Playless Hinge System With Releasable Pin for Minimal Door Clearance
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Solution Overview
Problem
Traditional hinges require excessive thickness and recessing, leading to space constraints and axial load issues, causing sagging, vibrations, and abrasive wear, especially in applications with limited space or heavy loads.
Innovation Solution
A hinge system with adjustable top and bottom assemblies that allow for precise horizontal and vertical positioning, featuring an axial load arm and releasable hinge pin, which minimizes clearance and supports heavy loads while concealing hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional hinges are used to support door opening and closing, then the door can rotate about a fixed axis, but the hinge requires excessive thickness and recessing which creates space constraints
Solution Approach 1:
The hinge system is divided into separate components: a hinge body mounted on the door and a hinge strike mounted on the frame, connected by a hinge pin. This segmentation allows the hinge to function without requiring excessive thickness in the door material, as the pivot mechanism is distributed across multiple parts rather than requiring a single thick recess.
Solution Approach 2:
The hinge design transitions from a traditional single-plane recessed hinge to a three-dimensional configuration where the hinge pin protrudes from the door surface. This dimensional change allows the rotation axis to extend beyond the door face, eliminating the need for deep recesses while maintaining rotational functionality.
2Force
If traditional hinges are used to support heavy axial loads, then the door can be supported, but the hinge sags and deforms over time causing vibrations and abrasive wear
Solution Approach 1:
The hinge incorporates a spring-loaded mechanism that applies a counteracting force to the axial load. The spring continuously pushes against the hinge pin, creating a pre-load that compensates for the door's weight and external forces, preventing sagging and maintaining consistent contact between hinge components.
Solution Approach 2:
The hinge design changes the mechanical parameters of the connection by using a spring-loaded pin instead of a rigid fixed pin. This allows the hinge to dynamically adjust its stiffness and contact pressure, maintaining optimal load distribution and reducing abrasive wear under varying axial loads.
3Ease of manufacture
If traditional hinges require recessing in the door, then the hinge can be mounted, but it requires minimum thickness and multiple layers of material
Solution Approach 1:
The hinge design extracts the rotation mechanism from the door's internal structure and places it on the external surface. Instead of recessing the hinge into the door thickness, the hinge pin mounts on the door face and connects to a strike on the frame, eliminating the need for complex multi-layer door construction.
4Ease of operation
If traditional hinges are used in confined spaces, then the door can be installed, but the excessive clearance required limits installation options
Solution Approach 1:
The hinge components are designed to nest compactly against the door and frame surfaces. The hinge pin and strike are configured to minimize protrusion and clearance requirements, allowing the door to be installed in confined spaces where traditional hinges would require excessive gap space.
Data Source
AI summary
The invention presents an innovative design for door hinge systems to eliminate excessive spacing between the door and jamb, offering use of the hinge system in more limited spaces. The invention also allows use of a hinge system for use in hidden or secret panel doors. The invention comprises a bottom hinge assembly comprising an axial load arm capable of distributing weight, and a top hinge assembly comprising a releasable hinge pin to provide a high degree of customization for users.