Vehicle cargo door hinge

Abstract

The described hinges comprise first and second brackets pivotally coupled to each other and configured to couple the vehicle body and the vehicle door, respectively. A catch member is pivotally coupled to either of the first and second bracket, configured to move between an open lockout position and a free open position and biased to the open lockout position when the second bracket is at a lockout angle. The catch member comprises a slot configured to engage a lockout pin when the catch is in the open lockout position and is disengaged from the lockout pin when the catch member moves to the free open position. A lockout member is coupled to one of the catch member and second bracket, and is configured to selectively lock the second bracket against motion in the door close direction when the second bracket is at the lockout angle.

Description

VEHICLE CARGO DOOR HINGECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority from United States Provisional Patent Application Number 63 / 682,108 filed on August 12, 2024, the contents being incorporated herein by reference.TECHNICAL FIELD

[0002] This disclosure relates to hinges, and more particularly to automotive door hinges that facilitate the opening and closure of a vehicle door in relation to a vehicle body and an automotive cargo door hinge.BACKGROUND

[0003] In general, automotive door hinges include a vehicle door component and a vehicle body component rigidly mounted onto a vehicle door and a vehicle body, respectively. In many cases, the door component is rotationally connected to the body component using a pivot pin rigidly mounted to either of the door component and the body component, with the other of the door component and the body component being free to rotate about the pivot pin. However, in some cases, the pivot pin may float such that both the door component and body component can rotate or pivot freely about the pivot pin.

[0004] Typical commercial cargo vans have rear cargo doors that can be opened to about 180 degrees or 270 degrees from a closed position to allow access to the cargo area for loading and unloading. In daily use, however, the doors are regularly opened to only about 90 degrees, and it is desirable to be able to secure the door in that position to prevent the doors from swinging out and hitting other vehicles or obstructing nearby traffic.

[0005] Accordingly, it would be advantageous to create an automotive door hinge with the ability to lock a door from opening and / or closing beyond a particular number of degrees from the closed position.SUMMARY

[0006] Described herein are hinges adapted to rotationally couple a vehicle door and a vehicle body comprising a first bracket, a second bracket, at least one pivot pin, a lockout pin, a catch member, a first biasing means and a lockout member. The first bracket isconfigured to couple to one of the vehicle body and the vehicle door. The second bracket is configured to couple to the other one of the vehicle body and the vehicle door. The at least one pivot pin is configured to pivotally couple the first bracket to the second bracket and to enable the second bracket to move, relative to the first bracket, in a door open direction to a door open position and in a door close direction opposite the door open direction to a door closed position. The lockout pin is fixedly coupled to one of the first bracket and the second bracket. The catch member is pivotally coupled to the other one of the first bracket and the second bracket via a catch pin. The catch member is configured to move between an open lockout position and a free open position. The catch member comprises a slot configured to engage the lockout pin when the catch member is in the open lockout position. When moving from the open lockout position to the free open position, the slot is disengaged from the lockout pin. The first biasing means is configured to bias the catch member to the open lockout position when the second bracket is at a lockout angle. The lockout member is coupled to one of the catch member and the second bracket, the lockout member being configured to selectively lock the second bracket against motion in the door close direction when the second bracket is at the lockout angle. When the catch member is in the open lockout position the second bracket is prevented from further movement in the door open direction. When the catch member is in the free open position the second bracket is free to move further in the door open direction.

[0007] According to some embodiments, the first biasing means comprises a torsional spring, a compression spring, a coil spring or a leaf spring.

[0008] According to some embodiments, the lockout member further comprises a lockout tab configured to enable selective toggling of the relative position of the lockout member to the catch member. According to some embodiments, the lockout tab is overmolded onto the lockout member.

[0009] According to some embodiments, the lockout member is pivotally coupled to the one of the catch member and the second bracket, and comprises a limiting feature configured to engage a corresponding limiting feature of the catch member. The lockout member is configured to move in and out of abutting engagement with the lockout pin. When the lockout member is in abutting engagement with the lockout pin, the corresponding limiting feature of the catch member is in a first limiting position in respect of the limiting feature and the second bracket is prevented from moving in the door close direction. When the lockout member is out of abutting engagement with the lockout pin, the corresponding limiting featureof the catch member is in a second limiting position in respect of the limiting feature and the second bracket is free to move in the door close direction.

[0010] According to some embodiments, the lockout member is stamped from sheet metal.

[0011] According to some embodiments, the hinges comprise a second biasing means that is configured, when in a first configuration of the catch member relative to the lockout member, to bias the lockout member into abutting engagement with the lockout pin and, when in a second configuration of the catch member relative to the lockout member, to bias the lockout member out of abutting engagement with the lockout pin. According to some embodiments, the second biasing means comprises an over center spring. According to some embodiments, the over center spring comprises a torsional spring, a compression spring, a coil spring or a leaf spring.

