hinge

Abstract

A hinge for coupling components for pivotal movement relative to one another includes a housing. A torque engine is positionable within the housing. The torque engine provides frictional resistance to pivotal movement of the components, and includes a shaft and a torque element frictionally engaging the shaft. A clip defines a recess to provide a partial or full seal against ingress of material at the at least one torque element radially inwardly relative to the pivot axis defined by the shaft. The clip provides a partial or full seal against egress of lubricant at the least one torque element radially outwardly relative to the pivot axis. The at least two end caps defines an aperture aligned with the pivot axis and has a leg portion extending radially outwardly relative to the pivot axis and received in the recess defined by the clip. Plural bushings are configured to reduce backlash.

Description

[0001] HINGE

[0002] This application is related to and claims the benefit of priority of U.S. Provisional Application No. 63 / 568,252, entitled HINGE, filed on March 21, 2024, the contents of which are incorporated herein by reference in their entirety for all purposes.

[0003] FIELD OF THE INVENTION

[0004] The present invention relates generally to hinges that can be used to pivotally connect components in a system.

[0005] BACKGROUND OF THE INVENTION

[0006] Various types of mechanical hinges are available to connect components in a pivoting relationship. A friction hinge, also referred to as a "constant torque hinge" or "position hinge," is one type of hinge used on apparatuses that feature a pivoting door, panel, lid or other part that opens and closes about a pivot axis. In a typical friction hinge, a pivot shaft has an outer surface that bears against the inner surface of another part, creating mechanical interference in the hinge. This mechanical interference holds components in a stable position after they are pivoted and released, which is desirable for holding components in any position. The mechanical interference also adds a tactile "quality feel" to the movement of components, providing substantially constant resistance to rotation to improve the user experience during the closing and opening efforts.

[0007] It is desirable to prevent or limit escape of lubricant (e.g. grease) from an interior space of the hinge during a conventional overmolding process for manufacturing friction hinges.

[0008] SUMMARY OF THE INVENTION

[0009] The drawbacks of conventional friction hinges are addressed in many respects by hinges, assemblies, methods, and systems in accordance with the invention.

[0010] In a first aspect of the invention, a hinge is provided. The hinge is configured for coupling components for pivotal movement relative to one another. The hinge includes a housing and a torque engine. The torque engine is positioned within the housing and configured to provide frictional resistance to pivotal movement of the components. The torque engine includes a shaft, at least one torque element, a clip, and at least two end caps. The shaft defines a pivot axis and extends between a proximal end and a distal end opposite the proximal end. The at least one torque element frictionally engages the shaft and has a leg portion extending radially outwardly relative to the pivot axis defined by the shaft. The clip defines a recess configured to receive at least the leg portion of the at least one torque element. The clip is configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft. The clip is also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft. The at least two end caps are positionable adjacent the at least one torque element. The at least one pair of end caps defines an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip. The at least two end caps configured to provide a partial or full seal against ingress of material and egress of lubricant.

[0011] In another aspect of the invention, a torque engine configured to provide frictional resistance to pivotal movement of components is provided. The torque engine includes a shaft, at least one torque element, a clip, and at least two end caps. The shaft defines a pivot axis and extends between a proximal end and a distal end opposite the proximal end. The at least one torque element frictionally engages the shaft and has a leg portion extending radially outwardly relative to the pivot axis defined by the shaft. The clip defines a recess configured to receive at least the leg portion of the at least one torque element. The clip is configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft. The clip is also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft. The at least two end caps are positionable adjacent the at least one torque element. The at least two end caps defines an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip.

[0012] In yet another aspect of the invention, a hinge for coupling components for pivotal movement relative to one another is provided. The hinge includes a housing, a shaft, a clip, at least two end caps, and plural bushings. The shaft defines a pivot axis and extends between a proximal end and a distal end opposite the proximal end. The clip defines a recess configured to receive at least the leg portion of the at least two end caps. The clip is configured to provide a partial or full seal against ingress of material at the leg portion of the at least two end caps radially inwardly relative to the pivot axis defined by the shaft. The clip is also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least two end caps radially outwardly relative to the pivot axis defined by the shaft. The at least two end caps defines an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip.

[0013] In still another aspect of the invention, a hinged system is provided. The hinged system includes a first component and a second component. The hinged system also includes a hinge coupling the first component to the second component in a pivot connection so as to allow pivotal movement of the first component relative to the second component. The hinge includes a housing and a torque engine. The torque engine is positioned within the housing and configured to provide frictional resistance to pivotal movement of the components. The torque engine includes a shaft, at least one torque element, a clip, and at least one end cap. The shaft defines a pivot axis and extends between a proximal end and a distal end opposite the proximal end. The at least one torque element frictionally engages the shaft and has a leg portion extending radially outwardly relative to the pivot axis defined by the shaft. The clip defines a recess configured to receive at least the leg portion of the at least one torque element. The clip is configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft. The clip is also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft. The at least two end caps are positionable adjacent the at least one torque element. The at least two end caps defines an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip. The at least two end caps are configured to provide a partial or full seal against ingress of material and egress of lubricant.

[0014] In another aspect of the invention, a hinge subassembly is provided. The hinge subassembly is configured for use with components having pivotal movement relative to one another. The hinge subassembly includes a torque engine configured to provide frictional resistance to pivotal movement of the components. The torque engine includes a shaft, at least one torque element, a clip, and at least two end caps. The shaft defines a pivot axis and extends between a proximal end and a distal end opposite the proximal end. The at least one torque element frictionally engages the shaft and has a leg portion extending radially outwardly relative to the pivot axis defined by the shaft. The clip defines a recess configured to receive at least the leg portion of the at least one torque element. The clip is configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft. The clip is also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft. The at least two end caps are positionable adjacent the at least one torque element. The at least two end caps defines an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip. The at least two end caps configured to a partial or full seal against ingress of material and egress of lubricant.

