Pre-assembled friction hinge module, hinging system and method of manufacturing thereof

Abstract

A hinging system includes a pre-assembled hinge module configured to couple a first component to a second component. The pre-assembled hinge module includes a shaft, a torque element frictionally engaging the shaft, and a housing. The housing includes a cover, a sidewall, and a back wall defining an interior space enclosed within the housing. The interior space receives the torque element within the housing. The cover defines a first aperture and the back wall defines a second aperture, the first and second apertures aligned with a pivot axis of the shaft. The shaft extends at least through the first aperture, the interior 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 relates generally to friction hinges, and more specifically to pre-assembled friction hinge modules that can be used for components in a pivotally connected system. Background Technology

[0002] Various types of mechanical hinges can be used to connect components in a pivoting relationship. Friction hinges (also known as "constant torque hinges" or "positioning hinges") are hinges used on devices characterized by pivoting doors, plates, or other components that open and close about a pivot axis. Friction hinges are commonly used to connect laptop screens to keyboards, and in the automotive industry to booms connected to center consoles, among many other applications.

[0003] In a typical friction hinge, the pivot has an outer surface that abuts against the inner surface of another component to create mechanical interference within the hinge. This mechanical interference allows the components to remain in a stable position after they have been pivoted and released, which is desirable for holding components such as doors and booms in any position. The mechanical interference also adds a tactile “texture” to the movement of doors and booms, providing a substantially constant rotational resistance during the effort to close and open, thus engaging the user experience.

[0004] Traditional friction hinges used in center consoles are typically manufactured as large assemblies with multiple components. These assemblies may include large brackets designed for installation inside the vehicle and other stamped parts. The relatively large size of these hinge assemblies adds significant weight to the console. Furthermore, the stamped parts require additional tools for manufacturing. Summary of the Invention

[0005] The friction hinge module, system, and method according to the present invention address the shortcomings of conventional friction hinge assemblies in several aspects.

[0006] In a first aspect of the invention, a pre-assembled hinge module is configured to connect a first component to a second component for pivoting 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 sidewalls, a rear wall, and a cover, the sidewalls, rear wall, and 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 cover defines a first hole and the rear wall defines a second hole, the first and second holes being aligned with the pivot axis of the shaft, the shaft extending 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; and wherein the housing is separate from the second component and configured to be mounted to the second component. This novel design allows for the use of lighter material supports, such as molded plastic or castings. Additionally, the novel design allows for a reduction in the number of components, such as eliminating component riveting rivets or other unnecessary components in the design.

[0007] In another aspect of the invention, a method for manufacturing a hinge module is provided, the method comprising the steps of: placing a torque element within an internal space of a housing; aligning a hole defined in the rear wall of the housing with a hole defined in the torque element to form a channel; inserting a shaft through the channel; placing a cover adjacent to the torque element such that the end of the shaft is exposed through a hole in the cover; and pressing the sidewalls along the periphery to secure the cover relative to the housing.

[0008] In another aspect of the invention, a hinge module assembly is configured to connect a first component to a second component for pivoting movement relative to each other. The hinge module assembly includes: a first pre-assembled hinge module configured to control relative pivoting movement of the first and second components along a first pivoting direction; and a second pre-assembled hinge module configured to control relative pivoting movement of the first and second components along a second pivoting direction opposite to the first pivoting direction. Both the first and second pre-assembled hinge modules include: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing including sidewalls, a rear wall, and a cover, the sidewalls, rear wall, and 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 cover defines a first hole and the rear wall defines a second hole, the first and second holes being aligned with the pivot axis of the shaft, the shaft extending 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; and wherein the housing is separate from the second component and configured to be mounted to the second component.

[0009] In another aspect of the invention, a hinge system is configured to connect a first component to a second component for pivoting movement relative to each other. The pre-assembled hinge module system includes: a shaft defining a pivot axis, the shaft being separate from the first component and 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 an 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 invention, a hinge system includes: a first component; a second component; and a pre-assembled hinge module that pivotally connects the first component to the second component to allow 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 within the housing, wherein the internal space is configured to receive the torque element; wherein a cover defines a first hole and a rear wall defines a second hole, the first and second holes being aligned with the pivot axis of the shaft, the shaft extending at least through the first hole, the internal 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. Attached Figure Description

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

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

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

[0014] Figure 1C yes Figure 1A Side view of the pre-assembled hinge module;

[0015] Figure 2A This 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 supplied separately;

[0016] Figure 2B yes Figure 2A Side view of the pre-assembled hinge module;

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

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

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

[0020] Figure 3A yes Figure 1A Front view of the torque element of the hinge module;

[0021] Figure 3B yes Figure 1A A sectional view of the torque element of the hinge module taken along line 3B–3B.

[0022] Figure 3C yes Figure 1A A three-dimensional view of the torque element of the hinge module;

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

[0024] Figure 4A yes Figure 1A Front view of the hinge module cover;

[0025] Figure 4B yes Figure 1A Side view of the cover of the hinge module;

[0026] Figure 4C yes Figure 1A The front view of the cover of the hinge module shows line 4E–4E;

[0027] Figure 4D yes Figure 1A A three-dimensional view of the cover of the hinge module;

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

[0029] Figure 4F yes Figure 1A A magnified view of the top of the hinge module's cover;

[0030] Figure 4G yes Figure 1A A magnified view of the bottom of the hinge module's cover;

[0031] Figure 5A yes Figure 1A A three-dimensional view of the hinge module's axis;

[0032] Figure 5B yes Figure 1A The side view of the hinge module's shaft also shows an enlarged view of a portion of the shaft's outline;

[0033] Figure 5C yes Figure 1A Front view of the hinge module's axis;

[0034] Figure 6A yes Figure 2A A 3D view of the adapter for the hinge module;

[0035] Figure 6B yes Figure 2A Front view of the adapter for the hinge module;

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

[0037] Figure 6D yes Figure 2A A magnified view of the end of the adapter of the hinge module;

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

[0039] Figure 8 yes Figure 2A An exploded view of the hinge module;

[0040] Figure 9 It is a set of two pre-assembled hinge modules according to another exemplary embodiment of the present invention, each hinge module showing an adapter that can be supplied separately;

[0041] Figure 10A It comes from Figure 9 A cross-sectional view of the hinge module of the assembly, showing the torque element in the first position;

[0042] Figure 10B It comes from Figure 9 A cross-sectional view of the hinge module of the group, showing the torque element in the second position;

[0043] Figure 11A It comes from Figure 9 The front view of the hinge module of the assembly shows the rear wall attached to the side wall in the first position;

