Preassembled Friction Hinge Module for Lightweight Console Assembly
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Solution Overview
Problem
Conventional friction hinge assemblies used in center consoles are large, heavy, and require significant manufacturing tooling, limiting their efficiency and practicality due to their complex assembly of large brackets and stamped parts.
Innovation Solution
A preassembled friction hinge module design featuring a shaft with a torque element and a housing that allows for lighter materials like molded plastic, reduces component count, and simplifies manufacturing by integrating the torque element within the housing, enabling easier assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional friction hinge assemblies are manufactured as large assemblies of stamped parts, then the hinge provides sufficient structural strength and frictional resistance, but the weight and device complexity increase significantly
Solution Approach 1:
The patent combines multiple separate stamped parts into a single integrated housing structure that contains the torque element. This merging reduces the total number of components and eliminates the need for additional brackets and mounting hardware, thereby reducing weight while maintaining structural strength through the integrated design.
Solution Approach 2:
The patent employs composite construction by integrating the torque element within a molded housing structure. This composite approach allows the use of lighter materials for the housing while maintaining the frictional resistance function, reducing overall weight compared to traditional all-metal stamped part assemblies.
2Reliability
If conventional friction hinge assemblies use large stamped parts and brackets, then the hinge provides adequate durability and frictional engagement, but the manufacturing complexity and tooling requirements increase
Solution Approach 1:
The patent merges multiple manufacturing operations into a single molded housing structure. Instead of requiring separate stamping operations for brackets, mounting plates, and torque element housings, the integrated design can be produced in one molding operation, significantly reducing manufacturing complexity and tooling requirements while maintaining durability.
Solution Approach 2:
The patent segments the hinge into a modular preassembled unit with a standardized housing and torque element configuration. This segmentation allows for standardized manufacturing processes and simplifies assembly into the final application, reducing overall manufacturing complexity while maintaining reliability through consistent quality control.
3Reliability
If conventional friction hinge assemblies are designed as large preassembled units, then the hinge provides stable frictional engagement, but the assembly size and installation complexity increase
Solution Approach 1:
The patent nests the torque element within the housing structure, creating a compact preassembled unit. This nesting arrangement maintains stable frictional engagement between the torque element and shaft while minimizing the overall assembly size, making it easier to install in space-constrained applications compared to conventional dispersed component designs.
4Adaptability or versatility
If conventional friction hinge assemblies use multiple separate components, then the hinge allows for adjustable friction settings, but the number of parts and assembly steps increase
Solution Approach 1:
The patent combines the friction adjustment mechanism within the integrated housing structure, eliminating the need for separate adjustment components. The torque element can be adjusted for friction settings while remaining contained within the single housing unit, maintaining adaptability while reducing component count and simplifying assembly procedures.
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 new design results in a lighter, more efficient hinge module that reduces manufacturing complexity and weight, while maintaining consistent frictional resistance for user experience, making it suitable for various applications such as automotive center consoles.
Implementation Method 1
a torque element frictionally engaging the shaft; The mechanical interference holds components in a stable position after they are pivoted and released
Implementation Method 2
the shaft extending through at least the first aperture, the interior space of the housing, and the second aperture
Data Source
AI summary
A hinged system includes a preassembled hinge module for pivotally coupling a first component to a second component. The preassembled hinge module includes a shaft, a torque element frictionally engaging the shaft, and a housing. The housing includes a cover, a side wall, and a rear wall that define an interior space enclosed within the housing. The interior space receives the torque element inside the housing. The cover defines a first aperture, and the rear wall defines a second aperture, the first aperture and the second aperture aligned with a pivot axis of the shaft. The shaft extends through at least the first aperture, the interior space, and the second aperture. The shaft is separate from, and configured to be mounted to, the first component. The housing is separate from, and configured to be mounted to, the second component.