[0015] In yet another aspect of the invention, a method for manufacturing a hinge having a torque engine is provided. The method includes assembling at least one torque element, a shaft, and at least two end caps to form the torque engine. When assembled, a channel is formed by the at least one torque element, the shaft, and the at least two end caps. The method also includes providing a clip to secure at least a leg portion of the at least one torque element and provide a partial or full seal against ingress of material into the channel and egress of lubricant from the channel. The at least two end caps are also configured to provide a partial or full seal against ingress of material into the channel and egress of lubricant from the channel. Further, the method includes molding a molding material about the torque engine.

[0016] In still another aspect of the invention, hinge for coupling components for pivotal movement relative to one another is provided. The hinge includes a torque engine positioned within the housing and configured to provide frictional resistance to pivotal movement of the components. The torque engine includes a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end. The torque engine also includes bushings mounted to the shaft. The bushings include a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft, with each of the bushings having an outer surface including rounded convex peaks and a rounded concave valley interposed between each adjacent pair of the rounded convex peaks. A polymeric housing is molded over the torque engine for engagement with the bushings of the torque engine. The engagement between the polymeric housing and the bushings of the torque engine includes engagement between the outer surface of the bushings and an inner surface of the molded polymeric housing.

[0017] In another aspect of the invention, a torque engine is provided. The torque engine is configured to be positioned within a housing of a hinge for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components. The torque engine has a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end. The torque engine also includes bushings mounted to the shaft. The bushings include a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft, with each of the bushings having an outer surface including rounded convex peaks and a rounded concave valley interposed between each adjacent pair of the rounded convex peaks. A polymeric housing is molded over the torque engine for engagement with the bushings of the torque engine. The engagement between the polymeric housing and the bushings of the torque engine includes engagement between the outer surface of the bushings and an inner surface of the molded polymeric housing.

[0018] In another aspect of the invention, a bushing system is disclosed. The bushing system is configured to be mounted to a shaft of a torque engine to be positioned within a housing of a hinge for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components. The bushing has an outer surface including at least three rounded convex peaks and a rounded concave valley having an arcuate contour interposed between each adjacent pair of the at least three rounded convex peaks.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The foregoing summary and the following description will be better appreciated and understood in conjunction with the non-limiting examples illustrated in the attached drawing figures, of which:

[0021] FIGS. 1A-1F depict views of a hinge in accordance with an exemplary embodiment of the invention;

[0022] FIG. 1G depicts a cross-section view of the hinge of FIG. IF, taken along line 1G-1G;

[0023] FIG. 1H depicts a cross-section view of the hinge of FIG. IF, taken along line 1H-1H;

[0024] FIG. II depicts a bottom view of the hinge of FIG. 1A;

[0025] FIG. 1J depicts a cross-section view of the hinge of FIG. II, taken along line IJ- IJ;

[0026] FIGS. 2A-2D depict views a torque engine in accordance with an exemplary embodiment of the invention;

[0027] FIG. 2E depicts an exploded view of the torque engine of FIGS. 2A-2D;

[0028] FIG. 3A depicts an exploded view of the torque engine of FIGS. 2A-2D, without the clip in accordance with an exemplary embodiment of the invention; FIGS. 3B-3D depict views of the torque engine of FIG. 3A;

[0029] FIGS. 4A-4D depict views of a clip in accordance with an exemplary embodiment of the invention;

[0030] FIGS. 5A-5C depict views of a bushing in accordance with an exemplary embodiment of the invention;

[0031] FIG. 5D depicts a cross-section view of the bushing of FIG. 5C, taken along line 5D-5D;

[0032] FIGS. 6A-6C depict views of a bushing in accordance with another exemplary embodiment of the invention;

[0033] FIG. 6D depicts a cross-section view of the bushing of FIG. 6C, taken along line 6D-6D;

[0034] FIGS. 7A-7C depict views of an end cap in accordance with an exemplary embodiment of the invention;

[0035] FIG. 8 depicts a method of manufacturing the hinge in accordance with an exemplary embodiment of the invention; and

[0036] FIG. 9 depicts a hinged system in accordance with an exemplary embodiment of the invention.

[0037] DETAILED DESCRIPTION

[0038] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.

[0039] Additionally, various forms and embodiments of the invention are illustrated in the figures. It will be appreciated that the combination and arrangement of some or all features of any of the embodiments with other embodiments is specifically contemplated herein. Accordingly, this detailed disclosure expressly includes the specific embodiments illustrated herein, combinations and sub-combinations of features of the illustrated embodiments, and variations of the illustrated embodiments.

[0040] Referring generally to the figures, the hinge utilizes a torque-generation part (e.g., a torque engine), which generates a customizable torque output. As will be discussed further below, the hinge may be incorporated in a system, for facilitating pivotal movement between two components.

[0041] Referring to FIGS. 1A-1J, and according to one aspect of the invention, a hinge 100 for coupling components for pivotal movement relative to one another is disclosed. In a non-limiting example, the coupling components comprise a movable first component (e.g. a lid of a box or housing or enclosure) and a second component (e.g. a frame or a sidewall of the box or housing or enclosure). A hinge assembly may comprise two hinges 100.

