Deployable Flap Hinge With Integrated Preload for Noise Reduction
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Solution Overview
Problem
Existing deployable flap hinges for pedestrian protection lack a preload force in the idle position, leading to tolerances that cause disruptive noises due to relative movement of hinge components.
Innovation Solution
A cost-effective and space-saving deployable flap hinge design incorporates a preload element formed from a metal strip, integrated into the flap hinge structure, providing a constant preload force through a spring portion and support portion, ensuring reliable and permanent preloading without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If no preload means is provided in the idle position, then the device complexity is reduced and manufacturing cost is lowered, but tolerances cause disruptive noises due to relative movement of hinge components
Solution Approach 1:
The preload means is integrated into the lower flap part as a monolithic structure, merging the preload function with the existing hinge component. This eliminates the need for separate preload components, maintaining low device complexity while providing the necessary preload force to prevent noise from relative movement between hinge parts.
Solution Approach 2:
The lower flap part serves dual functions: it acts as both a structural hinge component and a self-contained preload means. The preload means is formed as an integral part of the lower flap part, allowing it to automatically provide preload force without requiring external actuation or additional systems.
2Object-generated harmful factors
If additional preload components are added to provide preload force, then operating noise is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of adding separate preload components, the invention merges the preload function into the existing lower flap part. The preload means is formed as an integral structure within the lower flap part, combining multiple functions into a single component and avoiding increased device complexity.
Solution Approach 2:
The lower flap part is designed to perform multiple functions simultaneously: it serves as a structural hinge component and as a preload means. This multi-functionality eliminates the need for dedicated preload components, reducing overall device complexity while providing noise reduction.
3Reliability
If additional preload components are added to provide preload force, then preload reliability is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The preload means is formed as an integral part of the lower flap part through a single manufacturing process. This merging eliminates the need for separate manufacturing and assembly of preload components, reducing manufacturing cost and assembly complexity while ensuring reliable preload through monolithic construction.
Solution Approach 2:
The lower flap part is self-sufficient, providing both structural support and preload functionality through its integrated design. This self-service approach eliminates dependency on additional components and their associated manufacturing and assembly processes, reducing costs while maintaining reliability.
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
The solution effectively reduces operating noise and minimizes the risk of fatigue fracture by maintaining a consistent preload force between hinge components, ensuring reliable operation and longevity.
Implementation Method 1
a spring portion (11b) which adjoins the support portion (11a) and is less thick in cross section than the support portion (11a), in particular having a contour that is bent in the direction towards the upper flap part (4)
Data Source
AI summary
A deployable flap hinge includes a flap part (2) corresponding to a flap (A). The flap part (2) has a flap upper part (4) and a flap lower part (5), a body part (3) corresponding to a vehicle body (B), a first joint assembly (6) connecting the flap part (2) and the body part (3) in an articulated manner, and a second joint assembly (7) connecting the flap upper part (4) and the flap lower part (5) to one another in an articulated manner. The flap upper part (4) can be swivelled relative to the flap lower part (5) between a resting position and a deployed position. The deployable flap hinge also includes a locking assembly (40) for locking the deploying movement of the flap upper part (4), and a pretensioning device (10) for pretensioning the flap upper part (4) in the direction of the deployed position. The pretensioning device (10) includes a pretensioning element (11) formed as a single piece from a part of the flap hinge (1).