[0044] Figure 11B It comes from Figure 9 The front view of the hinge module of the assembly shows the rear wall attached to the side wall in the second position;

[0045] Figure 12This 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 second position;

[0046] Figure 13A yes Figure 12 A 3D view of the adapter for the hinge module;

[0047] Figure 13B yes Figure 12 Side view of the adapter of the hinge module;

[0048] Figure 13C yes Figure 12 Rear view of the adapter for the hinge module;

[0049] Figure 13D yes Figure 12 Top view of the adapter for the hinge module;

[0050] Figure 14A yes Figure 12 Front view of the hinge module cover;

[0051] Figure 14B yes Figure 12 Side view of the cover of the hinge module;

[0052] Figure 14C yes Figure 12 A three-dimensional view of the cover of the hinge module;

[0053] Figure 15A yes Figure 12 A perspective view of the housing of the hinge module, showing the rear wall and side walls;

[0054] Figure 15B yes Figure 15A An enlarged view of the internal space of the hinge module's housing;

[0055] Figure 15C yes Figure 15A Front view of the internal space of the hinge module housing;

[0056] Figure 15D yes Figure 15A A cross-sectional view taken along line 15C–15C of the internal space of the hinge module housing, showing the inner surface of the sidewall;

[0057] Figure 15E yes Figure 15A Side view of the housing of the hinge module;

[0058] Figure 15F yes Figure 15A The hinge module housing along Figure 15C Bottom view of the cross section taken by line 15F in the middle;

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

[0060] Figure 16B yes Figure 16A Front view of the torque element;

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

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

[0063] Figure 17 This 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 This is a perspective view of a pre-assembled hinge module according to an exemplary embodiment of the present invention, showing a cover that fits into a portion of the sidewall in a fluid-sealed press-fit manner.

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

[0066] Figure 20 yes Figure 19 Rear perspective view of the pre-assembled hinge module, 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 the 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 the pre-assembled hinge module, showing a first torque element in the second orientation and a second torque element in the 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 the 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 the pre-assembled hinge module, showing the first torque element, the second torque element, the third torque element, and the fourth torque element in the second orientation.

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

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

[0077] Figure 24C This is a side view of the housing of the pre-assembled hinge module shown in Figure 24A.

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

[0079] Figure 24E The edge of the housing of the pre-assembled hinge module of Figure 24A is depicted. Figure 24D The side view of the cross section taken from line 24E-24E.

[0080] Figure 24F The edge of the housing of the pre-assembled hinge module of Figure 24A is depicted. Figure 24D The bottom view of the cross section taken by line 24F-24F.

[0081] Figure 24G It is part of the internal space of the housing of the pre-assembled hinge module in Figure 24A. Figure 24D A magnified view of (24G-24G) in the image.

[0082] Figure 25 A perspective view of the housing of a pre-assembled hinge module according to another exemplary embodiment of the present invention is shown, with a second mark corresponding to a second mounting position.

[0083] Figure 26 A perspective view of the housing of a pre-assembled hinge module according to another exemplary embodiment of the present invention is shown, illustrating a second mark and a larger housing size.

[0084] Figure 27 A perspective view of the housing of a pre-assembled hinge module according to another exemplary embodiment of the present invention is shown, illustrating a first marking and a larger housing size.

[0085] Figure 28 A group of two pre-assembled hinge modules according to another exemplary embodiment of the invention is depicted, each hinge module shown having no optional adapter that can be supplied separately, and having a second label.

[0086] Figures 29A-29B An embodiment of a top-to-bottom or top-down assembly process for a hinge module according to an exemplary scheme of the present invention is described. Detailed Implementation

[0087] Although the invention has been shown and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications in detail may be made within the scope and theme of the claims and without departing from the invention.

[0088] Furthermore, various forms and embodiments of the invention are illustrated in the accompanying drawings. It will be understood that combinations and arrangements of some or all features of any embodiment with other embodiments are specifically contemplated herein. Therefore, this detailed disclosure explicitly includes the specific embodiments shown herein, combinations and sub-combinations of features of the illustrated embodiments, and variations of the illustrated embodiments.

[0089] Generally refer to Figure 1- Figure 18A pre-assembled hinge module 500 is configured to connect a first component 110 to a second component 120 for pivoting movement relative to each other. The pre-assembled hinge module 500 includes: a shaft 460 defining a pivot axis 462; a torque element 480 frictionally engaging the shaft 460, the torque element 480 having a periphery defining a recess 482; and a housing 440 having sidewalls 444, a rear wall 446, and a cover 442, the sidewalls 444 and rear wall 446 and the cover 442 together defining 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, and the sidewalls 446 of the housing 440 have extensions into the housing 440. A pawl or protrusion 486 in the internal space 448 extends into a recess 482 defined in the periphery of the torque element 480, thereby restricting the 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 being aligned with the pivot axis 462 of the shaft 460, the shaft 460 extending 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 separate from the first component 110 and configured to be mounted to the first component; wherein the housing 440 is separate from the second component 120 and 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 configured to be mounted to the second component 120.

[0091] Torque element 480 defines a bore 484 aligned with pivot axis 462 of shaft 460, through which shaft 460 extends to frictionally engage with torque element 480.

[0092] The sidewall 444 has an inner surface 454 (which is complementary to the pawl 486), the inner surface being configured to secure 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] An extension 446b of the rear wall 446 defines a third hole 447 for receiving a mounting fastener 205 to mount the housing 440 to the second component 120.

[0096] The rear wall 446 and side wall 444 of the shell 440 are integrally formed into a single monolithic structure separate from the cover 442.

[0097] The pre-assembled hinge module 500 may include multiple torque elements 480 of the friction-engaging shaft 460.

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

[0099] The internal space 448 forms a storage container 448a, which holds a certain amount of lubricant 490.

[0100] A method for assembling a hinge module 500 is also provided, the method comprising: placing a torque element 480 within an interior space 480 of a housing 440 having a rear wall 4446 and a side wall 444 that together at least partially define the interior space 448; applying a lubricant 490 to an edge 488 of the torque element 480. Figure 3A In the process of aligning a hole 447 defined in the rear wall 446 of the housing 440 with a hole 443 defined in the torque element 480 to form a channel 401; inserting a shaft 460 through the channel 401; placing a cover 442 adjacent to the torque element 480 such that the end 464 of the shaft 460 is exposed through the hole 443 defined in the cover 442, and the cover 442 extends at least partially into the interior space 448 of the housing 440; and deforming the side wall 444 of the housing 440 to secure the cover 442 relative to the housing 440.

