GB2506431A

GB2506431A - Hinge eg for a motor vehicle dihedral door or other access panel

Info

Publication number: GB2506431A
Application number: GB201217480A
Authority: GB
Inventors: Mitch Giulietti
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2012-10-01
Filing date: 2012-10-01
Publication date: 2014-04-02
Anticipated expiration: 2032-10-01
Also published as: GB2506431B; GB201217480D0

Abstract

A hinge assembly, eg for a vehicle door that lifts as it opens (dihedral or butterfly door), comprises a tubular support member 21 having a cross-section with a minor dimension along a first axis Y2 and a major dimension along a second axis X2, at least a portion of the tubular support member 21 being twisted about its longitudinal axis Z2. The cross-section may be elliptical, oval, rectangular or polygonal. The tubular support member may extend between a hinge mount 3 located in front of the A-pillar (6, fig.5A) and door support member 5. A first coupling 19 is located at a first end of the tubular support member 21 and defines a hinge pivot axis X1. The tubular support member 21 may be made in two sections, eg from carbon fibres in resin, then joined together eg lengthwise. The hinge assembly may be used for a vehicle bonnet (hood), boot (trunk) cover panel, convertible hood or folding hardtop. It may be part of a more complex articulation, eg a four bar hinge.

Description

HINGE

TECHNICAL FIELD

The present invention relates to a hinge. More particularly, but not exclusively, the present invention relates to a hinge for mounting a motor vehicle door. The present invention also relates to a vehicle door; a vehicle; and a method of manufacturing a hinge member.

BACKGROUND

A conventional vehicle door is pivotally mounted by a pair of vertically spaced door hinges.

However, this arrangement does not readily lend itself to a dihedral vehicle door which lifts as it opens. To accommodate this pivoting action, it is more appropriate to use a single door hinge to enable the door to pivot about a single pivot point. The strength and stiffness requirements for a single hinge door are greater than a conventional two hinge door and, therefore, the door hinge assembly is often larger and heavier.

At least in certain embodiments, the present invention sets out to overcome or ameliorate at least some of the shortcomings associated with prior art hinges.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to a hinge member; a hinge assembly; a vehicle door; a vehicle; and a method of manufacturing a hinge member.

In a further aspect of the present invention there is provided a hinge member comprising: a tubular support member having a cross section with a minor cross section dimension along a first axis and a major cross section dimension along a second axis, and having a generally centrally disposed longitudinal axis; and a first coupling defining a first pivot axis, the first coupling being located at a first end of the tubular support member; wherein at least a portion of the tubular support member is twisted about said longitudinal axis. This arrangement can provide a very stiff hinge member capable of supporting dynamic and static operating loads. By twisting the tubular support member about its longitudinal axis, the hinge member can be strengthened in the different planes in which loads are applied at the mating piece and the mounting bracket when the hinge member is in an open or closed position (static loads); and during opening/closing cycles (dynamic loads).

The pitch of the twist of the tubular support member about its longitudinal axis can be uniform or non-uniform. The tubular support member can be twisted along part or all of its length.

The hinge member has particular applications in relation to motor vehicles. The hinge member could form part of a hinge assembly for pivotally mounting a vehicle door or a vehicle panel, such as a bonnet (hood) cover or boot (trunk) cover. In use, two hinge members could be used to support a vehicle door. However, at least in certain embodiments, a single hinge member of the type described herein can be used for supporting the vehicle door. The hinge member could, for example, be mounted to the vehicle door or formed integrally with the vehicle door. The hinge member can provide a single pivot door hinge.

The first coupling can be a first pivoting coupling for pivotally mounting the hinge member.

The first coupling can, for example, comprise a mating piece or a bush for receiving a clevis pin. At the first end of the tubular support member, the second axis of the tubular support member (i.e. the axis coincident with the major cross section dimension) and the first pivot axis can be arranged at least substantially in the same plane. The second axis and the first pivot axis can be located in a first plane. The second axis and the first pivot axis could be arranged parallel to each other. Alternatively, the second axis can be inclined relative to the first pivot axis.

A second coupling can be provided at a second end of the tubular support member.

The second coupling can comprise a mounting bracket for providing a fixed mounting point.

Alternatively, the second coupling can be a second pivoting coupling defining a second pivot axis. The second coupling can, for example, comprise a mating piece or a bush for receiving a clevis pin. A hinge member having first and second pivoting couplings can provide complex articulation, for example as part of a four (4) bar hinge.

At the second end of the tubular support member, the second axis of the tubular support member and a (longitudinal) mounting axis of the mounting bracket can be arranged at least substantially in the same plane. The mounting axis of the mounting bracket can extend along a major axis of the mounting bracket. The second axis and the mounting axis of the mounting bracket can be located in a second plane. The second axis of the tubular support member and the mounting axis of the mounting bracket could be arranged parallel to each other. Alternatively, the second axis can be inclined relative to the mounting axis of the mounting bracket.

