Door alignment hinge system

Abstract

Described herein is an automotive door alignment hinge system. The system comprises a hinge with separate door half and body half segments adapted to be mounted to a vehicle door and a vehicle body respectively, a first aperture in one of the door half segment and the body half segment, and an alignment spacer plate comprising an alignment feature configured to receive a fastener therethrough. The other one of the door half segment and the body half segment comprises a corresponding alignment feature. The alignment feature and the corresponding alignment feature are sized to interface with minimal clearance to position the hinge along an optimal pivot axis. The first aperture is sized to receive the fastener therethrough with a loose-fit clearance.

Description

DOOR ALIGNMENT HINGE SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from United States Provisional Patent Application Number 63 / 595,517 filed on November 2, 2023 and United States Provisional Patent Application Number 63 / 606,281 filed on December 5, 2023, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates to door hinges for automotive vehicles, and more particularly to door hinge alignment systems.BACKGROUND

[0003] In the automotive field, from a quality and performance perspective, vehicle doors should fit well with vehicle bodies. The doors, mounted on hinges, should be able to fit into door receiving structures or profiles of the vehicle body with acceptable margins and tolerances. Of course, doors are mounted to a vehicle body on hinges. The body half and door half hinge segments should align to have proper fit, acceptable gaps between the doors and body, and flush contact between the doors and body panels, weather seals, bumpers, and associated vehicle door components.

[0004] Typically, a complete hinge comprising assembled door half and body half hinge segments and a pivot pin is connected to the door and body rather than assembling the hinge in place on an assembly line. The body with the doors is then painted, using various methods, to create a painted body shell. This ensures that the doors and body are appropriately fitted together in the correct orientation. Typically, the doors are then removed from the body, with the hinges remaining fastened either to the doors or the body, and the body and doors move separately through the assembly process until they are again reconnected when the vehicle more closely approaches its final configuration. The hinge, connected to either the door or the body, is refastened to the other of the door and the body at this stage.

[0005] This mounting, dismounting, and remounting of the doors to the body assists in achieving proper registration of the doors and body, and uniform painting, but is labor intensive. In addition, although the risk is decreased with modern robotic methods of assembly,each mounting, dismounting, and remounting of the doors to the body creates the possibility of scratching or other damage to the doors, the body, or both. It would be an advantage to simplify the manufacturing process, including painting. Painting of the doors and body separately would provide greater flexibility in the painting process, but could lead to difficulties in final registration of the doors with the body with acceptable fit, tolerances, margins, etc. Accordingly, it would be advantageous to overcome these disadvantages, and to provide an alternative process for vehicle painting and assembly.SUMMARY

[0006] According to some embodiments, there is provided an automotive door alignment hinge system comprising a hinge, a first aperture and an alignment spacer plate. The hinge comprises separate door half and body half segments adapted to be mounted to a vehicle door and a vehicle body respectively. The first aperture is in one of the door half segment and the body half segment. The alignment spacer plate comprises an alignment feature configured to receive a fastener therethrough. The other one of the door half segment and the body half segment comprises a corresponding alignment feature. The alignment feature and the corresponding alignment feature are sized to interface with minimal clearance to position the hinge along an optimal pivot axis. The first aperture is sized to receive the fastener therethrough with a loose-fit clearance.

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

[0008] According to some embodiments, the automotive door alignment hinge system further comprises a door checker. According to some embodiments, the door checker comprises a needle checker.

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

[0010] According to some embodiments, when the alignment feature comprises the at least one alignment cone, the at least one alignment cone is adapted to mate non-rotationally with a corresponding shaped opening in the door checker along the optimal pivot axis and to be fastened to the door checker with a checker fastener to securely connect the door halfsegment and the body half segment, wherein the corresponding shaped opening is the corresponding alignment feature.

[0011] According to some embodiments, the at least one alignment cone and the opening in the door checker have corresponding polygonal shapes. According to some embodiments, the at least one alignment cone comprises a base with a truncated square pyramidal shape, an upper section with a tapered square shape and a hollow core to allow passage of the checker fastener. According to some embodiments, one or more comers of the base and the upper section are beveled.

[0012] According to some embodiments, the checker fastener is a screw or a bolt. According to some embodiments, the checker fastener is a torque reaction fastener adapted to be fully clamped.

[0013] According to some embodiments, when the alignment feature comprises the alignment aperture, the fastener comprises the corresponding alignment feature.

