arrangement on the
`hinge pin,
`wherein each of the second hinge knuckles comprises
`a second hinge knuckle configuration comprising a
`tubular central opening for accepting the second

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