Door alignment hinge system

Abstract

Described herein is a motor vehicle door alignment hinge system. The system includes a hinge having a door half section and a body half section adapted to be mounted to a vehicle door and a vehicle body, respectively, a first aperture in one of the door half section and the body half section, and an alignment spacer plate including an alignment feature configured to receive a fastener therethrough. The other of the door half section and the body half section includes a corresponding alignment feature. The alignment feature and the corresponding alignment feature are sized to engage with a minimum gap to position the hinge along an optimal pivot axis. The first aperture is sized to receive the fastener therethrough with a loose fit gap.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 595,517, filed November 2, 2023, and U.S. Provisional Patent Application No. 63 / 606,281, filed December 5, 2023, the contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to door hinges for motor vehicles, and more specifically to door hinge alignment systems. Background Technology

[0003] In the automotive field, from a quality and performance perspective, vehicle doors should fit well with the vehicle body. Doors mounted on hinges should be able to be fitted into the door receiving structure or contour of the vehicle body with acceptable allowances and tolerances. Of course, the door is mounted to the vehicle body via hinges. The body semi-hinged sections and the door semi-hinged sections should be aligned to achieve proper fit, acceptable clearance between the door and the body, and flush contact between the door and body panels, weatherstripping, bumpers, and related vehicle door components.

[0004] Typically, instead of assembling the hinges on-site on an assembly line, a complete hinge assembly consisting of assembled door and body half-hingers and a pivot pin is attached to the door and body. The body with the door is then painted using various methods to form a painted body shell. This ensures the door and body are properly aligned and assembled. The door is then typically removed from the body, with the hinges still fastened to either the door or body, and the body and door move independently during assembly until they are reattached as the vehicle approaches its final configuration. At this stage, the hinges attached to either the door or body are re-fastened to the other of the door and body.

[0005] This process of installing, removing, and reinstalling car doors helps achieve proper alignment and uniform painting between the doors and the body, but it is labor-intensive. Furthermore, while modern robotic assembly methods reduce risk, each installation, removal, and reinstallation of a door carries the potential for scratches or damage to the door, body, or both. Simplifying the manufacturing process (including painting) would be an advantage. Painting the doors and body separately would offer greater flexibility in the painting process, but could lead to difficulties in achieving acceptable alignment, tolerances, and allowances between the doors and body. Therefore, it is advantageous to overcome these drawbacks and provide an alternative process for vehicle painting and assembly. Summary of the Invention

[0006] According to some embodiments, a vehicle door alignment hinge system is provided, comprising a hinge member, a first orifice, and an alignment spacer plate. The hinge member includes a separate door half and a body half, the door half and the body half being adapted to be mounted to a vehicle door and a vehicle body, respectively. The first orifice is located in one of the door half and the body half. The alignment spacer plate includes an alignment feature configured to receive a fastener passing through the alignment feature. The other of the door half and the body half includes a corresponding alignment feature. The dimensions of the alignment feature and the corresponding alignment feature are set to engage with minimal clearance to position the hinge member along an optimal pivot axis. The dimensions of the first orifice are set to receive a fastener passing through the first orifice with a loose fit clearance.

[0007] According to some embodiments, the alignment feature includes an alignment orifice or at least one alignment cone securely fastened to the alignment spacer plate.

[0008] According to some embodiments, the vehicle door alignment hinge system further includes a door inspector. According to some embodiments, the door inspector includes a needle-type inspector.

[0009] According to some embodiments, when the alignment feature includes the at least one alignment cone, the at least one alignment cone is adapted to engage with the corresponding alignment feature along the optimal pivot axis.

[0010] According to some embodiments, when the alignment feature includes the at least one alignment cone, the at least one alignment cone is adapted to engage non-rotatably with a corresponding shaped opening in the door inspector along the optimal pivot axis, and is adapted to fasten the at least one alignment cone to the door inspector by inspector fasteners to securely connect the door half section and the body half section, wherein the corresponding shaped opening is the corresponding alignment feature.

[0011] According to some embodiments, the at least one alignment cone and the opening in the door inspector have corresponding polygonal shapes. According to some embodiments, the at least one alignment cone includes a base with a truncated square pyramid shape, an upper section with a tapered square shape, and a hollow core allowing the inspector fasteners to pass through. According to some embodiments, one or more corners of the base and the upper section are beveled.

