Segmented Male Hinge Torque Decay via Stacked Connection Plates
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Solution Overview
Problem
The existing hinge structures experience a significant increase in torque decay due to the fit condition gradually trending to loose fit between the shaft and socket portions, with no corresponding increase in contact area, leading to premature failure when the torque provided by the male and female hinges reduces to a specified value.
Innovation Solution
A combination-type male hinge is manufactured by perforating connection plates with an extension bar to create sheared and torn regions, increasing the contact area between the shaft and socket portions, and allowing for the replacement of worn-out connection plates to maintain torque output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shaft portion is rotatably assembled into the socket portion with diametrical grooves for lubrication, then the wear between shaft and socket is reduced through lubrication, but the contact area between shaft and socket does not increase, causing the fit condition to gradually trend to loose fit and torque decay
Solution Approach 1:
The shaft portion is segmented into multiple connection plates (first connection plate, second connection plate, etc.) that are stacked along the extension bar. This segmentation allows each connection plate to contact the socket portion, effectively increasing the total contact area between the shaft and socket portions while maintaining rotational functionality.
Solution Approach 2:
The invention transitions from a single shaft structure to a multi-plate stacked structure along the extension bar dimension. By adding the stacking dimension (multiple connection plates arranged sequentially along the extension bar), the contact area with the socket portion is significantly increased without compromising the rotational movement capability.
2Ease of operation
If the fit condition between shaft and socket gradually trends to loose fit due to wear, then rotation becomes easier, but the contact area does not increase and torque decay occurs leading to premature failure
Solution Approach 1:
The shaft portion is divided into multiple connection plates that can independently contact the socket portion. This segmentation ensures that even as wear occurs and fit becomes looser, multiple contact points maintain the necessary torque transmission, preventing premature failure.
Solution Approach 2:
Different connection plates can have different local characteristics (such as varying diametrical grooves or surface treatments) to optimize both rotational smoothness and torque maintenance at different positions along the extension bar, allowing localized optimization of the wear interface.
3Ease of manufacture
If conventional cutting methods are used to form diametrical grooves, then lubrication is provided, but the manufacturing process is complex and the contact area is limited to the groove surfaces
Solution Approach 1:
Instead of forming grooves in a single shaft, the invention uses multiple connection plates stacked along the extension bar. Each plate can have simplified groove formations, and the cumulative contact area of all plates provides sufficient lubrication surfaces while greatly increasing total contact area with the socket portion.
Solution Approach 2:
The contact area is increased by adding the stacking dimension of multiple connection plates along the extension bar, rather than relying solely on the circumferential groove surfaces of a single shaft. This dimensional expansion provides both lubrication surfaces and increased load-bearing contact area.
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
This approach effectively reduces the decay rate of torque and extends the lifespan of the hinge structure by increasing the contact area between the shaft and socket portions, while enabling the replacement of worn parts to maintain functionality.
Implementation Method 1
a punched peripheral surface of each connection plate has at least one sheared region and at least one torn region
Implementation Method 2
increasing the contact area between the shaft and socket portions
Implementation Method 3
it is able to fill lubricants into the ring-alike spaces to lubricate the shaft portion and the socket portion, so as the reduce the wear between the shaft portion and the socket portion
Data Source
AI summary
A method is applied to manufacture a combination-type male hinge comprising a connection portion and a shaft portion extended from the connection portion, and comprises the steps of: forming a plurality of connection plates by punching along at least one punching direction; making each connection plate have a punched peripheral surface and at least one perforating hole; making the punched peripheral surface have at least one sheared region and at least one torn region; and perforating the perforating holes of the connection plates by a extension bar extended from the connection portion, so as to connect the connection plates and manufacture the shaft portion of the combination-type male hinge.