US-20260125943-A1 - CONTINUOUS LOCKING HINGE ASSEMBLIES AND FOLDING DOOR ASSEMBLIES INCLUDING THE SAME

US20260125943A1US 20260125943 A1US20260125943 A1US 20260125943A1US-20260125943-A1

Abstract

A threshold assembly has an interior side, an exterior side opposite the interior side, a top side, and a bottom side opposite the top side and includes a substrate and a sill deck. The sill deck is attached to the substrate and includes a deck cover and a sill track. The deck cover may be positioned over a portion of the substrate. The deck cover extends towards the exterior side of the threshold assembly. The sill track has an attachment wall, an exterior wall, and a bottom wall, the attachment wall is positioned on an exterior side of the substrate. The exterior wall is positioned on an exterior side of the attachment wall and defines the exterior side of the threshold assembly. The attachment wall and the exterior wall define a channel therebetween with the channel being open upward and closed on the bottom by the bottom wall.

Inventors

Cody McMillian
Austin Mundy
Chris Keziah
Luke Baker

Assignees

ENDURA PRODUCTS, LLC

Dates

Publication Date: 20260507
Application Date: 20251219

Claims (20)

1 . A continuous hinge assembly for a door panel system, the hinge assembly comprising: a first leaf configured to secured to an edge of a first door panel; a second leaf configured to secure to an edge of the second door panel, the second leaf pivotally coupled to the first leaf, the hinge assembly having a closed position in which the first leaf and the second leaf are configured to support the first door panel and the second door panel with interior surfaces thereof coplanar with one another, the hinge assembly having an open position in which the first leaf and the second leaf are configured to support the first door panel and the second door panel with interior surfaces thereof out of plane with one another; a handle mounted to one of the first leaf or the second leaf, the handle having a first end segment and a second end segment opposite the first end segment, the handle configured to be engaged to transition the hinge assembly between the closed position and the open position thereof; a locking mechanism disposed within the one of the first leaf or the second leaf, the locking mechanism including a bottom shoot bolt and a top shoot bolt, the locking mechanism having a locked configuration in which the top shoot bolt and the bottom shoot bolt extend from the one of the first leaf or the second leaf to prevent the hinge assembly from moving towards the open position from the closed position and an unlocked configuration in which the hinge assembly is allowed to move towards the open position from the closed position; and a lock lever pivotally coupled to the handle, the lock lever including an end portion, the lock lever having a locked state in which the end portion of the lock lever is disposed adjacent to the first end segment of the handle and an unlocked state in which the end portion is disposed adjacent to the second end segment, the locked state corresponding to the locked configuration of the locking mechanism and the unlocked state corresponding the unlocked configuration of the locking mechanism.
2 . The hinge assembly according to claim 1 , wherein the locking mechanism further comprises: a bottom shoot bolt rack coupled to the bottom shoot bolt; a top shoot bolt rack coupled to the top shoot bolt; and a rack gear disposed between and meshingly engaged with the bottom shoot bolt rack and the top shoot bolt rack, the lock lever coupled to the rack gear such that pivoting the lock lever between the locked state and the unlocked state simultaneously translates the bottom shoot bolt rack and the top shoot bolt rack in opposite directions from one another.
3 . The hinge assembly according to claim 1 , further comprising a throw adjustment mechanism that adjusts a throw distance of the top shoot bolt or the bottom shoot bolt in the locked configuration thereof.
4 . The hinge assembly according to claim 3 , wherein the throw adjustment mechanism includes a plurality of ports that are spaced apart from one another by a distance and a first adjustment point, the throw adjustment mechanism configured to adjust the throw distance by an integer of the distance based on the port aligned with the first adjustment point.
5 . The hinge assembly according to claim 4 , wherein the throw adjustment mechanism includes a second adjustment point separated from the first adjustment point by an integer and a half distance from the first adjustment point such that the throw distance is adjustable by a half integer of the distance.
6 . The hinge assembly according to claim 1 , wherein the hinge assembly is configured as a floating hinge.
7 . A handle assembly comprising: a handle having a first end segment, a second end segment opposite the first end segment, and a handle side surface; and a lock lever pivotally coupled to the handle, the lock lever including an end portion and a lever side surface, the lock lever having a locked state in which the end portion of the lock lever is disposed adjacent to the first end segment of the handle and an unlocked state in which the end portion is disposed adjacent to the second end segment of the handle, in the locked state and the unlocked state the lock lever side surface positioned congruent to the handle side surface.
8 . The handle assembly according to claim 7 , wherein the handle has an interior surface that extends from the first end segment to the second end segment, the lock lever having an interior surface, in one of the locked state or the unlocked state the interior surface of the lock lever is congruent with the interior surface of the handle.
9 . The handle assembly according to claim 8 , wherein in the other of the locked state or the unlocked state the interior surface of the lock lever is non-congruent with the interior surface of the handle.
10 . The handle assembly according to claim 7 , wherein a position of the end portion of the lock lever relative to the handle provides a visual indication of the state of the lock lever.
11 . The handle assembly according to claim 7 , wherein the end portion of the lock lever is formed to provide visual indication that the lock lever is in the locked state or the unlocked state.
12 . The handle assembly according to claim 8 , wherein a position of the end portion of the lock lever relative to the handle provides a visual indication of the state of the lock lever.
13 . A continuous hinge assembly for a door panel system, the hinge assembly comprising: a first leaf configured to secured to an edge of a first door panel; a second leaf configured to secure to an edge of a second door panel, the second leaf pivotally coupled to the first leaf, the hinge assembly having a closed position in which the first leaf and the second leaf are configured to support the first door panel and the second door panel with interior surfaces thereof coplanar with one another, the hinge assembly having an open position in which the first leaf and the second leaf are configured to support the first door panel and the second door panel with interior surfaces thereof out of plane with one another; a handle mounted to one of the first leaf or the second leaf, the handle having a first end segment and a second end segment opposite the first end segment, the handle configured to be engaged to transition the hinge assembly between the closed position and the open position hereof; and a lock lever pivotally coupled to the handle, the lock lever including an end portion, the lock lever having a locked state in which the end portion of the lock lever is disposed adjacent to the first end segment of the handle and the hinge assembly is prevented from moving towards the open position from the closed position, the locking lever having an unlocked state in which the end portion is disposed adjacent to the second end segment and the hinge assembly is allowed to move towards the open position from the closed position.
