Preassembled friction hinge module, hinged system, and method for making preassembled friction hinge modules and systems

Abstract

A hinge system includes a pre-assembled hinge module for pivotally coupling a first component to a second component. The pre-assembled hinge module includes: a shaft; a torque element that frictionally engages the shaft; and a housing. The housing includes a cover, a sidewall, and a rear wall, the cover, sidewall, and rear wall defining an internal space enclosed within the housing. The internal space receives the torque element within the housing. The cover defines a first aperture, and the rear wall defines a second aperture, the first aperture and the second aperture being aligned with a pivot axis of the shaft. The shaft extends at least through the first aperture, the internal space, and the second aperture. The shaft is separate from the first component and configured to be mounted to the first component. The housing is separate from the second component and configured to be mounted to the second component.

Description

Technical Field

[0001] The present invention generally relates to friction hinges, and more particularly, to a pre-assembled friction hinge module for components that can be used in a pivotally connected system. Prior Art

[0002] Various types of mechanical hinges can be used to connect components in a pivotal relationship. A friction hinge (also referred to as a "constant torque hinge" or "positioning hinge") is one such hinge that is used on devices characterized by a pivoting door, panel, or other component that opens and closes about a pivot axis. Friction hinges are commonly used to connect laptop computer screens to keyboards, and in the automotive industry to connect armrests to center consoles and in many other applications.

[0003] In a typical friction hinge, the pivot shaft has an outer surface that abuts against an inner surface of another component to create mechanical interference in the hinge. This mechanical interference causes the component to remain in a stable position after it is pivoted and released, which is desirable for holding components such as doors and armrests in any position. The mechanical interference also adds a tactile "feel" to the movement of the door and armrest, providing a substantially constant rotational resistance during the effort to close and open, thus enhancing the user experience.

[0004] Conventional friction hinges used in center consoles are typically manufactured as large assemblies with multiple components. The assembly may include large brackets and other stamped parts designed to be mounted inside an automobile. These hinge assemblies are relatively large in size, adding significant weight to the console. Additionally, the stamped parts require additional tools to manufacture. Summary of the Invention

[0005] The disadvantages of conventional friction hinge assemblies are addressed in various aspects by the friction hinge module, system, and method according to the present invention.

[0006] In a first aspect of the present invention, a pre-assembled hinge module is configured to couple a first component to a second component for pivotal movement relative to each other. The pre-assembled hinge module includes: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing including a side wall, a rear wall, and a lid, the side wall, the rear wall, and the lid together defining an internal space within the housing, wherein the internal space is configured to receive the torque element within the housing; wherein the lid defines a first hole and the rear wall defines a second hole, the first hole and the second hole being aligned with the pivot axis of the shaft, wherein the shaft extends at least through the first hole, the internal space of the housing, and the second hole; wherein the shaft is separated from the first component and is configured to be mounted to the first component; and wherein the housing is separated from the second component and is configured to be mounted to the second component. This new design allows the use of lighter material brackets, such as molded plastics or castings. Additionally, the new design also allows for a reduction in the number of components, such as removing component riveting rivets or other unnecessary components in the design.

[0007] In another aspect of the present invention, a method for manufacturing a hinge module is provided, the method including the steps of: placing a torque element within an internal space of a housing; aligning a hole defined in a rear wall of the housing with a hole defined in the torque element to form a passage; inserting a shaft through the passage; placing a lid adjacent to the torque element such that an end portion of the shaft is exposed through a hole of the lid; and squeezing the side wall along a perimeter to secure the lid relative to the housing.

[0008] In another aspect of the present invention, a set of hinge modules is configured to couple a first component to a second component for pivotal movement relative to each other. The set of hinge modules includes: a first pre-assembled hinge module configured to control the relative pivotal movement of the first component and the second component along a first pivotal direction; and a second pre-assembled hinge module configured to control the relative pivotal movement of the first component and the second component along a second pivotal direction opposite to the first direction. The first pre-assembled hinge module and the second pre-assembled hinge module each include: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing including a side wall, a rear wall, and a lid. The side wall, the rear wall, and the lid together define an internal space within the housing. The internal space is configured to receive the torque element within the housing. The lid defines a first hole and the rear wall defines a second hole. The first hole and the second hole are aligned with the pivot axis of the shaft. The shaft extends at least through the first hole, the internal space of the housing, and the second hole. The shaft is separated from the first component and is configured to be mounted to the first component. And the housing is separated from the second component and is configured to be mounted to the second component.

[0009] In another aspect of the present invention, a hinge system is configured to couple a first component to a second component for pivotal movement relative to each other. The pre-assembled hinge module includes: a shaft defining a pivot axis, the shaft being separated from the first component and being configured to be mounted to the first component; a torque element frictionally engaging the shaft; a housing accommodating the torque element; and an adapter having one end configured to be fixedly coupled to the shaft and an opposite end configured to be releasably coupled to the first component.

[0010] In another aspect of the present invention, a hinge system includes: a first component; a second component; and a pre-assembled hinge module pivotally coupling the first component to the second component to permit pivotal movement of the first component relative to the second component. The pre-assembled hinge module includes: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing defining an internal space enclosed within the housing. The internal space is configured to receive the torque element. The lid defines a first hole and the rear wall defines a second hole. The first hole and the second hole are aligned with the pivot axis of the shaft. The shaft extends at least through the first hole, the internal space of the housing, and the second hole. The shaft is mounted to the first component. And the housing is mounted to the second component. Brief Description of the Drawings

[0011] The above summary and the following description will be better understood and appreciated in conjunction with the non-limiting examples shown in the accompanying drawings, in which:

[0012] Figure 1A is a perspective view of a pre-assembled hinge module according to an exemplary embodiment of the present invention;

[0013] Figure 1B is a top view of the pre-assembled hinge module of Figure 1A;

[0014] Figure 1C is a side view of the pre-assembled hinge module of Figure 1A;

[0015] Figure 2A is a perspective view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing an adapter that can be provided separately;

[0016] Figure 2B is a side view of the pre-assembled hinge module of Figure 2A;

[0017] Figure 2C is a cross-sectional view of the housing of the hinge module of Figure 2A taken along line 2C-2C, showing a torque element fastened within the housing;

[0018] Figure 2D is a top view of the pre-assembled hinge module of Figure 2A;

[0019] Figure 2E is a front view of the pre-assembled hinge module of Figure 2A, showing the cover;

[0020] Figure 3A is a front view of the torque element of the hinge module of Figure 1A;

[0021] Figure 3B is a cross-sectional view of the torque element of the hinge module of Figure 1A taken along line 3B–3B;

[0022] Figure 3C is a perspective view of the torque element of the hinge module of Figure 1A;

[0023] Figure 3D is an enlarged view of a portion of the peripheral surface of the torque element of Figure 3A, showing a recess in the periphery of the torque element;

[0024] Figure 4A is a front view of the cover of the hinge module of Figure 1A;

[0025] Figure 4B is a side view of the cover of the hinge module of Figure 1A;

[0026] Figure 4C is a front view of the cover of the hinge module of Figure 1A, showing line 4E–4E;

[0027] Figure 4D is a perspective view of the cover of the hinge module of Figure 1A;

[0028] Figure 4E is a cross-sectional view of the cover of the hinge module of Figure 1A taken along line 4E–4E;

[0029] Figure 4F is an enlarged view of the top of the cover of the hinge module of Figure 1A;

[0030] Figure 4G is an enlarged view of the bottom of the cover of the hinge module of Figure 1A;

[0031] Figure 5A is a perspective view of the shaft of the hinge module of Figure 1A;

[0032] Figure 5B is a side view of the shaft of the hinge module of Figure 1A, also showing an enlarged view of a part of the contour of the shaft;

[0033] Figure 5C is a front view of the shaft of the hinge module of Figure 1A;

[0034] Figure 6A is a perspective view of the adapter of the hinge module of Figure 2A;