[0042] As best shown in FIGS. 1H and 2E, the hinge 100 comprises a housing 102 configured to enclose or house one or more components of the hinge 100. Non-limiting examples of the housing 102 material includes metal (e.g. stainless steel, etc.), polymeric or plastic components, and combinations thereof. In an exemplary embodiment, housing 102 comprises nylon. As best illustrated in FIGS. 1A-1J, the housing 102 has a hollow portion 104 and a mounting portion 106. The hollow portion 104 is depicted in the figures as being generally cylindrical, but the geometry of the hollow portion 104 may be selected based on the characteristics of one or more components of the hinge 100. In a non-limiting example, the geometry of the hollow portion 104 may be based on the size and shape of one or more components of the hinge 100 configured to be contained therein (discussed further below). The mounting portion 106 includes a mounting surface configured for fixed coupling with one of the coupling components. As such, the mounting surface of the mounting portion 106 may have a size, shape, or structure depending on a feature (e.g. exterior surface, etc.) of one of the coupling components. In an exemplary embodiment, the mounting portion 106 includes a plurality of holes configured to receive a fastener or other known attachment mechanisms for coupling the housing 102 to one of the coupling components.

[0043] Positioned within the housing is a torque generation part, such as a torque engine 110. As illustrated in FIGS. 2A-2E and 3A-3D, the torque engine 110 is configured to provide frictional resistance to pivotal movement of the components. In an exemplary embodiment, the torque engine 110 includes a shaft 112 defining a pivot axis 114 and extending between a proximal end 112a and a distal end 112b opposite the proximal end 112a. Proximal end 112a and distal end 112b defines a coupling surface such as a spline or knurled surface, which can cooperate with respective plural bushings 140 (discussed below).

[0044] The torque engine 110 further includes at least one torque element 116 frictionally engaging the shaft 112. In an exemplary embodiment, the torque element 116 comprises plural torque elements 116. Additionally or optionally, as best shown in FIGS. 2E and 3A, the torque elements have a leg portion 118 extending radially outward relative to the pivot axis 114. The amount of frictional resistance provided by torque element 116 depends in part on the amount of surface area of the torque element 116 that contacts shaft 112. Accordingly, the thickness of a single torque element 116 can be varied to change the frictional resistance. Also, the respective dimensions (e.g. outer dimension of the shaft 112 and inner dimension of the torque element 116) can be modified to increase or decrease the frictional resistance. For example, the amount of frictional resistance provided by hinge 100 can be increased by placing plural or additional torque elements 116 within housing 102 to increase the total thickness of torque elements 116, and / or by replacing torque element 116 with a thicker torque element having a greater surface area in contact with shaft 112. One skilled in the art would understand from the description herein that the number of torque elements 116 is not limited to that illustrated in FIGS. 2A-2E and 3A-3D, for example.

[0045] FIGS. 2E and 3A, for example, illustrates the plural torque elements 116 as being arranged in a first orientation. However, one skilled in the art would understand that the plural torque elements 116 may be arranged in a second orientation that is different from the first orientation. It should also be understood that the plural torque elements 116 may be arranged in any combination of the first and second orientations. The orientation of the plural torque elements 116 can be used to provide symmetrical torque (same frictional resistance in both directions of rotation) or asymmetrical torque (different frictional resistances in opposite directions of rotation). For example, if all torque elements 116 are positioned or oriented in the same direction, then the torque elements 116 will typically provide asymmetrical torque. Alternatively, if equal numbers of torque elements 116 are positioned or oriented in the opposite direction, then the torque elements 116 will typically provide symmetrical torque. Further, it should be understood that the more torque elements 116 are included, the greater the torque provided.

[0046] In an exemplary embodiment, the torque engine 110 includes a clip 160. The clip 160 is formed from metal material, such as aluminum. Referring to FIGS. 4A-4D, the clip 160 defines a recess 162 configured to receive at least the leg portion 118 of the at least one torque element 116. The clip 160 is configured to provide a partial or full seal against ingress of material at the leg portion 118 of the at least one torque element 116 radially inwardly relative to the pivot axis 114 defined by the shaft 112. Additionally or optionally, the clip 160 is configured to provide a partial or full seal against egress of lubricant (e.g. grease) at the leg portion 118 of the at least one torque element 116 radially outwardly relative to the pivot axis 114 defined by the shaft 112. In an exemplary embodiment, the recess 162 is sized and shaped to accommodate or secure at least the leg portion 118 of the at least one torque element 116. In this way, the clip 160 is configured to reduce or prevent backlash, which may be quantified as an angular displacement between the first or second component at a first position (e.g. horizontal or vertical position) to the first or second component at a second position when subjected to a specific load to meet the resistance of the torque engine 110. By reducing backlash, the hinge 100 can have reduced spring back when the actuating torque is removed. Accordingly, the amount of motion (specified in degrees) that results when the hinge 100 moves back after a force that is moving the hinge 100 is removed, can be reduced.

[0047] While other embodiments are contemplated, a mounting surface 146 of bushings 140 of the torque engine 110 can include alternating hex peaks 172 and hex flats or valleys 174. The hex flats or valleys 174 can include a concave surface. The mounting surface 146 can also define one or more recesses 176. The hinge 100 can have a maximum degree of backlash of 2°, more preferably of 1°, and more preferably of 0.5°. Such maximum degree of backlash can be maintained after 20,000 cycles of operation of the hinge 100.