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

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

[0103] The deformation step includes deforming the edge surface of the sidewall 444 of the housing 440 to at least partially contact the outer surface of the cover 442, thereby restricting the movement of the cover 442 from the interior space 448 of the housing.

[0104] The deformation step includes pressing at least a portion of the sidewall 444 of the housing 440 inward into the internal space 448 of the housing 440 and into contact with the cover 442.

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

[0106] The following steps are performed by initiating an action generally along the direction of the common components: 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 sidewall 444 of the housing 440.

[0107] The sidewall 444 of the housing 440 extends upward from the rear wall 446 and performs the following steps by acting in a top-down manner generally along the 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 sidewall 444 of the housing 440.

[0108] The deformation step includes: deforming the sidewall 444 of the housing 440 radially inward from the outer surface 444b of the sidewall 444 to secure the cover 442 relative to the housing 440.

[0109] The housing 440 has an inner surface 454 on its sidewall 444, which corresponds in position to the outer surface 480a of the torque element 480. The method further includes forcing the cover 442 against the sidewall 444 of the housing 440 to move the pawl 486 toward the outer surface of the torque element.

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

[0111] The method includes: forcing the cover 442 against a 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 inward relative to the side wall 444 of the housing 440 into the recess 482 of the torque element 480.

[0112] A hinge module assembly 300 is configured to connect a first component 110 to a second component 120 for pivoting movement relative to each other. The hinge module assembly 300 includes: a first pre-assembled hinge module 400 configured to control relative pivoting movement of the first and second components along a first pivoting direction; and a second pre-assembled hinge module 500 configured to control relative pivoting movement of the first and second components along a second pivoting direction opposite to the first pivoting direction. Both the first and second pre-assembled hinge modules include: a shaft 460 defining a pivot axis 462; a torque element 480 frictionally engaging the shaft 460, the torque element 480 having a periphery defining a recess 482; and a housing 440 having sidewalls 444, a rear wall 446, and a cover 442, the sidewalls 444 and rear wall 446 and the cover 442 together defining the housing 440. An internal space 448 is provided within a housing 440, wherein the internal space 448 is configured to receive a torque element 480 within the housing 440, and a sidewall 446 of the housing 440 has a pawl 486 extending into the internal space 448 within the housing 440. The pawl 486 extends into a recess 482 defined in the periphery of the torque element 480, thereby restricting movement of the torque element 480 relative to the housing 440. A cover 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 a pivot axis 462 of a shaft 460, the shaft 460 extending at least through the first hole 443, the internal space 448 of the housing 440, and the second hole 447. The shaft 460 is separate from the first component 110 and configured to be mounted to the first component. The housing 440 is separate from the second component 120 and configured to be mounted to the second component.

[0113] The housing 440 of the first pre-assembled hinge module 400 includes a first mark 420 corresponding to a first mounting position, and the second pre-assembled hinge module 500 includes a second mark 520 corresponding to a second mounting position opposite to the first mounting position.

[0114] A pre-assembled hinge module system 600 is configured to connect a first component 110 to a second component 120 for pivoting movement relative to each other. The pre-assembled hinge module system 600 includes: a shaft 460 defining a pivot axis 462, the shaft 460 being separate from the first component 110 and configured to be mounted to the first component; a torque element 480 frictionally engaging the shaft 460; a housing 440 accommodating the torque element 480; and an adapter 491 having 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] Shaft 460 mates with adapter 491, which defines a counterbore opening to receive a portion of end 466 of shaft 460.

[0116] A hinge system 100 includes: a first component 110; a second component 120; and a hinge system 100 including pre-assembled hinge modules that pivotally connect the first component 110 to the second component 120 to allow pivoting movement of the first component 110 relative to the second component 120. Each pre-assembled hinge module includes: a shaft 460 defining a pivot axis 462; a torque element 480 frictionally engaging the shaft 460; and a housing 440 defining an internal space 448 within the housing 440. The internal space 448 is configured to receive a torque element 480; 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 being aligned with the pivot axis 462 of the shaft 460, the shaft 460 extending at least through the first hole 443, the internal space 448 of the housing 440 and the second hole 447; the shaft 460 is separate from the first component 110 and configured to be mounted to the first component; the housing 440 is separate from the second component 120 and configured to be mounted to the second component.

[0117] For more specific reference Figure 7 The diagram illustrates an articulated system 100 according to one embodiment. The articulated system 100 can be applied to various applications of one or more friction hinges that include relative pivoting movement of control components. For example, the articulated system 100 can be included in various types of enclosed systems used in motor vehicles, ships, and / or aircraft, including but not limited to various types of compartments, cabinets, hatches, receptacles, overhead bins, and storage units.

[0118] In the current example, the articulation system 100 is contained in the center console of the vehicle. The articulation system 100 includes a first component in the form of a console seat 110 and a second component in the form of a cover 120. The cover 120 is pivotally connected to the seat 110. This pivotal connection allows the cover 120 to pivot relative to the seat 110 between an open position and a closed position. The cover 120 is connected to the seat 110 via a pair of hinge modules 200 (one on each side of the cover). Each hinge module 200 is a pre-assembled unit configured for universal mounting to components requiring friction hinges. Thus, the hinge modules 200 can be mounted on various types of components and in various arrangements.

[0119] Now for reference Figure 9A hinge module assembly 300 according to an embodiment of the present invention is shown. The hinge module assembly 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 connect a first component to a second component for pivoting movement relative to each other along a pivot axis. The first pre-assembled hinge module 400 is mounted at a first point along the pivot axis, and the second pre-assembled hinge module 500 is mounted at a second point along the pivot axis. Thus, the first pre-assembled hinge module 400 and the second pre-assembled hinge module 500 are configured to control pivoting 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 may be mounted in a mirror arrangement on a central control console, with the hinge modules mounted on opposite sides of a cover.

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

[0121] Each hinge module 400 and 500 is designed for mounting on a specific side or at a specific location on the pivot axis relative to the cover, such that the hinge modules apply the same amount of frictional resistance to pivoting movement in the same direction. Pre-assembled hinge module 400 is designed to attach the cover to the left side of the console housing, while pre-assembled hinge module 500 is designed to attach the cover to the right side of the console housing.

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

[0123] Each side of the console has a mounting surface with a recess conforming to only one of the contour shapes 430 and 530, such that each side of the console will accept only one of the hinge modules 400 and 500. This ensures that hinge modules 400 and 500 are mounted on the correct side of the console. Both hinge modules 400 and 500 comprise the same components. Therefore, only the components of hinge module 500 will be described; it should be understood that hinge module 400 also includes similar portions designed to generate frictional resistance in opposite directions.