[0012] According to some embodiments, the limiting feature comprises an orifice of the lockout member and the corresponding limiting feature comprises a fixed pin coupled to the catch member. When the catch member is in the first limiting position, the fixed pin is in a first position within the orifice. When the catch member is in the second limiting position, the fixed pin is in a second position within the orifice away from the first position. According to some embodiments, the lockout tab is configured for selective toggling of the lockout member and the fixed pin between the first position and the second position within the orifice. According to some embodiments, the lockout tab is overmolded onto the lockout member.

[0013] According to some embodiments, the limiting feature comprises an arm of the lockout member and the corresponding limiting feature comprises a pair of opposing bumpers of the catch member. When the lockout member is in the first limiting position, the arm of the lockout member abuts one of the pair of opposing bumpers. When the lockout member is in the second limiting position, the arm of the lockout member abuts the other one of the pair of opposing bumpers.

[0014] According to some embodiments, one or more of the first bracket, the second bracket and the catch member is stamped from sheet metal.

[0015] According to some embodiments, the lockout angle is an interior angle between the second bracket in a door closed position and the second bracket in a door open position when the catch member is in the open lockout position. According to someembodiments, the lockout angle is in a range of about 45 degrees to about 270 degrees, preferably about 90 degrees..

[0016] According to some embodiments, the hinges further comprise an intermediary linkage assembly configured to pivotally couple the first bracket to the second bracket. The at least one pivot pin comprises a plurality of pivot pins arranged to couple the first bracket and the second bracket to the intermediary linkage assembly. According to some embodiments, the first bracket, the second bracket and the intermediary linkage assembly together are configured as a four-bar linkage. Further, the intermediary linkage assembly comprises at least a first intermediary linkage and a second intermediary linkage overlapped by the first intermediary linkage and configured to pivot about a virtual axis when the second bracket moves in the door open direction and in the door closed direction. According to some embodiments, the intermediary linkage assembly comprises at least one component stamped from sheet metal.

[0017] According to some embodiments, the catch member further comprises a positioning stop configured to abut the second bracket while the second bracket is moved in the door close direction and to position the open slot of the catch member for engagement of the slot with the lockout pin when the catch member is moving towards the open lockout position from the free open position. According to some embodiments, the positioning stop is overmolded onto the catch member.

[0018] According to some embodiments, the hinges further comprise at least one spacing element. According to some embodiments, the at least one spacing element is overmolded onto the catch pin.

[0019] According to some embodiments, the slot is configured such that when the catch member is in the open lockout position the second bracket is prevented from further movement in both the door open direction and the door close direction.

[0020] According to some embodiments, the first bracket comprises one of a body bracket and a door bracket, and the second bracket comprises the other one of the body bracket and the door bracket.

[0021] According to some embodiments, the hinges further comprise a door checker mechanism.

[0022] According to some embodiments, the lockout pin is configured to fail prior to either of the first bracket and the second bracket under an applied failure load. Accordingto some embodiments, the lockout pin is configured to fail prior to the intermediary linkage assembly under an applied failure load.

[0023] According to some embodiments, the hinges further comprise a catch release tab configured to selectively release the catch member to the free open position. According to some embodiments, the catch release tab is overmolded onto the catch member.

[0024] Further aspects of the claimed subject matter will be apparent from the following description and explanations.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] 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:

[0026] FIG. 1 depicts a pair of hinges mounted on a vehicle door, according to a non-limiting embodiments;

[0027] FIG. 2 depicts a hinge with a selectable lockout in which the catch member is in the open lockout position, according to a first set of non-limiting embodiments;

[0028] FIG. 3 A depicts an elevation view the hinge of FIG. 2;

[0029] FIG. 3B depicts a bottom perspective view of the hinge of FIG. 2;

[0030] FIGS. 3C and 3D depict a lockout member and the movement of the fixed pin, according to non-limiting embodiments;

[0031] FIGS. 4A and 4B depict the interior angles between the first bracket and the second bracket in door open position (DOP) and door closed position (DCP), including the relative angles therebetween, according to non-limiting embodiments;

[0032] FIG. 5 depicts the hinge of FIG. 2 in which the catch member is in the free open position and the lockout member is in the abutting engagement position, according to non-limiting embodiments;

[0033] FIG. 6 depicts the hinge of FIG. 2 in which the catch member is in the open lockout position and the lockout member is in the abutting engagement position, according to non-limiting embodiments;

[0034] FIG. 7 depicts the hinge of FIG. 2 in the closed position, according to nonlimiting embodiments;

[0035] FIG. 8 depicts the hinge of FIG. 2 in the 245-degree door open position, according to non-limiting embodiments;

[0036] FIG. 9 depicts a hinge with a releasable lockout, according to a second set of non-limiting embodiments;