[0014] According to some embodiments, the one of the door half segment and the body half segment further comprises a second aperture and the alignment spacer plate comprises a corresponding aperture, wherein the second aperture and the corresponding aperture are configured to receive a second fastener therethrough.

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

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

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

[0018] According to some embodiments, there is provided a method of manufacturing the automotive door alignment hinge system. The method comprises locating the alignment spacer plate on the one of the door half segment and the body half segment,wherein the optimal pivot axis is determined using a robot, and fastening the alignment spacer plate to the one of the door half segment and the body half segment.

[0019] According to some embodiments, the method further comprises measuring the dimensions of each of the vehicle door and the vehicle body profile which receives the door to assist the robot in determining the optimal pivot axis.

[0020] According to some embodiments, measuring the vehicle door dimensions and the vehicle body profile dimensions comprises laser scanning.

[0021] According to some embodiments, the method further comprises determining a registry of the vehicle door and the vehicle body using a temporary fixture.

[0022] Further aspects will be apparent from the following description and explanations.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] For a better understanding of the various embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:

[0024] FIG. 1 depicts a schematic of a vehicle body and vehicle door having upper and lower hinges, according to non- limiting embodiments;

[0025] FIG. 2A depicts a perspective view of an automotive door alignment hinge system having the alignment spacer plate fastened to the body half hinge segment, according to non- limiting embodiments;

[0026] FIG. 2B depicts an exploded view of the automotive door alignment hinge system of FIG. 2A;

[0027] FIG. 3 A depicts a perspective view of the automotive door alignment hinge system of FIG. 2A comprising a door checker, according to non-limiting embodiments;

[0028] FIG. 3B depicts an exploded view of the automotive door alignment hinge system of FIG. 3A;

[0029] FIGS. 4A and 4B, in assembled and exploded views, depict an automotive door alignment hinge system having the alignment spacer plate fastened to the door half hinge segment, according to non-limiting embodiments;

[0030] FIGS. 5A and 5B depict the automotive door alignment hinge system of FIGS. 4 A and 4B having a door checker, according to non-limiting embodiments;

[0031] FIG. 5C depicts the door checker and body half hinge segment of FIGS. 5 A and 5B;

[0032] FIG. 6A depicts an automotive door alignment hinge system in which the alignment feature comprises an alignment cone and in which the alignment spacer plate is fastened to the body half hinge segment, according to non-limiting embodiments;

[0033] FIG. 6B depicts a partially exploded view of the automotive door alignment hinge system of FIG. 6A;

[0034] FIGS. 6C and 6D depict perspective views of the alignment spacer plate and the body half hinge segment of FIGS. 6 A and 6B;

[0035] FIG. 6E depicts a rear perspective view of the door half hinge segment of FIGS. 6A and 6B having a corresponding alignment feature, according to non-limiting embodiments;

[0036] FIG. 7A depicts a perspective view of the automotive door alignment hinge system of FIGS. 6A to 6E having a door checker, according to non- limiting embodiments;

[0037] FIG. 7B depicts a partially exploded view of the automotive door alignment hinge system of FIG. 7A;

[0038] FIG. 7C depicts a rear perspective view of the door half hinge segment of FIGS. 7 A and 7B having a corresponding alignment feature, according to non-limiting embodiments;

[0039] FIG. 8A depicts an automotive door alignment hinge system having a door checker and in which the alignment spacer plate is fastened to the door half hinge segment, according to non- limiting embodiments;

[0040] FIG. 8B depicts a partially exploded view of the automotive door alignment hinge system of FIG. 8A; and

[0041] FIG. 9 depicts a flow chart of a method of manufacturing an automotive door alignment hinge system, according to non-limiting embodiments.

[0042] The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.DETAILED DESCRIPTION

[0043] We have devised a door hinge alignment system and method for assembling the hinge which typically permits proper assembly of the vehicle doors to the vehicle body only once during vehicle assembly. The described system and method also typically permit the doors and the body to be painted separately, prior to being connected via the hinge.