[0035] Figure 6B is a front view of the adapter of the hinge module of Figure 2A;

[0036] Figure 6C is a cross-sectional view of the adapter of the hinge module of Figure 2A taken along line 6C–6C;

[0037] Figure 6D is an enlarged view of the end of the adapter of the hinge module of Figure 2A;

[0038] Figure 7 is a perspective view of a hinge system according to an exemplary embodiment of the present invention;

[0039] Figure 8 is an exploded view of the hinge module of Figure 2A;

[0040] FIG. 9 is a collection of two pre-assembled hinge modules according to another exemplary embodiment of the present invention, each hinge module shown with an adapter that can be provided separately;

[0041] FIG. 10A is a cross-sectional view of the hinge module from the collection of FIG. 9, showing the torque element in the first position;

[0042] FIG. 10B is a cross-sectional view of the hinge module from the collection of FIG. 9, showing the torque element in the second position;

[0043] FIG. 11A is a front elevation view of the hinge module from the collection of FIG. 9, showing the rear wall attached to the side wall in the first position;

[0044] FIG. 11B is a front elevation view of the hinge module from the collection of FIG. 9, showing the rear wall attached to the side wall in the second position;

[0045] FIG. 12 is an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing the adapter, the first torque element in the first position, and the second torque element in the second position;

[0046] FIG. 13A is a perspective view of the adapter of the hinge module of FIG. 12;

[0047] FIG. 13B is a side view of the adapter of the hinge module of FIG. 12;

[0048] FIG. 13C is a rear view of the adapter of the hinge module of FIG. 12;

[0049] FIG. 13D is a top view of the adapter of the hinge module of FIG. 12;

[0050] FIG. 14A is a front elevation view of the cover of the hinge module of FIG. 12;

[0051] FIG. 14B is a side view of the cover of the hinge module of FIG. 12;

[0052] FIG. 14C is a perspective view of the cover of the hinge module of FIG. 12;

[0053] FIG. 15A is a perspective view of the housing of the hinge module of FIG. 12, showing the rear wall and the side walls;

[0054] Figure 15B is an enlarged view of the internal space of the housing of the hinge module of Figure 15A;

[0055] Figure 15C is a front elevation view of the internal space of the housing of the hinge module of Figure 15A;

[0056] Figure 15D is a sectional view taken along line 15D–15D in Figure 15C of the internal space of the housing of the hinge module of Figure 15A, showing the inner surface of the side wall;

[0057] Figure 15E is a side elevation view of the housing of the hinge module of Figure 15A;

[0058] Figure 15F is a cross-sectional bottom view of the housing of the hinge module of Figure 15A taken along line 15F-15F in Figure 15C;

[0059] Figure 16A is a perspective view of a torque element according to another exemplary embodiment of the present invention;

[0060] Figure 16B is a front elevation view of the torque element of Figure 16A;

[0061] Figure 16C is a sectional view of the torque element of Figure 16A taken along line 16C-16C;

[0062] Figure 16D is an enlarged view of a portion of the torque element of Figure 16A;

[0063] Figure 17 is an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing an adapter, a first torque element in a first position, and a second torque element in a first position; and

[0064] Figure 18 is a perspective view of a pre-assembled hinge module according to an exemplary embodiment of the present invention, showing a cover plate mating with a portion of the side wall in a fluid-tight crimped manner.

[0065] Figure 19 is a perspective view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing an optionally provided adapter that can be provided separately.

[0066] Figure 20 is a rear perspective view of the pre-assembled hinge module of Figure 19, with the attached adapter not shown.

[0067] Figure 21A depicts an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing a first torque element in a first orientation and a second torque element in a first orientation.

[0068] Figure 21B depicts an exploded view of a pre-assembled hinge module, showing a first torque element in a first orientation and a second torque element in a second orientation.

[0069] Figure 21C depicts an exploded view of a pre-assembled hinge module, showing a first torque element in a second orientation and a second torque element in a second orientation.

[0070] Figure 22A depicts an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing a first torque element, a second torque element, and a third torque element in a first orientation.

[0071] Figure 22B depicts an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing a first torque element, a second torque element, and a third torque element in a second orientation.

[0072] Figure 23A depicts an exploded view of a pre-assembled hinge module according to another exemplary embodiment of the present invention, showing a first torque element, a second torque element, a third torque element, and a fourth torque element in a first orientation.

[0073] Figure 23B depicts an exploded view of a pre-assembled hinge module, showing a first torque element and a second torque element in a first orientation and a third torque element and a fourth torque element in a second orientation.

[0074] Figure 23C depicts an exploded view of a pre-assembled hinge module, showing a first torque element, a second torque element, a third torque element, and a fourth torque element in a second orientation.

[0075] Figure 24A depicts a rear perspective view of the housing of a pre-assembled hinge module, showing a first mark corresponding to a first mounting position.

[0076] Figure 24B depicts a perspective view of the housing of the pre-assembled hinge module of Figure 24A.

[0077] FIG. 24C is a side view of the housing of the pre-assembled hinge module of FIG. 24A.

[0078] FIG. 24D is a front view of the housing of the pre-assembled hinge module of FIG. 24A, showing the recess configured to receive the lubricant.

[0079] FIG. 24E depicts a cross-sectional side view of the housing of the pre-assembled hinge module of FIG. 24A taken along line 24E-24E in FIG. 24D.

[0080] FIG. 24F depicts a cross-sectional bottom view of the housing of the pre-assembled hinge module of FIG. 24A taken along line 24F-24F in FIG. 24D.

[0081] FIG. 24G is an enlarged view of a portion of the internal space of the housing of the pre-assembled hinge module of FIG. 24A (24G-24G in FIG. 24D).

[0082] FIG. 25 depicts a perspective view of the housing of a pre-assembled hinge module according to another exemplary aspect of the present invention, showing a second mark corresponding to the second installation position.

[0083] FIG. 26 depicts a perspective view of the housing of a pre-assembled hinge module according to another exemplary aspect of the present invention, showing the second mark and a larger housing size.

[0084] FIG. 27 depicts a perspective view of the housing of a pre-assembled hinge module according to another exemplary aspect of the present invention, showing the first mark and a larger housing size.

[0085] FIG. 28 depicts a set of two pre-assembled hinge modules according to another exemplary embodiment of the present invention, showing each hinge module without an optionally provided adapter and having a second mark.

[0086] FIGS. 29A-29B depict an example of a process for top-to-bottom or top-down assembly of a hinge module according to an exemplary aspect of the present invention. Embodiments

[0087] Although the present invention has been illustrated and described with reference to specific embodiments, the present invention is not intended to be limited to the details shown. On the contrary, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the present invention.

[0088] In addition, various forms and embodiments of the present invention are shown in the drawings. It should be understood that combinations and configurations of some or all of the features of any embodiment are specifically contemplated herein. Accordingly, this detailed disclosure specifically includes the specific embodiments shown herein, combinations and sub - combinations of the features of the shown embodiments, and variations of the shown embodiments.

[0089] Generally referring to FIGS. 1 - 18, a pre - assembled hinge module 500 is configured to couple a first component 110 to a second component 120 for pivotal movement relative to each other. The pre - assembled hinge module 500 includes: a shaft 460 that defines a pivot axis 462; a torque element 480 that frictionally engages the shaft 460, the torque element 480 having a perimeter that defines a recess 482; and a housing 440 that has side walls 444, a rear wall 446, and a cover 442. The side walls 444, the rear wall 446, and the cover 442 together define an internal space 448 within the housing 440. Wherein, the internal space 448 is configured to receive the torque element 480 within the housing 440. The side walls 444 of the housing 440 have a pawl or protrusion 486 that extends into the internal space 448 of the housing 440. The pawl or protrusion 486 extends into the recess 482 defined in the perimeter of the torque element 480, thereby restricting movement of the torque element 480 relative to the housing 440. Wherein, the cover 442 defines a first hole 443 and the rear wall 446 defines a second hole 447. The first hole 443 and the second hole 447 are aligned with the pivot axis 462 of the shaft 460. Wherein the shaft 460 extends at least through the first hole 443, the internal space 448 of the housing 440, and the second hole 447. Wherein, the shaft 460 is separated from the first component 110 and is configured to be mounted to the first component. Wherein, the housing 440 is separated from the second component 120 and is configured to be mounted to the second component.