The major cross section dimension is greater than the minor cross section dimension. The S cross-sectional profile of the tubular support member can be symmetrical about said first axis and/or said second axis. The cross-sectional profile of the tubular support member can be oval or elliptical. The cross-sectional profile could also be rectangular or polygonal.

The cross section of the tubular support member could vary along its longitudinal axis. For example, the size and/or shape of the cross section of the tubular support member could vary along its length. Alternatively, the cross section of the tubular support member could be substantially uniform along its length. An angular orientation of the major/minor axis relative to the longitudinal axis could be uniform or vary along the length of the tubular support member. For example, varying the angular orientation of the major/minor axis could twist the profile of the tubular support member along its length. It will be appreciated that a combination of these arrangements could be employed without departing from the present invention.

The longitudinal axis of the tubular support member could be rectilinear. Alternatively, the longitudinal axis could be curved along its length. Accordingly, the longitudinal axis of the tubular support member can have an arcuate profile. The curvature of the longitudinal axis can increase or decrease as it extends from said first end of the tubular support member, for example forming a compound curve. Alternatively, the curvature of the longitudinal axis can be substantially constant (and non-zero) along the length of the tubular support member.

The carbon fibres can be twisted about the longitudinal axis of the tubular support member.

This twisting can enhance the distribution of loads through the hinge.

The tubular support member could be formed as a single component. For example, the tubular support member could be formed by winding a filament around a mandrel.

Alternatively, the tubular support member can be formed in two longitudinal halves (each having a C-section, for example) which can then be bonded together along their edges to form the tubular section.

The first coupling can comprise a mating piece. The mating piece can be configured to receive a clevis pin about which the hinge member pivots. One or more bearing surfaces can be provided in the mating piece for cooperating with the clevis pin. For example, a bearing such as a roller bearing can be provided in the mating piece. A stop member can be provided for inhibiting rotation of the hinge member. The stop member can, for example, engage a cooperating surface on a hinge mount to limit relative rotation of the hinge member.

The second coupling can comprise a mounting bracket. The mounting bracket can be adapted for mounting a vehicle door to the hinge member. The mounting bracket can be arranged perpendicular to the longitudinal axis of the tubular support member. Alternatively, the mounting bracket can be arranged at an angle relative to said longitudinal axis.

The hinge member can have a third coupling for attaching a biasing mechanism. The biasing mechanism can comprise a spring or gas mechanism. For example, the biasing mechanism can comprise a gas strut. The third coupling can be provided on the mounting bracket or the tubular support member. The third coupling can comprise a bush for receiving a connector pin to pivotally couple the biasing mechanism to the hinge member.

The tubular support member is hollow to reduce the weight of the hinge member. The tubular support member could be formed from a metal alloy, for example by casting and/or machining. Alternatively, the tubular support member can be made of a composite material.

For example, the tubular support member can be made of carbon fibre reinforced resin. The tubular support member could have a metallic core over-bound with a composite material.

The tubular support member, the mounting bracket and the mating piece can be formed integrally from the same material. The use of a composite material to form the hinge member enables a complex internal shape to be formed.

In a still further aspect of the present invention there is provided a hinge member for a vehicle door, the hinge member comprising: a support member having a first end and a second end; and a first coupling defining a first pivot axis, the first coupling being located at the first end of the tubular support member; wherein the support member is a hollow tubular support member. The tubular support member can, for example, have a transverse cross-section which is oval, circular, rectangular or polygonal. The tubular support member can be formed from a composite material comprising a woven material and a resin. The tubular support member can have a generally centrally disposed longitudinal axis. The woven material can comprise a plurality of fibres that can be twisted about the longitudinal axis of the tubular support member. The fibres can thereby form a partial or complete spiral or helix about the longitudinal axis of the tubular support member.

The longitudinal axis of the tubular support member could be curved along its length, for example having an arcuate profile. The curvature of the longitudinal axis can increase or decrease from the first end of the tubular support member towards the second end of the tubular support member, for example forming a compound curve. Alternatively, the curvature of the longitudinal axis can be substantially constant (and non-zero) along the length of the tubular support member.

The first coupling can, for example, be a mating piece or a bush for receiving a clevis pin. A second coupling can be provided at the second end of the tubular support member. The second coupling can be a mounting bracket for providing a fixed mounting point.

Alternatively, the second coupling can be a second pivoting coupling defining a second pivot axis. The hinge member can thereby provide more complex articulation, for example as part of a four (4) bar hinge.

In a yet further aspect of the present invention there is provided a hinge assembly comprising a hinge member as described herein. The hinge member can be coupled to a hinge mount to be fixedly mounted on the vehicle. The hinge assembly can comprise one of said hinge members or a plurality of said hinge members.