[0044] According to some embodiments, the described automotive door alignment hinge system comprises an alignment spacer plate interposed between the door half and body half hinge segments. These may be referred to, alternatively, simply as door half segments and body half segments. The alignment spacer plate comprises an alignment feature configured to receive a fastener therethrough to join the door half and body half segments. One of the door half and body half segments comprises a corresponding alignment feature. The other of the door half and body half segments comprises an aperture configured to receive the fastener therethrough. The alignment feature and the corresponding alignment feature are sized to interface with minimal clearance to position the hinge along an optimal pivot axis for the assembled hinge. The aperture in the door half or body half segment is sized to receive the fastener with a loose-fit clearance, which permits adjustment of the hinge segments to achieve an optimal axis around which the door will pivot on the hinge in relation to the body. This loose-fit connection also prevents damage to the paint on the door and body half hinge segments during insertion of the fastening pin through the alignment spacer plate.

[0045] According to some embodiments, the alignment feature comprises an alignment aperture. According to some embodiments, the alignment feature comprises an alignment cone that is adapted to mate with the corresponding alignment feature along the optimal pivot axis.

[0046] Using appropriate measurement and mapping of the door profile and the body structure which receives the door, an optimal pivot axis may be determined. The shapes and profiles of the vehicle door and the body structure which will receive the door may be measured using laser scanning, or other suitable measuring means. This measuring method allows custom fitting of each door to each corresponding body structure, providing precision and flexibility. Alternatively, a temporary fixture may be used to register the door to the body. With the body half hinge segment fastened to the body, a robot having the optimal pivot axis coordinates typically locates the alignment spacer plate on the body half segment. Thedifference in play between the loose-fit clearance of the aperture in the hinge segment and fastener, and the minimal clearance, close-fit, between the alignment feature of the spacer plate and the corresponding alignment feature permits fore-aft and cross car adjustment of door position in relation to the body while maintaining final minimal clearance for the fastener. Fore-aft alignment facilitates gap control while cross car alignment facilitates a flush fit of the door and body. The alignment spacer plate is then fastened, according to some embodiments, to the body half segment so that the door half segment can be assembled with the body half segment via the fastener.

[0047] It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the exemplary aspects of the present application described herein. However, it will be understood by those of ordinary skill in the art that the exemplary aspects described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the exemplary aspects described herein. Also, the description is not to be considered as limiting the scope of the exemplary aspects described herein. Any systems, method steps, method blocks, components, parts of components, and the like described herein in the singular are to be interpreted as also including a description of such systems, method steps or tasks, components, parts of components, and the like in the plural, and vice versa.

[0048] Attention is directed to FIG. 1 , which depicts a schematic of a vehicle body 1 and door 3 having upper door hinge 5 and lower door hinge 7, and FIGS. 2A and 2B, which depict automotive door alignment hinge system 100, according to non-limiting embodiments. Automotive door alignment hinge system 100 comprises a hinge having separate door half segment 102 and body half segment 104 adapted to be mounted to vehicle door 3 and vehicle body 1, respectively. One of door half segment 102 and body half segment 104, such as body half segment 104, includes first aperture 106. Aperture 106 is sized to receive a fastener, such as fastener pin 112, therethrough with a loose-fit clearance which, as noted above, permits adjustment of the hinge segments to achieve an optimal hinge axis. Although first aperture 106 is depicted in body half segment 104 in FIGS. 2A and 2B, according to some embodiments, door half segment 102 may comprise first aperture 106 (see, for example, FIGS. 4A to 5B).

[0049] As discussed above, the described automotive door alignment hinge system 100 further comprises an alignment spacer plate 108 having an alignment feature 110 configured to receive a fastener therethrough. Alignment feature 110 may take a variety of forms. According to one set of embodiments, alignment feature 110 is an alignment aperture 116. According to another set of embodiments, alignment feature 110 comprises an alignment cone, which is discussed in more detail further below.

[0050] The other one of door half segment 102 and body half segment 104 comprises a corresponding alignment feature sized to interface with the alignment feature with minimal clearance to position the hinge along an optimal pivot axis, such as hinge axis A. For example, according to some embodiments, door half segment 102 comprises, unitarily or as an assembly, a fastener, such as pin 112, or other projection having a shoulder 114 sized and shaped to fit into alignment aperture 116 with minimal clearance along the optimal pivot axis for the hinge.

