Integral Hinge Knuckles for Electronic Safe Doors

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Solution Overview

Problem

Conventional hinge mechanisms in electronic safes are aesthetically unpleasing due to external welds and costly, with potential weak points for attacks, and existing solutions either compromise on security or aesthetics or increase the safe's volume.

Innovation Solution

The integration of hinge knuckles directly into the safe door and sidewall eliminates external welds and employs a removable hinge pin arrangement, providing superior strength and security while allowing for easier manufacturing, maintenance, and reconfiguration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If commercial hinges with flanges are used and welded to the safe and door, then the hinge mechanism provides functional connectivity, but external welds create unsightly cosmetic appearance and increase manufacturing cost

Engineering Contradiction:

Improvecosmetic appearanceVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The hinge knuckles are merged directly into the door and side wall structures, eliminating separate flanges and external welds. The door knuckle is formed as an integral part of the door, and the side wall knuckle is formed as an integral part of the side wall, creating a seamless appearance without visible external welding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The external flanges and their associated welds are extracted/removed from the design. Instead of using separate flange components that require external welding, the hinge functionality is achieved through integral knuckles formed directly on the door and side wall surfaces.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If flange-based hinge mechanisms are used, then the hinge provides structural connection, but the external welds create potential weak points for attack

Engineering Contradiction:

Improvehinge structural strengthVSAvoidvulnerability to attack

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

By merging the hinge knuckles into the integral structures of the door and side wall, the hinge mechanism becomes part of the overall structural framework rather than a separate attached component. This integration eliminates the flange-weld interfaces that create vulnerability points, as the knuckles are formed as continuous structural elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The design converts what would traditionally be vulnerable external weld interfaces into beneficial integral structures. The knuckles are formed as continuous, seamless parts of the door and side wall, transforming the potential weakness of external connections into the strength of integrated structural elements.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If hinges are mounted on the outside of the door and safe wall, then the hinge mechanism is accessible for installation, but it negatively impacts aesthetics and increases the safe's volume

Engineering Contradiction:

Improveinstallation accessibilityVSAvoidsafe volume

Core Design Contradiction:

Ease of operationVSVolume of stationary object

Solution Approach 1:

The hinge knuckles are merged into the surfaces of the door and side wall, with the knuckle bodies formed as integral extensions of these surfaces. This integration eliminates the need for external mounting space, as the hinge structure occupies no additional external volume beyond the thin profile of the knuckle formations on the existing surfaces.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If multiple external welds are used to secure hinge flanges and knuckles, then the hinge connection is secured against attacks, but the manufacturing cost increases significantly

Engineering Contradiction:

Improvehinge securityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By forming the knuckles as integral parts of the door and side wall through rolling or forming operations during manufacturing, the need for multiple separate welding operations is eliminated. The structural security previously achieved through multiple welds is now achieved through the continuous integral structure, significantly reducing manufacturing complexity and cost.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10119322B2Electronic safes and hinge mechanisms for electronic safe

Publication Date: 2018.11.06 ELLENBY TECHNOLOGIES INC

AI summary

An electronic safe and hinge combination is addressed in which hinges are integrally formed from a door plate and safe wall plate, such as a safe side wall. No exterior welds are employed so that a strong and aesthetically pleasing fascia results. Additionally, a hinge and removable hinge pin arrangement is provided which allows the safe body to be constructed separately from the doors and mated together during final assembly, as well as, facilitating repair of a damaged door and retrofitting one door for another for an in the field upgrade. An electronic drop safe is described employing two or more doors and mounted to a safe having a sidewall with an integrally formed hinge.