14 . The hinge assembly according to claim 13 , wherein the hinge assembly is configured as a floating hinge.
15 . The hinge assembly according to claim 13 , wherein the handle defines a finger well with the one of the first leaf or the second leaf, the finger well configured to provide a grip for a user to transition the hinge assembly between the open position and the closed position.
16 . The hinge assembly according to claim 13 , wherein the handle includes a handle side surface and the lock lever includes a lever side surface, the lever side surface congruent with the handle side surface in the locked state and the unlocked state.
17 . The hinge assembly according to claim 13 , wherein the handle has an interior surface that extends from the first end segment to the second end segment, the lock lever having an interior surface, in one of the locked state or the unlocked state the interior surface of the lock lever is congruent with the interior surface of the handle.
18 . The hinge assembly according to claim 17 , wherein in the other of the locked state or the unlocked state the interior surface of the lock lever is non-congruent with the interior surface of the handle.
19 . The hinge assembly according to claim 13 , wherein a position of the end portion of the lock lever relative to the handle provides a visual indication of the state of the lock lever.
20 . The hinge assembly according to claim 13 , wherein the end portion of the lock lever is formed to provide visual indication that the lock lever is in the locked state or the unlocked state.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a Continuation Application of U.S. patent application Ser. No. 18/423,484, filed Jan. 26, 2024, which claims priority to, and the benefit of, U.S. Provisional Application No. 63/441,594, filed Jan. 27, 2023, the contents of which are hereby incorporated in their entirety. FIELD OF DISCLOSURE The present disclosure relates to folding door assemblies. More particularly, the present disclosure relates to folding door assemblies including a continuous locking hinge assembly including a locking feature and/or an integrated weather seal. BACKGROUND Folding door assemblies can provide for large openings between building spaces when open and can prevent liquid intrusion, prevent thermal conduction, and/or provide acoustic isolation when closed. Typically, folding door assemblies include door panels that are connected to each other by multiple, surface-mounted hinges located on edges of each door panel. The end panels may utilize pivot hinges at the top and bottom of their outermost edges and the panels can be supported by roller hardware or bogies attached near the top ends such that the panels hang from and are guided by an overhead rail or track. The panels can be guided at the bottom by roller hardware that rides in a sill or on a floor track. The roller hardware is typically installed in grooves, channels, or mortises that are machined in the top and bottom ends of the panels. To lock the panels in a closed position, locking hardware can be mounted to the panel edge or face and be driven into the sill. The locking hardware may be flush on the panel or may be installed within an end of a panel requiring machining of the end of the panel. In the closed position, the gaps or spaces between adjacent panels are sealed by weather seals attached to each panel. To attach the weather seals, each panel is machined to include mounting slots along the edges to receive the weather seals. SUMMARY This disclosure relates generally to door panel assemblies having continuous hinge assemblies that include pivots, roller assemblies, weather seals, and/or a locking system. The hinge assemblies may be secured to the door panels without requiring additional machining of the panels, e.g., grooves, channels, or mortises. The door panel assemblies may include an adjustment mechanism to adjust a gap between adjacent door panels. In an embodiment of the present disclosure, a continuous hinge assembly includes a first leaf, a second leaf, an upper pivot, and a lower pivot. The first leaf has an uppermost end and a lowermost end and is configured to be secured to an edge of a first panel with the uppermost end disposed adjacent a top end of the first panel and the lowermost end disposed adjacent a bottom end of the first panel. The second leaf has an uppermost end and a lowermost end and is configured to be secured to an edge of a second panel adjacent the edge of the first panel with the uppermost end disposed adjacent a top end of the second panel and the lowermost end disposed adjacent a bottom end of the second panel. The upper pivot is formed between the first leaf and the second leaf and is disposed adjacent the uppermost ends of the first and second leaves. The lower pivot is formed between the first leaf and the second leaf and is disposed adjacent the lowermost ends of the first and second leaves. The upper and lower pivots are coaxially aligned with one another to define a pivot axis between the first and second leaves. The first and second leaves are configured to pivot relative to one another about the pivot axis. The first and second leaves have a closed position in which the first and second panels are aligned on edges with one another to form an extended wall and an open position in which the first and second panel are out of alignment with one another. In embodiments, the continuous hinge assembly includes a locking assembly having an upper shoot bolt with an upper tip. The locking assembly may have a retracted position in which the upper tip of the upper shoot bolt is disposed at or below the uppermost end of the hinge assembly and an extended position in which the upper tip of the upper shoot bolt extends in a direction parallel to the pivot axis above the uppermost end of the hinge assembly. The upper shoot bolt may be configured to be disposed between the edge of the first panel and the edge of the second panel in the closed position. The locking assembly may include an upper shoot bolt guide secured to the first leaf adjacent the uppermost end thereof. The upper shoot bolt guide may define a pair of finger catches on opposite sides thereof. The first leaf may include a pair of opposed retaining fingers with each of the retaining fingers received within one of the pair of finger catches to secure the upper shoot bolt guide relative to the first leaf. In some embodiments, the locking assembly includes a lower shoot bolt having a lower tip. In the retracted posit