[0090] The rear wall 446 of the housing of the pre - assembled hinge module 500 may include a universal mounting surface 449 that is configured to be mounted to the second component 120.

[0091] The torque element 480 defines a hole 484 that is aligned with the pivot axis 462 of the shaft 460. Wherein the shaft 460 extends through the hole 484 to frictionally engage the torque element 480.

[0092] The side wall 444 has an inner surface 454 (which is complementary to the pawl 486), and the inner surface is configured to fasten the torque element 480 within the housing 440 and prevent the torque element 480 from rotating relative to the housing 440.

[0093] The inner surface 454 defines one or more ridges 456 for fastening the torque element 480.

[0094] The rear wall 446 extends beyond the side wall 444 to form an extension 446b.

[0095] The extension 446b of the rear wall 446 defines a second hole 447, and the third hole is used to receive the mounting fastener 205 to mount the housing 440 to the second component 120.

[0096] The rear wall 446 and the side wall 444 of the housing 440 are integrally formed as a single body of an integral structure separated from the cover 442.

[0097] The pre-assembled hinge module 500 may include a plurality of torque elements 480 that frictionally engage the shaft 460.

[0098] The internal space 448 receives the torque element 480 in a form-locking fit.

[0099] The internal space 448 forms a reservoir 448a that houses a certain amount of lubricant 490.

[0100] A method for assembling the hinge module 500 is also provided, and the method includes: placing the torque element 480 within the internal space 448 of the housing 440, which has a rear wall 446 and a side wall 444 that together at least partially define the internal space 448; applying the lubricant 490 to the edge 488 (Figure 3A) of the torque element 480; aligning the second hole 447 defined in the rear wall 446 of the housing 440 with the first hole 443 defined in the torque element 480 to form a passage 401; inserting the shaft 460 through the passage 401; placing the cover 442 adjacent to the torque element 480 such that the end 464 of the shaft 460 is exposed through the first hole 443 defined in the cover 442, and the cover 442 at least partially extends into the internal space 448 of the housing 440; and deforming the side wall 444 of the housing 440 to fasten the cover 442 relative to the housing 440.

[0101] The method for assembling the hinge module 500 further includes: placing the cover 442 such that the cover 442 extends within the internal space 448 of the housing 440.

[0102] The edge surface 444a of the side wall 444 of the housing 440 extends beyond the outer surface 442b of the cover 442.

[0103] The deforming step includes: deforming the edge surface of the side wall 444 of the housing 440 to at least partially contact the outer surface 442b of the cover 442, thereby restricting the movement of the cover 442 from the internal space 448 of the housing.

[0104] The deforming step includes: pressing at least a part of the side wall 444 of the housing 440 inwardly towards the internal space 448 of the housing 440 and contacting the cover 442.

[0105] These steps are sequentially performed in the described order.

[0106] The following steps are performed by actions generally initiated along a common assembly direction: placing the torque element 480 within the internal space 448 of the housing 440, inserting the shaft 460 through the channel 401, placing the cover 442 adjacent to the torque element 480, and deforming the side wall 444 of the housing 440.

[0107] The side wall 444 of the housing 440 extends upward from the rear wall 446, and the following steps are performed by actions generally performed in a top-down manner along a common assembly direction: placing the torque element 480 within the internal space 448 of the housing 440, placing the cover 442 adjacent to the torque element 480, and deforming the side wall 444 of the housing 440.

[0108] The deforming step includes: deforming the side wall 444 of the housing 440 radially inwardly from the outer surface 444b of the side wall 444 to fasten the cover 442 relative to the housing 440.

[0109] The side wall 444 of the housing 440 is provided with an inner surface 454 that is positioned corresponding to the outer surface 480a of the torque element 480, and the method further includes: forcing the cover 442 against the side wall 444 of the housing 440 to move the pawl 486 towards the outer surface of the torque element.

[0110] The inner surface 454 of the side wall 444 of the housing 440 is or includes a pawl 486, and the outer surface of the torque element is a recess 482, and the method further includes: forcing the cover 442 against the pawl 486 of the side wall 444 of the housing 440 so that the material of the pawl 486 moves into the recess 482 of the torque element 480.

[0111] The method includes: forcing the cover 442 against the pawl 486 of the side wall 444 of the housing 440 in a direction toward the rear wall 446 of the housing 440 so that the material of the pawl 486 moves into the recess 482 of the torque element 480 in a direction inward relative to the side wall 444 of the housing 440.

[0112] An assembly of hinge modules 300 is configured to couple a first component 110 to a second component 120 for pivotal movement relative to each other. The assembly of hinge modules 300 includes: a first pre-assembled hinge module 400 configured to control the relative pivotal movement of the first and second components in a first pivotal direction; and a second pre-assembled hinge module 500 configured to control the relative pivotal movement of the first and second components in a second pivotal direction opposite to the first pivotal direction. The first pre-assembled hinge module and the second pre-assembled hinge module each include: a shaft 460 defining a pivot axis 462; a torque element 480 frictionally engaging the shaft 460, the torque element 480 having a perimeter defining a recess 482; and a housing 440 having a side wall 444, a rear wall 446, and a cover 442. The side wall 444, the rear wall 446, and the cover 442 together define an internal space 448 within the housing 440. The internal space 448 is configured to receive the torque element 480 within the housing 440. The side wall 444 of the housing 440 has a pawl 486 extending into the internal space 448 of the housing 440. The pawl 486 extends into the recess 482 defined in the perimeter of the torque element 480, thereby restricting movement of the torque element 480 relative to the housing 440. The cover 442 defines a first hole 443 and the rear wall 446 defines a second hole 447. The first hole 443 and the second hole 447 are aligned with the pivot axis 462 of the shaft 460. The shaft 460 extends at least through the first hole 443, the internal space 448 of the housing 440, and the second hole 447. The shaft 460 is separated from the first component 110 and is configured to be mounted to the first component. And the housing 440 is separated from the second component 120 and is configured to be mounted to the second component.

[0113] The housing 440 of the first pre-assembled hinge module 400 includes a first marking corresponding to a first installation position. In some embodiments of the present disclosure, the first marking includes a surface indentation or groove 420 on the right side, and the second pre-assembled hinge module 500 includes a second marking corresponding to a second installation position opposite the first installation position. In some embodiments of the present disclosure, the second marking includes a surface indentation or groove 520 on the left side.

[0114] A pre-assembled hinge system 600 is configured to couple a first component 110 to a second component 120 for pivotal movement relative to each other. The pre-assembled hinge system 600 includes: a shaft 460 that defines a pivot axis 462, the shaft 460 being separated from the first component 110 and configured to be mounted to the first component; a torque element 480 that frictionally engages the shaft 460; a housing 440 that houses the torque element 480; and an adapter 491 that has an end 492 configured to be fixedly coupled to the shaft 460 and an opposite end 493 configured to be releasably coupled to the first component 110.

[0115] The shaft 460 mates with the adapter 491, and the adapter 491 defines a counterbore opening to receive a portion of the end 466 of the shaft 460.