[0051] During assembly, alignment spacer plate 108 is affixed to one of the door half and body half segments. For example, according to some embodiments, alignment spacer plate 108 is affixed to body half segment 104 (see FIGS. 2A to 3B). However, according to some embodiments, alignment spacer plate 108 is affixed to the door half segment 102 (see FIGS. 4A to 5B). Any suitable means for affixing alignment spacer plate 108 to one of door half segment 102 and body half segment 104 is contemplated. For example, according to some embodiments, alignment spacer plate 108 is affixed using an adhesive. The adhesive may comprise an epoxy, which may be ultraviolet (UV) light curable, depending on the material selected for the alignment spacer plate 108. According to some embodiments, alignment spacer plate 108 is affixed to one of the door half and body half segments using mechanical fasteners (see, for example, FIGS. 6A to 8B).

[0052] The alignment spacer plate 108 may be formed of any suitable material. For example, sheet metal, which is low-cost, typically works well. According to some embodiments, an alignment spacer plate 108 formed of sheet metal may be fastened to the body half segment 104 using conventional mechanical fastening means, including screws, rivets, bolts, or other means. Alignment spacer plate 108 may also be provided with an adhesive on the flat plate side facing the respective hinge segment. A regular adhesive which immediately adheres to the respective hinge segment may be employed, although this leaves little scope for shifting the alignment spacer plate 108 after it has contacted the respective hinge segment. Itis beneficial to use an adhesive which provides scope for movement of the alignment spacer plate 108 for adjustment after initial contact with the respective hinge segment. This could be a heat curable epoxy, for example, or another suitable adhesive.

[0053] Alternatively, the alignment spacer plate 108 may be formed of glass fiber or other light transmissible material. Although of higher cost than sheet metal, the glass fiber alignment spacer plate 108 is less likely to mar the surface of either the door half segment or the body half segment than a sheet metal alignment spacer plate 108. The alignment aperture 116 can also be formed with precision. In the case of a glass fiber alignment spacer plate, if improved location of the fastener into the alignment aperture 116 is desired, it is more convenient to bevel the end of the fastener rather than the alignment aperture 1 16 itself, although both options are available, as with a sheet metal alignment spacer plate 108. With glass fiber, using conventional fasteners to connect the alignment spacer plate 108 to the body half segment is possible, although less ideal than with a sheet metal plate. As noted above, an adhesive may also be used, as with a sheet metal plate. Preferably, an epoxy adhesive may be applied to the flat side of the glass fiber alignment spacer plate 108 to be fixed to the respective hinge segment. When located on the respective hinge segment to provide the optimal pivot axis, A, the alignment spacer plate 108 may be fixed to the body half segment using a suitable curing means, such as ultraviolet (UV) light. The glass fiber construction is typically transparent to UV light; other materials which permit transmission of UV light may also be used to achieve this type of epoxy curing. An UV light source may be affixed to the robot which locates the alignment spacer plate 108 on the respective hinge segment. The robot may clamp the alignment spacer plate 108 to the respective hinge segment until fixation is complete. Other means to hold the alignment spacer plate 108 in place include friction, mechanical quick release, or vacuum. Also, front and rear door alignment spacer plates may be bonded in position simultaneously or sequentially if adjacent doors or body structures are required for positioning reference. When the epoxy has cured and the alignment spacer plate 108 is fixed, the robot may be withdrawn.

[0054] The flat face of the alignment spacer plate 108 may be beveled at the alignment aperture 116 on its open side, distal from the respective hinge segment and adjacent to the other respective hinge segment when assembled, to assist the fastener to be located in and through the alignment aperture 116. Alternatively, the exposed end of the fastener may be beveled to assist in the location of the fastener in and through the alignment aperture. Forexample, according to some embodiments, shoulder 114 may be beveled to assist in locating pin 112 in and through alignment aperture 116.

[0055] Finally, with the alignment spacer plate 108 fixed to the respective hinge segment, the other respective hinge segment, with its associated fastening pin, may be mounted to the respective hinge segment, and fastened in place. Typically, a torque reaction fastener which is fully clamped may be used to complete the hinge assembly. Alternative suitable fasteners may also be employed.

[0056] According to some embodiments, automotive door alignment hinge system 100 further comprises a door checker, such as door checker 118 (see FIGS. 3A, 3B, 5A to 5C). For example, a so-called needle checker, such as that described in U.S. Patent No. 7,461,432 (the contents of which are incorporated by reference), may be used.

[0057] Particularly when automotive door alignment hinge system 100 comprises a door checker or other torque generating element, the automotive door alignment hinge system 100 may comprise a second aperture 120 in one of door half segment 102 and body half segment 104 and a corresponding aperture 122 in the alignment spacer plate 108 (see, for example, FIGS. 3B, 5B and 5C). Second aperture 120 and corresponding aperture 122 are configured to receive a second fastener therethrough, such as fastener 124, which may counteract some of the torque generated by the door checker during use of automotive door alignment hinge system 100.