[0048] Still further, as shown in FIGS. 2A-2E and 3A-3D, the torque engine 110 includes at least two end caps 150. In an exemplary embodiment, the at least two end caps 150 are each positionable adjacent the at least one torque element 116. Additionally or optionally, the at least two end caps each comprises a polymeric material (e.g. nylon). The at least two end caps 150 and a molding material are configured to partially melt or join together during an injection molding process to form housing 102, for example. As illustrated in FIGS. 7A-7C, the at least two end caps 150 each defines an aperture 152 aligned with the pivot axis 114 of the shaft 112. Additionally or optionally, the at least two end caps 150 each has a leg portion 154 extending radially outwardly relative to the pivot axis 114 defined by the shaft 118. In a non-limiting example, the recess 162 of the clip 160 is sized and shaped to accommodate or secure at least the leg portion 118 of the at least one torque element 116 and the at least two end caps 150. Additionally or optionally, the shaft 112, the at least one torque element 116, and the at least two end caps 150 together defined a channel 170 (FIG. 3D). The channel 170 is configured to receive lubricant, such as grease. In this configuration, the clip 160 and / or the at least two end caps 150 is configured to prevent ingress of material (e.g. polymer) into the channel 170, such as during an injection molding process to form housing 102. Additionally or optionally, the clip 160 and / or the at least two end caps 150 is configured to prevent egress of lubricant from the channel 170.

[0049] In an exemplary embodiment, the torque engine 110 includes plural bushings 140. As shown for example, in FIGS. 2A-2E and 3A-3D, the plural bushings 140 comprises a proximal bushing 140a connected to the proximal end 112a of the shaft 112 and a distal bushing 140b connected to the distal end 112b of the shaft 112. As best shown in FIGS. 5A-5D and 6A-6D, the plural bushings 140 includes a respective head 142 and opening 144 configured to receive the proximal end 112a of the shaft 112 or the distal end 112b of the shaft 112.

[0050] In an exemplary embodiment, the head 142 of the proximal bushing 140a (FIGS. 5A-5D) and the head 142 of the distal bushing 140b (FIGS. 6A-6D) each comprise a respective mounting surface 146 configured to secure the torque engine 110 in the housing 102. The shape and size of the mounting surface 146 or of the bushing 140 generally was selected to reduce or prevent backlash.

[0051] One skilled in the art would understand from the description herein that backlash may be quantified as an angular displacement between the first or second component at a first position (e.g. horizontal or vertical position) to the first or second component at a second position when subjected to a specific load to meet the resistance of the torque engine 110. Backlash can be measured using a fixture. A force (e.g. 4.5-5 N force) can be applied at an edge of the fixture to record backlash angle. A digital protractor can be mounted to the backlash fixture plate that is oriented as close to 0 degrees as possible and the protractor can be zeroed out. After applying the force (e.g., 4.5-5 N load) to the edge of the plate, angular displacement can be recorded. In such a test, backlash measured can be considered the angular displacement between the panel at rest as compared to the panel subjected to a specific load to meet the resistance of the torque engine.

[0052] In an exemplary embodiment, the hinge 100 comprising bushings 140 provides the hinge 100 with a maximum degree of backlash in a range between 0.5° and 2° of angular displacement. In a non-limiting example, the bushing 140 comprise metal (e.g. aluminum) and a maximum degree of backlash is in a range between 0.5° and 1°. In another non-limiting example, the bushing 140 comprise metal (e.g. zinc die cast) and a maximum degree of backlash is in a range between 0.5° and 2°. To achieve this reduction in backlash to become 2° or less, or 1° or less, or 0.5° or less, the mounting surface 146 comprise alternating hex peaks 172 and hex flats or valleys 174 to create a generally star-shaped geometry, as illustrated for example, by FIGS. 1J, 5A, and 6A. The hex flats 174 comprise a concave surface and one or more recesses 176 (FIGS. 5C and 6C). This design was discovered to increase the surface area of the bushing provided areas for material (e.g. polymer, resin, etc.) to flow into during an overmolding process, for example. The geometry of reducing the sharp edges of the head 142 was discovered to lead to reduced stress concentrations and more effective stress distribution.

[0053] Additionally or optionally, the hinge 100 includes a spacer 180 positioned between the at least two end caps 150 and the at least one torque element 116. It should be noted that the exploded views illustrated in FIGS. 2E and 3A do not reflect the intended relative placement of one or more components of the hinge, including spacers 180 which are intended to be positionable between the respective one of the at least two end caps and the at least torque element 116 as explained above. The spacers 180 are utilized as placeholders within the clip 160 when a predetermined number of the at least one torque element 116 are used. In an exemplary embodiment, the predetermined number is 11 or less torque elements 116. In this configuration, the spacers 180 are provided for radial support of one or more components of the hinge 100 to ensure a flow characteristic (e.g. flow rate, etc.) of molding material during an injection molding process, for example, is not required to vary based on the number of torque elements 116 is used.

[0054] In operation, the components, such as the first component and the second component, are configured for pivotal movement relative to one another along a first rotational direction (e.g. clockwise). Additionally or optionally, the components are configured for pivotal movement relative to one another along the first rotational direction and a second rotational direction (e.g. counterclockwise), and the second rotational direction is different from the first rotational direction. In an exemplary embodiment, the first rotational direction corresponds to a torque direction of reverse torque 190 (FIG. 1H) and the second rotational direction corresponds to a torque direction of forward torque 192 (FIG. 1H). Additionally or optionally, the components are configured for pivotal movement relative to one another between a fully closed position and a fully open position.