[0124] Now for reference Figures 1A-1C The hinge module 500 includes a housing 440 and a shaft 460 defining a pivot axis 462. The housing 440 has a cover 442, sidewalls 444, and a rear wall 446. In one embodiment, as... Figure 2A , Figure 2B and Figure 2D As shown, the hinge module 500 includes: a housing 440 having a cover 442, a side wall 444, and a rear wall 446; and a shaft 460, coupled to an end 492 of an adapter 491, the adapter 491 having an opposing end 493 configured to be releasably coupled to a first component. Figure 8 In the middle, the cover 442, side wall 444, and rear wall 446 define the internal space 448. For example... Figure 2C As shown, the internal space 448 is configured to receive the torque element 480. Figure 3A – Figure 3D In the middle, torque element 480 defines a recess 482, which extends through a portion of torque element 480. Figure 16A – Figure 16D Another embodiment of the torque element 480 is shown, which defines a recess 482 extending through a portion of the torque element 480. Additionally, the torque element 480 defines a hole 484 for frictionally engaging a shaft 460.

[0125] refer to Figure 2C The sidewall 444 has a pawl 486 that extends into an interior space 448 within the housing 440. The pawl can be provided in the form of a pointed or rounded ridge, extension, profile, or any form that extends an inner surface of any wall of the housing into the interior space. The pawl 486 extends into a recess 482 defined in the periphery 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 periphery of the torque element can be provided with a pawl extending outward into a recess formed in the wall of the housing; in other words, by placing the recess on the housing and placing the pawl on the torque element, Figure 2C The arrangement of the recesses and pawls shown can be reversed, or vice versa.

[0126] The amount of frictional resistance provided by torque element 480 depends in part on the surface area of ​​the torque element in contact with shaft 460. Therefore, the thickness of a single torque element can be changed to alter the frictional resistance. Additionally, individual dimensions (external dimensions of the shaft and internal dimensions of the torque elements) can be modified to increase or decrease the frictional resistance.

[0127] exist Figure 2C In this configuration, only one torque element 480 is visible. However, it will be understood that one or more additional torque elements may be accommodated 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 of ​​the friction engagement shaft 460, and thus increases the amount of frictional resistance provided by the hinge module 500.

[0128] The amount of frictional resistance provided by the hinge module 500 can be increased 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. Furthermore, in Figure 2C In this configuration, the torque element 480 is placed in the first position. However, it will be understood that, as Figures 10A-10B As seen, the torque element 480 can be placed within the internal space 448 in the second position. Specifically, as Figure 12 As shown, torque element 480a can be placed in a first position and torque element 480b can be placed in a second position. Figure 17 In this configuration, torque element 480a and torque element 480b can be placed in a first position. Torque element 480a can also be placed in a second position (not shown).

[0129] The position of the torque element can be used to provide symmetrical torque (the same frictional resistance in both rotational directions) or asymmetrical torque (different frictional resistance in opposite rotational directions).

[0130] Figure 4A , Figure 4C and Figure 4D A cover 442 is depicted, comprising a first hole 443 and two surface features (such as indentations 442a) that allow the component to be processed in an electroplating bath, prevent component buildup, and prevent electroplating material from adhering to the surface. In another embodiment, as by Figures 14A-14C As shown, cover 442 defines the first hole 443. Furthermore, Figure 15A The rear wall 446 defining the second hole 447 is shown. The first hole 443 and the second hole 447 are axially aligned with each other. Figure 1A – Figure 1CAs shown, 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] Brief reference Figure 14C Note that in this embodiment, cover 442 does not include dent 442a. Instead, Figure 14C The cover 442 depicted can be formed from a pre-plated material. Therefore, in this embodiment, the dent 442a is not required.

[0132] refer to Figures 5A-5C The shaft 460 has a proximal end 464 and a distal end 466 opposite to the proximal end. The distal end 466 includes a head 463 with a reduced diameter relative to the rest 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 the first component.

[0133] Now for reference Figure 8 According to another embodiment of the invention, the pre-assembled hinge module 500 includes a connecting element in the form of a shaft 460, a cover 442, a torque element 480, a housing 440, and an adapter 491, the connecting element having a proximal end 492 configured to be fixedly connected to the shaft 460, and an opposite end 493 configured to be releasably connected to a first component.

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

[0135] By providing an adapter, such as adapter 491, the pre-assembled hinge module can be adapted for use in systems constructed for disassembly. For example, shaft 460 can be designed for permanent or semi-permanent attachment to the console of a vehicle. This attachment can be expected to prevent or resist accidental disassembly, tampering, or accidental loosening of the hinge module. If it is desired to adapt the pre-assembled hinge module for use in systems constructed for disassembly, an adapter, such as adapter 491, can be provided to convert the hinge assembly into an easier-to-disassemble component. This is advantageous for facilitating the repair and replacement of the hinge assembly, the renewal of the hinge assembly, or disassembly for cleaning or access to internal components.

[0136] like Figure 15A As shown, the rear wall 446 provides a universal mounting surface 449, which can be mounted to a housing, cover, or other component of the center console. Furthermore, the rear wall 446 extends beyond the housing 440 to form an extension 446b. The extension 446b defines a hole 446c for receiving mounting fasteners, such as… Figure 7 The screw 205 shown is used to mount the housing 440 to the console housing or cover.

[0137] refer to Figure 15A – Figure 15D The sidewalls 444 and rearwall 446 of the housing 440 are integrally formed as a single, monolithic structure separate from the cover 442. The rearwall 446, in the form of a flat mounting plate 470, mates with the sidewall 444 in a fluid-tight manner. This configuration allows for the formation of a one-piece housing base, which can be formed by molding, casting, stamping, machining, or other known processes. Alternatively, however, the sidewalls 444 and rearwall 446 of the housing 440 can be formed separately and subsequently joined together by means such as welding, adhesives, thermal bonding, or mechanical fastening.

[0138] like Figure 2C As shown, the internal space 448 of the housing 440 receives the torque element 480 in a form-locking manner. Specifically, the inner surface 454 extending along the interior of the sidewall 444 includes a pawl-like engagement surface, such as a sharp ridge 456. External pressure applied along the periphery of the sidewall causes the ridge 456 to engage the recess 482 of the torque element 480, maintaining the torque element in a form-locking fit. In another embodiment, as... Figures 15A-15C As shown, the inner surface 454 includes a pawl-shaped engagement surface with a rounded edge 457.