[0058] Attention is directed to FIGS. 6A to 8B, which depict automotive door alignment hinge system 200, according to non-limiting embodiments, and in which like or similar elements are denoted by like or similar numbers in FIGS. 1 to 5C. For simplicity and ease of understanding, discussion of the elements and features depicted in FIGS. 6A to 8B will focus on certain similarities and differences from those depicted in FIGS. 1 to 5C.

[0059] Similarly to automotive door alignment hinge system 100, automotive door alignment hinge system 200 comprises a hinge with separate door half segment 102 and body half segment 104 adapted to be mounted to a vehicle door 3 and a vehicle body 1 respectively. One of door half segment 102 and body half segment 104 comprises a first aperture 106 (see, for example, aperture 106 in body half segment 104 shown in FIG. 6D). First aperture 106 is also sized to receive a fastener therethrough with a loose-fit clearance.

[0060] Automotive door alignment hinge system 200 further comprises alignment spacer plate 208. Similarly to alignment spacer plate 108, alignment spacer plate 208 comprisesan alignment feature 110 configured to receive a fastener therethrough (such as fastener 228); however, the alignment feature 110 comprises at least one alignment cone 216 securely fastened to alignment spacer plate 208. Any suitable means for securely fastening the alignment cone 216 to the alignment spacer plate 208 is contemplated. For example, according to some embodiments, the alignment cone 216 is rivetted onto alignment spacer plate 208. According to some embodiments, alignment cone 216 may be formed unitarily with the alignment spacer plate 208, such as by casting.

[0061] Alignment cone 216 is adapted to mate with a corresponding alignment feature of the other one of door half segment 102 and body half segment 104 along the optimal pivot axis, such as hinge axis A (for example, corresponding alignment feature 226 of door half segment 102). For example, according to some embodiments, the corresponding alignment feature 226 comprises an opening corresponding in shape and / or size to the alignment cone 216.

[0062] Similarly to automotive door alignment hinge system 100, automotive door alignment hinge system 200 may comprise a door checker, such as door checker 218. For example, a so-called needle checker, such as that described in U.S. Patent No. 7,461,432 (the contents of which are incorporated by reference), may be used.

[0063] According to some embodiments, corresponding alignment feature 226 comprises a corresponding shaped opening in the door checker 218 along the optimal pivot axis, A, and is adapted to be fastened to the door checker 218 with a checker fastener 228 to securely connect the door half segment 102 and the body half segment 104. According to some embodiments, the checker fastener 228 is a screw or a bolt. According to some embodiments, the checker fastener 228 is a torque reaction fastener adapted to be fully clamped. Any suitable fastener is contemplated.

[0064] Alignment cone 216 may take a variety of shapes. Although the term “cone” is used herein, it is understood that any suitably shaped projection is contemplated. For example, according to some embodiments, alignment cone 216 has a cubic shape or a polygonal shape. According to some embodiments, the alignment cone 216 and the corresponding alignment feature 226 have corresponding polygonal shapes. According to some embodiments, alignment cone 216 comprises a base with a truncated square pyramidal shape, an upper section with a tapered square shape and a hollow core to allow passage of the checker fastener (see, for example, alignment cone 216 shown in FIG. 7B). According to someembodiments, one or more corners of the base and upper section, such as corners 230, are beveled.

[0065] As noted above, a vehicle door 3 may be fastened to a vehicle body 1 by two or more hinges. For example, upper and lower hinges 5, 7 are illustrated in FIG. 1. With that in mind, according to some embodiments, automotive door alignment hinge systems 100 and 200 each comprise upper and lower hinges. In particular, according to some embodiments, door half segment 102 comprises an upper door half segment and a lower door half segment, body half segment 104 comprises an upper body half segment and a lower body half segment, and the alignment spacer plate 108, 208 comprises an upper alignment plate and a lower alignment spacer plate.