[0012] According to some embodiments, the inspector fastener is a screw or bolt. According to some embodiments, the inspector fastener is a reaction torque fastener suitable for being fully clamped.

[0013] According to some embodiments, when the alignment feature includes the alignment orifice, the fastener includes the corresponding alignment feature.

[0014] According to some embodiments, one of the door half section and the body half section further includes a second opening, and the alignment spacer plate includes a corresponding opening, wherein the second opening and the corresponding opening are configured to receive a second fastener passing through the second opening and the corresponding opening.

[0015] According to some embodiments, the alignment spacer plate is formed of glass fiber.

[0016] According to some embodiments, the alignment spacer plate is fastened to the vehicle body half or the door half using an adhesive. According to some embodiments, the adhesive is an epoxy resin. According to some embodiments, the epoxy resin is photocurable using ultraviolet (UV) light, and the alignment spacer plate is formed of a light-transmitting material.

[0017] According to some embodiments, the door half section includes an upper door half section and a lower door half section, the body half section includes an upper body half section and a lower body half section, and the alignment spacer plate includes an upper alignment spacer plate and a lower alignment spacer plate.

[0018] According to some embodiments, a method for manufacturing the vehicle door alignment hinge system is provided. The method includes: positioning the alignment spacer plate on one of the door half and the vehicle body half, wherein an optimal pivot axis is determined using a robot; and fastening the alignment spacer plate to one of the door half and the vehicle body half.

[0019] According to some embodiments, the method further includes measuring the dimensions of each of the vehicle door and the vehicle body profile for receiving the door, to help the robot determine the optimal pivot axis.

[0020] According to some implementations, measuring the vehicle door dimensions and the vehicle body outline dimensions includes laser scanning.

[0021] According to some embodiments, the method further includes using temporary fixtures to determine the registration of the vehicle doors and the vehicle body.

[0022] Further aspects of the invention will become apparent from the following description and illustration. Attached Figure Description

[0023] To better understand the various implementations described herein and to more clearly demonstrate how to put these implementations into practice, reference will now be made only to the accompanying drawings, in which: Figure 1 A schematic diagram of a vehicle body and a vehicle door having an upper hinge and a lower hinge, according to a non-limiting embodiment, is depicted. Figure 2A A perspective view of a motor vehicle door alignment hinge system having an alignment spacer plate fastened to a half-hinged section of the vehicle body, according to a non-limiting embodiment, is depicted. Figure 2B Depicting Figure 2A Exploded view of the vehicle door alignment hinge system; Figure 3A A door inspector is described according to a non-limiting embodiment. Figure 2A A three-dimensional diagram of the alignment hinge system of a motor vehicle door; Figure 3B Depicting Figure 3A Exploded view of the vehicle door alignment hinge system; Figure 4A and Figure 4B The assembly and exploded views depict a motor vehicle door alignment hinge system having an alignment spacer plate fastened to a door half-hinged section, according to a non-limiting embodiment. Figure 5A and Figure 5B A door inspector is depicted according to a non-limiting embodiment. Figure 4A and Figure 4B The vehicle door is aligned with the hinge system; Figure 5C Depicting Figure 5A and Figure 5B Door inspection device and body semi-hinged section; Figure 6A A motor vehicle door alignment hinge system according to a non-limiting embodiment is described, wherein the alignment features include an alignment cone and wherein an alignment spacer plate is fastened to a body half-hinged section. Figure 6B Depicting Figure 6A A partially exploded view of the hinge system of a motor vehicle door. Figure 6C and Figure 6D Depicting Figure 6A and Figure 6B A three-dimensional view of the alignment spacer plate and the semi-hinged section of the vehicle body; Figure 6E A description of a non-limiting embodiment is provided. Figure 6A and Figure 6B A rear-view perspective view of the door semi-hinged section with corresponding alignment features. Figure 7A A door inspector is depicted according to a non-limiting embodiment. Figures 6A to 6E A three-dimensional diagram of the alignment hinge system of a motor vehicle door; Figure 7B Depicting Figure 7A A partially exploded view of the hinge system of a motor vehicle door. Figure 7C A description of a non-limiting embodiment is provided. Figure 7A and Figure 7B A rear-view perspective view of the door semi-hinged section with corresponding alignment features. Figure 8A A non-limiting embodiment of a motor vehicle door alignment hinge system is described, which includes a door inspector and wherein an alignment spacer plate is fastened to a door half-hinged section. Figure 8B Depicting Figure 8A A partially exploded view of the vehicle door alignment hinge system; and Figure 9 A flowchart is shown of a method for manufacturing a motor vehicle door alignment hinge system according to a non-limiting embodiment.

