Invisible Concealed Hinge with Deep-Drawn Box Structure
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Solution Overview
Problem
Conventional invisible hidden door hinges require complex geometric shapes and high precision in manufacturing, leading to material inefficiency and increased costs due to the need for thick metal structures to ensure mechanical strength, which can result in aesthetically unpleasant and installation-challenged designs.
Innovation Solution
A structurally perfected invisible hidden hinge design that utilizes a single metal sheet to create a box-shaped support structure with a concave shape, allowing for reduced material thickness while maintaining mechanical strength, and incorporates movable inserts and bodies with integral articulation devices to adjust position, all fabricated using deep drawing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal structures with thick walls are used to ensure mechanical strength, then the hinge can support heavy doors, but the material consumption increases and costs rise
Solution Approach 1:
The patent employs thin-walled metal sheets formed into box-shaped structures through deep drawing processes. These thin-walled structures provide sufficient mechanical strength for supporting heavy doors while dramatically reducing material consumption compared to conventional thick-walled constructions. The thin-walled design is achieved by optimizing the forming process and structural geometry.
Solution Approach 2:
The patent utilizes curved surfaces and optimized geometries in the box-shaped structures formed from metal sheets. The curved surfaces distribute mechanical stresses more effectively, allowing thinner wall sections to maintain the required strength for door support while reducing overall material usage.
2Manufacturing precision
If complex geometric shapes with numerous details are manufactured with high precision, then the hinge operation is ensured, but the manufacturing complexity and costs increase
Solution Approach 1:
The hinge is divided into separate modular components including connecting bodies, support structures, and articulation devices that can be manufactured independently using standardized deep drawing processes. This segmentation allows each component to be produced with consistent precision while simplifying the overall manufacturing system and reducing complexity.
Solution Approach 2:
The patent optimizes key parameters such as wall thickness, box shape dimensions, and material properties to achieve the required precision and functionality. By carefully controlling these parameters during the deep drawing process, high precision is obtained without increasing structural complexity or manufacturing difficulty.
3Quantity of substance
If the hinge structure is simplified to reduce material usage, then costs decrease, but the mechanical performance may be compromised
Solution Approach 1:
The patent employs composite construction by nesting multiple metal sheets into box-shaped structures, creating a composite structure that achieves high strength-to-weight ratio. This composite approach allows material reduction while maintaining or even improving mechanical performance through the synergistic effect of multiple layers working together.
Solution Approach 2:
The curved surfaces and optimized geometries in the thin-walled box structures provide superior stress distribution compared to flat structures. This geometric optimization allows the simplified thin-walled design to achieve the same or better mechanical performance as thicker structures, ensuring reliability while reducing material usage.
Data Source
Figure 1(a)~2
Figure 3(a)
Figure 4(a)~4(d)
AI summary
In a invisible hidden door hinge (1), a first connecting body (2a) and a second connecting body (2b) are connected together by an articulation device (3) which allows the relative movement between a condition of opening and a closed condition in which the first (2a) and the second (2b) connecting body define a seat in which the articulation device (3). The articulation device (3) comprises at least one arm (32) with a first end (32a) on the first connecting body (2a) and a second end (32b), opposite to the second, on the second connecting body (2b). Said arm (32) is shaped from a respective single metal sheet in a single concave piece with concavity facing towards a reference plane parallel to the length direction (Z1, Z2) of the connection bodies (2a,2b) and passing through the ends (32a,32b) of the first arm (32).