[0139] exist Figure 2C In the case of housing 440, the internal space 448 forms a chamber or reservoir 448a, which is suitable for storing a certain amount of lubricant (such as grease 490). Along edge 488 ( Figure 3A Grease 490 is applied, wherein edge 488 engages shaft 460 in a frictional engagement manner. Sidewall 444, cover 442, and rear wall 446 in the form of metering plate 470 form a sealed chamber or reservoir that prevents lubricant applied to torque element 480 from leaking out of housing 440 and prevents dirt and other solid and / or liquid contaminants from entering housing.

[0140] The pre-assembled hinge module 400 can be used to pivotally connect 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 shaft 460 is inserted through a pivot hole in the first and second components. 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 mounting plate 470 can be attached between multiple ribs on the first component, as shown in FIG1. ​​A recess 420 in mounting plate 470 mates with a similarly shaped protrusion on the first component to ensure that hinge module 400 is mounted on the correct side of the pivot axis. The distal end 466 of shaft 460 protrudes through the first and second components, exposing an annular recess 467.

[0142] A separately supplied E-ring or other connecting element is attached to surround the annular recess 467 to secure the shaft 460 to the second component and prevent the shaft from being pulled out or removed from the first and second components, thereby connecting the first and second components together in a pivotal manner. The same process is then performed to mount the hinge module 500 on the opposite sides of the first and second components.

[0143] Finally, according to one embodiment and referring to the components of hinge module 500, a method for manufacturing a pre-assembled hinge module includes the step of placing torque element 480 within the internal space 448 of housing 440. Then, as Figure 10B As shown, the hole 484 of the torque element 480 is aligned with the hole 447 of the mounting plate 470 to form a channel 401. Next, a shaft 460 is inserted through the channel 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, a cover 442 is placed adjacent to the torque element 480 in a form-locking fit, such that the end of the shaft 460 is exposed through the hole 443 of the cover 442. Now refer to Figure 18 The sidewall 444 is pressed along the periphery to secure the cover 442 relative to the housing 440, such that the sidewall 444 engages with the cover 442 in a rigid or fluid-tight manner. Thus, the cover 442, sidewall 444, and mounting plate 470 form the housing 440, which encloses the torque element 480 and grease 490 within the housing 440. The hinge module 500 is now pre-assembled and ready for installation to pivotally connect the two components.

[0144] like Figure 15FAs shown in the cross-sectional view, the inner surface of the sidewall of the housing provides a pair of opposing pawls. On the pawls, a portion of the sidewall rises upward, forming an outwardly extending, downward-facing groove. The upwardly extending portion of the pawl provides a surface against which the cover can be supported when placed over a part within the sidewall. More specifically, due to the recess formed at the pawl location, the torque element extends downward toward the bottom and rear wall of the housing. However, the cover does not have a recess and therefore rests on the top of the pawls, more specifically on the top of the upwardly raised portion of the pawls.

[0145] If will pass Figure 15F Understandably, when the cover is pressed down against the pawl, the material of the upward-rising pawl can deform downwards and towards the center of the internal space of the housing. Therefore, the material of the pawl deforms and flows inwards and into the recesses of the torque elements, thus securing them firmly in place within the housing.

[0146] To facilitate efficient, rapid, and / or low-cost assembly, hinge modules can be assembled in a top-down manner, with all or almost all assembly movements occurring from top to bottom or along any other single direction, rather than requiring lateral and vertical movements. Such top-to-bottom or top-down assembly allows for the use of simple fasteners and manufacturing techniques, while also reducing potential misalignments that might be associated with combinations of downward, lateral, or angled assembly movements.

[0147] For example, refer to Figure 12 The base component of the housing can be laid flat on the support surface. Then, one or more torque elements can be inserted downwards from top to bottom into the internal space or region of the housing base. A lubricant such as grease 490 can be applied to the recess 482 of the torque element 480. Then, a shaft can also be inserted through the housing along the top-to-bottom axis of the assembly. Finally, a cover can also be placed on top of the torque elements or multiple torque elements using a downward movement from top to bottom. In this way, all or almost all components of the hinge module can be assembled in a top-to-bottom arrangement.

[0148] Additionally, the final or near-final step of capturing or otherwise engaging the cover into or against the base of the housing can also be accomplished through a push-to-the-bottom or downward movement. For example, the pressing of the walls of the housing base can be performed by moving a tool downwards to engage the outward and upward edges of the walls of the housing base, thereby forcing those upper wall portions downwards and slightly inwards to surround, engage, or capture the cover. This downward pressing or deforming movement again facilitates simple tools and simple movements, reducing the risk of tool misalignment and misalignment of hinge module components. The pressing action can be provided by a die or tool or any other mechanism capable of deforming the upper walls of the housing base.

[0149] As an example, Figure 18 An example of a hinge module is shown, wherein a cover engages within the base of a housing. Specifically, the cover has been positioned within an internal region 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, such as Figure 18 As shown, the upper portion of the base wall of the housing is rolled up and slightly bent inwards above the peripheral edge portion of the cover, thereby securing the cover in place and providing a partial or complete seal to prevent the ingress of solid and / or liquid contaminants. Additionally, the secure cover prevents or restricts the escape of grease or lubricant from the internal space of the housing. A lubricant, such as grease 490, is applied to the recess 482 of the torque element 480.

[0150] According to another exemplary embodiment of the present invention, reference is now made to Figures 19-20 The pre-assembled hinge module 700 is configured to connect a first component (not shown) to a second component (not shown) for pivoting relative to each other.

[0151] The pre-assembled hinge module 700 includes a shaft 702 defining a pivot axis 704. The shaft 702 is separate from and configured to be mounted to a first component (not shown). The shaft 702 is configured to mate with a coupling element (such as an adapter 710) defining 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 opposing end 714, the end 712 being configured to be securely coupled to the end 716 of the shaft 702, and the opposing end 714 being configured to be releasably coupled to the first component (not shown).

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

[0153] The torque element 706 (as seen at least in Figures 21A-21C) is configured to frictionally engage the shaft 702. Furthermore, the torque element 706 has a periphery defining a recess 736, and the sidewall 724 of the housing 708 includes a pawl or protrusion 740 extending into an internal space 718 within the housing 708. The pawl 740 is configured to secure the torque element 706 within the housing 708 and prevent rotation of the torque element 706 relative to the housing 708. The torque element 706 (as seen at least in Figures 21A-21C) also defines a bore 732 aligned with the pivot axis 704 of the shaft 702, through which the shaft 702 extends at least, while the shaft 702 frictionally engages with the torque element 706.