In a still further aspect of the present invention there is provided a vehicle door comprising a hinge assembly as described herein. The present invention also relates to a vehicle comprising a hinge assembly as described herein.

In a yet still further aspect of the present invention there is provided a method of manufacturing a hinge member comprising a tubular support member, the method comprising forming first and second sections of the tubular support member separately and then joining the first and second sections together. The first and second sections can define respective first and second sides of the tubular support member. The first and second sections can be joined lengthwise. The joins between the first and second sections can extend substantially coincident with a major cross section or a minor cross section of the tubular support member. The first and second sections could be butt jointed together or they could overlap one another to form lap joints. The method could comprise moulding the first and second sections from a composite material, for example carbon fibres embedded in a resin. The first and second sections could be moulded in female moulds. A first coupling and/or a second coupling can be integrally formed with one or other of said first and second sections. Alternatively, the first coupling and/or the second coupling can be formed separately and attached when the first and second sections are joined together.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. For example, features described with reference to one embodiment are applicable to all embodiments, unless such features are incompatible.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which: Figure 1 shows a front perspective view of a left hand door hinge in accordance with an embodiment of the present invention; Figure 2 shows a bottom perspective view of the door hinge of Figure 1; Figure 3 shows overlaid representations of the door hinge in closed, intermediate and open configurations; Figures 4A-C show the door hinge in open and closed configurations; and Figures 5A and SB show the vehicle door in open and closed positions.

DETAILED DESCRIPTION

An embodiment of a dihedral door hinge assembly 1 in accordance with the present invention will now be described with reference to the accompanying Figures. The hinge assembly 1 is intended to pivotally mount a door 2 of a motor vehicle V. The illustrated hinge assembly 1 is for the left hand door of the motor vehicle and it will be appreciated that the features of the hinge assembly 1 are reversed for a right hand door. For the sake of brevity, only the left hand hinge assembly 1 is described herein.

As shown in Figure 1, the hinge assembly 1 comprises a hinge mount 3 and a door support member 5. The hinge mount 3 is fixedly mounted in front of the vehicle A-pillar 6. In the present embodiment the hinge mount 3 is a discrete component mounted to the vehicle, but the hinge mount 3 could alternatively be integrally formed with the vehicle for example as S part of a vehicle body or chassis tub. The vehicle door 2 is fixedly mounted to the door support member 5 which in turn is pivotally mounted to the hinge mount 3. The hinge assembly 1 in the present embodiment provides the only hinge point for mounting the vehicle door 2. In the present embodiment, the door support member 5 is a separate component which is mounted to the vehicle door. However, the door support member 5 could be integrally formed with the vehicle door 2.

In the example shown, the hinge mount 3 is a single component formed or machined from aluminium or other suitable metal and comprises a mounting plate 7, a front plate 9, a top support lug 11 and a bottom support lug 13. The mounting plate 7 and the front plate 9 are angularly inclined relative to each other to form a recess for receiving the door support member 5 when the vehicle door 2 is closed, as illustrated in Figures 1 and 2. The top and bottom support lugs 11, 13 form a clevis and carry a high tensile strength steel clevis pin 15 which defines a pivot axis Xl. A projection 17 is provided at the leading edge of the front plate 9 and arranged to limit travel of the door support members.

The door support member 5 comprises a cylindrical mating piece 19, a tubular member 21 and a door mounting plate 23. In the example shown in the Figures, the door support member 5 is made of carbon fibre reinforced resin formed in two parts along the longitudinal axis. The two parts are moulded separately and then joined together in a secondary bonding and curing operation. The mating piece 19 is provided at a first end of the tubular member 21 and is machined to accept bushings to mount bearings (not shown) for the clevis pin 15.

The mating piece 19 thereby forms a female joint member for mounting to the clevis pin 15 supported in the clevis formed by the top and bottom support lugs 11, 13. The resulting clevis joint pivotally mounts the door support memberS and, therefore, the vehicle door 2.

A stop member 25 is integrated into the mating piece 19 for contacting the projection 17 to limit the pivoting motion of the door support member 5. The door mounting plate 23 is substantially rectangular and is provided at a second end of the tubular member 21. The door mounting plate 23 has four reinforcement bushes 27 (as shown in detail in Figure 2),located in corresponding mounting apertures 29 for receiving mechanical fasteners, such as threaded bolts, to mount the vehicle door 2. The bushes 27 control and manage the compressive forces exerted on the plate 23 when secured to the vehicle door 2 by the mechanical fasteners. As shown in Figure 2, a strut mounting bush 31 is provided in a sidewall of the tubular member 21, below the door mounting plate 23, for mounting a distal end of a gas strut 33. The gas strut 33 is mounted between the strut mounting bush 31 and a suitable mounting location on the vehicle (not shown) so as to assist opening of the vehicle S door 2 in use. It will be appreciated that the gas strut 33 may be replaced by a resilient member or actuator arranged to assist the user in opening the vehicle door 2 by providing at least some of the required door opening force.