[0037] FIGS. 10A and 10B depict a door checker, according to an embodiment of the prior art;

[0038] FIG. 11 depicts a catch member, according to a first set of non-limiting embodiments;

[0039] FIG. 12 depicts a catch member, according to a second set of non-limiting embodiments;

[0040] FIG. 13 depicts a hinge having spacing elements, according to non-limiting embodiments;

[0041] FIGS. 14A and 14B depict front and rear views of the hinge of FIG. 2 having a door checker mechanism, according to non-limiting embodiments;

[0042] FIGS. 15A to 15C depict ahinge with a selectable lockout in a configuration locking the second bracket against motion in the door close direction when the second bracket is positioned at the lockout angle of 90 degrees, according to a third set of non-limiting embodiments;

[0043] FIGS. 15D to 15F depict the hinge of FIGS. 15A to 15C with the selectable lockout in a configuration allowing for the free movement of the second bracket in the door close direction;

[0044] FIG. 15G depicts the hinge of FIGS. 15A to 15F in a door closed configuration in which the catch member is in a free open position, according to non-limiting embodiments; and

[0045] FIG. 15H depicts the hinge of FIGS. 15A to 15F in a fully open configuration with the catch member disengaged from the lock pin, according to non-limiting embodiments.

[0046] 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

[0047] Herein are described vehicle cargo door hinges which are configured to releasably lock the door against unintentional opening beyond a particular range, such as beyond 90 degrees from a closed position. For example, according to some embodiments, the described hinges provide an opening lockout that is configured to lock motion of the door in a door open direction at about 90 degrees or other selected angle (i.e., the door is unable to be opened beyond 90 degrees from the closed position).

[0048] It will be appreciated that 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. Further aspects of the invention will be apparent from the attached images and explanations. The particular arrangement of the elements described herein may be modified as will be apparent to those skilled in the art.

[0049] According to some embodiments, the opening lockout can be disengaged, manually or by operation of an electromechanical control device, to allow the door to be opened beyond or about 90 degrees or other predetermined position in respect of the door closed position. According to some embodiments, the described hinges are also configured to provide a selectable closing lockout to lock the door against motion in the door close direction at a particular position (e.g., the door may be locked against closing the door from a particular door or hinge position, such as 90 degrees from the closed position or other lockout angle). The closing lockout may be engaged or disengaged manually or by any other suitable means (such as by operation of an electromechanical control device). When deselected, the closing lockout does not prevent the door from being closed.

[0050] According to some embodiments, the described hinges are operated in combination or conjunction with a door checker mechanism to hold the door at other desirable positions. The door checker mechanism typically provides some resistance that is overcome with force applied to the door by the user. For example, according to some embodiments, the door checker mechanism can be configured to provide some resistance to closing at 90 degrees even when the closing lockout is deselected. An example of such a door checker is described in U.S. Patent No. 6,481,056, the contents of which are incorporated by reference herein. However, any suitable door checker mechanism is contemplated.

[0051] When opening the vehicle door, the opening lockout automatically engages when the door is opened to the lockout angle (such as when the vehicle door has been opened 90 degrees or other lockout angle from the closed position). The opening lockout prevents the door from opening further until the user disengages the catch member. When the catch member is disengaged the door can be moved further in the door open direction.

[0052] When closing the vehicle door, the closing lockout can be selected or deselected. When selected or otherwise engaged, the closing lockout (also referred to herein as a lockout member) will prevent the door from moving in a door close direction when the vehicle door is at the open lock out position. If the vehicle door is being closed from a position greater than the open lockout position, the motion of the vehicle door in the door close direction will be stopped when it reaches the open lock out position. When the lockout member is disengaged the vehicle door can be closed, even beyond the open lockout position.

[0053] According to some embodiments, the described hinges provide the above functionality in a reduced device package size. For example, according to some embodiments, the described hinges comprise a four-bar linkage having a plurality of pivot points that allows the hinge to be folded into a smaller package size than a two-bar hinge having a single pivot point.

[0054] Attention is directed to FIGS. 1 to 8 and 13 which depict a hinge 100 or hinges 100 adapted to rotationally couple a vehicle door and a vehicle body (such as vehicle door 2 and vehicle body 4 shown in FIG. 1). According to some embodiments, hinge 100 comprises a first bracket 102 and a second bracket 104. First bracket 102 is configured to couple to one of the vehicle body 4 and the vehicle door 2. Second bracket 104 is configured to couple to the other one of the vehicle body 4 and the vehicle door 2. For example, first bracket 102 may comprise one of a body bracket and a door bracket (such as body bracket 106)and second bracket 104 comprises the other one of the body bracket and the door bracket (such as door bracket 108). Hinge 100 further comprises at least one pivot pin, such as pivot pin 110, configured to pivotally couple the first bracket 102 to the second bracket 104 and to enable the second bracket 104 to move, relative to the first bracket 102, in a door open direction (DO) to a door open position (DOP) (FIG. 4B) and in a door close direction (DC) opposite the door open direction (DO) to a door closed position (DCP) (FIG. 7). The second bracket 104 and the first bracket 102 are mountable to the respective vehicle door or vehicle body using any of fixed fasteners, welding, bonding, riveting or other suitable means.

