Roller Hinge Assembly with Reinforced Tubular Bushing
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Solution Overview
Problem
Existing roller hinge constructions for multi-panel articulating sectional doors face increased stress and structural issues due to load distribution, leading to higher material and labor costs, as well as potential premature degradation if not properly aligned and installed.
Innovation Solution
A roller hinge assembly using multiple uniformly sized hinges with a single tubular roller bushing and reinforcement members to ensure alignment and distribute loads, allowing for a single standard hinge assembly that can be used as a unit or combined with others to support panel rollers, reducing manufacturing and installation costs while enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If oversized hinges or multiple hinges are positioned adjacent the lateral edges to address increased stress, then the structural strength is improved, but the material cost and installation complexity increase
Solution Approach 1:
The hinge assembly is divided into multiple standard-sized hinge units (typically three) that are evenly spaced along the lateral edge of the door panel. Each hinge unit is a separate, standardized component that can be independently manufactured and installed, yet they work together as a unified support system to distribute and bear the increased lateral stresses.
Solution Approach 2:
Multiple standard hinge units are combined along the lateral edge to create a composite hinge assembly that collectively provides the necessary structural strength. The hinges are merged through their shared function of supporting the roller assembly and door panel, creating a distributed support system that addresses stress issues without requiring oversized individual components.
2Strength
If multiple hinges are positioned adjacent the lateral edges to address increased stress, then the load distribution is improved, but the installation labor cost increases
Solution Approach 1:
The same standard hinge unit design is used throughout the door panel assembly, serving multiple functions: connecting adjacent door panels, supporting the roller assembly, and distributing lateral stresses. This universal hinge design allows for standardized manufacturing and simplified installation procedures, reducing labor costs despite the increased number of hinges required.
Solution Approach 2:
Rather than changing the size or design parameters of individual hinges to handle increased loads, the solution changes the quantity parameter by installing multiple standard hinges. This approach maintains the simplicity and standardization of individual hinge units while achieving the required load distribution through increased number of components.
3Stress or pressure
If hinges are oversized to address increased stress at lateral edges, then the stress resistance is improved, but the material cost increases
Solution Approach 1:
The stress resistance function is segmented across multiple standard-sized hinge units rather than concentrated in a single oversized hinge. Each standard hinge bears a portion of the total load, and the collective arrangement of multiple hinges along the lateral edge provides the necessary stress resistance while using standard material quantities per unit.
Solution Approach 2:
The solution changes the quantity parameter (number of hinges) rather than the size parameter (dimensions of individual hinges). By installing multiple standard hinges instead of fewer oversized hinges, the total material cost is optimized while achieving the required stress resistance through distributed load bearing.
Data Source
AI summary
A roller hinge assembly for connecting articulating door panels and simultaneously supporting a laterally extending panel support roller assembly includes one or more hinge units each having a male hinge strap and a female hinge strap. The structural integrity of one or more of the hinge units is supplemented by a reinforcing, slotted tubular member fitted over the roller axle support bushing which extends between and simultaneously engages opposed, spaced hinge strap arms. Two or more such hinge units may be arrayed laterally or side by side co-joined by a single hinge pin. Further, to insure appropriate alignment, a single tubular roller bushing may co-join the male or the female hinge units.