[0024] The embodiments, examples, and alternatives described in the foregoing paragraphs, claims, or the following description and drawings, including any aspect or feature of their respective aspects or corresponding features, may be employed independently or in any combination. Features described in connection with one embodiment apply to all embodiments unless those features are incompatible. Detailed Implementation

[0025] We have designed a door hinge alignment system and a method for assembling the hinge, which typically allows for the proper assembly of a vehicle door to the vehicle body in a single step during vehicle assembly. The described system and method also typically allow the door and body to be painted separately before being joined by the hinge.

[0026] According to some embodiments, the described motor vehicle door alignment hinge system includes an alignment spacer plate positioned between a door half-hinged section and a body half-hinged section. These sections may also be simply referred to as door half-sections and body half-sections. The alignment spacer plate includes alignment features configured to receive fasteners passing through the alignment features to engage the door half-section and the body half-section. One of the door half-section and the body half-section includes a corresponding alignment feature. The other of the door half-section and the body half-section includes an orifice configured to receive fasteners passing through the orifice. The dimensions of the alignment features and the corresponding alignment features are set to engage with minimal clearance to position the hinge along an optimal pivot axis for the assembled hinge. The dimensions of the orifice in the door half-section or body half-section are set to receive fasteners with a loose fit clearance, which allows adjustment of the hinge section to achieve an optimal axis for the door to pivot relative to the body on the hinge. This loose fit connection also prevents damage to the paint on the door and body semi-hinged sections during the insertion of the fastening pin through the alignment spacer plate.

[0027] According to some embodiments, the alignment feature includes an alignment aperture. According to some embodiments, the alignment feature includes an alignment cone adapted to mate with the corresponding alignment feature along an optimal pivot axis.

[0028] The optimal pivot axis can be determined by properly measuring and mapping the door profile and the body structure that receives the door. Laser scanning or other suitable measuring methods can be used to measure the shape and profile of the vehicle door and the body structure that will receive it. This measurement method allows for customized fitting of each door to its corresponding body structure, providing both precision and flexibility. Alternatively, temporary jigs can be used to align the door to the body. With the body half-hinged section fastened to the body, a robot with the optimal pivot axis coordinates typically positions the alignment spacer plate on the body half-section. The difference between the following—the allowance for loose fit clearance between the orifice and the fastener in the hinged section, and the allowance for tight fit of the alignment features of the spacer plate with the corresponding alignment features—allows for fore-aft and lateral adjustments to the door position relative to the body while maintaining the final minimum clearance of the fasteners. Fore-aft alignment helps with clearance control, while lateral alignment helps with flush fit between the door and the body. Then, according to some embodiments, the alignment spacer plate is fastened to the vehicle body half section, so that the door half section can be assembled with the vehicle body half section by the fastener.

[0029] It should be understood that, for simplicity and clarity, reference numerals may be repeated in the figures where deemed appropriate to indicate corresponding or similar elements. Furthermore, numerous specific details have been set forth to provide a thorough understanding of the exemplary aspects of this application described herein. However, those skilled in the art will understand that the exemplary aspects described herein can be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the exemplary aspects described herein. Likewise, this description should not be construed as limiting the scope of the exemplary aspects described herein. Any system, method step, method block, component, component portion, etc., described herein in the singular should be construed as also including such systems, method steps or tasks, components, component portions, etc., described in the plural, and vice versa.