[0055] The hinge further comprises a lockout pin 112 that is fixedly or rigidly coupled to one of the first bracket 102 and the second bracket 104.

[0056] A catch member 114 is pivotally coupled to the other one of the first bracket 102 and the second bracket 104 via a catch pin 116 (FIG. 2). Catch member 114 is configured to move between an open lockout position (FIG. 2) and a free open position (FIG. 5). Catch member 114 comprises a slot 118 configured to engage lockout pin 112 when the catch member 114 is in the open lockout position (shown in FIG. 2). When moving from the open lockout position to the free open position, slot 118 disengages from lockout pin 112. As shown in FIG. 11, slot 118 comprises an interior face 120 that slopes towards the catch pin 116 such that the lockout pin 112 is able to travel along the sloped interior face 120 towards the pivot point of the catch member 114 (the catch pin 116 in this example) as the second bracket 104 and the catch member 114 moves to the closed door position. The slot 118 further comprises a transverse interior face 122 opposite the sloped interior face 120 that abuts the lockout pin 112 while in the open lockout position and resists further movement of the second bracket 104 in the door open position. When the catch member 114 is in the open lockout position the second bracket 104 is prevented from further movement in the door open direction (DO) and when the catch member 114 is in the free open position the second bracket 104 is free to move further in the door open direction (DO).

[0057] Hinge 100 further comprises a first biasing means 124 configured to bias the catch member 114 to the open lockout position when the second bracket 104 is at a lockout angle (LA) (FIGS. 2 and 6) (what is meant herein by “lockout angle” is described further below). For example, as shown in FIGS. 2, 3A and 3B, the first biasing means 124 may comprise a coil spring having a first end 126 abutting a fixed pin 128 coupled to the catch member 114 and a second end 130 which abuts the second bracket 104, pushing the catchmember 114 towards the lockout pin 112 with the transverse interior face 122 of the slot 118 abutting the lockout pin 112. However, any suitable biasing means or combination of biasing means is contemplated for first biasing means 124. For example, according to some embodiments, first biasing means 124 comprises a torsional spring, a compression spring, a coil spring or a leaf spring.

[0058] The orientation of the second bracket 104 in respect of the first bracket 102 when the catch member 114 is in the open lockout position can be predetermined. According to some embodiments, the second bracket 104 is at the lockout angle (LA)when the catch member 114 is in the open lockout position (engaged with the lockout pin 112; see, for example, FIG. 4A). In particular, the lockout angle (LA) is an interior angle (IA) between the second bracket 104 in the door closed position (DCP) and the second bracket 104 in a door open position (DOP) when the catch member 114 is in the open lockout position. According to some embodiments, the lockout angle (LA) is in a range of about 45 degrees to about 270 degrees and is preferably about 90 degrees. For example, in reference to FIGS. 4A and 4B, when the first bracket 102 and the second bracket 104 are in the door closed position (DCP), there is an interior angle A between them. When the catch member 114 is in the open lockout position (engaged with the lockout pin 112) (FIG. 4A) and the second bracket 104 is in a door open position, the interior angle between the first bracket 102 and the second bracket 104 is interior angle B. As a result, the lockout angle (LA) is the difference between interior angle B and interior angle A, shown as angle C in FIG. 4B.

[0059] According to some embodiments, the catch member 114 further comprises a catch release tab 132 configured to selectively release the catch member 114 to the free open position upon, for example, manual actuation (see, for example, FIG. 2). According to some embodiments, the catch release tab 132 is overmolded onto the catch member 114.

[0060] The described hinges further comprise features which enable movement of the second bracket 104 to be restricted in the door close direction (DC). In particular, hinge 100 comprises a lockout member 134 coupled to one of the catch member 114 and the second bracket 104. Lockout member 134 is configured to selectively lock the second bracket 104 against motion in the door close direction (DC) when the second bracket 104 is at the lockout angle (LA).

