Automotive Door Hinge Segmented Angle Brackets
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Solution Overview
Problem
Automotive hinges require complex configurations that result in significant material waste during press forming, due to the complex shapes needed for mounting and pivot axis features, making the process inefficient and costly.
Innovation Solution
The pivot pin is used as a primary structural component to connect multiple press-formed angle brackets, eliminating the need for a structural bridge and reducing material usage by facilitating both assembly and rotary motion between the door and body components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If complex press-formed components are used to accommodate mounting surfaces and pivot axis features, then structural integrity is maintained, but material waste increases significantly
Solution Approach 1:
The hinge components are divided into separate press-formed angle brackets that are connected by the pivot pin, rather than using single complex press-formed pieces. This segmentation allows each component to be simpler in shape, reducing material waste during press forming while maintaining structural integrity through the pin connection
Solution Approach 2:
The pivot pin serves multiple functions simultaneously: it connects the door component angle brackets to the body component angle brackets, provides the pivot axis for rotation, and replaces the need for separate structural bridges. This merging of functions reduces the number of parts and simplifies the press-formed shapes required
2Ease of manufacture
If complex configurations are used to provide mounting surfaces and pivot axis features, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
By segmenting the hinge into separate angle brackets connected by a pivot pin, each component can be manufactured using simpler press-formed shapes that are more cost-effective. The standardization of these modular components further reduces manufacturing complexity and cost
Solution Approach 2:
The pivot pin is designed as a universal component that performs multiple functions: structural connection between components, provision of pivot axis, and replacement for structural bridges. This multi-functionality reduces the overall device complexity while meeting all functional requirements
3Loss of substance
If single piece components are used, then structural integrity is maintained, but scrap material is generated during press forming
Solution Approach 1:
The invention segments the traditional single-piece hinge components into multiple simpler angle brackets that are connected by a pivot pin. This segmentation allows each press-formed component to have a simpler geometry that generates less scrap material, while the assembly of these segments maintains the required structural integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material waste and costs by allowing the use of simpler press-formed components, improving material efficiency and reducing scrap, while maintaining structural integrity and facilitating rotary motion.
Implementation Method 1
The pivot pin is configured to be rigidly attached to one of the hinge components while the other component freely rotates around the pivot pin via one or more bearing surfaces
Implementation Method 2
The pivot pin comprises a central cylindrical pivot surface with a central diameter adapted to allow rotation of the pivot bushing thereabout, a first end and a second end, wherein the central cylindrical pivot surface is positioned between the first and second ends and the first and second ends are adapted to structurally connect the first and second door angle brackets respectively
Data Source
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AI summary
An automotive hinge assembly (30) comprises a) a door component (40) constructed from first and second press formed door angle brackets (46, 47), the first and second press formed door angle brackets (46, 47) being separate and spaced apart such that the first and second press formed door angle brackets (46, 47) do not touch each other when assembled, and wherein the first and second press formed door angle brackets (46, 47) are adapted to be mounted to a vehicular closure panel (27); b) a body component (60) constructed from first and second separate press formed body angle brackets (66, 67), the body component (60) including a pivot axis aperture (63) configured to accept a pivot bushing (80) and the body component (60) is adapted to be mounted to a vehicular body structure (28); c) a pivot pin (90, 100, 110) configured to structurally connect the first and second press formed door angle brackets (46, 47) while holding the door component (40) and the body component (60) in structural assembly and facilitating rotary motion between the door component (40) and the body component (60), the pivot pin (90, 100) being the only structural connection between the first and second press formed door angle brackets; wherein the pivot pin (90, 100) comprises a central cylindrical pivot surface (91,101) with a central diameter adapted to allow rotation of the pivot bushing (80) thereabout; a first end and a second end; wherein the central cylindrical pivot surface (91, 101) is positioned between the first and second ends and the first and second ends are adapted to structurally connect the first and second door angle brackets respectively.