Shutter Hinge Using Continuous Fiber Reinforced Plastic
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Solution Overview
Problem
Existing shutter designs suffer from appearance deterioration due to creep deformation, particularly in high-temperature environments, and struggle with adjusting operating force effectively.
Innovation Solution
The use of continuous fiber reinforced plastic or pre-preg sheets as hinge base materials, which provide enhanced strength, rigidity, and creep-resistant properties, allowing for easy bending and reducing thickness, while maintaining a decorative film with printed patterns without thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cushioning sheet is used as hinge base material in conventional shutters, then the shutter can bend and slide, but creep deformation occurs over time causing pattern distortion and appearance deterioration
Solution Approach 1:
The patent applies composite materials by combining a resin base material with continuous fibers (glass fibers, carbon fibers, or organic fibers) embedded within it. This composite structure provides both the flexibility needed for bending and sliding operations and the dimensional stability to prevent creep deformation. The fibers reinforce the resin matrix, maintaining the hinge base material's shape even under repeated stress and high-temperature conditions, thus preventing pattern distortion while enabling smooth shutter operation.
2Reliability
If the cushioning sheet thickness is increased to reduce creep deformation, then appearance stability improves, but operating force increases
Solution Approach 1:
The composite material structure with continuous fibers embedded in resin provides high strength-to-weight ratio and stiffness. This allows the hinge base material to maintain sufficient thickness for creep resistance while the fiber reinforcement ensures that the required operating force remains within acceptable limits. The fibers carry the load efficiently, preventing the need for excessive thickness that would make the shutter difficult to open and close.
3Ease of operation
If the cushioning sheet thickness is decreased to reduce operating force, then ease of operation improves, but bend lines become visible and appearance deteriorates
Solution Approach 1:
The continuous fiber reinforcement in the composite hinge base material provides structural integrity even at reduced thicknesses. The fibers prevent the formation of visible bend lines by distributing stress uniformly throughout the material during sliding operations. This allows the shutter to be made thinner and easier to operate while maintaining a smooth, high-quality appearance without the defects associated with conventional cushioning sheets.
4Ease of manufacture
If conventional materials are used in high-temperature environments, then manufacturing is simple, but thermal deformation occurs causing pattern distortion
Solution Approach 1:
The composite hinge base material consisting of resin and continuous fibers exhibits superior thermal stability compared to conventional materials. The fiber reinforcement restricts thermal expansion and prevents deformation even in high-temperature environments such as automotive interiors during summer. The patent specifically mentions that the shutter can be used in conditions where the ambient temperature reaches 70°C or higher without causing the decorative film or pattern to distort, while still being manufacturable through conventional molding processes.
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
The solution effectively prevents appearance deterioration from creep deformation and reduces the operating force required for sliding, ensuring a stable and aesthetically maintained shutter performance even in high-temperature conditions.
Implementation Method 1
the sheet formed of the continuous fiber reinforced plastic, or the sheet produced by using the pre-preg material excels in the creep-resistant property
Implementation Method 2
a decorative film 5 firmly attached to an upper face, i.e., an outer face of the hinge base material 4
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
A shutter (2) is formed to be capable of bending in a sliding direction, and slides along a pair of guide grooves (18) including a curved portion (18b) at one portion thereof, the guide grooves being provided on two sides, facing each other, of an opening of a device main member and a shutter storage side, to open and close the opening. The shutter includes a shutter base material (3) sliding along the guide grooves in a state wherein corresponding portions fit into the guide grooves; and a hinge base material (4) disposed on an outer face of the shutter base material. Also, the hinge base material is a sheet formed by a continuous fiber reinforced plastic.