Hinge Bearing With Tolerance Ring To Limit Wear
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Solution Overview
Problem
Residential hinges experience uneven wear and excessive clearance due to concentrated loads on the hinge pin, leading to looseness and particulate accumulation between components as the door moves, which is not effectively addressed by existing designs.
Innovation Solution
A hinge assembly with a thrust bearing and radial bearing that includes tolerance rings to limit relative rotation and distribute loads, reducing wear on the hinge pin and knuckles while maintaining smooth door movement by using softer materials for the bearings and adjusting the gap sizes to control installation efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If metal hinge pins contact metal hinge knuckles directly, then the hinge structure is simple, but concentrated loads cause uneven wear and increase clearance over time
Solution Approach 1:
A bearing is introduced as an intermediary component between the hinge pin and knuckle. The bearing includes a raceway that receives the hinge pin and a land that contacts the knuckle, distributing the concentrated load across multiple contact points and reducing wear on both the pin and knuckle surfaces.
Solution Approach 2:
The bearing is constructed with composite materials featuring a softer outer surface layer (such as polymer or composite) over a harder core. This composite structure allows the softer surface to conform to the knuckle and distribute loads while the harder core provides structural strength and longevity.
2Ease of operation
If clearance between hinge components is reduced, then looseness and chuck are minimized, but manufacturing precision requirements increase
Solution Approach 1:
The bearing is designed with specific dimensional parameters including an outer diameter that matches the knuckle, an inner diameter that fits the hinge pin, and a thickness that provides adequate clearance. These parameter adjustments allow the bearing to minimize looseness while accommodating manufacturing tolerances.
Solution Approach 2:
The bearing incorporates a flexible or compliant element that can dynamically adjust to variations in component dimensions. This dynamic capability allows the bearing to compensate for manufacturing tolerances and maintain optimal clearance during operation.
3Reliability
If softer materials are used for bearings, then wear is reduced and loads are distributed, but the bearing strength decreases
Solution Approach 1:
The bearing uses composite construction with a softer outer surface material (polymer or composite) over a harder inner core. The softer outer layer provides wear resistance and load distribution by conforming to the knuckle surface, while the harder inner core maintains structural strength and load-bearing capacity.
Solution Approach 2:
Different regions of the bearing have different material properties optimized for their specific functions. The outer surface is softer for wear resistance and load distribution, while the inner core is harder for structural strength. This local differentiation of material quality resolves the contradiction between softness for wear resistance and hardness for strength.
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 reduces wear on the hinge components, minimizes looseness and particulate accumulation, and distributes loads radially, ensuring smooth door operation and extended hinge assembly lifespan.
Implementation Method 1
A bearing limits relative rotation between the first knuckle and the hinge pin
Implementation Method 2
A tolerance ring between the hinge pin and the first knuckle urges the bearing away from the axis
Data Source
AI summary
An example hinge includes a hinge pin extending along an axis and a first knuckle for receiving the hinge pin. The first knuckle is rotatable about the axis. A second knuckle for receiving the hinge pin and is rotatable about the axis. At least one bearing limits relative rotation between the first hinge knuckle and the hinge pin. The example hinge assembly may include a tolerance ring between the hinge pin and the first knuckle to urge the bearing away from the axis. An example method of producing a hinge includes the steps of permitting a first hinge plate to move relative a hinge pin and limiting movement of a second hinge plate relative a hinge pin. The method biases a bearing adjacent the hinge pin to limit movement of the second hinge plate relative the hinge pin.