[0030] Please refer to Figure 1 as well as Figure 2A and Figure 2B , Figure 1 A schematic diagram depicts a vehicle body 1 and a door 3 having an upper door hinge 5 and a lower door hinge 7. Figure 2A and Figure 2B A vehicle door alignment hinge system 100 according to a non-limiting embodiment is depicted. The vehicle door alignment hinge system 100 includes a hinge having separate door half section 102 and body half section 104, the door half section and the body half section being adapted to be mounted to a vehicle door 3 and a vehicle body 1, respectively. One of the door half section 102 and the body half section 104, for example, the body half section 104, includes a first aperture 106. The aperture 106 is sized to receive a fastener (e.g., a fastening pin 112) passing through the aperture 106 with a loose fit clearance, which, as described above, allows adjustment of the hinge section to achieve an optimal hinge axis. Although the first aperture 106 is in Figure 2A and Figure 2B The door half section 102 is depicted as being located in the vehicle body half section 104, but according to some embodiments, the door half section 102 may include a first opening 106 (see example...). Figures 4A to 5B ).

[0031] As described above, the described vehicle door alignment hinge system 100 also includes an alignment spacer plate 108 having an alignment feature 110 configured to receive a fastener passing through it. The alignment feature 110 can take various forms. According to one set of embodiments, the alignment feature 110 is an alignment aperture 116. According to another set of embodiments, the alignment feature 110 includes an alignment cone, which will be discussed in further detail below.

[0032] The other of the door half section 102 and the body half section 104 includes a corresponding alignment feature, the dimensions of which are set to engage with the alignment feature with minimal clearance to position the hinge along an optimal pivot axis (e.g., hinge axis A). For example, according to some embodiments, the door half section 102 integrally or as a component includes a fastener (e.g., pin 112) or other protrusion having a shoulder 114 whose size and shape are set to fit with minimal clearance into an alignment aperture 116 along the optimal pivot axis of the hinge.

[0033] During assembly, the alignment spacer plate 108 is secured to one of the door half section and the body half section. For example, according to some embodiments, the alignment spacer plate 108 is secured to the body half section 104 (see [link]). Figures 2A to 3B However, according to some embodiments, the alignment spacer plate 108 is fixed to the door half section 102 (see...). Figures 4A to 5B Any suitable means for securing the alignment spacer plate 108 to one of the door half section 102 and the body half section 104 is contemplated. For example, according to some embodiments, the alignment spacer plate 108 is secured using an adhesive. The adhesive may include an epoxy resin, which may be UV-curable, depending on the material chosen for the alignment spacer plate 108. According to some embodiments, the alignment spacer plate 108 is secured to one of the door half section and the body half section using mechanical fasteners (see, for example...). Figures 6A to 8B ).

[0034] The alignment spacer plate 108 can be formed from any suitable material. For example, low-cost sheet metal often works well. According to some embodiments, the alignment spacer plate 108 formed from sheet metal can be fastened to the vehicle body half section 104 using conventional mechanical fastening devices, including screws, rivets, bolts, or other means. The alignment spacer plate 108 may also have an adhesive on the flat side facing the corresponding hinge section. Conventional adhesives that adhere directly to the corresponding hinge section can be used, although this leaves almost no space for movement of the alignment spacer plate 108 after it contacts the corresponding hinge section. It is advantageous to use an adhesive that provides space for movement of the alignment spacer plate 108 after initial contact with the corresponding hinge section. For example, this could be a thermosetting epoxy resin or other suitable adhesive.

[0035] Alternatively, the alignment spacer plate 108 can be formed of fiberglass or other light-transmitting materials. Although more expensive than sheet metal, the fiberglass alignment spacer plate 108 is less likely to damage the surface of the door or body half compared to a sheet metal alignment spacer plate 108. The alignment aperture 116 can also be precisely formed. For the fiberglass alignment spacer plate, if improved positioning of the fasteners into the alignment aperture 116 is desired, beveling the ends of the fasteners is more convenient than beveling the alignment aperture 116 itself, although both options are feasible, just as with the sheet metal alignment spacer plate 108. For fiberglass, it is possible to attach the alignment spacer plate 108 to the body half using conventional fasteners, but it is not as ideal as using sheet metal. As mentioned above, adhesives can also be used, just as with sheet metal. Preferably, an epoxy resin adhesive can be applied to the flat side of the fiberglass alignment spacer plate 108 to secure it to the corresponding hinge section. When positioned on the corresponding hinge segment to provide the optimal pivot axis A, the alignment spacer plate 108 can be secured to the vehicle body segment using a suitable curing method (e.g., ultraviolet (UV) light). Fiberglass structures are typically transparent to UV light; other materials that allow UV light transmission can also be used to achieve this type of epoxy curing. A UV light source can be attached to a robot that positions the alignment spacer plate 108 on the corresponding hinge segment. The robot can clamp the alignment spacer plate 108 onto the corresponding hinge segment until fixation is complete. Other means of holding the alignment spacer plate 108 in place include friction, mechanical release, or vacuum. Furthermore, if positioning reference for adjacent doors or body structures is required, the front door alignment spacer plate and the rear door alignment spacer plate can be positioned simultaneously or sequentially. Once the epoxy has cured and the alignment spacer plate 108 is secured, the robot can withdraw.