[0154] The cover 720 defines a first hole 722 (as seen at least in Figures 21A-21C) and the rear wall 724 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 hole 722 of the cover 720, the hole 732 of the torque element 706, the internal space 718 of the housing 708, and the hole 728 of the rear wall 726.

[0155] The sidewall 724 has an inner surface 738 (which is complementary to the pawl 740) 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 sidewall 724 to form an extension 744.

[0156] The extension 744 of the rear wall 726 defines a third hole 745 for receiving mounting fasteners (e.g. Figure 7 The screws 205 are used to install the housing 708 to the second component (not shown). In addition, the rear wall 726 and side wall 724 of the housing 708 can be integrally formed as a single unit of an integral structure separate from the cover 720.

[0157] Referring to Figures 21A-21C, the pre-assembled hinge module 700 may include a plurality of torque elements 706 for frictionally engaging the shaft 702. An internal space 718 receives one or more torque elements 706 in a form-locking manner. As seen in Figure 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 FIG21B, a first torque element 706a may be arranged in a first position and a second torque element 706b may be arranged in a second position. Finally, as seen in FIG21C and according to yet another exemplary embodiment of the present invention, the first torque element 706a may be arranged in a second position and the second torque element 706b may be arranged in a second position.

[0159] Furthermore, although Figures 21A-21C depict the hinge module 700 as including the adapter 710, it should be understood that the size and shape of the hinge module 700 may be configured to accommodate other types of connecting elements constructed for releasable connection to the first component (not shown). It should also be understood that the hinge module 700 may not include connecting elements 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, the size and shape of which can be configured to receive a plurality of torque elements 706, including a first torque element 706a, a second torque element 706b, and a third torque element 706c. As seen in FIG22A, torque elements 706a, 706b, and 706c are all arranged in a first position. As shown in FIG22B, the first torque element (706a), the second torque element (706b), and the third torque element (706c) are arranged in a second position. It should be understood that the plurality of torque elements 706 can be arranged in any combination of the first and second positions.

[0161] According to another exemplary embodiment of the present invention, a pre-assembled hinge module 700 includes a housing 708, the housing being sized and shaped to receive four torque elements 706, 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 FIG23A, torque elements 706a, 706b, 706c, and 706d are all arranged in a first position. As shown in FIG23B, the first torque element (706a) and the second torque element (706b) are arranged in the first position, while the third torque element (706c) and the fourth torque element (706d) are arranged in a second position. Finally, as depicted in FIG23C, torque elements 706a, 706b, 706c, and 706d are all arranged in the second position. It should be understood that multiple torque elements 706 can be arranged in any combination of the first and second positions.

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

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

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

[0165] In addition, Figure 24B and Figure 25 Together, they define a first pair or group of hinge modules 700 according to an embodiment of the invention. As shown in FIG24B, hinge module 700 may include a first mark 756 corresponding to a first mounting position (not shown). Alternatively or additionally, hinge module 700 may include a second mark 758 corresponding to a second mounting position (not shown), such as Figure 25 What I saw.

[0166] same, Figure 26 and Figure 27 Together, they define a second pair or second set of housings for a hinge module 700 according to another embodiment of the invention. For example... Figure 26 As shown, the hinge module 700 is sized and shaped to accommodate a plurality of torque elements 706, and also includes a first mark 758 corresponding to a first mounting position (not shown). Alternatively or additionally, the hinge module 700 is also sized and shaped to accommodate a plurality of torque elements 706, and also includes a second mark 756 corresponding to a second mounting position (not shown), such as... Figure 27 As previously described, the positioning of torque element 706 can be used to provide symmetrical torque (the same frictional resistance in both rotational directions) or asymmetrical torque (different frictional resistance in opposite rotational directions). For example, if all torque elements are positioned or oriented in the same direction, the torque elements will typically provide asymmetrical torque. Alternatively, if an equal number of torque elements are positioned or oriented in opposite directions, the torque elements will typically provide symmetrical torque. Furthermore, it should be understood that the more torque elements 706 included, the greater the torque provided.

[0167] Similarly, Figure 28 A third pair or group of hinge modules 700 according to yet another embodiment of the invention is depicted, wherein each hinge module 700 does not include a connecting element (such as an adapter 710). One of the hinge modules 700 includes a first mark 756 corresponding to a first mounting position (not shown). Alternatively or additionally, another hinge module 700 includes a second mark 758 corresponding to a second mounting position (not shown).

[0168] Finally, refer to Figures 29A-29BA method for assembling a hinge module 700 is also provided. Generally, the method includes the steps of: applying a lubricant (such as grease 760) to a shaft 702 (step 5); pressing at least a portion of a cover 720 into an interior space 718 (step 8); injecting the lubricant (such as grease 760) into the interior space 718 via a channel 750 defined in a rear wall 726 of a housing 708 (step 9); and rotating the shaft 702 about a pivot axis 704 to dispense the lubricant 760 along a groove 746 defined in the rear wall 726 of the housing 708 (step 10), the groove 746 being configured to guide the lubricant 760 from the channel 750 defined in the rear wall 726 of the housing 708. Figure 29A and Figure 29B A method is described in which steps are performed sequentially in the order described and shown, but it should be understood that the steps can be performed in any order.

[0169] For specific references Figure 29A Regarding steps 1 and 6, according to one aspect of the invention, the method of assembling the hinge module 700 may include attaching a portion of the end 716 of the shaft 702 to a connecting element, such as an adapter 710. The connecting element is described in step 1.

[0170] Regarding steps 2-4 and according to one aspect of the invention, step 2 is performed before step 3, which involves applying lubricant 760 to torque element 706. Step 2 is to align a hole (such as 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 invention, and with regard to steps 4, 6, and 8, the following steps are performed by initiating an action generally along a common component direction: step 4, placing the torque element 706 within the internal space 718 of the housing 708; step 6, inserting the shaft 702 through the channel formed by aligning the hole 722 of the cover 720 and the hole 732 of the torque element 706; step 8, placing the cover 720 adjacent to the torque element 706; and step 8, deforming the sidewall 724 of the housing 708. This can be, for example, a top-to-bottom or bottom-to-top direction, wherein components are assembled along a common axis and / or along a common direction, thereby reducing or eliminating manipulation or repositioning of components during assembly. According to one embodiment, components can be stacked one after another in a downward direction along a common axis.

[0172] Additionally or optionally, lubricant 760 may be applied to the outer surface of shaft 702, such as Figure 29A See step 5.