[0116] A hinge system 100 includes: a first component 110; a second component 120; and a hinge system 100 that includes pre-assembled hinge modules that pivotally couple the first component 110 to the second component 120 to permit pivotal movement of the first component 110 relative to the second component 120. Each pre-assembled hinge module includes: a shaft 460 that defines a pivot axis 462; a torque element 480 that frictionally engages the shaft 460; and a housing 440 that defines an internal space 448 within the housing 440, wherein the internal space 448 is configured to receive the torque element 480; wherein a lid 442 defines a first hole 443 and a rear wall 446 defines a second hole 447, the first hole 443 and the second hole 447 being aligned with the pivot axis 462 of the shaft 460, wherein the shaft 460 extends at least through the first hole 443, the internal space 448 of the housing 440, and the second hole 447; wherein the shaft 460 is separated from the first component 110 and configured to be mounted to the first component; and wherein the housing 440 is separated from the second component 120 and configured to be mounted to the second component.

[0117] Referring more specifically to FIG. 7, there is shown a hinge system 100 according to one embodiment. The hinge system 100 can be utilized in various applications incorporating one or more friction hinges for controlling the relative pivotal movement of components. For example, the hinge system 100 can be incorporated into various types of enclosure systems used on motor vehicles, boats, and / or aircraft, including but not limited to various types of compartments, cabinets, hatches, receptacles, overhead luggage bins, and storage units.

[0118] In the present example, the hinge system 100 is incorporated into the center console of an automobile. The hinge system 100 includes a first component in the form of a console receptacle 110 and a second component in the form of a lid. The lid is pivotally coupled to the receptacle 110. This pivotal coupling allows the lid to pivot relative to the receptacle 110 between an open position and a closed position. The lid is coupled to the receptacle 110 by a pair of hinge modules 200 (one on each side of the lid). Each hinge module 200 is a pre-assembled unit that is configured to be generally mounted to components requiring a friction hinge. As such, the hinge module 200 can be mounted to various types of assemblies and in various configurations.

[0119] Now referring to FIG. 9, there is shown a set of hinge modules 300 according to an embodiment of the present invention. The set of hinge modules 300 includes a first pre-assembled hinge module 400 and a second pre-assembled hinge module 500. The first pre-assembled hinge module 400 and the second pre-assembled hinge module 500 are configured to couple a first component to a second component for pivotal movement relative to each other along a pivot axis. The first pre-assembled hinge module 400 is mounted along the pivot axis at a first point, and the second pre-assembled hinge module 500 is mounted along the pivot axis at a second point. As such, the first pre-assembled hinge module 400 and the second pre-assembled hinge module 500 are configured to control the pivotal movement at opposite ends of the pivot axis between the two components. For example, the pre-assembled hinge module 400 and the pre-assembled hinge module 500 can be mounted in a mirror configuration on the center console, where the hinge modules are mounted on opposite sides of the lid.

[0120] The pre-assembled hinge modules 400 and 500 apply frictional resistance to resist pivotal movement. The amount of frictional resistance applied by the hinge module 400 is the same as the amount of frictional resistance applied by the hinge module 500. In another embodiment of the present invention, the amount of frictional resistance applied by the hinge module 400 is different from the amount of frictional resistance applied by the hinge module 500. When the hinge modules 400 and 500 are installed, the hinge module 400 applies frictional resistance in a first direction, and the hinge module 500 applies frictional resistance in a second direction opposite to the first direction. In another embodiment of the present invention, the hinge module 400 applies frictional resistance in the first direction, and the hinge module 500 applies frictional resistance in the first direction. For this reason, the pre-assembled hinge modules 400 and 500 must be installed on the correct side of the boom.

[0121] Each of the hinge modules 400 and 500 is designated for installation at a specific side or position relative to the cover on the pivot axis, so that the hinge module applies the same amount of frictional resistance to the pivotal movement in the same direction. The pre-assembled hinge module 400 is designed to couple the cover to the left side of the console receptacle, and the pre-assembled hinge module 500 is designed to couple the cover to the right side of the console receptacle.

[0122] The hinge modules 400 and 500 include geometric features that ensure that the hinge modules are installed only on the correct side of the console. Specifically, the hinge module 400 includes a surface indentation or groove 420 on the right side, and the hinge module 500 includes a surface indentation or groove 520 on the left side. Thus, the hinge module 400 has a contour shape 430 that is a mirror image of the contour shape 530 of the hinge module 500.

[0123] The mounting surface on each side of the console has a recess with a shape that conforms to only one of the contour shapes 430 and 530, so that each side of the console will accept only one of the hinge modules 400 and 500. This ensures that the hinge modules 400 and 500 are installed on the correct side of the console. The hinge modules 400 and 500 both include the same components. Therefore, only the components of the hinge module 500 will be described, and it should be understood that the hinge module 400 also includes similar parts designed to generate frictional resistance in the opposite direction.

[0124] Referring now to FIGS. 1A - 1C, the hinge module 500 includes a housing 440 and a shaft 460 defining a pivot axis 462. The housing 440 has a lid 442, side walls 444, and a rear wall 446. In one embodiment, as shown in FIGS. 2A, 2B, and 2D, the hinge module 500 includes: a housing 440 having a lid 442, side walls 444, and a rear wall 446; and a shaft 460 coupled to an end 492 of an adapter 491, the adapter 491 having an opposite end 493 configured to releasably couple to a first component. In FIG. 8, the lid 442, side walls 444, and rear wall 446 define an internal space 448. As shown in FIG. 2C, the internal space 448 is configured to receive a torque element 480. In FIGS. 3A - 3D, the torque element 480 defines a recess 482 that extends through a portion of the torque element 480. FIGS. 16A - 16D illustrate another embodiment of the torque element 480 that defines a recess 482 that extends through a portion of the torque element 480. Additionally, the torque element 480 defines a bore 484 for frictionally engaging the shaft 460.

[0125] Referring to FIG. 2C, the side wall 444 has a pawl 486 that extends into the internal space 448 within the housing 440. The pawl can be provided in the form of a pointed or rounded ridge, extension, contour, or any form that extends the inner surface of any wall of the housing into the internal space. The pawl 486 extends into a recess 482 defined in the perimeter of the torque element 480, thereby securing the torque element 480 within the housing 440 and restricting rotational movement of the torque element 480 relative to the housing 440. Alternatively, the perimeter of the torque element can be provided with a pawl to extend outwardly into a recess formed in the wall of the housing; in other words, by placing the recess on the housing and the pawl on the torque element, the recess and pawl configuration shown in FIG. 2C can be reversed, and vice versa.

[0126] The amount of frictional resistance provided by the torque element 480 depends in part on the amount of surface area of the torque element that contacts the shaft 460. Thus, the thickness of a single torque element can be varied to vary the frictional resistance. Additionally, the respective dimensions (the outer dimension of the shaft and the inner dimension of the torque element) can be modified to increase or decrease the frictional resistance.

[0127] In FIG. 2C, only one torque element 480 is visible. However, it should be understood that one or more additional torque elements can be received in the internal space 448 and stacked adjacent to the torque element 480. Placing additional torque elements adjacent to the torque element 480 increases the total surface area for frictionally engaging the shaft 460 and thus increases the amount of frictional resistance provided by the hinge module 500.

[0128] By placing additional torque elements in the internal space 448 to increase the total thickness of the torque elements, and / or by replacing the torque element 480 with a thicker torque element having a larger surface area in contact with the shaft 460, the amount of frictional resistance provided by the hinge module 500 can be increased. Additionally, in FIG. 2C, the torque element 480 is placed in the first position. However, it should be understood that, as seen in FIGS. 10A-10B, the torque element 480 can be placed within the internal space 448 in the second position. Specifically, as shown in FIG. 12, the torque element 480a can be placed in the first position and the torque element 480b can be placed in the second position. In FIG. 17, the torque element 480a can be placed in the first position and the torque element 480b can be placed in the first position. The torque element 480a can be placed in the second position and the torque element 480b can be placed in the second position (not shown).

[0129] The positioning of the torque elements can be used to provide symmetric torque (equal frictional resistance in both rotational directions) or asymmetric torque (different frictional resistance in opposite rotational directions).