[0066] Attention is directed to FIG. 9, which depicts example method 300 of manufacturing any of the automotive door alignment hinge systems described herein. In order to assist in the explanation of method 300, it will be assumed that method 300 is performed using the automotive door alignment hinge systems depicted in FIGS. 2 A to 8B and the various components as described herein. However, it is understood that method 300 can be varied, and need not work exactly as discussed herein, and that such variations are within the scope of the present application. It is also emphasized, however, that method 300 need not be performed in the exact sequence as shown, unless otherwise indicated; and likewise various blocks may be performed in parallel rather than in sequence. Hence, the elements of method 300 are referred to herein as “blocks” rather than “steps”. Further, more or fewer elements than indicated herein may be performed.

[0067] At block 302, the alignment spacer plate 108, 208 is located on one of door half segment 102 and body half segment 104 (such as on body half 104 as shown in FIG. 2A). For example, according to some embodiments, after the optimal pivot axis has been determined by a robot, the alignment spacer plate 108, 208 is loosely placed on the door half segment 102 or body half segment 104, lining up the center of the alignment feature 110 with that of the first aperture 106 and the optimal pivot axis, such as hinge axis A. According to some embodiments, to assist the robot in determining the optimal pivot axis, method 300 further comprises measuring the dimensions of each of the vehicle door 3 and vehicle body 1 which receives the vehicle door 3. Such measuring may comprise laser scanning; however, any suitable means of performing this measuring is contemplated. Alternatively, a temporary fixture may be used to register the vehicle door 3 to the vehicle body 1.

[0068] At block 304, the alignment spacer plate 108, 208 is fastened to the respective one of door half segment 102 and body half segment 104. For example, as discussed above, the alignment spacer plate 108, 208 may be fastened to the respective one of door half segment 102 and body half segment 104 by an adhesive, such as an epoxy. The epoxy may be UV light curable, particularly when the alignment spacer plate 108, 208 is manufactured from a light transmissible material, such as glass fiber.

[0069] In embodiments, the various components of the automotive door alignment hinge system may be manufactured using various manufacturing methods, such as stamping, forging, and casting. In embodiments, the various components of the automotive door alignment hinge system may be fabricated from various types of materials, such as metal and plastic. In some embodiments, a lubricant or a material with impregnated lubricant may be used.

[0070] Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the above examples are only illustrations of one or more implementations. The scope, therefore, is only to be limited by the claims appended hereto.

[0071] It will also be understood that for the purposes of this application, "at least one of X, Y, and Z" or "one or more of X, Y, and Z" language can be construed as X only, Y only, Z only, or any combination of two or more items X, Y, and Z (e.g., XYZ, XYY, YZ, ZZ, XX, XY).

[0072] In the present application, components may be described as being "configured to" or "enabled to" perform one or more functions. Generally, it is understood that a component that is configured to or enabled to perform a function is configured to or enabled to perform the function, or is suitable for performing the function, or is adapted to perform the function, or is operable to perform the function, or is otherwise capable of performing the function.

[0073] Additionally, components in the present application may be described as being "operatively connected to", "operatively coupled to", and the like, to other components. It is understood that such components are connected or coupled to each other in a manner to perform a certain function. It is also understood that "connections", "coupling" and the like, as recited in the present application include direct and indirect connections between components.

[0074] References in the application to "one embodiment", "an embodiment", "an implementation", "a variant", etc., indicate that the embodiment, implementation or variant described may include a particular aspect, feature, structure, or characteristic, but not every embodiment, implementation or variant necessarily includes that aspect, feature, structure, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such module, aspect, feature, structure, or characteristic with other embodiments, whether or not explicitly described. In other words, any module, element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility, or it is specifically excluded.

[0075] It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as "solely", "only", and the like, in connection with the recitation of claim elements or use of a "negative" limitation. The terms "preferably", "preferred", "prefer", "optionally", "may", and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature.

[0076] The singular forms "a", "an", and "the" include the plural reference unless the context clearly dictates otherwise. The term "and / or" means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase "one or more" is readily understood by one of skill in the art, particularly when read in context of its usage.

[0077] The term "about" can refer to a variation of± 5%, ± 10%, + 20%, or+ 25% of the value specified. For example, "about 50" percent can in some embodiments carry a variation from 45 to 55 percent. For integer ranges, the term "about" can include one or two integers greater than and / or less than a recited integer at each end of the range. Unless indicated otherwise herein, the term "about" is intended to include values and ranges proximate to the recited range that are equivalent in terms of the functionality of the composition, or the embodiment.

[0078] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompassany and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc.