[0036] The flat surface of the alignment spacer plate 108 may be beveled at the alignment orifice 116 on its open side (i.e., the side away from the corresponding hinge segment and adjacent to another corresponding hinge segment during assembly) to help position the fastener in and through the alignment orifice 116. Alternatively, the exposed end of the fastener may be beveled to help position the fastener in and through the alignment orifice. For example, according to some embodiments, the shoulder 114 may be beveled to help position the pin 112 in and through the alignment orifice 116.

[0037] Finally, with the alignment spacer plate 108 fixed to the corresponding hinge segment, another corresponding hinge segment, along with its associated fastening pin, can be installed onto and secured in place. Typically, a fully clamped reaction torque fastener can be used to complete the hinge assembly. Alternatively, suitable alternative fasteners may be used.

[0038] According to some embodiments, the vehicle door alignment hinge system 100 also includes a door inspector, such as door inspector 118 (see [link]). Figure 3A , Figure 3B , Figures 5A to 5C For example, a so-called needle-type inspection device can be used, such as the one described in U.S. Patent No. 7,461,432 (the contents of which are incorporated herein by reference).

[0039] In particular, when the vehicle door alignment hinge system 100 includes a door checker or other torque generating element, the vehicle door alignment hinge system 100 may include a second opening 120 located in one of the door half section 102 and the body half section 104, and a corresponding opening 122 located in the alignment spacer plate 108 (see, for example...). Figure 3B , Figure 5B and Figure 5C The second aperture 120 and the corresponding aperture 122 are configured to receive a second fastener (e.g., fastener 124) passing through the second aperture 120 and the corresponding aperture 122, which can counteract some of the torque generated by the door inspector during use of the vehicle door alignment hinge system 100.

[0040] Please refer to Figures 6A to 8B , Figures 6A to 8B A motor vehicle door alignment hinge system 200 according to a non-limiting embodiment is depicted, wherein the same or similar elements are used... Figures 1 to 5C The same or similar numbers are represented in the same way. For simplicity and ease of understanding, the same or similar numbers are represented in the same way. Figures 6A to 8B The discussion of the elements and features described herein will focus on their relationship with... Figures 1 to 5C The similarities and differences between the elements and features described in the text.

[0041] Similar to the vehicle door alignment hinge system 100, the vehicle door alignment hinge system 200 includes a hinge having a separate door half section 102 and a body half section 104, the door half section and the body half section being adapted to be mounted to a vehicle door 3 and a vehicle body 1, respectively. One of the door half section 102 and the body half section 104 includes a first opening 106 (see example...). Figure 6D (The opening 106 in the body half section 104 shown). The size of the first opening 106 is also set to receive fasteners passing through the first opening 106 with a loose fit clearance.

[0042] The vehicle door alignment hinge system 200 also includes an alignment spacer plate 208. Similar to the alignment spacer plate 108, the alignment spacer plate 208 includes an alignment feature 110 configured to receive a fastener (e.g., fastener 228) passing through it; however, the alignment feature 110 includes at least one alignment cone 216 securely fastened to the alignment spacer plate 208. Any suitable means for securely fastening the alignment cone 216 to the alignment spacer plate 208 is contemplated. For example, according to some embodiments, the alignment cone 216 is riveted to the alignment spacer plate 208. According to some embodiments, the alignment cone 216 may be integrally formed with the alignment spacer plate 208, for example, by casting.

[0043] The alignment cone 216 is adapted to mate with a corresponding alignment feature (e.g., a corresponding alignment feature 226 of the door half section 102 and the body half section 104) along an optimal pivot axis (e.g., hinge axis A). For example, according to some embodiments, the corresponding alignment feature 226 includes an opening that corresponds in shape and / or size to the alignment cone 216.