[0061] Lockout member 134 may take a variety of forms. For example, according to some embodiments, lockout member 134 is pivotally coupled to the one of the catch member114 and the second bracket 104, such as to second bracket 104 via the catch pin 116 as shown in FIGS. 2to 3B and4Ato 8. Lockout member 134 comprises a limiting feature 136 configured to engage a corresponding limiting feature 138 of the catch member 114, such as fixed pin 128 (discussed further below). Lockout member 134 is configured to move in and out of abutting engagement with the lockout pin 112 (see FIGS. 2 and 6 showing an example of lockout member 134 pivoting about the catch pin 116 to the abutting engagement position and the out of abutting engagement position with the lockout pin). When the lockout member 134 is in abutting engagement with the lockout pin 112, the corresponding limiting feature 138 of the catch member 114 is in a first limiting position in respect of the limiting feature 138 and the second bracket 104 is prevented from moving in the door close direction (DC). When the lockout member 134 is out of abutting engagement with the lockout pin 112, the corresponding limiting feature 138 of the catch member 114 is in a second limiting position in respect of the limiting feature 136 and the second bracket 104 is free to move in the door close direction (DC).

[0062] Limiting feature 136 and corresponding limiting feature 138 may take a variety of forms. According to some embodiments, limiting feature 136 comprises an orifice 140 of lockout member 134 and corresponding limiting feature 138 comprises fixed pin 128 coupled to catch member 114 (FIGS. 2, 3C, 3D). Orifice 140 is configured to engage fixed pin 128 such that movement of the fixed pin 128 is limited to within orifice 140. When the lockout member 134 is in abutting engagement with the lockout pin 112, the fixed pin 128 is in a first position within the orifice 140 (FIG. 3C) and the second bracket 104 is prevented from moving in the door close direction (DC) (FIG. 6). When the lockout member 134 is out of abutting engagement with the lockout pin 112, the fixed pin 128 is in a second position within the orifice 140 away from the first position (FIG. 3D) and the second bracket 104 is free to move in the door close direction (DC), pivoting about the catch pin 116. Other configurations of limiting feature 136 and corresponding limiting feature 138 are contemplated, which will be discussed further below in reference to another example embodiment of hinge 100.

[0063] According to some embodiments, hinge 100 further comprises a second biasing means 142 that is configured, when in a first configuration of the catch member 114 relative to the lockout member 134 (FIG. 6), to bias the lockout member 134 into abutting engagement with the lockout pin 112. When in a second configuration of the catch member 114 relative to the lockout member 134 (FIG. 2), the second biasing means 142 is configuredto bias the lockout member 134 out of abutting engagement with the lockout pin 112. The second biasing means 142 comprises any devices or combination of devices suitable for biasing the catch member 114 relative to the lockout member 134 in both the first and second configurations. According to some embodiments, the second biasing means 142 comprises an over center mechanism, such as an over center spring. For example, the second biasing means 142 may comprise a torsional spring, a leaf spring, a coil spring or a compression spring. According to some embodiments, when the second biasing means 134 is an over center spring, the second biasing means 142 moves between a first stable position in respect of the fixed pin 128, biasing the lockout member 134 in one position in respect of the catch member 114 (see, for example, FIG. 6) and a second stable position, biasing the lockout member 134 in a second position in respect of the catch member 114 (see, for example, FIG. 2). It is understood that any suitable means for biasing the lockout member 134 relative to the catch member 114 is contemplated.

[0064] According to some embodiments, lockout member 134 is configured for manual actuation. For example, the lockout member 134 may further comprise a lockout tab 144 configured to enable selective toggling of the relative position of lockout member 134 to catch member 114. According to some embodiments, as shown in FIG. 5, lockout tab 144 is configured to selectively toggle lockout member 134 and fixed pin 128 between the first position (FIG. 3C) and the second position (FIG. 3D). Any suitable means of manufacturing lockout tab 144 is contemplated. For example, according to some embodiments, lockout tab 144 is overmolded onto lockout member 134.

[0065] According to some embodiments, the described hinges further comprise means to guide or position one or more of the catch member 114 and the lockout member 134 into position for engagement with the fixed pin 128. For example, according to some embodiments, the catch member 114 comprises a positioning stop 146 configured to abut the second bracket 104 while the second bracket 104 is moved in the door close direction (DC) and to position the open slot 118 of the catch member 114 for engagement with the lockout pin 112 when the catch member 114 is moving towards the open lockout position from the free open position (FIGS. 2 and 8). According to some embodiments, positioning stop 146 is overmolded onto catch member 114.

[0066] The described hinges may comprise elements or mechanisms for spacing hinge components from each other. According to some embodiments, the described hingesmay comprise at least one spacing element 148 (FIG. 13). According to some embodiments, the at least one spacing element 148 is overmolded onto catch pin 116.

