Integrated Hinge and Locking Mechanism for Vehicle Electrical Covers
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Solution Overview
Problem
Vehicle electrical system components often require covers that balance ease of access with secure locking and cost-effectiveness, as existing solutions either lack adequate security or feature complex, expensive hinges and securing mechanisms.
Innovation Solution
A plastic cover with an integrated 'living hinge' and locking mechanism, featuring a pivoting cover portion connected to a main body via a thinner hinge section that flexes for access and thicker sections for stability, along with a locking mechanism using post and clamping features for secure closure, all molded as a single piece to reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cover is designed to provide easy access to underlying electrical components, then ease of operation is improved, but adequate locking and securing capability deteriorates
Solution Approach 1:
The patent combines the hinge and locking mechanism into a single integrated component molded from the same plastic material. The hinge portion and locking features are formed as one piece, eliminating the need for separate hinge components and fasteners. This integration maintains easy pivoting operation while providing adequate securing capability through the unified structure.
Solution Approach 2:
The integrated hinge component serves multiple functions simultaneously: it acts as the pivoting mechanism that enables easy access, provides structural support, and incorporates locking features that secure the cover in the closed position. This multi-functionality resolves the contradiction by combining ease of operation and reliable locking in a single component.
2Reliability
If complex and expensive hinges and securing features are used to provide adequate locking, then reliability is improved, but manufacturing cost deteriorates
Solution Approach 1:
The patent merges the hinge and locking features into a single integrated component that is molded as one piece from the same plastic material. This eliminates the need for multiple separate parts, complex assemblies, and expensive fasteners, thereby reducing manufacturing cost while maintaining adequate locking capability through the integrated design.
Solution Approach 2:
The entire integrated hinge and locking mechanism is formed from the same plastic material using injection molding. This homogeneity simplifies manufacturing by eliminating material transitions, multiple molding processes, and complex assembly operations, thereby reducing production costs while ensuring consistent locking performance.
3Reliability
If multiple separate hinge and locking components are used, then locking capability is improved, but device complexity deteriorates
Solution Approach 1:
The patent combines multiple separate components (hinge and locking features) into a single integrated structure molded from one piece of plastic material. This integration reduces the total number of parts, simplifies assembly, and lowers device complexity while maintaining adequate locking capability through the unified design.
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 provides easy access to underlying components while ensuring secure closure, reducing manufacturing expenses and eliminating the need for separate hinge components, thus offering a cost-effective and secure cover for vehicle electrical system components.
Implementation Method 1
a thinner hinge section that flexes
Data Source
AI summary
A cover for a vehicle electrical system component, such as a pre-fuse assembly, that includes an integrated hinge and locking mechanism. The integrated hinge allows a pivoting cover portion to easily be rotated out of the way in order to give access to an underlying component (e.g., a jump post), while the integrated locking mechanism allows that same cover to be securely locked onto itself when no access is needed. The cover is not limited to a pre-fuse assembly and may be used with other vehicle electrical system components, such as a power distribution device (e.g., a power distribution box, an electrical connection box, a junction box assembly, etc.), a wire harness protector, etc.