[0055] Still further, the first component 2100 and second component 2200 of a hinged system 2000 (FIG. 9) are generally configured for pivotal movement relative to one another along a first rotational direction (e.g. clockwise) or a second rotational direction (e.g. counterclockwise). Still further, the first and second components 2100, 2200 are generally configured for pivotal movement relative to one another between a first position (e.g. fully closed position) and a second position (e.g. a fully open position). In an exemplary embodiment, lubricant (e.g. grease) is applied to the at least the leg portions 118 of the at least one torque element 116 in order to facilitate effective pivotal movement of the first and second components 2100, 2200. One would understand from the description herein that the exemplary system 2000 for coupling components 2100, 2200 for pivotal movement relative to one another is not limited to the illustrated examples. Thus, hinge system 1000 can be utilized in a variety of applications that incorporate one or more friction hinges 100 for controlling relative pivot motion of components (e.g. components 2100, 2200). For example, hinge system 2000 can be incorporated into various types of closure systems used on motor vehicles, watercraft and / or aircraft, including but not limited to various types of compartments, cabinets, hatches, receptacles, overhead bins, and storage units.

[0056] One would understand from the description herein that the exemplary hinge for coupling components for pivotal movement relative to one another is not limited to the illustrated examples. Multiple types of hinges (e.g. a free-swinging hinge, a torque or friction hinge, a detent hinge, a removeable hinge, a concealed hinge, a barrel down hinge, and 180-degree fold flat hinge, etc.) having a housing and an exemplary torque engine positioned within the housing, as discussed above, would be within the spirit and scope of the invention. In addition, the hinged system 2000 includes at least one hinge 100 and another type of hinge that is different from hinge 100.

[0057] Turning now to FIG. 8, a method for manufacturing a hinge having a torque engine id disclosed. The method 1000 includes one or more steps including assembling at least one torque element, a shaft, and at least two end caps to form the torque engine, wherein when assembled, a channel is formed; providing a clip to secure at least a leg portion of the at least one torque element and provide a partial or full seal against ingress of material into the channel and egress of lubricant from the channel; and molding a molding material about the torque engine. Additionally or optionally, method 1000 includes connecting a proximal bushing to a proximal end of the shaft and a distal bushing connected to a distal end of the shaft. Additional details of method 1000 are set forth below with respect to the elements of hinge 100.

[0058] In step 1100, a torque engine is formed. In an exemplary embodiment, at least one torque element 116, a shaft 112, and at least two end caps 150 are assembled to form the torque engine 110. The at least one torque element includes an opening and the at least two end caps 150 each includes an aperture 152, and both the opening and the aperture 152 are aligned with the pivot axis 114 of the shaft 112, such that when assembled, the shaft 112 extends through the opening and aperture 152. In general, the shaft 112 is in partial or full contact with one or more components of hinge 100, including the at least one torque element 116 and the at least two end caps 150. Still further, in an assembled configuration, a channel 170 (FIG. 3D) is formed by the at least one torque element 116, the shaft 112, and the at least two end caps 150.

[0059] In step 1200, a clip is provided. In an exemplary embodiment, the clip 160 is provided to receive or secure at least a leg portion 118 of the at least one torque element 116. Prior to providing the clip 160, lubricant (e.g. grease) may be applied to the shaft 112, at least the leg portion 118 of the at least one torque element 116, or at least the leg portion 154 of the at least two end caps 150, or a combination thereof. Additionally or optionally, the clip 160 and / or the at least two end caps 150 is configured to provide a partial or full seal against ingress of material (e.g. polymer, molding material, etc.) into the channel 170 and egress of lubricant (e.g. grease) from the channel 170.

[0060] In step 1300, molding material is molded about the torque engine. In an exemplary embodiment, the molding material is molded about the torque engine 110, thereby forming housing 102. In one non-limiting example, the torque engine 110 is placed into a mold and the molding material is injected into the mold.

[0061] According to additional aspects of the invention, a hinge 100 is provided for coupling components for pivotal movement relative to one another, the hinge 100 including: a torque engine 110 positioned within the housing 102 and configured to provide frictional resistance to pivotal movement of the components, the torque engine 110 having a shaft 112 defining a pivot axis 114 and extending between a proximal end 112a and a distal end 112b opposite the proximal end 112a, and bushings 140 mounted to the shaft 112, the bushings 140 including a proximal bushing 140a connected to the proximal end 112a of the shaft 112 and a distal bushing 140b connected to the distal end 112b of the shaft 112b, each of the bushings 140 having an outer surface 146 including rounded convex peaks and a rounded concave valley interposed between each adjacent pair of the rounded convex peaks. The hinge 100 also includes a polymeric housing 102 molded over the torque engine 110 for engagement with the bushings 140 of the torque engine 110. The engagement between the polymeric housing 102 and the bushings 140 of the torque engine 110 includes engagement between the outer surface 146 of the bushings and an inner surface of the molded polymeric housing 102. The hinge 100 has a maximum degree of backlash of 2° after 20,000 cycles of operation of the hinge 100.

[0062] The hinge 100 can have a maximum degree of backlash of 1° after 20,000 cycles of operation of the hinge 100, or a maximum degree of backlash of 0.5° after 20,000 cycles of operation of the hinge. At least one of the bushings 140 can have an outer surface including at least three of the rounded convex peaks 172. At least one of the bushings 140 can have an outer surface including at least six of the rounded convex peaks 172. At least one of the bushings 140 can have an outer surface including at least three of the rounded convex peaks 172. The rounded concave valley 174 interposed between each adjacent pair of the rounded convex peaks 172 of the outer surface of at least one of the bushings 140 can include an arcuate contour.

