Dual-Axis Overmolded Hinge for 180° Rotation in Compact Assemblies
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Solution Overview
Problem
Existing hinges face challenges in achieving a large range of motion while maintaining a compact size, low assembly time, and minimizing part count and cost.
Innovation Solution
A dual-axis over-molded hinge design with two separate shafts and friction elements, allowing 180° rotation without protrusion, and a single injection molding process to integrate friction assemblies, enabling consistent torque and modular adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hinge is designed with a large range of motion, then the rotational capability is improved, but the overall size and profile increase
Solution Approach 1:
The hinge design places one shaft and its associated friction element inside the housing of another shaft assembly. The first shaft is at least partially contained within the first molded housing, and the second shaft is at least partially contained within the second molded housing, with both shafts working together to achieve 180° rotation while maintaining a compact profile.
Solution Approach 2:
The dual-axis configuration allows the hinge to achieve rotation in two different dimensions or planes. The first shaft provides rotation about a first axis, and the second shaft provides rotation about a second axis, enabling complex motion patterns within a compact volume.
2Ease of operation
If a hinge uses multiple separate components to achieve dual-axis rotation, then the rotational capability is improved, but the assembly time and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple hinge functions into a single integrated device. Both shafts and their associated friction elements are contained within a single housing structure that can be manufactured in one injection cycle, eliminating the need for separate assembly operations and reducing the total part count.
Solution Approach 2:
The single housing structure serves multiple functions: it contains both shaft assemblies, provides structural support for dual-axis rotation, and integrates the friction elements for torque control. This multi-functional design reduces the need for separate components.
3Manufacturing precision
If a hinge is designed with separate manufacturing steps for different components, then the manufacturing precision is improved, but the production time and cost increase
Solution Approach 1:
The mold tooling is designed with all features for both shaft assemblies and the housing integrated beforehand. The injection cycle is configured to form all components in the correct positions during a single manufacturing process, eliminating the need for subsequent assembly operations.
Solution Approach 2:
The manufacturing process merges multiple成型 operations into a single injection cycle. The mold tooling simultaneously forms the housing and both shaft assemblies with their friction elements integrated, achieving both manufacturing precision and high productivity.
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 design achieves a compact, efficient hinge with consistent torque, reduced manufacturing costs, and simplified assembly, suitable for applications requiring flush configurations and varying torque needs.
Implementation Method 1
friction elements embedded in the shaft overmold portions
Data Source
AI summary
One aspect is an overmolded hinge device having a first and a second shaft, each having first and second ends. A first friction element is mounted on the first shaft. A first molded housing is at least partially enclosing the first shaft and a second molded housing is at least partially enclosing the second shaft. A first molded outer link is at least partially enclosing each of the first and second shafts and a second molded outer link is at least partially enclosing each of the first and second shafts. One of the first molded housing and the first molded outer link enclose the first friction element