[0067] The described hinges may be configured to provide some resistance or checking at positions other than the open lockout position. According to some embodiments, the described hinges further comprise a door checker mechanism, such as door checker mechanism 152 shown in the embodiment of hinge 100 depicted in FIGS. 14A and 14B and the embodiment of hinge 300 depicted in FIG. 15F (described further below). According to some embodiments, the described hinges may incorporate a door checker mechanism as a separate component. According to some embodiments, the door checker mechanism is incorporated as an integral component with the hinge. For example, the door checker mechanism may be mounted to the hinge via one or more mounting holes (see, for example, mounting hole 154 shown in FIGS. 2 and 14A). As noted above, a suitable door checker mechanism is described in U.S. Patent No. 6,481,056 (shown in FIGS. 10A and 10B). However, any suitable door checker mechanism is contemplated.

[0068] Attention is directed to FIGS. 9 and 12, which depicts a hinge 200 and components thereof, according to a second set of non-limiting embodiments. Like or similar elements are denoted by like or similar numbers in FIGS. 1 to 8, 11 and 13 to 14B. For simplicity and ease of understanding, discussion of the elements and features depicted in FIGS. 9 and 12 will focus on certain similarities and differences.

[0069] Hinge 200 is configured to provide a lockout in both the door open direction (DO) and the door close direction (DC) without inclusion of a lockout member 134 as described above in respect of hinge 100. For example, as shown in FIG. 12, the slot 218 of the catch member 214 is configured such that when the catch member 214 is in the open lockout position the second bracket 104 is prevented from further movement in both the door open direction (DO) and the door close direction (DC). The slot 218 comprises two opposing interior faces 250, individually referred to as interior face 250A and interior face 250B. Unlike the embodiment depicted in FIG. 11, the interior face closer to the catch pin, interior face 250B, is not sloped towards the second pin. As a result, when the catch member 214 is in the open lockout position, the lockout pin 112 is prevented from traveling out of the slot 218 when the second bracket 104 is moved in the door close direction (DC) as well as the door open direction (DC).

[0070] According to some embodiments, the described hinges may comprise features that enable providing similar functionality to that described above but in a smaller package size. Attention is directed to FIGS. 15A to 15H, which depict a hinge 300 and components thereof, according to a third set of non-limiting embodiments. Like or similar elements are denoted by like or similar numbers in FIGS. 1 to 8, 11 and 13 to 14B. For simplicity and ease of understanding, discussion of the elements and features depicted in FIGS. 15A to 15H will focus on certain similarities and differences.

[0071] Similarly to hinge 100, hinge 300 comprises a first bracket 302 and a second bracket 304. First bracket 302 is configured to couple to one of vehicle body 4 and vehicle door 2. For example, first bracket 302, when configured to couple to the vehicle body 4, may be referred to herein as body bracket 306, and second bracket 304, when configured to couple to the vehicle door 2, may be referred to herein as door bracket 308. First bracket 302 and second bracket 304 are pivotally coupled to each other. However, instead of being directly pivotally coupled to each other, first bracket 302 and second bracket 304 are pivotally coupled to each other via an intermediary linkage assembly 356. A plurality of pivot pins 310 are arranged to couple the first bracket 302 and the second bracket 304 to the intermediary linkage assembly 356. In the example embodiment depicted in FIGS. 15A to 15H, four pivot pins are utilized; however, any suitable number of pivot pins or other pivot enabling features are contemplated.

[0072] Intermediary linkage assembly 356 is configured such that a package size of hinge 300 is smaller than that of a two-bar linkage, such as that exemplified by hinges 100 and 200, when in the door closed configuration. For example, hinge 100 in the door closed configuration (FIG. 4B) takes up a larger sized design envelope than hinge 300 in the door closed configuration (FIG. 15G).

[0073] Any suitable configuration of intermediary linkage assembly 356 to pivotally couple the first bracket 302 to the second bracket 304 is contemplated. For example, in the depicted example embodiment, first bracket 302, second bracket 304 and intermediary linkage assembly 356 are together configured as a four-bar linkage. The depicted four-bar linkage comprises at least a first intermediary linkage 356A and a second intermediary linkage 356B. Second intermediary linkage 356B is overlapped by first intermediary linkage 356A (i.e., in overlapping relationship with first intermediary linkage 356A). Intermediary linkage assembly 356 is configured to pivot about a virtual axis, such as virtual axis V, when the secondbracket 304 moves in the door open direction (DO) and in the door close direction (DC) (FIG. 15C).