[0079] As will also be understood by one skilled in the art, all language such as "up to", "at least", "greater than", "less than", "more than", "or more", and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into subranges as discussed above. In the same manner, all ratios recited herein also include all subratios falling within the broader ratio.

Claims

CLAIMS1. An automotive door alignment hinge system comprising: a hinge with separate door half and body half segments adapted to be mounted to a vehicle door and a vehicle body respectively; a first aperture in one of the door half segment and the body half segment; and an alignment spacer plate comprising an alignment feature configured to receive a fastener therethrough; wherein the other one of the door half segment and the body half segment comprises a corresponding alignment feature; wherein the alignment feature and the corresponding alignment feature are sized to interface with minimal clearance to position the hinge along an optimal pivot axis; wherein the first aperture is sized to receive the fastener therethrough with a loose-fit clearance.

2. The automotive door alignment hinge system of claim 1 , wherein the alignment feature comprises an alignment aperture or at least one alignment cone securely fastened to the alignment spacer plate.

3. The automotive door alignment hinge system of either claim 1 or claim 2 further comprising a door checker.

4. The automotive door alignment hinge system of claim 3, wherein the door checker comprises a needle checker.

5. The automotive door alignment hinge system of any one of claims 2 to 4, wherein when the alignment feature comprises the at least one alignment cone, the at least one alignment cone is adapted to mate with the corresponding alignment feature along the optimal pivot axis.

6. The automotive door alignment hinge system of either claim 3 or claim 4, wherein when the alignment feature comprises the at least one alignment cone, the at least one alignment cone is adapted to mate non-rotationally with a corresponding shaped opening in the door checkeralong the optimal pivot axis and to be fastened to the door checker with a checker fastener to securely connect the door half segment and the body half segment, wherein the corresponding shaped opening is the corresponding alignment feature.

7. The automotive door alignment hinge system of claim 6, wherein the at least one alignment cone and the opening in the door checker have corresponding polygonal shapes.

8. The automotive door alignment hinge system of either claim 6 or claim 7, wherein the at least one alignment cone comprises a base with a truncated square pyramidal shape, an upper section with a tapered square shape and a hollow core to allow passage of the checker fastener.

9. The automotive door alignment hinge system of claim 8, wherein one or more comers of the base and the upper section are beveled.

10. The automotive door alignment hinge system of any one of claims 6 to 9, wherein the checker fastener is a screw or a bolt.

11. The automotive door alignment hinge system of claim 10, wherein the checker fastener is a torque reaction fastener adapted to be fully clamped.

12. The automotive door alignment hinge system of either claim 1 or claim 2, wherein when the alignment feature comprises the alignment aperture, the fastener comprises the corresponding alignment feature.

13. The automotive door alignment hinge system of any one of claims 1 to 12, wherein the one of the door half segment and the body half segment further comprises a second aperture and the alignment spacer plate comprises a corresponding aperture, the second aperture and the corresponding aperture are configured to receive a second fastener therethrough.

14. The automotive door alignment hinge system of any one of claims 1 to 13, wherein the alignment spacer plate is formed from glass fiber.

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

16. The automotive door alignment hinge system of claim 15, wherein the adhesive is an epoxy.

17. The automotive door alignment hinge system of claim 16, wherein the epoxy is curable using ultraviolet (UV) light and the alignment spacer plate is formed of a light transmissible material.

18. The automotive door alignment hinge system of any one of claims 1 to 17, wherein: the door half segment comprises an upper door half segment and a lower door half segment; the body half segment comprises an upper body half segment and a lower body half segment; and the alignment spacer plate comprises an upper alignment spacer plate and a lower alignment spacer plate.

19. A method of manufacturing the automotive door alignment hinge system of any one of claims 1 to 18, comprising: locating the alignment spacer plate on the one of the door half segment and the body half segment, wherein the optimal pivot axis is determined using a robot; and fastening the alignment spacer plate to the one of the door half segment and the body half segment.

20. The method of manufacturing the automotive door alignment hinge system of claim 19 further comprising measuring the dimensions of each of the vehicle door and a vehicle body profile which receives the door to assist the robot to determine the optimal pivot axis.

21. The method of manufacturing the automotive door alignment hinge system of claim 20, wherein measuring the vehicle door dimensions and the vehicle body profile dimensions comprises laser scanning.

22. The method of manufacturing the automotive door alignment hinge system of claim 19 further comprising determining a registry of the vehicle door and the vehicle body using a temporary fixture.

Images