[0130] FIGS. 4A, 4C, and 4D depict the cover 442, which includes a first hole 443 and two surface features (such as dimples 442a) that will allow the component to be processed in an electroplating bath, prevent component stacking, and prevent electroplating material from adhering to the surface. In another embodiment, as shown in FIGS. 14A-14C, the cover 442 defines a first hole 443. Additionally, FIG. 15A shows the rear wall 446 that defines a second hole 447. The first hole 443 and the second hole 447 are axially aligned with each other. As shown in FIGS. 1A–1C, the shaft 460 extends at least through the first hole 443, the internal space 448, and the second hole 447 such that the first hole 443 and the second hole 447 are aligned with the shaft 460.

[0131] Briefly referring to FIG. 14C, it should be noted that in this embodiment the cover 442 does not include dimples 442a. Instead, the cover 442 depicted in FIG. 14C can be formed from a pre-plated material. Therefore, in this embodiment, the dimples 442a are not required.

[0132] Referring to FIGS. 5A-5C, the shaft 460 has a proximal end 464 and a distal end 466 opposite the proximal end. The distal end 466 includes a head 463 having a reduced diameter relative to the other portions of the shaft 460. The distal end 466 defines a coupling surface 467 (such as a splined or knurled surface) that can cooperate with a coupling element to connect the hinge module to a first component.

[0133] Referring now to FIG. 8, according to another embodiment of the present invention, the pre-assembled hinge module 500 includes a shaft 460, a cover 442, a torque element 480, a housing 440, and a coupling element in the form of an adapter 491 having a proximal end 492 configured to be fixedly coupled to the shaft 460 and an opposite end 493 configured to be releasably coupled to a first component.

[0134] In one embodiment, as shown in FIGS. 6A–6D, the adapter 491 defines a countersunk opening to receive a portion of the end of the shaft 460. In another embodiment, as shown in FIGS. 12, 13A–13D, the adapter 494 defines an opening 495 configured to receive a portion of the end of the shaft 460 and an opposite end 496 configured to be releasably coupled to a first component. It should be understood that according to the present invention, other types of couplings may be attached to the distal end of the shaft 460.

[0135] By providing an adapter such as the adapter 491, the pre-assembled hinge module can be made suitable for use in a system configured for disassembly. For example, the shaft 460 can be designed to be permanently or semi-permanently fixed to the console of an automobile. Such fixation is desirable to prevent or resist accidental disassembly, tampering, or accidental loosening of the hinge module. If it is desired to make the pre-assembled hinge module suitable for use in a system configured for disassembly, an adapter such as the adapter 491 can be provided to convert the hinge assembly into a more easily disassembled assembly. This is advantageous for facilitating the repair and replacement of the hinge assembly, the updating of the hinge assembly, or the disassembly for cleaning or accessing internal components.

[0136] As shown in FIG. 15A, the rear wall 446 provides a universal mounting surface 449 that can be mounted to a receptacle, cover, or other component of the center console. Additionally, the rear wall 446 extends beyond the housing 440 to form an extension 446b. The extension 446b defines a hole 446c for receiving a mounting fastener, such as the screw 205 shown in FIG. 7, to mount the housing 440 to the console receptacle or cover.

[0137] Referring to FIGS. 15A–15D, the side wall 444 and the rear wall 446 of the housing 440 are integrally formed as a single unitary structure separate from the cover 442. The rear wall 446 in the form of a flat mounting plate 470 mates with the side wall 444 in a fluid-tight manner. This configuration allows for the formation of a one-piece housing body that can be formed by molding, casting, stamping, machining, or other known processes. However, alternatively, the side wall 444 and the rear wall 446 of the housing 440 can be formed separately and then joined to each other, such as by welding, adhesives, thermal bonding, or mechanical fastening.

[0138] As shown in FIG. 2C, the internal space 448 of the housing 440 receives the torque element 480 in a form-fitting manner. Specifically, the inner surface 454 extending internally along the side wall 444 includes engagement surfaces in the form of pawls, such as sharp ridges 456. External pressure applied along the periphery of the side wall causes the ridges 456 to engage recesses 482 of the torque element 480, holding the torque element in a form-fitting manner. In another embodiment, as shown in FIGS. 15A - 15C, the inner surface 454 includes engagement surfaces in the form of pawls having a circular edge 457.

[0139] In FIG. 2C, the internal space 448 of the housing 440 forms a chamber or reservoir 448a that is adapted to store a quantity of lubricant 490, such as grease. Grease is applied along the edge 488 (FIG. 3A), where the edge 488 engages the shaft 460 in a frictionally engaging manner. The side wall 444, the cover 442, and the rear wall 446 in the form of the mounting plate 470 form a sealed chamber or reservoir that prevents the lubricant applied to the torque element 480 from leaking out of the housing 440 and prevents dirt and other solid and / or liquid contaminants from entering the housing.

[0140] The pre-assembled hinge module 400 can be used in the following manner to pivotally couple a first component to a second component. The hinge module 400 arrives at the installer in a pre-assembled state and has an appropriate number of torque elements 480 in the housing 440. Thus, the hinge module 400 is ready for installation.

[0141] The distal end 466 of the shaft 460 is inserted through pivot holes in the first and second components. The housing 440 is attached to the first component by passing a screw 205 or other fastener forward through a hole 446c in an extension 446b of the rear wall 446. Additionally, the outer edge 478 of the mounting plate 470 can be attached between a plurality of ribs on the first component, as shown in FIG. 1. The recess 420 in the mounting plate 470 mates with a similarly shaped protrusion on the first component to ensure that the hinge module 400 is installed on the correct side of the pivot axis. The distal end 466 of the shaft 460 projects through the first and second components such that an annular recess, i.e., the coupling surface 467, is exposed.

[0142] A separately provided E-ring or other coupling element is attached to surround the annular recess (i.e., the coupling surface 467) to fasten the shaft 460 to the second component and prevent the shaft from being withdrawn or pulled out from the first and second components, thereby coupling the first and second components together in a pivotable connection. This same procedure is then carried out to install the hinge module 500 on the opposite sides of the first and second components.

[0143] Finally, according to one embodiment and with reference to the components of the hinge module 500, a method for manufacturing a pre-assembled hinge module includes: placing the torque element 480 in the internal space 448 of the housing 440. Then, as shown in FIG. 10B, align the hole 484 of the torque element 480 with the second hole 447 of the mounting plate 470 to form a passage 401. Next, insert the shaft 460 through the passage 401 such that the shaft 460 extends through the internal space 448 of the housing 440 to frictionally engage with the torque element 480. The shaft 460 is tightly held in frictional engagement by the torque element 480 to prevent it from being pulled out of the housing 440. Then, place the cover 442 in a form-locking fit adjacent to the torque element 480 such that the end of the shaft 460 is exposed through the first hole 443 of the cover 442. Now referring to FIG. 18, squeeze the side wall 444 along the perimeter to fasten the cover 442 relative to the housing 440 such that the side wall 444 mates with the cover 442 in a solid or fluid-tight connection. Thus, the cover 442, the side wall 444, and the mounting plate 470 form the housing 440, which encloses the torque element 480 and the grease (lubricant 490) within the housing 440. The hinge module 500 is now pre-assembled and ready to be installed to pivotally connect two components.

[0144] As shown in the cross-sectional view of FIG. 15F, the inner surface of the side wall of the housing provides a pair of opposing pawls. On the pawls, a portion of the side wall rises upward, thereby forming an outward-facing downward or downward-extending groove. The upward-extending portion of the pawl provides a surface against which the cover can be supported when the cover is placed over the parts within the side wall. More specifically, due to the recess formed in the torque element at the pawl location, the torque element extends downward toward the bottom and the rear wall of the housing. However, the cover has no recess, so it will be supported on the top of the pawl, more specifically, on the top of the upwardly rising portion of the pawl.

