Three knuckle hinge with bushing inserts in center knuckle and method of making same

Claim 2

A three knuckle hinge comprising: (a) a first leaf including an attachment portion and an elongated knuckle portion centrally located on one edge of said attachment portion, said knuckle portion being axially continuous and one-piece and having a passage extending axially therethrough; (b) a pair of bearing inserts located at the opposite ends of said knuckle portion and extending into said axial passage, each of said inserts being one-piece and integrally formed with a tubular body portion of generally circular cross section and a radially outwardly extending flange portion at one end of said tubular body portion abutting the adjacent end of said knuckle portion, said tubular body portion having ribs on the outer surface therein deformed to provide frictional engagement with said knuckle portion to inhibit relative rotation, wherein the body portions of said bearing inserts have ribs on the inner surface thereof spaced along the inner walls (c) a second leaf including an attachment portion and a pair of spaced apart knuckle portions along one edge of said attachment portion with said knuckle portion of said first leaf disposed therebetween and the adjacent surface of the flange portions of said inserts directly abutting said knuckle portions of said second leaf, said knuckle portions of said second hinge leaf having an axially extending passage therein coaxial with said passage of said knuckle portion of said first leaf; and

Claim 3

(d) hinge pin means extending through said passages of said knuckle portions of said first and second leaves and in said inserts, said hinge pin means being engaged with said knuckle portions of said second leaf to prevent relative movement therebetween and being rotatable in said bearing inserts to provide a pivotal connection between said first and second leaves, said hinge pin means comprising two pin elements extending into said passages defined in said knuckle portions from opposite ends of said second leaf, said inner surface thereby providing the bearing surfaces for said hinge pin elements.

Claim 4

(d) hinge pin means extending through said passages of said knuckle portions of said first and second leaves and in said inserts, said hinge pin means being engaged with said knuckle portions of said second leaf to prevent relative movement therebetween and being rotatable in said bearing inserts to provide a pivotal connection between said first and second leaves, said hinge pin means comprising two pin elements extending into said passages defined in said knuckle portions from opposite ends of said second leaf, said inner surface thereby providing the bearing surfaces for said hinge pin elements.

Claim 5

The hinge in accordance with claim 1 wherein each of said pin elements includes an end cap disposed outwardly of the cooperating knuckle portion.

Claim 6

The hinge in accordance with claim 1 wherein each of said knuckle portions of said second leaf have a projection on the inner surface thereof engaged with the hinge pin elements to provide mechanical engagement therebetween.

Claim 7

The hinge in accordance with claim 1 wherein said hinge pin elements have a circumferential groove therein and said knuckle portions of said second leaf each have a projection thereon extending and engaged in said groove of the adjacent hinge pin element.

Claim 8

In a method for assembling a three knuckle hinge, the steps comprising: (a) providing a first hinge leaf including an attachment portion and an elongated knuckle portion centrally located on one edge of said attachment portion, said knuckle portion being one-piece and axially continuous and having a passage extending axially therethrough; (b) inserting into the opposite ends of said kunckle a pair of one-piece bearing inserts integrally formed with a tubular body portion seating in said passage of said knuckle portion and a radially outwardly extending flange portion abutting the ends of said knuckle portion, said bearing inserts having ribs on the inner and outer surface thereof deforming said ribs to frictionally engage said knuckle portion to inhibit relative rotation; (c) assembling to first hinge leaf a second hinge leaf including an attachment portion and a pair of knuckle portions spaced apart along one end of said attachment portion, said knuckle portion of said first leaf being disposed between said pair of knuckle portions of said second leaf, said flange portions of said inserts directly abutting the adjacent surfaces of the ends of said knuckle portions of said second leaf, said knuckle portions of said second hinge having an axially extending passage therein coaxial with said passage of said first hinge leaf; and (d) inserting a pair of hinge pin elements into the outer ends of said knuckle portions of said second leaf and thence into said inserts and into engagement with said inner ribs and knuckle portion of said first leaf to pivotally connect and first and second leaves, said hinge pin elements being engaged with said knuckle portions of said second hinge leaf to prevent relative rotation therebetween said inner ribs providing bearing surfaces for said hinge pin elements.

Claim 9

In a method for assembling a three knuckle hinge, the steps comprising: (a) providing a first hinge leaf including an attachment portion and an elongated knuckle portion centrally located on one edge of said attachment portion, said knuckle portion being one-piece and axially continuous and having a passage extending axially therethrough; (b) inserting into the opposite ends of said kunckle a pair of one-piece bearing inserts integrally formed with a tubular body portion seating in said passage of said knuckle portion and a radially outwardly extending flange portion abutting the ends of said knuckle portion, said bearing inserts having ribs on the inner and outer surface thereof deforming said ribs to frictionally engage said knuckle portion to inhibit relative rotation; (c) assembling to first hinge leaf a second hinge leaf including an attachment portion and a pair of knuckle portions spaced apart along one end of said attachment portion, said knuckle portion of said first leaf being disposed between said pair of knuckle portions of said second leaf, said flange portions of said inserts directly abutting the adjacent surfaces of the ends of said knuckle portions of said second leaf, said knuckle portions of said second hinge having an axially extending passage therein coaxial with said passage of said first hinge leaf; and (d) inserting a pair of hinge pin elements into the outer ends of said knuckle portions of said second leaf and thence into said inserts and into engagement with said inner ribs and knuckle portion of said first leaf to pivotally connect and first and second leaves, said hinge pin elements being engaged with said knuckle portions of said second hinge leaf to prevent relative rotation therebetween said inner ribs providing bearing surfaces for said hinge pin elements.

Claim 10

The method in accordance with claim 5 wherein said pin elements have end caps at one end thereof and are inserted into said passages of said knuckle portions until said end caps abut the ends of the knuckle portions of said second leaf.

Claim 11

The method in accordance with claim 5 wherein the inner surface of said knuckles of said second. hinge leaf are provided with projections, engaging said projections with hinge pin elements to effect mechanical engagement therebetween.

Claim 12

The method in accordance with claim 5 wherein there is included tthe step of swaging end caps on said hinge pin elements to engage said pin means with said knuckle portions of said second hinge leaf.

Claim 13

The method in accordance with claim 5 wherein there is including the step of swaging said knuckle portions of said second hinge leaf to interlock with said hinge pin elements. means.

Claim 14

The method in accordance with claim 5 wherein said hinge pin elements have a circumferential groove and said knuckle portions of said second hinge leaf are swaged to deform metal thereof into said groove.