[0063] According to another aspect, a torque engine 110 can be configured to be positioned within a housing 1020of a hinge 100 for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components, the torque engine 110 including a shaft 112 defining a pivot axis 114 and extending between a proximal end 112a and a distal end 112b opposite the proximal end 112a, and bushings 140 mounted to the shaft 112, the bushings 140 including a proximal bushing 140a connected to the proximal end 112a of the shaft 112 and a distal bushing 140b connected to the distal end 112b of the shaft 112, each of the bushings 140 having an outer surface including rounded convex peaks 172 and a rounded concave valley 174 interposed between each adjacent pair of the rounded convex peaks 172. A polymeric housing 102 can thereafter be molded over the torque engine 110 for engagement with the bushings 140 of the torque engine 110, wherein the engagement between the polymeric housing 102 and the bushings 140 of the torque engine 110 includes engagement between the outer surface of the bushings 140 and an inner surface of the molded polymeric housing 102 and the hinge 100 has a maximum degree of backlash of 2° after 20,000 cycles of operation of the hinge 100.

[0064] According to another aspect, a bushing system is configured to be mounted to a shaft of a torque engine to be positioned within a housing of a hinge for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components, the bushing including an outer surface including at least three rounded convex peaks and a rounded concave valley having an arcuate contour interposed between each adjacent pair of the at least three rounded convex peaks.

[0065] While 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. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.

Claims

What is Claimed:

1. A hinge for coupling components for pivotal movement relative to one another, the hinge comprising: a housing; a torque engine positioned within the housing and configured to provide frictional resistance to pivotal movement of the components, the torque engine including: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end, at least one torque element frictionally engaging the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft, a clip defining a recess configured to receive at least the leg portion of the at least one torque element, the clip configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft, the clip also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft, and at least two end caps positionable adjacent the at least one torque element, the at least two end caps defining an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip, the at least two end caps configured to provide a partial or full seal against ingress of material and egress of lubricant.

2. The hinge of claim 1, wherein the at least one torque element comprises plural torque elements frictionally engaging the shaft.

3. The hinge of claim 1, wherein the shaft, the at least one torque element, and the at least two end caps together define a channel.

4. The hinge of claim 1, wherein the lubricant includes grease.

5. The hinge of claim 1, further comprising plural bushings, the plural bushings comprising a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft.

6. The hinge of claim 5, wherein the proximal end and the distal end of the shaft define a coupling surface comprising a spline or knurled surface configured to cooperate with the respective plural bushings.

7. The hinge of claim 5, wherein the proximal bushing and the distal bushing each includes a head and an opening configured to receive the proximal end or distal end of the shaft.

8. The hinge of claim 7, wherein the head of the proximal bushing and the distal bushing comprises a mounting surface configured to secure the torque engine in the housing.

9. The hinge of claim 1, wherein the housing includes a mounting portion configured to be connected to one of the components.

10. The hinge of claim 1, wherein the components are configured for pivotal movement relative to one another along a first rotational direction.

11. The hinge of claim 10, wherein the components are configured for pivotal movement relative to one another along a first rotational direction and a second rotational direction, and the second rotational direction is different from the first rotational direction.

12. The hinge of claim 10, wherein the components are configured for pivotal movement relative to one another between a fully closed position and a fully open position.

13. The hinge of claim 1, wherein the clip is formed from aluminum.

14. The hinge of claim 1, wherein the clip is configured to reduce backlash.

15. The hinge of claim 3, wherein the clip, the at least two end caps, or a combination thereof is configured to prevent ingress of polymer into the channel during an injection molding process.

16. The hinge of claim 3, wherein the clip, the at least two end caps, or a combination thereof is configured to prevent egress of lubricant from the channel.

17. The hinge of claim 1, wherein the at least two end caps each comprises nylon.

18. The hinge of claim 1, wherein the at least two end caps and a molding material are configured to partially melt or join together during an injection molding process.

19. A torque engine configured to provide frictional resistance to pivotal movement of components, the torque engine comprising: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end; at least one torque element frictionally engaging the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft; a clip defining a recess configured to receive at least the leg portion of the at least one torque element, the clip configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft, the clip also configured toprovide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft; and at least two end caps positionable adjacent the at least one torque element, the at least two end caps each defining an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip.

20. The torque engine of claim 19, wherein the at least one torque element comprises plural torque elements frictionally engaging the shaft.

21. The torque engine of claim 19, wherein the shaft, the at least one torque element, and the at least two end caps together define a channel configured to contain the lubricant.

22. The torque engine of claim 21, wherein the lubricant includes grease.

23. The torque engine of claim 19, further comprising plural bushings, the plural bushings comprising a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft.

24. The torque engine of claim 23, wherein the proximal end and the distal end of the shaft define a coupling surface comprising a spline or knurled surface configured to cooperate with the respective plural bushings.

25. The torque engine of claim 23, wherein the proximal bushing and the distal bushing each includes a head and an opening configured to receive the proximal end or distal end of the shaft.

26. The torque engine of claim 19, wherein the clip is formed from aluminum.

27. The torque engine of claim 19, wherein the clip is configured to reduce backlash.

28. The torque engine of claim 21, wherein the clip is configured to prevent ingress of polymer into the channel during an injection molding process.