[0173] Regarding step 7, connecting the shaft 702 to the adapter 710 may include inserting the shaft 702 into a channel formed by the hole 722 of the alignment cover 720, the hole 732 of the torque element 706, and the countersunk opening of the adapter 710. Figures 6A-6D The adapter 710 can then be applied to the end or end portion of the shaft 702.

[0174] Refer to step 8 (e.g.) Figure 29B (See) and according to another aspect of the invention, the step of pressing, riveting, or otherwise deforming at least a portion of the cover 720 toward the interior space 718 (see) Figure 29B Arrow 762 in the diagram includes a cover 720 arranged such that the cover 720 extends within the interior space 718 of the housing. Furthermore, the step of pressing, riveting, or otherwise deforming at least a portion of the cover 720 toward the interior space 718 includes deforming the edge surface 764 of the sidewall 724 of the housing 708. Figure 29B Step 8), the edge surface extends beyond the outer surface 766 of the cover 720.

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

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

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

[0178] Regarding step 10, the rotation step causes the lubricant 760 to be dispensed along the lateral portion 752 of the groove 746, which is oriented to extend in a lateral direction relative to the pivot axis 704 of the shaft 702 (see...). Figure 24D The rotation step 10 may also include dispensing lubricant 760 such that a certain amount of lubricant 760 is contained in a reservoir formed by the internal space 718.

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

Claims

1. A pre-assembled hinge module configured for coupling a first component to a second component for pivotal movement relative to one another, the pre-assembled hinge module comprising: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing having a side wall, a back wall, and a cover, the side wall and the back wall and the cover together defining an interior space within the housing, wherein the interior space is configured to receive the torque element within the housing; wherein the cover defines a first aperture and the back wall defines a second aperture, the first aperture and the second aperture being aligned with the pivot axis of the shaft, the shaft extending at least through the first aperture, the interior space of the housing, and the second aperture; wherein the shaft is separate from the first component and is configured to be mounted to the first component; wherein the housing is separate from the second component and is configured to be mounted to the second component; and wherein the back wall of the housing defines a groove, the groove defined in the back wall of the housing and the torque element together defining a receptacle configured to receive a lubricant.

2. The pre-assembled hinge module of claim 1, further comprising a detent or protrusion extending into the interior space within the housing. the detent or protrusion extending into a recess defined in a periphery of the torque element, thereby limiting movement of the torque element relative to the housing.

3. The preassembled hinge module of claim 2, wherein, the detent or protrusion extending into a recess defined in the housing.

4. The preassembled hinge module of claim 2, wherein, the interior space forms a reservoir, the reservoir containing a lubricant.

5. The preassembled hinge module of claim 1, wherein, the back wall of the housing defines a channel, the channel defined in the back wall of the housing being configured to receive a lubricant.

6. The preassembled hinge module of claim 1, wherein, the back wall of the housing further defines a groove, the groove defined in the back wall of the housing being in communication with the channel defined in the back wall of the housing to flow a lubricant into the channel and the groove.

7. The preassembled hinge module of claim 6, wherein, the lubricant comprises grease.

8. The preassembled hinge module of claim 1, wherein, the groove has a transverse portion oriented to extend in a transverse direction relative to the pivot axis of the shaft.

9. The preassembled hinge module of claim 1, wherein, the groove has a radial portion oriented to extend in a radial direction relative to the pivot axis.

10. The preassembled hinge module of claim 1, wherein, the back wall of the housing includes a universal mounting surface configured to be mounted to the second component.

11. The preassembled hinge module of claim 1, wherein, the torque element defines an aperture aligned with the pivot axis of the shaft, the shaft extending through the aperture in frictional engagement with the torque element.

12. The preassembled hinge module of claim 1, wherein, the side wall has an inner surface complementary to the detent or protrusion configured to secure the torque element within the housing and prevent rotation of the torque element relative to the housing.

13. The preassembled hinge module of claim 2, wherein, the inner surface defines one or more ridges for securing the torque element.

14. The preassembled hinge module of claim 13, wherein, the back wall extends beyond the side wall to form an extension.

15. The preassembled hinge module of claim 1, wherein, the extension of the back wall defines a third aperture for receiving a mounting fastener to mount the housing to the second component.

16. The preassembled hinge module of claim 15, wherein, the back wall and the side wall of the housing are integrally formed as a single body of unitary construction separate from the cover.

17. The preassembled hinge module of claim 1, wherein, ​ 18. The pre-assembled hinge module of claim 1, comprising a plurality of torque elements frictionally engaging the shaft.

19. The preassembled hinge module of claim 1, wherein, The interior space receives the torque element in a form-locking fit.

20. A method for assembling a hinge module, the method comprising: placing a torque element within an interior space of a housing, the housing having a rear wall and a side wall together at least partially defining the interior space; applying a lubricant to the torque element; aligning a hole defined in the rear wall of the housing with a hole defined in the torque element to form a passageway; inserting a shaft through the passageway; placing a cover adjacent the torque element such that an end portion of the shaft is exposed through a hole defined in the cover and the cover at least partially extends into the interior space of the housing; deforming the side wall of the housing to secure the cover relative to the housing; applying a lubricant to the shaft; pressing at least a portion of the cover toward the interior space; injecting lubricant into the interior space via a channel defined in the rear wall of the housing; and rotating the shaft about a pivot axis to distribute lubricant along a groove defined in the rear wall of the housing, the groove configured to direct lubricant flow from the channel defined in the rear wall of the housing.

21. The method for assembling a hinge module of claim 20, the step of aligning a hole defined in the rear wall of the housing with a hole defined in the torque element preceding the step of applying a lubricant to the torque element.

22. The method for assembling a hinge module of claim 20, further comprising coupling an end portion of the shaft to an adapter.

23. The method for assembling a hinge module according to claim 22, wherein, The step of inserting a shaft through the passageway comprises the step of coupling the end portion of the shaft to the adapter.

24. The method for assembling a hinge module of claim 20, further comprising placing the cover such that the cover extends within the interior space of the housing.

25. The method for assembling a hinge module according to claim 24, wherein, An edge surface of the side wall of the housing extends beyond an outer surface of the cover.

26. The method for assembling a hinge module according to claim 25, wherein, The step of deforming comprises deforming an edge surface of the side wall of the housing to at least partially contact an outer surface of the cover, thereby limiting movement of the cover from the interior space of the housing.

27. The method for assembling a hinge module of claim 20, wherein, The step of deforming comprises pressing at least a portion of the side wall of the housing inward toward the interior space of the housing and into contact with the cover.

28. The method for assembling a hinge module of claim 20, wherein, The step of injecting comprises injecting lubricant into a groove defined in the rear wall of the housing via a channel defined in the rear wall of the housing.