[0044] Similar to the vehicle door alignment hinge system 100, the vehicle door alignment hinge system 200 may include a door inspector, such as door inspector 218. For example, a so-called needle inspector may be used, such as that described in U.S. Patent No. 7,461,432 (the contents of which are incorporated herein by reference).

[0045] According to some embodiments, the corresponding alignment feature 226 includes a corresponding shaped opening located in the door inspector 218 along the optimal pivot axis A, and is adapted to be fastened to the door inspector 218 by an inspector fastener 228 to securely connect the door half section 102 and the body half section 104. According to some embodiments, the inspector fastener 228 is a screw or bolt. According to some embodiments, the inspector fastener 228 is a reaction torque fastener adapted to be fully clamped. Any suitable fastener is contemplated.

[0046] The alignment cone 216 can take various shapes. Although the term "cone" is used herein, it should be understood that any suitable shape of protrusion is contemplated. For example, according to some embodiments, the alignment cone 216 has a cubic or polygonal shape. According to some embodiments, the alignment cone 216 and the corresponding alignment feature 226 have corresponding polygonal shapes. According to some embodiments, the alignment cone 216 includes a base with a truncated square pyramid shape, an upper segment with a tapered square shape, and a hollow core that allows inspector fasteners to pass through (see example...). Figure 7B(See the aligned cone 216 shown). According to some embodiments, one or more corners (e.g., corner 230) of the base and upper segment are beveled.

[0047] As described above, the vehicle door 3 can be fastened to the vehicle body 1 by two or more hinges. For example, the upper hinge 5 and the lower hinge 7 are... Figure 1 As shown in the diagram. With this in mind, according to some embodiments, the vehicle door alignment hinge systems 100 and 200 each include an upper hinge and a lower hinge. Specifically, according to some embodiments, the door half section 102 includes an upper door half section and a lower door half section, the body half section 104 includes an upper body half section and a lower body half section, and the alignment spacer plates 108 and 208 include an upper alignment spacer plate and a lower alignment spacer plate.

[0048] Please refer to Figure 9 , Figure 9 An example method 300 for manufacturing any of the motor vehicle door alignment hinge systems described herein is illustrated. To aid in explaining method 300, it will be assumed that method 300 uses... Figures 2A to 8B The method described herein involves aligning the vehicle door with the hinge system and various components as described herein. However, it should be understood that method 300 can vary and does not need to operate exactly as discussed herein, and such variations are within the scope of this application. It should also be emphasized that, unless otherwise stated, method 300 does not need to be performed in the exact order shown; and similarly, the various blocks can be performed in parallel rather than sequentially. Therefore, the elements of method 300 are referred to herein as “blocks” rather than “steps.” Furthermore, more or fewer elements may be performed than those indicated herein.

[0049] In frame 302, the alignment spacer plates 108, 208 are positioned on one of the door half section 102 and the body half section 104 (e.g., as shown in the image). Figure 2A The alignment spacers 108, 208 are loosely placed on the door half 102 or the body half 104 after the robot has determined the optimal pivot axis, as shown in some embodiments. The center of the alignment feature 110 is aligned with the center of the first opening 106 and the optimal pivot axis (e.g., hinge axis A). According to some embodiments, to assist the robot in determining the optimal pivot axis, method 300 further includes measuring the dimensions of each of the vehicle door 3 and the vehicle body 1 that receives the vehicle door 3. Such measurements may include laser scanning; however, any suitable means of performing the measurement is contemplated. Alternatively, temporary jigs may be used to align the vehicle door 3 with the vehicle body 1.

[0050] In frame 304, the alignment spacer plates 108, 208 are fastened to a corresponding one of the door half section 102 and the body half section 104. For example, as described above, the alignment spacer plates 108, 208 can be fastened to the corresponding one of the door half section 102 and the body half section 104 by an adhesive (e.g., epoxy resin). The epoxy resin can be UV-curable, especially when the alignment spacer plates 108, 208 are made of a light-transmitting material (e.g., fiberglass).

[0051] In some embodiments, the various components of the vehicle door alignment hinge system can be manufactured using various manufacturing methods (e.g., stamping, forging, and casting). In other embodiments, the various components of the vehicle door alignment hinge system can be made from various types of materials (e.g., metals and plastics). In some embodiments, lubricants or materials impregnated with lubricants can be used.