29. The torque engine of claim 21, wherein the clip is configured to prevent egress of lubricant from the channel.

30. The torque engine of claim 19, wherein the at least two end caps each comprises nylon.

31. A hinge for coupling components for pivotal movement relative to one another, the hinge comprising: a housing; a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end;at least two end caps each defining an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft; a clip defining a recess configured to receive at least the leg portion of the at least two end caps, the clip configured to provide a partial or full seal against ingress of material at the leg portion of the at least two end caps radially inwardly relative to the pivot axis defined by the shaft, the clip also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least two end caps radially outwardly relative to the pivot axis defined by the shaft; and plural bushings comprising a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft, wherein the plural bushings are configured to reduce backlash.

32. The hinge of claim 31, wherein the proximal end and the distal end of the shaft define a coupling surface comprising a spline or knurled surface configured to cooperate with the respective plural bushings.

33. The hinge of claim 31, wherein the proximal bushing and the distal bushing each includes a head and an opening configured to receive the proximal end or distal end of the shaft.

34. The hinge of claim 31, wherein the clip is formed from aluminum.

35. The hinge of claim 31, wherein the clip is configured to reduce backlash.

36. The hinge of claim 31, wherein the shaft and the at least two end caps together define a channel configured to contain the lubricant.

37. The hinge of claim 36, wherein the clip is configured to prevent ingress of polymer into the channel during an injection molding process.

38. The hinge of claim 36, wherein the clip is configured to prevent egress of lubricant from the channel.

39. The hinge of claim 31, wherein the at least two end caps each comprises nylon.

40. The hinge of claim 31, wherein the hinge has a maximum degree of backlash of 2°.

41. The hinge of claim 40, wherein the plural bushings comprise metal.

42. The hinge of claim 31, wherein the mounting surface comprises alternating hex peaks and hex flats or valleys.

43. The hinge of claim 42, the hex flats or valleys comprising a concave surface.

44. The hinge of claim 31, wherein the mounting surface defines one or more recesses.

45. The hinge of claim 40, wherein the hinge has a maximum degree of backlash of 1°.

46. The hinge of claim 40, wherein the hinge has a maximum degree of backlash of 0.5°.

47. The hinge of claim 40, wherein the maximum degree of backlash is maintained after 20,000 cycles of operation of the hinge.

48. A hinged system comprising: a first component; a second component; and a hinge coupling the first component to the second component in a pivot connection so as to allow pivotal movement of the first component relative to the second component, the hinge including: a housing; a torque engine positioned within the housing and configured to provide frictional resistance to pivotal movement of the components, the torque engine comprising: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end, at least one torque element frictionally engaging the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft, a clip defining a recess configured to receive at least the leg portion of the at least one torque element, the clip configured to provide a partial or full seal against ingress of material at the leg portion of the at least one torque element radially inwardly relative to the pivot axis defined by the shaft, the clip also configured to provide a partial or full seal against egress of lubricant at the leg portion of the at least one torque element radially outwardly relative to the pivot axis defined by the shaft, and at least two end caps positionable adjacent the at least one torque element, the at least two end caps defining an aperture aligned with the pivot axis of the shaft and having a leg portion extending radially outwardly relative to the pivot axis defined by the shaft and received in the recess defined by the clip, the at least two end caps configured to provide a partial or full seal against ingress of material, the at least two end caps also configured to provide a partial or full seal against egress of lubricant.

49. The system of claim 48, wherein the at least one torque element comprises plural torque elements frictionally engaging the shaft.

50. The system of claim 48, wherein the shaft, the at least one torque element, and the at least two end caps together define a channel.

51. The system of claim 48, wherein the lubricant includes grease.

52. The system of claim 48, further comprising plural bushings, the plural bushings comprising a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft.

53. The system of claim 52, wherein the proximal end and the distal end of the shaft define a coupling surface comprising a spline or knurled surface configured to cooperate with the respective plural bushings.

54. The system of claim 52, wherein the proximal bushing and the distal bushing each includes a head and an opening configured to receive the proximal end or distal end of the shaft.

55. The system of claim 54, wherein the head of the proximal bushing and the distal bushing comprises a mounting surface configured to secure the torque engine in the housing.

56. The system of claim 48, wherein the housing includes a mounting portion configured to be connected to one of the first and second components.

57. The system of claim 48, wherein the first and second components are configured for pivotal movement relative to one another along a first rotational direction.

58. The system of claim 57, wherein the first and second components are configured for pivotal movement relative to one another along a first rotational direction and a second rotational direction, and the second rotational direction is different from the first rotational direction.

59. The system of claim 48, wherein the first and second components are configured for pivotal movement relative to one another between a fully closed position and a fully open position.

60. The system of claim 48, wherein the clip is formed from aluminum.

61. The system of claim 48, wherein the clip is configured to reduce backlash.

62. The system of claim 50, wherein the clip is configured to prevent ingress of polymer into the channel during an injection molding process.

63. The system of claim 50, wherein the clip is configured to prevent egress of lubricant from the channel.

64. The system of claim 48, wherein the at least two end caps each comprises nylon.

65. The system of claim 48, wherein the at least two end caps and a molding material are configured to partially melt or join together during an injection molding process.

66. A hinge subassembly configured for use with components having pivotal movement relative to one another, the hinge subassembly comprising:a torque engine positioned within the housing and configured to provide frictional resistance to pivotal movement of the components, the torque engine comprising: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end, a torque element frictionally engaging the shaft, a clip comprising an inner surface configured to receive at least a leg portion of the torque element, the clip configured to provide a partial or full seal against ingress of contaminants into the torque engine and egress of lubricant from the torque engine, and at least two end caps positionable adjacent the torque element and secured by the clip, the at least two end caps each defining an aperture aligned with the pivot axis of the shaft.