[0074] Similarly to hinge 100, hinge 300 comprises a lockout member 134 coupled to one of the catch member 114 and the second bracket 304, and configured to selectively lock the second bracket 304 against motion in the door close direction when the second bracket 304 is at the lockout angle. Furthermore, similarly to hinge 100, lockout member 134 is pivotally coupled to one of the catch member 114 and the second bracket 304, and comprises a limiting feature 136 that is configured to engage a corresponding limiting feature 138 of the catch member 114. However, in contrast to hinge 100, the configuration of lockout member 134, limiting feature 138 and corresponding limiting feature 136 have been modified. Lockout member 134 of hinge 300, specifically referred to herein as lockout member 358, is pivotally coupled to catch member 114 via, for example, pivot pin 360 (FIG. 15A). Limiting feature 138 of hinge 300 comprises an arm of lockout member 358, such as arm 362, and the corresponding limiting feature 136 comprises a pair of opposing bumpers 364 of catch member 114. Lockout member 358 pivots about pivot pin 360 such that arm 362 is enabled to move between two limiting positions, a first limiting position in which lockout member 134 abuts lockout pin 112 to prevent second bracket 304 from moving in the door close direction (FIGS. 15A, 15B) and a second limiting position in which lockout member 358 is out of abutting engagement with lockout pin 112 to allow second bracket 304 to freely move in the door close direction (FIGS. 15D, 15E). When lockout member 358 is in the first limiting position arm 362 abuts one of the pair of opposing bumpers 364, such as bumper 364 A (FIG. 15B), and when lockout member 358 is in the second limiting position arm 362 abuts the other one of the pair of opposing bumpers 364, such as bumper 364B (FIG. 15E).

[0075] Any suitable method of manufacturing the described hinges is contemplated. For example, according to some embodiments, one or more of first bracket 102, 302, second bracket 104, 304, catch member 114, 214 and intermediary linkage 356 is stamped from sheet metal. According to some embodiments, intermediary linkage 356 comprises at least one component that is stamped from sheet metal. According to some embodiments, lockout member 134 is stamped from sheet metal.

[0076] According to some embodiments, the described hinges comprise certain service features. For example, according to some embodiments, lockout pin 112 is configured to fail prior to one or more of the first bracket 102, 302, the second bracket 104, 304 and theintermediary linkage 356 when under an applied failure load (resulting from, for example, user abuse). As a result, the hinge can be fixed by replacing lockout pin 112 and the hinge put back into service (instead of requiring the entire hinge to be replaced or the door needing further repair). For example, as shown in FIG. 2, lockout pin 112 comprises a reduced cross-sectional region 168. Other means to configure the lockout pin 112 to preferentially fail or otherwise break under an applied failure load are contemplated.

[0077] The particular arrangement of the elements described herein may be modified as will be apparent to those skilled in the art. For example, the elements may be rearranged such that operation of the hinge is reversed. According to some embodiments, the positions of the lockout pin and the catch pin are reversed in that the lockout pin is coupled to the door bracket and the catch pin is coupled to the body bracket. Operation would be similar to that described above (e.g., the slot of the catch member engages the lockout pin, now coupled to the first bracket, when the catch member is in the open lockout position and, when moving from the open lockout position to the free open position, the slot disengages from the lockout Pin).

[0078] 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).

[0079] 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.

[0080] 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.

[0081] References in the application to "one embodiment", "an embodiment", "an implementation", "a variant", etc., indicate that the embodiment, implementation or variantdescribed 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.

[0082] 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 of the invention.

[0083] 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.

[0084] 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.

[0085] 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 encompass any 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 includeseach 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.

[0086] 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.

[0087] 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.

Claims

CLAIMSWhat is claimed is:

1. A hinge adapted to rotationally couple a vehicle door and a vehicle body, comprising: a first bracket configured to couple to one of the vehicle body and the vehicle door; a second bracket configured to couple to the other one of the vehicle body and the vehicle door; at least one pivot pin configured to pivotally couple the first bracket to the second bracket and to enable the second bracket to move, relative to the first bracket, in a door open direction to a door open position and in a door close direction opposite the door open direction to a door closed position; a lockout pin fixedly coupled to one of the first bracket and the second bracket; a catch member pivotally coupled to the other one of the first bracket and the second bracket via a catch pin, wherein: the catch member is configured to move between an open lockout position and a free open position; the catch member comprises a slot configured to engage the lockout pin when the catch member is in the open lockout position; and when moving from the open lockout position to the free open position, the slot disengages from the lockout pin; a first biasing means configured to bias the catch member to the open lockout position when the second bracket is at a lockout angle; and a lockout member coupled to one of the catch member and the second bracket, the lockout member being configured to selectively lock the second bracket against motion in the door close direction when the second bracket is at the lockout angle; wherein: when the catch member is in the open lockout position the second bracket is prevented from further movement in the door open direction, and when the catch member is in the free open position the second bracket is free to move further in the door open direction.

2. The hinge of claim 1, wherein the lockout member further comprises a lockout tab configured to enable selective toggling of the relative position of the lockout member to the catch member.

3. The hinge of claim 2, wherein the lockout tab is overmolded onto the lockout member.

4. The hinge of any one of claims 1 to 3, wherein: the lockout member is pivotally coupled to the one of the catch member and the second bracket, and comprises a limiting feature configured to engage a corresponding limiting feature of the catch member; the lockout member is configured to move in and out of abutting engagement with the lockout pin; when the lockout member is in abutting engagement with the lockout pin, the corresponding limiting feature of the catch member is in a first limiting position in respect of the limiting feature and the second bracket is prevented from moving in the door close direction; and when the lockout member is out of abutting engagement with the lockout pin, the corresponding limiting feature of the catch member is in a second limiting position in respect of the limiting feature and the second bracket is free to move in the door close direction.