[0052] Those skilled in the art will understand that many alternative implementations and modifications may exist, and the above examples are merely illustrative of one or more embodiments. Therefore, the scope is limited only by the appended claims.

[0053] It should also be understood that, for the purposes of this application, the language “at least one of X, Y and Z” or “one or more of X, Y and Z” can be interpreted as only X, only Y, only Z, or any combination of two or more items X, Y and Z (e.g., XYZ, XYY, YZ, ZZ, XX, XY).

[0054] In this application, a component may be described as being "configured to" or "enabled to" perform one or more functions. Generally, it should be understood that a component configured to or enabled to perform a function is configured to or enabled to perform that function, or is adapted to perform that function, or is operable to perform that function, or is otherwise capable of performing that function.

[0055] Additionally, components in this application may be described as being "operationally connected to," "operationally coupled to," or similarly connected to other components. It should be understood that such components are connected or coupled to each other in a manner that performs a certain function. It should also be understood that the terms "connection," "coupling," etc., used in this application include both direct and indirect connections between components.

[0056] References to "an implementation," "implementation," "mode of implementation," "variation," etc., in this application indicate that the described implementation, mode of implementation, or variation may include specific aspects, features, structures, or characteristics, but not every implementation, mode of implementation, or variation necessarily includes that aspect, feature, structure, or characteristic. Furthermore, such phrases may, but do not necessarily, refer to the same implementation mentioned in other parts of the specification. Moreover, when a specific aspect, feature, structure, or characteristic is described in conjunction with an implementation, the influence or connection of such module, aspect, feature, structure, or characteristic with other implementations is within the knowledge of those skilled in the art, whether explicitly described or not. In other words, any module, element, or feature can be combined with any other element or feature in different implementations unless there is an obvious or inherent incompatibility, or specific exclusion.

[0057] It should also be noted that claims can be drafted to exclude any optional elements. Therefore, this statement is intended as a basis for reference in incorporating elements of the claims, using exclusive terms (such as "only," "only," etc.) or using the restrictive term "negative." The terms "preferred," "ideally," "preferred," "optionally," "may," and similar terms are used to indicate that the mentioned item, condition, or step is an optional (non-essential) feature.

[0058] The singular forms “a,” “an,” and “the” include plural references unless the context clearly specifies otherwise. The term “and / or” means any one of the listed items, any combination of the listed items, or all items associated with this term. The phrase “one or more” is readily understood by those skilled in the art, especially when read in the context of its use.

[0059] The term "about" can refer to a variation of ±5%, ±10%, ±20%, or ±25% of a specified value. For example, "about 50%" may include a variation of 45% to 55% in some embodiments. For integer ranges, the term "about" may include one or both integers greater than and / or less than each end of the range. Unless otherwise stated herein, the term "about" is intended to include values ​​and ranges that are close to functionally equivalent to the stated ranges in the composition or embodiment.

[0060] As those skilled in the art will understand, for any and all purposes, particularly in providing a written description, all ranges referred to herein also encompass any and all possible subranges and combinations thereof, as well as the individual values ​​constituting the range, particularly integer values. The ranges referred to include every particular value, integer, decimal, or identity within that range. Any range listed can be readily considered to adequately describe and implement the decomposition of that same range into at least two, three, four, five, or ten equal parts. As a non-limiting example, each range discussed herein can be readily decomposed into a lower third, a middle third, and an upper third, etc.

[0061] As those skilled in the art will also understand, all terms such as “up to,” “at least,” “greater than,” “less than,” “more than,” “or more,” including the numbers mentioned, and such terms refer to a range that can subsequently be broken down into subranges as described above. In the same manner, all ratios referred to herein also include all sub-ratios falling within a wider range.

Claims

1. A vehicle door alignment hinge system, the vehicle door alignment hinge system comprising: A hinge having separate door half and body half sections, the door half and the body half sections being adapted to be respectively mounted to a vehicle door and a vehicle body; The first opening is located in one of the door half section and the body half section; as well as Alignment spacer plate, the alignment spacer plate including alignment features configured to receive fasteners passing through the alignment features; The other of the door half and the body half includes corresponding alignment features; The dimensions of the alignment feature and the corresponding alignment feature are set to engage with minimal clearance to position the hinge along the optimal pivot axis; The size of the first orifice is set to receive a fastener passing through the first orifice with a loose fit clearance.