[0145] As will be understood by reference to FIG. 15F, when the cover is pressed downward against the pawl, the material of the upwardly rising pawl can be deformed downward and toward the center of the internal space of the housing. Thus, the material of the pawl will be deformed and cold flow inward and into the recess of the torque element, thereby firmly holding it in place within the housing.

[0146] To facilitate efficient, rapid, and / or low-cost assembly, the hinge module can be assembled in a top-down manner, where all or nearly all of the assembly movements are from top to bottom or along any other single direction, rather than requiring assembly steps with lateral and up-and-down movements. Such top-to-bottom or top-down assembly enables the use of simple fastening devices and manufacturing techniques, while also reducing the potential misalignment that may be associated with a combination of downward and lateral or angled assembly movements.

[0147] For example, referring to FIG. 12, the base member of the housing can be placed flat on a support surface. Then, one or more torque elements can be inserted into the internal space or area of the housing base from top to bottom in a downward direction. A lubricant 490 such as grease can be applied to the recess 482 of the torque element 480. Then, the shaft can also be inserted through the housing along the top-to-bottom axis of the assembly. Finally, the cover can also be placed on top of the torque element using a top-to-bottom downward movement. In this way, all or nearly all of the components of the hinge module can be assembled together in a top-down configuration.

[0148] In addition, the final or near-final step of capturing or otherwise engaging the cover within or against the base of the housing can also be accomplished by a top-to-bottom or downward movement. For example, the crimping of the wall of the housing base can be performed by moving a tool in a downward direction to engage the outward and upward edges of the wall of the housing base, thereby forcing the upper wall portion downward and slightly inward to enclose, engage, or capture the cover. This downward crimping or deformation movement again facilitates simple tools and simple movements, which reduces the risk of tool misalignment and misalignment of the components of the hinge module. The crimping action can be provided by a die or tool or any other mechanism capable of deforming the upper wall of the base of the housing.

[0149] As an example, FIG. 18 shows an example of a hinge module, where the cover is engaged within the base of the housing. Specifically, the cover has been positioned within the internal area of the housing base such that the outer or peripheral surface of the cover is directly within the inner surface of the wall of the housing base. As a final step, as shown in FIG. 18, the upper portion of the wall of the housing base is curled and slightly bent inwardly above the peripheral edge portion of the cover, thereby fixing the cover in place and providing a partial or complete seal to prevent the entry of solid and / or liquid contaminants. In addition, the fastened cover prevents or restricts the escape of grease or lubricant from the internal space of the housing. A lubricant 490 such as grease is applied to the recess 482 of the torque element 480.

[0150] According to another exemplary embodiment of the present invention, now referring to FIGS. 19-20, a pre-assembled hinge module 700 is configured to couple a first component (not shown) to a second component (not shown) for pivotal movement relative to each other.

[0151] The pre-assembled hinge module 700 includes a shaft 702 that defines a pivot axis 704. The shaft 702 is separated from the first component (not shown) and is configured to be mounted to the first component. The shaft 702 is configured to cooperate with a coupling element, such as adapter 710, that defines a countersunk opening to receive a portion of an end 716 of the shaft 702. More specifically, the adapter 710 includes an end 712 and an opposite end 714. The end 712 is configured to be fixedly coupled to the end 716 of the shaft 702, and the opposite end 714 is configured to be releasably coupled to the first component (not shown).

[0152] The hinge module 700 includes a housing 708 that is separated from the second component (not shown) and is configured to be mounted to the second component. Specifically, the rear wall 726 of the housing 708 of the pre-assembled hinge module 700 may include a universal mounting surface 730 (FIG. 20) that is configured to be mounted to the second component (not shown). The housing 708 further includes or is configured to receive a cover 720, and also includes side walls 724, a rear wall 726 - cover 720. The side walls 724 and the rear wall 726 together define an internal space 718 of the housing 708 (see FIG. 25), wherein the internal space 718 is configured to receive and / or contain a torque element 706, which will be discussed further below.

[0153] The torque element 706 (as seen in at least FIGS. 21A-21C) is configured to frictionally engage the shaft 702. In addition, the torque element 706 has a perimeter that defines a recess 736, and the side wall 724 of the housing 708 includes a pawl or protrusion 740 that extends into the internal space 718 of the housing 708. The pawl 740 is configured to secure the torque element 706 within the housing 708 and prevent the torque element 706 from rotating relative to the housing 708. The torque element 706 (as seen in at least FIGS. 21A-21C) also defines a hole 732 that is aligned with the pivot axis 704 of the shaft 702, wherein the shaft 702 extends through the hole 732 while the shaft 702 is in frictional engagement with the torque element 706.

[0154] The cover 720 defines a first hole 722 (as seen in at least FIGS. 21A - 21C), and the rear wall 726 defines a second hole 728 - the first hole 722 and the second hole 728 are aligned with the pivot axis 704 of the shaft 702 such that the shaft 702 extends at least through the first hole 722 of the cover 720, the hole 732 of the torque element 706, the internal space 718 of the housing 708, and the second hole 728 of the rear wall 726.

[0155] The side wall 724 has an inner surface 738 (which is complementary to the pawl 740), and the inner surface is configured to secure the torque element 706 within the housing 708 and prevent the torque element 706 from rotating relative to the housing 708. The inner surface 738 defines one or more ridges 742 for securing the cover 720. The rear wall 726 extends beyond the side wall 724 to form an extension 744.

[0156] The extension 744 of the rear wall 726 defines a third hole 745 for receiving a mounting fastener (such as the screw 205 in FIG. 7) to mount the housing 708 to a second component (not shown). Additionally, the rear wall 726 and the side wall 724 of the housing 708 may be integrally formed as a single unitary structure separate from the cover 720.

[0157] Referring to FIGS. 21A - 21C, the pre - assembled hinge module 700 may include a plurality of torque elements 706 for frictionally engaging the shaft 702. The internal space 718 receives one or more torque elements 706 in a form - locking fit. As seen in FIG. 21A, an exploded view of the pre - assembled hinge module 700 according to an exemplary embodiment of the present invention shows a first torque element 706a in a first orientation (or position) and a second torque element 706b in a first position.

[0158] According to another exemplary embodiment of the present invention and as shown in FIG. 21B, the first torque element 706a may be configured in a first position and the second torque element 706b may be configured in a second position. Finally, as seen in FIG. 21C and according to yet another exemplary embodiment of the present invention, the first torque element 706a may be configured in a second position and the second torque element 706b may be configured in a second position.

[0159] In addition, although FIGS. 21A - 21C depict the hinge module 700 as including an adapter 710, it should be understood that the size and shape of the hinge module 700 may be configured to receive other types of coupling elements that are configured for releasably coupling to a first component (not shown). It should also be understood that the hinge module 700 may not include a coupling element such as the adapter 710.

[0160] According to another exemplary embodiment of the present invention, the pre-assembled hinge module 700 includes a housing 708 sized and shaped to receive a plurality of torque elements 706, the plurality of torque elements including a first torque element 706a, a second torque element 706b, and a third torque element 706c. As seen in FIG. 22A, the torque elements 706a, 706b, and 706c are all disposed in a first position. As shown in FIG. 22B, the first torque element (706a), the second torque element (706b), and the third torque element (706c) are disposed in a second position. It should be understood that the plurality of torque elements 706 can be configured in any combination of the first position and the second position.

[0161] According to yet another exemplary embodiment of the present invention, the pre-assembled hinge module 700 includes a housing 708 sized and shaped to receive four torque elements 706, the torque elements including a first torque element 706a, a second torque element 706b, a third torque element 706c, and a fourth torque element 706d. As seen in FIG. 23A, the torque elements 706a, 706b, 706c, and 706d are all disposed in a first position. As shown in FIG. 23B, the first torque element (706a) and the second torque element (706b) are disposed in the first position, while the third torque element (706c) and the fourth torque element (706d) are disposed in the second position. Finally, as depicted in FIG. 23C, the torque elements 706a, 706b, 706c, and 706d are all disposed in the second position. It should be understood that the plurality of torque elements 706 can be configured in any combination of the first position and the second position.