29. The method for assembling a hinge module according to claim 28, wherein, The step of rotating causes lubricant to be distributed along a transverse portion of the groove, the transverse portion oriented to extend in a transverse direction relative to the pivot axis of the shaft.

30. The method for assembling a hinge module according to claim 29, wherein, The lubricant is contained in a reservoir formed by the interior space.

31. The method for assembling a hinge module of claim 20, wherein, The steps are executed sequentially in the order recited.

32. The method for assembling a hinge module of claim 20, wherein, The steps of placing the torque element within the interior space of the housing, inserting the shaft through the passageway, placing the cover adjacent the torque element, and deforming the side wall of the housing are executed by initiating action generally along a common assembly direction.

33. The method for assembling a hinge module according to claim 32, wherein, The side wall of the housing extends upwardly from the rear wall thereof, and the following steps are performed generally along the common assembly direction in a top-to-bottom orientation: placing the torque element within the interior space of the housing, placing the cover adjacent the torque element, and deforming the side wall of the housing.

34. The method for assembling a hinge module according to claim 33, wherein, The deforming step includes deforming the side wall of the housing radially inwardly from an outer surface of the side wall to secure the cover relative to the housing.

35. The method for assembling a hinge module of claim 20, further comprising placing the cover such that the cover extends within the interior space of the housing.

36. The method for assembling a hinge module of claim 35, wherein, An edge surface of the side wall of the housing extends beyond an outer surface of the cover.

37. The method for assembling a hinge module of claim 36, wherein, The deforming step includes deforming an edge surface of the side wall of the housing to at least partially contact an outer surface of the cover, thereby limiting movement of the cover from the interior space of the housing.

38. The method for assembling a hinge module of claim 20, wherein, The deforming step includes pressing at least a portion of the side wall of the housing inwardly toward the interior space of the housing and into contact with the cover.

39. The method for assembling a hinge module of claim 20, wherein, The steps are performed sequentially in the order recited.

40. The method for assembling a hinge module of claim 20, wherein, The following steps are performed by initiating action generally along the common assembly direction: placing the torque element within the interior space of the housing, inserting the shaft through the passage, placing the cover adjacent the torque element, and deforming the side wall of the housing.

41. The method for assembling a hinge module of claim 40, wherein, The side wall of the housing extends upwardly from the rear wall thereof, and the following steps are performed generally along the common assembly direction in a top-to-bottom orientation: placing the torque element within the interior space of the housing, placing the cover adjacent the torque element, and deforming the side wall of the housing.

42. The method for assembling a hinge module of claim 40, wherein, The deforming step includes deforming the side wall of the housing radially inwardly from an outer surface of the side wall to secure the cover relative to the housing.

43. The method for assembling a hinge module of claim 40, wherein, The side wall of the housing is provided with an inner surface that corresponds in position to an outer surface of the torque element, the inner surface of the side wall of the housing including a detent or projection, the method further comprising forcing the cover against the side wall of the housing to move material of the detent or projection toward the outer surface of the torque element.

44. The method for assembling a hinge module of claim 43, wherein, And the outer surface of the torque element is a recess, the method further comprising forcing the cover against the detent or projection of the side wall of the housing to move material of the detent or projection into the recess of the torque element.

45. The method for assembling a hinge module of claim 43, further comprising forcing the cover against the detent or projection of the side wall of the housing in a direction toward the rear wall of the housing to move material of the detent or projection into the recess of the torque element in a direction inwardly relative to the side wall of the housing.

46. A set of hinge modules configured for coupling a first component to a second component for pivotal movement relative to one another, the set of hinge modules comprising: A first pre-assembled hinge module configured to control relative pivotal movement of the first and second components in a first pivotal direction; And a second pre-assembled hinge module configured to control relative pivotal movement of the first and second components in a second pivotal direction opposite the first pivotal direction, the first and second pre-assembled hinge modules each comprising: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing having a side wall and a back wall and a cover, the side wall and the back wall and the cover together defining an interior space within the housing, wherein the interior space is configured to receive the torque element within the housing; wherein the cover defines a first aperture and the back wall defines a second aperture, the first aperture and the second aperture aligned with the pivot axis of the shaft, the shaft extending at least through the first aperture, the interior space of the housing, and the second aperture; wherein the shaft is separate from the first component and is configured to be mounted to the first component; wherein the housing is separate from the second component and is configured to be mounted to the second component; and wherein the back wall of the housing defines a recess, the recess defined in the back wall of the housing and the torque element together defining a receptacle configured to receive a lubricant.

47. The set of hinge modules of claim 46, wherein, The housing of the first pre-assembled hinge module includes a first indicium corresponding to a first mounting position, the second pre-assembled hinge module includes a second indicium corresponding to a second mounting position, the second mounting position opposite the first mounting position.

48. A pre-assembled hinge module system configured for coupling a first component to a second component for pivotal movement relative to one another, the pre-assembled hinge module comprising: a shaft defining a pivot axis, the shaft separate from the first component and configured to be mounted to the first component; a torque element frictionally engaging the shaft; a housing containing the torque element, the housing having a back wall; an adapter having an end portion configured to be fixedly coupled to the shaft, and an opposite end portion configured to be releasably coupled to the first component; and wherein the back wall of the housing defines a recess, the recess defined in the back wall of the housing and the torque element together defining a receptacle configured to receive a lubricant.

49. The preassembled hinge module system of claim 48, wherein, The shaft cooperates with the adapter, the adapter defining a counterbore opening to receive a portion of an end portion of the shaft.

50. An articulating system comprising: a first component; a second component; and a hinge system comprising pre-assembled hinge modules pivotally coupling the first component to the second component to allow pivotal movement of the first component relative to the second component, each pre-assembled hinge module comprising: a shaft defining a pivot axis; a torque element frictionally engaging the shaft; and a housing defining an interior space within the housing, wherein the interior space is configured to receive the torque element, the housing having a back wall and a cover; wherein the cover defines a first aperture and the back wall defines a second aperture, the first aperture and the second aperture aligned with the pivot axis of the shaft, the shaft extending at least through the first aperture, the interior space of the housing, and the second aperture; wherein the shaft is mounted to the first component; wherein the housing is mounted to the second component; and wherein the back wall of the housing defines a recess, the recess defined in the back wall of the housing and the torque element together defining a receptacle configured to receive a lubricant. The rear wall of the housing defines a recess, the recess defined in the rear wall of the housing and the torque element together defining a receptacle configured to receive a lubricant.

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