2. The vehicle door alignment hinge system according to claim 1, wherein, The alignment feature includes an alignment orifice or at least one alignment cone securely fastened to the alignment spacer plate.

3. The vehicle door alignment hinge system according to claim 1 or 2, wherein the vehicle door alignment hinge system further includes a door inspector.

4. The motor vehicle door alignment hinge system according to claim 3, wherein, The door inspection device includes a needle-type inspection device.

5. The motor vehicle door alignment hinge system according to any one of claims 2 to 4, wherein, When the alignment feature includes the at least one alignment cone, the at least one alignment cone is adapted to engage with the corresponding alignment feature along the optimal pivot axis.

6. The vehicle door alignment hinge system according to claim 3 or 4, wherein, When the alignment feature includes the at least one alignment cone, the at least one alignment cone is adapted to engage non-rotatably with a corresponding shaped opening in the door inspector along the optimal pivot axis, and is adapted to fasten the at least one alignment cone to the door inspector by inspector fasteners to securely connect the door half and the body half, wherein the corresponding shaped opening is the corresponding alignment feature.

7. The vehicle door alignment hinge system according to claim 6, wherein, The at least one alignment cone and the opening in the door inspector have corresponding polygonal shapes.

8. The vehicle door alignment hinge system according to claim 6 or 7, wherein, The at least one alignment cone includes a base having a truncated square pyramid shape, an upper section having a tapered square shape, and a hollow core that allows the inspector fastener to pass through.

9. The motor vehicle door alignment hinge system according to claim 8, wherein, The base and one or more corners of the upper segment are obliquely cut.

10. The motor vehicle door alignment hinge system according to any one of claims 6 to 9, wherein, The fasteners of the inspector are screws or bolts.

11. The vehicle door alignment hinge system according to claim 10, wherein, The inspector fastener is a reaction torque fastener suitable for being fully clamped.

12. The motor vehicle door alignment hinge system according to claim 1 or 2, wherein, When the alignment feature includes the alignment orifice, the fastener includes the corresponding alignment feature.

13. The motor vehicle door alignment hinge system according to any one of claims 1 to 12, wherein, One of the door half section and the body half section further includes a second opening, and the alignment spacer plate includes a corresponding opening, the second opening and the corresponding opening being configured to receive a second fastener passing through the second opening and the corresponding opening.

14. The motor vehicle door alignment hinge system according to any one of claims 1 to 13, wherein, The alignment spacer plate is formed of glass fiber.

15. The motor vehicle door alignment hinge system according to any one of claims 1 to 14, wherein, The alignment spacer plate is fastened to the vehicle body half or the door half using adhesive.

16. The motor vehicle door alignment hinge system according to claim 15, wherein, The adhesive is epoxy resin.

17. The motor vehicle door alignment hinge system according to claim 16, wherein, The epoxy resin is curable using ultraviolet (UV) light, and the alignment spacer plate is formed of a light-transmitting material.

18. The motor vehicle door alignment hinge system according to any one of claims 1 to 17, wherein: The door half section includes an upper door half section and a lower door half section; The vehicle body section includes an upper vehicle body section and a lower vehicle body section; and The alignment spacer plate includes an upper alignment spacer plate and a lower alignment spacer plate.

19. A method for manufacturing a motor vehicle door alignment hinge system according to any one of claims 1 to 18, the method comprising: Positioning the alignment spacer plate on one of the door half and the body half, wherein a robot is used to determine the optimal pivot axis; and The alignment spacer plate is fastened to one of the door half and the body half.

20. The method of manufacturing a motor vehicle door alignment hinge system according to claim 19, the method further comprising measuring the dimensions of each of the vehicle door and the vehicle body profile for receiving the door, to help the robot determine the optimal pivot axis.

21. The method for manufacturing a motor vehicle door alignment hinge system according to claim 20, wherein, Measuring the dimensions of the vehicle doors and the vehicle body outline includes laser scanning.

22. The method for manufacturing a motor vehicle door alignment hinge system according to claim 19, the method further comprising determining the registration of the vehicle door and the vehicle body using a temporary fixture.

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