[0162] Referring now to FIGS. 24A-24G, the hinge module 700 includes a rear wall 726 of the housing 708 that defines a channel 750 (FIG. 24A) configured to receive a quantity of lubricant (such as grease (not shown)) or introduce a quantity of lubricant into the interior space 718 of the housing 708. As best seen in FIGS. 24B, 24D, and 24G, the channel 750 communicates with a groove 746 defined by an inner surface 734 of the rear wall 726 of the housing 708 to allow the lubricant to flow into the channel 750 and the groove 746.

[0163] In addition, the groove 746 and the torque element 706 together define a receptacle configured to receive a lubricant, which is then stored in a reservoir such as the internal space 718 (shown in FIGS. 24B, 24E, and 24F). As shown in FIGS. 24D and 24G, the groove may include a transverse portion 752 that is oriented to extend in a transverse direction relative to the pivot axis 704 of the shaft 702. In addition, the groove 746 includes a radial portion 754 that is oriented to extend in a radial direction relative to the pivot axis 704 of the shaft 702.

[0164] Now generally referring to FIGS. 24B and 25 - 28, a set of hinge modules is configured to couple a first component 110 to a second component 120 for pivotal movement relative to each other. The set of hinge modules includes: a first pre - assembled hinge module 700 configured to control the relative pivotal movement of the first component 110 and the second component 120 along a first pivotal direction; and a second pre - assembled hinge module 700 configured to control the relative pivotal movement of the first component and the second component along a second pivotal direction opposite to the first direction.

[0165] In addition, FIGS. 24B and 25 together define a first pair or first set of hinge modules 700 according to an embodiment of the present invention. As shown in FIG. 24B, the hinge module 700 may include a first mark 756 corresponding to a first installation position (not shown). Alternatively or additionally, the hinge module 700 may include a second mark 758 corresponding to a second installation position (not shown), as seen in FIG. 25.

[0166] Similarly, FIGS. 26 and 27 together define a second pair or second set of housings for the hinge module 700 according to another embodiment of the present invention. As shown in FIG. 26, the hinge module 700 is sized and shaped to receive a plurality of torque elements 706 and further includes a second mark 758 corresponding to a first installation position (not shown). Alternatively or additionally, the hinge module 700 is sized and shaped to receive a plurality of torque elements 706 and also includes a first mark 756 corresponding to a second installation position (not shown), as seen in FIG. 27. As previously mentioned, the positioning of the torque elements 706 can be used to provide symmetric torque (the same frictional resistance in both rotational directions) or asymmetric torque (different frictional resistances in opposite rotational directions). For example, if all torque elements are positioned or oriented in the same direction, the torque elements will typically provide asymmetric torque. Alternatively, if an equal number of torque elements are positioned or oriented in opposite directions, the torque elements will typically provide symmetric torque. In addition, it should be understood that the more torque elements 706 included, the greater the torque provided.

[0167] Similarly, FIG. 28 depicts a third pair or third set of hinge modules 700 according to another embodiment of the present invention, wherein each hinge module 700 does not include a coupling element (such as adapter 710). One of the hinge modules 700 includes a first marker 756 corresponding to a first mounting position (not shown). Alternatively or additionally, another hinge module 700 includes a second marker 758 corresponding to a second mounting position (not shown).

[0168] Finally, referring to FIGS. 29A-29B, a method for assembling hinge module 700 is also provided. Generally, the method includes the steps of: applying a lubricant 760 (such as grease) to shaft 702 (step 5); pressing at least a portion of cover 720 towards the internal space 718 (step 8); injecting a lubricant 760 (such as grease) into the internal space 718 via a channel 750 defined in the rear wall 726 of housing 708 (step 9); and rotating shaft 702 about pivot axis 704 to distribute lubricant 760 along a groove 746 defined in the rear wall 726 of housing 708 (step 10), the groove 746 being configured to direct the flow of lubricant 760 from a channel 750 defined in the rear wall 726 of housing 708. Although FIGS. 29A and 29B depict a method in which the steps are performed sequentially in the recited and shown order, it should be understood that the steps may be performed in any order.

[0169] Specifically referring to FIG. 29A and with respect to steps 1 and 6, according to one aspect of the present invention, the method of assembling hinge module 700 may include coupling a portion of an end 716 of shaft 702 to a coupling element, such as adapter 710. The coupling element is illustrated in step 1.

[0170] With respect to steps 2-4 and according to one aspect of the present invention, there is a step 2 prior to the step 3 of applying lubricant 760 to torque element 706, the step 2 being aligning a hole (such as second hole 728) defined in the rear wall 726 of housing 708 with a hole (such as hole 732) defined by torque element 706.

[0171] According to another aspect of the present invention and with respect to steps 4, 6, and 8, the following steps are performed by an action that generally starts along a common assembly direction: step 4 of placing the torque element 706 within the internal space 718 of the housing 708, step 6 of inserting the shaft 702 through a passage formed by aligning the first hole 722 of the alignment cover 720 with the hole 732 of the torque element 706, step 8 of placing the cover 720 adjacent to the torque element 706, and step 8 of deforming the side wall 724 of the housing 708. For example, this can be in a top-to-bottom or bottom-to-top direction, where the components are assembled along a common axis and / or in a common direction, thereby reducing or eliminating the manipulation or repositioning of components during assembly. According to one embodiment, the components can be stacked one by one in a downward direction and along a common axis.

[0172] Additionally or optionally, a lubricant 760 can be applied to the outer surface of the shaft 702, as seen in step 5 of FIG. 29A.

[0173] With respect to step 7, coupling the shaft 702 to the adapter 710 can include inserting the shaft 702 through a passage formed by aligning the first hole 722 of the alignment cover 720, the hole 732 of the torque element 706, and the reamed opening of the adapter 710 (FIGS. 6A - 6D). Then, the adapter 710 can be applied to the end or end portion of the shaft 702.

[0174] Referring to step 8 (as seen in FIG. 29B) and according to yet another aspect of the present invention, the step of pressing or riveting or otherwise deforming at least a portion of the cover 720 towards the internal space 718 (see arrow 762 in FIG. 29B) includes configuring the cover 720 such that the cover 720 extends within the internal space 718 of the housing 708. Additionally, the step of pressing or riveting or otherwise deforming at least a portion of the cover 720 towards the internal space 718 includes deforming the edge surface 764 of the side wall 724 of the housing 708 (step 8 of FIG. 29B), which edge surface extends beyond the outer surface 766 of the cover 720.

[0175] More specifically, the deforming step 8 may include pressing at least a portion of the side wall 724 of the housing 708 inwardly toward the interior space 718 of the housing 708 and into contact with the lid 720. In this way, the lid 720 is held in place relative to the housing 708. Preferably, for example, the deforming step 8 includes deforming the edge surface 764 of the side wall 724 of the housing 708 to at least partially contact the outer surface 766 of the lid 720, thereby restricting movement of the lid 720 in a direction away from the interior space 718 of the housing 708. Additionally or alternatively, the deforming step 8 includes deforming the side wall 724 of the housing 708 radially inwardly from the outer surface 768 of the side wall 724 to secure the lid 720 relative to the housing 708.

[0176] Furthermore, according to another aspect of the present invention, the side wall 724 of the housing 708 may extend upwardly from the rear wall 726 of the housing 708. Accordingly, the following steps are performed in a top-to-bottom orientation generally along a common assembly direction (e.g., parallel to or along the axis 704 of the shaft 702): step 4 of placing the torque element 706 within the interior space 718 of the housing 708, step 7 of placing the lid 720 adjacent to the torque element 706, and step 8 of deforming the side wall 724 of the housing 708.

[0177] Regarding step 9, and according to another aspect of the present invention, the injecting step 9 includes injecting a lubricant 760 via a channel 750 defined in the rear wall 726 of the housing 708 into a recess 746 defined in the rear wall 726 of the housing 708.

