Integrated Door Hinge Reinforcement for Simpler Vehicle Assembly
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Solution Overview
Problem
Existing vehicle door hinge designs require two separate reinforcements, increasing manufacturing complexity, time, and costs, and necessitate manual handling and gluing, which complicates the manufacturing process.
Innovation Solution
A single hinge reinforcement with a plate featuring aligned hinge seats, flanges, and a reinforcing floor, secured by spot welding without glue, simplifying the manufacturing process and reducing the number of welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate hinge reinforcements are used for upper and lower hinges, then each hinge can be properly reinforced, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent combines two separate hinge reinforcements (upper and lower) into a single integrated reinforcement structure. This single piece includes both the upper hinge reinforcement portion and the lower hinge reinforcement portion, eliminating the need for separate parts and their respective assembly operations. The merging reduces part count, simplifies manufacturing, and eliminates the need for multiple spot welds while maintaining the structural integrity and reinforcement function for both hinges.
2Reliability
If two separate hinge reinforcements are used, then each hinge receives proper reinforcement, but the production time and worker effort increase
Solution Approach 1:
The single integrated reinforcement structure allows workers to handle and install one piece instead of two separate reinforcements. This reduces the number of loading operations, positioning operations, and spot welding operations required during assembly. The consolidated design maintains adequate reinforcement for both upper and lower hinges while significantly reducing the time and effort required in the body shop during vehicle assembly.
3Reliability
If manual gluing is required for hinge reinforcements, then proper bonding is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent eliminates the gluing process entirely by designing a reinforcement structure that relies solely on spot welding for attachment. The single integrated reinforcement is configured to be properly secured through spot welds alone, removing the need for adhesive application, curing time, and associated quality control steps. This extraction of the gluing operation simplifies the manufacturing process while maintaining adequate bonding strength through the welded connection.
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
Simplifies manufacturing by eliminating the need for manual gluing and reducing the number of welds, thereby lowering costs and improving geometric quality.
Implementation Method 1
The first and second flanges are welded to an inner door
Data Source
AI summary
A door hinge reinforcement has a plate with a first hinge receiving seat and a second hinge receiving seat spaced axial from the first receiving seat along the plate. A window in the plate, the window positioned between the first and second receiving seats. A reinforcing floor at a terminal end of the plate. The floor is positioned transverse to the plate and adjacent the second receiving seat.