Concealed Door Hinge Sheet Metal Housing Reinforcement
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Solution Overview
Problem
Existing concealed door hinge technologies face limitations in mechanical stability, material efficiency, and production costs, with castings having limited mechanical properties and requiring complex tools, and milled versions requiring excessive material and complex machining.
Innovation Solution
A concealed door hinge design featuring two interlocking sheet metal housing parts that form a stable joint housing, allowing for non-cutting production and increased material thickness in stressed zones, with a multi-axis joint and bearing bushes for low-maintenance guidance, and adjustable reinforcement for enhanced stability and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cast parts are used for receiving bodies, then complex tools are avoided and production is simplified, but mechanical properties are limited and rework is required
Solution Approach 1:
The receiving body is constructed as a composite structure combining sheet metal housing parts with integrated reinforcement elements. The housing consists of outer and inner sheet metal parts that can be plugged into one another, with reinforcement plates attached to the back of lugs to increase material thickness in loaded areas. This composite construction achieves both ease of manufacture from sheet metal and enhanced mechanical properties through strategic reinforcement.
2Strength
If milled parts are used for receiving bodies, then mechanical properties are improved, but material consumption increases and complex machining is required
Solution Approach 1:
Instead of removing material through machining, the invention adds material strategically through reinforcement plates attached to the back of lugs. This changes the approach from subtractive manufacturing (milling) to additive reinforcement, maintaining high mechanical properties while minimizing material consumption. The reinforcement plates increase material thickness only in the specific areas where loads are transferred, rather than requiring the entire receiving body to be over-engineered with excess material.
3Ease of manufacture
If sheet metal parts are used for housing, then production cost is reduced and manufacturing is simplified, but stability and load-bearing capacity may be compromised
Solution Approach 1:
The sheet metal housing is constructed as a composite structure with outer and inner housing parts that can be plugged into one another, creating a multi-layer construction that enhances stability. Reinforcement plates are attached to the back of lugs to increase material thickness in loaded areas. This composite sheet metal construction maintains the cost advantages of sheet metal manufacturing while achieving the stability and load-bearing capacity typically associated with more substantial materials.
Solution Approach 2:
The housing design utilizes a three-dimensional plugged-together construction of outer and inner housing parts, creating stability through spatial arrangement rather than relying solely on material thickness. The reinforcement plates add another dimension of strength by being attached to the back surface of lugs, effectively increasing material thickness in critical areas without adding complexity to the overall sheet metal fabrication process.
4Strength
If material thickness is increased in stressed zones, then load-bearing capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The receiving body is segmented into distinct components: outer housing parts, inner housing parts, and separate reinforcement plates. This segmentation allows each component to be manufactured independently using standard sheet metal processes, then assembled together. The reinforcement plates are attached separately to the back of lugs, increasing material thickness in stressed zones without requiring complex integrated forming operations. This modular segmentation maintains manufacturing simplicity while achieving enhanced load-bearing capacity where needed.
Data Source
Figure 1
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AI summary
The hinge has a multi-axle joint (10), and two housings (20, 30) inserted into a narrow side of a door leaf and into a door frame, respectively. Fastening plates (21) are provided for fastening the housings with the door leaf and the door frame, respectively. One of the housings is formed from outer and inner housing parts (22, 23) that are plugged into each other. The housings are made from metal sheets, where the housing parts are connected with one another in a force-fit manner. A longitudinal hole is formed in the inner housing part, and a cylinder sleeve (25) is inserted into the hole.