5. The hinge of claim 4 further comprising: a second biasing means configured, when in a first configuration of the catch member relative to the lockout member, to bias the lockout member into abutting engagement with the lockout pin and, when in a second configuration of the catch member relative to the lockout member, to bias the lockout member out of abutting engagement with the lockout pin.

6. The hinge of claim 5, wherein the second biasing means comprises an over center spring.

7. The hinge of claim 6, wherein the over center spring comprises a torsional spring, a compression spring, a coil spring or a leaf spring.

8. The hinge of any one of claims 4 to 7, wherein: the limiting feature comprises an orifice of the lockout member and the corresponding limiting feature comprises a fixed pin coupled to the catch member;when the catch member is in the first limiting position, the fixed pin is in a first position within the orifice; and when the catch member is in the second limiting position, the fixed pin is in a second position within the orifice away from the first position.

9. The hinge of any one of claims 4 to 7, wherein: the limiting feature comprises an arm of the lockout member and the corresponding limiting feature comprises a pair of opposing bumpers of the catch member; when the lockout member is in the first limiting position, the arm of the lockout member abuts one of the pair of opposing bumpers; and when the lockout member is in the second limiting position, the arm of the lockout member abuts the other one of the pair of opposing bumpers.

10. The hinge of any one of claims 1 to 9, wherein the lockout angle is an interior angle between the second bracket in a door closed position and the second bracket in a door open position when the catch member is in the open lockout position, and wherein the lockout angle is in a range of about 45 degrees to about 270 degrees, preferably about 90 degrees.

11. The hinge of either of claim 2 or claim 3 combined with claim 8, wherein the lockout tab is configured for selective toggling of the lockout member and the fixed pin between the first position and the second position within the orifice.

12. The hinge of claim 11, wherein the lockout tab is overmolded onto the lockout member.

13. The hinge of any one of claims 1 to 12 further comprising: an intermediary linkage assembly configured to pivotally couple the first bracket to the second bracket; wherein the at least one pivot pin comprises a plurality of pivot pins arranged to couple the first bracket and the second bracket to the intermediary linkage assembly.

14. The hinge of claim 13, wherein: the first bracket, the second bracket and the intermediary linkage assembly together are configured as a four-bar linkage; and the intermediary linkage assembly comprises at least a first intermediary linkage and a second intermediary linkage overlapped by the first intermediary linkage and configuredto pivot about a virtual axis when the second bracket moves in the door open direction and in the door closed direction.

15. The hinge of either claim 13 or claim 14, wherein the intermediary linkage comprises at least one component stamped from sheet metal.

16. The hinge of any one of claims 1 to 12, wherein one or more of the first bracket, the second bracket and the catch member is stamped from sheet metal.

17. The hinge of any one of claims 1 to 16, wherein the catch member further comprises a positioning stop configured to abut the second bracket while the second bracket is moved in the door close direction and to position the open slot of the catch member for engagement of the slot with the lockout pin when the catch member is moving towards the open lockout position from the free open position.

18. The hinge of claim 17, wherein the positioning stop is overmolded onto the catch member.

19. The hinge of any one of claims 1 to 18, wherein the lockout member is stamped from sheet metal.

20. The hinge of any one of claims 1 to 19 further comprising at least one spacing element.

21. The hinge of claim 19, wherein the at least one spacing element is overmolded onto the catch pin.

22. The hinge of any one of claims 1 to 21, wherein the slot is configured such that when the catch member is in the open lockout position the second bracket is prevented from further movement in both the door open direction and the door close direction.

23. The hinge of any one of claims 1 to 22, wherein the first bracket comprises one of a body bracket and a door bracket, and the second bracket comprises the other one of the body bracket and the door bracket.

24. The hinge of any one of claims 1 to 23 further comprising a door checker mechanism.

25. The hinge of any one of claims 1 to 24, wherein the lockout pin is configured to fail prior to either of the first bracket and the second bracket under an applied failure load.

26. The hinge of any one of claims 13 to 15, wherein the lockout pin is configured to fail prior to the intermediary linkage assembly under an applied failure load.

27. The hinge of any one of claims 1 to 26, wherein the first biasing means comprises a torsional spring, a compression spring, a coil spring or a leaf spring.

28. The hinge of any one of claims 1 to 27 further comprising a catch release tab configured to selectively release the catch member to the free open position.

29. The hinge of claim 28, wherein the catch release tab is overmolded onto the catch member.

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