67. The subassembly of claim 66, wherein the at least one torque element comprises plural torque elements frictionally engaging the shaft.

68. The subassembly of claim 66, wherein the shaft, the at least one torque element, and the at least two end caps together define a channel.

69. The subassembly of claim 66, wherein the lubricant includes grease.

70. The subassembly of claim 66, further comprising plural bushings, the plural bushings comprising a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft.

71. The subassembly of claim 70, wherein the proximal end and the distal end of the shaft define a coupling surface comprising a spline or knurled surface configured to cooperate with the respective plural bushings.

72. The subassembly of claim 70, wherein the proximal bushing and the distal bushing each includes a head and an opening configured to receive the proximal end or distal end of the shaft.

73. The subassembly of claim 72, wherein the head of the proximal bushing and the distal bushing comprises a mounting surface configured to secure the torque engine in the housing.

74. The subassembly of claim 66, wherein the housing includes a mounting portion configured to be connected to one of the first and second components.

75. The subassembly of claim 66, wherein the first and second components are configured for pivotal movement relative to one another along a first rotational direction.

76. The subassembly of claim 75, wherein the first and second components are configured for pivotal movement relative to one another along a first rotationaldirection and a second rotational direction, and the second rotational direction is different from the first rotational direction.

77. The subassembly of claim 66, wherein the first and second components are configured for pivotal movement relative to one another between a fully closed position and a fully open position.

78. The subassembly of claim 66, wherein the clip is formed from aluminum.

79. The subassembly of claim 66, wherein the clip is configured to reduce backlash.

80. The subassembly of claim 68, wherein the clip is configured to prevent ingress of polymer into the channel during an injection molding process.

81. The subassembly of claim 68, wherein the clip is configured to prevent egress of lubricant from the channel.

82. The subassembly of claim 66, wherein the at least two end caps each comprises nylon.

83. The subassembly of claim 66, wherein the at least two end caps and a molding material are configured to partially melt or join together during an injection molding process.

84. A method for manufacturing a hinge having a torque engine, the method comprising: assembling at least one torque element, a shaft, and at least two end caps to form the torque engine, wherein when assembled, a channel is formed by the at least one torque element, the shaft, and the at least two end caps; providing a clip to secure at least a leg portion of the at least one torque element, wherein the clip, the at least two end caps, or a combination thereof are configured to provide a partial or full seal against ingress of material into the channel and egress of lubricant from the channel; and molding a molding material about the torque engine.

85. The method of claim 84, wherein the molding step comprises placing the torque engine into a mold and injecting the molding material into the mold.

86. The method of claim 84, further comprising connecting a proximal bushing to a proximal end of the shaft and a distal bushing connected to a distal end of the shaft.

87. A hinge for coupling components for pivotal movement relative to one another, the hinge comprising: a torque engine positioned within the housing and configured to provide frictional resistance to pivotal movement of the components, the torque engine including: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end, andbushings mounted to the shaft, the bushings including a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft, each of the bushings having an outer surface including rounded convex peaks and a rounded concave valley interposed between each adjacent pair of the rounded convex peaks; and a polymeric housing molded over the torque engine for engagement with the bushings of the torque engine; wherein the engagement between the polymeric housing and the bushings of the torque engine includes engagement between the outer surface of the bushings and an inner surface of the molded polymeric housing.

88. The hinge of claim 87, wherein the hinge has a maximum degree of backlash of up to 2° after 20,000 cycles of operation of the hinge.

89. The hinge of claim 88, wherein the hinge has a maximum degree of backlash of 1° after 20,000 cycles of operation of the hinge.

90. The hinge of claim 88, wherein the hinge has a maximum degree of backlash of 0.5° after 20,000 cycles of operation of the hinge.

91. The hinge of claim 87, wherein at least one of the bushings has an outer surface including at least three of the rounded convex peaks.

92. The hinge of claim 87, wherein at least one of the bushings has an outer surface including at least six of the rounded convex peaks.

93. The hinge of claim 87, wherein at least one of the bushings has an outer surface including at least three of the rounded convex peaks.

94. The hinge of claim 87, wherein the rounded concave valley interposed between each adjacent pair of the rounded convex peaks of the outer surface of at least one of the bushings includes an arcuate contour.

95. A torque engine configured to be positioned within a housing of a hinge for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components, the torque engine comprising: a shaft defining a pivot axis and extending between a proximal end and a distal end opposite the proximal end, and bushings mounted to the shaft, the bushings including a proximal bushing connected to the proximal end of the shaft and a distal bushing connected to the distal end of the shaft, each of the bushings having an outer surface including rounded convex peaks and a rounded concave valley interposed between each adjacent pair of the rounded convex peaks; anda polymeric housing molded over the torque engine for engagement with the bushings of the torque engine; wherein the engagement between the polymeric housing and the bushings of the torque engine includes engagement between the outer surface of the bushings and an inner surface of the molded polymeric housing.

96. The torque engine of claim 95, wherein the hinge, when the torque engine is positioned within the housing of the hinge, has a maximum degree of backlash of up to 2° after 20,000 cycles of operation of the hinge.

97. A bushing system configured to be mounted to a shaft of a torque engine to be positioned within a housing of a hinge for coupling components for pivotal movement relative to one another and configured to provide frictional resistance to pivotal movement of the components, the bushing comprising: an outer surface including at least three rounded convex peaks and a rounded concave valley having an arcuate contour interposed between each adjacent pair of the at least three rounded convex peaks.

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