3D-Printed Hinge Assembly With Engaging Bearings to Reduce Free Play
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Solution Overview
Problem
Existing hinge manufacturing methods, including additive processes like 3D printing, face challenges in achieving suitable flexibility and longevity in deformable areas while maintaining necessary rigidity and strength, and often result in excessive free play due to large component spacing.
Innovation Solution
A printed hinge assembly comprising two bodies irremovably and rotatably coupled along a rotational axis, with opposing radial and axial bearing surfaces that engage within a working range to fix the relative positions in both radial and axial directions, allowing for additive manufacturing by creating a continuous gap outside the working range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single piece or living hinge is created via additive manufacturing, then the need for multiple components and assembly is eliminated, but it becomes difficult to achieve suitable flexibility and longevity in deformable areas while maintaining necessary rigidity and strength
Solution Approach 1:
The hinge is divided into distinct functional zones: rigid bearing surfaces for structural support and deformable hinge regions for flexibility. This segmentation allows each zone to be optimized independently while manufactured as a single integrated component through additive manufacturing.
Solution Approach 2:
Different regions of the hinge are assigned different material properties and structural characteristics - the bearing surfaces are designed with high rigidity and strength, while the hinge regions are designed with controlled deformability. This local differentiation resolves the contradiction between overall rigidity and localized flexibility.
2Ease of manufacture
If traditional multi-piece hinges are manufactured via additive processes, then production flexibility is improved, but large spacing between components results in excessive free play over the working range
Solution Approach 1:
Multiple hinge components are merged into a single monolithic structure manufactured by additive manufacturing. The bearing pin and bearing surfaces are integrated into one continuous piece, eliminating gaps and misalignment issues that occur with assembled multi-component hinges, thereby reducing free play while maintaining additive manufacturing advantages.
3Strength
If bearing surfaces are continuously engaged to fix relative positions, then rigidity and strength are improved, but the hinge cannot be manufactured via printing or additive processing
Solution Approach 1:
The engagement state of the bearing surfaces transitions dynamically between engaged and disengaged positions. During operation, the bearing surfaces engage to provide strength and rigidity; during manufacturing, they are in a disengaged state that allows additive processing. This dynamic characteristic resolves the contradiction between strength requirements and manufacturing feasibility.
Data Source
AI summary
A hinge comprises a first body and a second body irremovably rotatably coupled along a rotational axis of the hinge. The first body and the second body comprise opposing radial bearing surfaces engaged only within a working rotational range of the hinge for fixing the relative position of the first body and the second body in a radial direction with respect to the rotational axis of the hinge. The first body and the second body further define opposing axial bearing surfaces engaged only within the working rotational range of the hinge for fixing the relative position of the first body and the second body in an axial direction with respect to the rotational axis of the hinge. The opposing radial bearing surfaces and the opposing axial bearing surfaces are not engaged outside of the working rotational range.