[0178] Regarding step 10, the rotating step distributes the lubricant 760 along the transverse portion 752 of the recess 746, which is oriented to extend in a transverse direction relative to the pivot axis 704 of the shaft 702 (see FIG. 24D). The rotating step 10 may also include distributing the lubricant 760 such that an amount of the lubricant 760 is contained within a reservoir formed by the interior space 718.

[0179] Although the preferred embodiments of the present invention have been shown and described herein, it is to be understood that such embodiments are provided by way of example only. Many variations, changes, and substitutions will occur to those skilled in the art without departing from the spirit of the present invention. Accordingly, it is intended that the appended claims cover all such modifications that fall within the spirit and scope of the present invention.

[0180] 1: Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Step 8: Step 9: Step 10: Step 11: Step 100: Hinge system 110: First component 120: Second component 200: Hinge module 205: Mounting fastener 300: Hinge module assembly 400: First pre - assembled hinge module 401: Channel 420: Surface indentation or groove 430: Contour shape 440: Housing 442: Cover 442a: Outer surface 442b: Outer surface 443: First hole 444: Side wall 444a: Edge surface 444b: Outer surface 446: Rear wall 446b: Extension 446c: Hole 447: Second hole 448: Internal space 448a: Storage 449: Universal mounting surface 454: Inner surface 456: Ridge 457: Circular edge 460: Shaft 462: Pivot axis 463: Head 464: End 466: End 467: Coupling surface 470: Flat mounting plate 478: Outer edge 480: Torque element 480a: Torque element 480b: Torque element 482: Recess 484: Hole 486: Pawl or projection 488: Edge 490: Lubricant 491: Adapter 492: End 493: Opposite end 494: Adapter 495: Opening 496: Opposite end 500: Pre-assembled hinge module 520: Surface indentation or groove 530: Contour shape 600: Pre-assembled hinge system 700: Pre-assembled hinge module 702: Shaft 704: Pivot axis 706: Torque element 706a: First torque element 706b: Second torque element 706c: Third torque element 706d: Fourth torque element 708: Housing 710: Adapter 712: End 714: Opposite end 716: End 718: Internal space 720: Cover 722: First hole 724: Side wall 726: Rear wall 728: Second hole 730: Universal mounting surface 732: Hole 734: Inner surface 736: Recess 738: Inner surface 740: Pawl or projection 742: Ridge 744: Extension 745: Third hole 746: Groove 750: Channel 752: Transverse portion 754: Radial portion 756: First mark 758: Second Mark 760: Lubricant 762: Arrow 764: Edge Surface 766: Outer Surface 768: Outer Surface 2C-2C: Line 3B–3B: Line 4E–4E: Line 6C–6C: Line 15D–15D: Line 15F-15F: Line 16C-16C: Line 24E-24E: Line 24F-24F: Line 24G-24G: Line

Claims

1. A pre-assembled hinge module configured to couple a first component to a second component for pivoting relative to each other, the pre-assembled hinge module comprising: a shaft defining a pivot axis; a torque element frictionally engaging the shaft, the torque element having a periphery defining a recess; and a housing having a side wall, a rear wall, and a cover, the side wall, the rear wall, and the cover together defining an internal space within the housing, wherein... The internal space is configured to receive the torque element within the housing, wherein the sidewall of the housing includes a circular pawl or protrusion extending into the internal space within the housing, the pawl or protrusion being configured to secure the torque element within the housing and restrict rotation of the torque element relative to the housing; wherein the cover defines a first hole and the rear wall defines a second hole, the first hole and the second hole being aligned with the pivot axis of the shaft, wherein the shaft extends at least through the first hole, the internal space of the housing, and the second hole; wherein the shaft is separate from the first component and configured to be mounted to the first component; wherein the housing is separate from the second component and configured to be mounted to the second component.

2. As in request item 1, a pre-assembled hinge module, wherein, The pawl or protrusion extends into a recess defined in a periphery of the torque element, thereby restricting the movement of the torque element relative to the housing.

3. As in request item 1, a pre-assembled hinge module, wherein, The rear wall of the housing defines a groove, and the groove defined in the rear wall of the housing and the torque element together define a housing, which is configured to receive a lubricant.

4. As in request item 3, a pre-assembled hinge module, wherein, The internal space forms a reservoir that holds the lubricant.

5. As in request item 1, a pre-assembled hinge module, wherein, The rear wall of the housing defines a channel, which is configured to receive a lubricant.

6. As in request item 5, a pre-assembled hinge module, wherein, The rear wall of the housing further defines a groove, which communicates with a channel defined in the rear wall of the housing, so that the lubricant flows into the channel and the groove.

7. As in request item 3, a pre-assembled hinge module, wherein, This lubricant includes grease.

8. As in request item 3, a pre-assembled hinge module, wherein, The groove has a lateral portion that is oriented to extend in a lateral direction relative to the pivot axis of the shaft.

9. As in request item 3, a pre-assembled hinge module, wherein, The groove has a radial portion that is oriented to extend in a radial direction relative to the pivot axis.

10. The pre-assembled hinge module as described in claim 1, wherein, The rear wall of the housing includes a universal mounting surface configured to be mounted to the second component.

11. As in request item 1, a pre-assembled hinge module, wherein, The torque element defines a hole aligned with the pivot axis of the shaft, through which the shaft extends and frictionally engages with the torque element.

12. As in request item 1, a pre-assembled hinge module, wherein, The sidewall has an inner surface that complements the pawl or protrusion and is configured to secure the torque element within the housing and prevent the torque element from rotating relative to the housing.

13. As in request item 1, a pre-assembled hinge module, wherein, The sidewall has an inner surface that complements the pawl or protrusion and is configured to secure the torque element within the housing and prevent the torque element from rotating relative to the housing. The inner surface defines one or more ridges for securing the torque element.

14. As in request item 1, a pre-assembled hinge module, wherein, The rear wall extends beyond the side wall to form an extension.

15. The pre-assembled hinge module as described in claim 14, wherein, The extension of the rear wall defines a third hole for receiving a mounting fastener to mount the housing to the second component.

16. As in claim 1, a pre-assembled hinge module, wherein, The rear wall and side wall of the housing are integrally formed as a single unit of construction separate from the cover.

17. The pre-assembled hinge module of claim 1, comprising a plurality of torque elements that frictionally engage the shaft.

18. The pre-assembled hinge module as described in claim 1, wherein, The internal space accommodates the torque element in a shape-locking manner.

19. The pre-assembled hinge module of claim 1, wherein at least a portion of a peripheral edge of the cover engages with a surface of an upper portion of a sidewall that extends inward and covers the portion of the peripheral edge of the cover, thereby securing the cover in place.

20. A hinge system comprising: a first component; and a second component; The system includes a hinge system comprising pre-assembled hinge modules that are pivotally coupled to the first component and the second component to allow pivotal movement of the first component relative to the second component. Each pre-assembled hinge module includes: a shaft defining a pivot axis; a torque element frictionally engaging the shaft, the torque element having a periphery defining a recess; and a housing having a cover, a rear wall, and a side wall, wherein the housing defines an internal space enclosed within the housing and the internal space is configured to receive the torque element, wherein the side wall of the housing includes a circular pawl or protrusion extending into the internal space within the housing, the pawl or protrusion being configured to secure the torque element within the housing and restrict rotation of the torque element relative to the housing. The cover defines a first hole and the rear wall defines a second hole, the first hole and the second hole being aligned with the pivot axis of the shaft, wherein the shaft extends at least through the first hole, the interior space of the housing and the second hole; wherein the shaft is mounted to the first component; and wherein the housing is mounted to the second component.

21. The hinge system of claim 20, wherein at least a portion of a peripheral edge of the cover engages with a surface of an upper portion of a sidewall that extends inward and covers that portion of the peripheral edge of the cover, thereby securing the cover in place.

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