Foldable Hinge Assembly with Living Hinge Barrel
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Solution Overview
Problem
Existing hinges require complex assembly, numerous components, and excessive strength, while also detracting from aesthetic appearance, and often necessitate removing doors from their frames for installation.
Innovation Solution
A foldable hinge assembly with contoured wing members connected by a living hinge, forming a hinge barrel upon folding, which allows for easy assembly without removing the door, using minimal hardware and tools, and featuring alignment bosses and internal radially extending ribs for alignment and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional hinges are assembled using multiple components and hardware, then the hinge provides sufficient strength and reliability, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple traditional hinge components into a single integrated hinge body. The hinge body includes an integrated barrel, leaves, and mounting features all formed as one piece through injection molding, eliminating the need for separate pins, plates, and fasteners that would otherwise be required to assemble a traditional hinge.
Solution Approach 2:
The single hinge body component performs multiple functions simultaneously: it provides the rotating barrel mechanism, the mounting leaves, the fastening features, and the structural support. This multi-functional design replaces what would traditionally require multiple specialized components working together.
2Strength
If traditional hinges use multiple fasteners and hardware for assembly, then the hinge achieves sufficient strength, but excessive assembly strength and numerous tools are required
Solution Approach 1:
The hinge body includes self-contained mounting features such as integrated screw holes, recesses, and alignment elements that guide the installation process. The design allows the hinge to be self-aligned and self-securing, reducing the need for precise manual positioning and excessive tightening force during assembly.
3Reliability
If traditional hinges are assembled with multiple components, then the hinge provides reliable function, but the assembly detracts from aesthetic appearance
Solution Approach 1:
By merging all functional components into a single smooth hinge body, the design eliminates visible seams, gaps, and protruding hardware that would mar the appearance. The integrated design presents a clean, uniform surface that can be painted or finished to match the door, while internally maintaining all necessary mechanical features for reliable operation.
4Manufacturing precision
If traditional hinges require door removal from frame for assembly, then proper installation is achieved, but installation time and complexity increase
Solution Approach 1:
The hinge body is pre-formed with all mounting features, alignment elements, and structural characteristics built in during manufacturing. This preliminary preparation allows the hinge to be directly installed onto the door and frame without requiring disassembly, as all necessary alignment and mounting capabilities are already integrated into the single component.
Data Source
AI summary
Briefly, the invention involves a hinge construction. The hinge construction includes a pair of contoured wing members connected at one end with a living hinge, each wing member including a portion of a hinge barrel. The wings are constructed to be folded around a hinge pin, forming the hinge barrel and positioning the wings in a generally parallel relationship with respect to each other. A portion of a wall or door jamb is positioned between the wings. Fasteners or the like are secured through the wings to fix the assembly, whereby the hinge pin is free to rotate within the barrel created by the folded wings.