The tubular member 21 is hollow and, as described herein, has a generally helical configuration. The tubular member 21 has a transverse cross-section having a major dimension along a first axis X2 and a minor dimension along a second axis Y2. The first and second axes X2, Y2 are orthogonal. In the present embodiment, the tubular member 21 has an oval cross-section and is symmetrical about both the first and second axes X2, Y2. The tubular member 21 has a longitudinal axis 72 which is generally centrally located (substantially coincident with the origin of the first and second axes X2, Y2) and perpendicular to the first and second axes X2, Y2. The longitudinal axis 72 is curved along the length of the tubular member 21. In the present embodiment, the longitudinal axis 72 has a substantially uniform (non-zero) curvature. The tubular member 21 is twisted about the longitudinal axis Z2 such that the first and second axes X2, Y2 undergo a rotational translation along the length of the tubular member 21. In the example shown, the pitch of the twist about the longitudinal axis 72 is substantially uniform along the length of the tubular member 21. The door mounting plate 23 has a major mounting axis X3 (arranged along a longitudinal axis) and a minor mounting axis Y3 (arranged along a transverse axis).

As shown in Figure 1, the tubular member 21 is configured such that the first axis X2 and the pivot axis Xl are co-planar at the first end of the tubular member 21 proximal the mating piece 19. This arrangement helps to provide additional strength at the interface between the tubular member 21 and the mating piece 19. In particular, the mating piece 19 is supported over its length to manage bending forces applied during opening/closing of the vehicle door 2. The door mounting plate 23 is arranged such that its major mounting axis X3 is substantially parallel with an expected dynamic loading force (for example, the force applied to open/close the vehicle door 2) and the static loading (for example, applied to the hinge by the vehicle door 2 and associated door components when the vehicle door 2 is in an open or closed position). The first axis X2 and the major mounting axis X3 of the door mounting plate 23 are co-planar at the second end of the tubular member 21 proximal the door mounting plate 23. This arrangement helps to provide additional strength at the interface between the tubular member 21 and the door mounting plate 23. The uniform pitch of the twist of the

S

tubular member 21 about its longitudinal axis Z2 between the first axis X2 and the major mounting axis X3 helps to distribute operational loads evenly along the tubular member 21.

This optimises the use of material to reduce unnecessary weight and packaging requirements.

The hinge mount 3 is fixedly mounted on the vehicle using suitable means, such as fasteners or bonding techniques. In use, the door support member 5 pivots about the pivot axis Xl defined by the clevis pin 15. As shown in Figure 1, the pivot axis Xl is inclined at an angle to the vertical (when the vehicle is on a horizontal surface) such that the vehicle door 2 lifts as it opens. The gas strut 33 applies a lifting force to assist a user when opening the vehicle door 2; and applies a damping force when the user is closing the vehicle door 2. The tubular member 21 allows for enhanced swing clearance and a greater door opening range.

The stop member 25 in the mating piece 19 contacts the projection 17 when the vehicle door 2 is fully open. The helical arrangement of the tubular member 21 according to the present invention can provide a lightweight structure which is configured to support normal operating loads. A second stop member and projection may be provided to set a limit of hinge travel in the closed position to aid adjustment of panel fit and finish relative to the vehicle body.

The operation of the hinge assembly 1 in accordance with the present embodiment is illustrated in Figures 3 and 4. An overlaid perspective view of the door support member 5 in a closed position (A), an intermediate position (B) and an open position (C) is shown in Figure 3. The gas strut 33 in the intermediate position (B) is omitted from Figure 3 for clarity.

A side view and a sectional view of the hinge assembly 1 with the door support member 5 in the closed position (A) and the open position (C) are shown in Figures 4A and 4B respectively. A plan view of the door support member 5 in the closed position (A) and the open position (C) is shown in Figure 4C.

A side of the vehicle 3 is shown in Figures 5A and SB to show the vehicle door 2 in a closed position (Figure 5A) and an open position (Figure SB). To assist with understanding the operation of the hinge assembly 1, the vehicle door 2 is shown in phantom and vehicle body panels have been omitted. As shown in Figure SA, the door support member S is in a closed position (A) partially disposed within the door mount 3 when the vehicle door 2 is closed. The door support member 5 travels to its open position (C) when the vehicle door 2 is opened.

The elongate form of the tubular member 21 creates an offset between the mating piece 19 and the door mounting plate 23 which increases clearance when the vehicle door 2 is opened, as shown in Figure SB. The gas strut 33 (omitted from Figure 5B for clarity) assists opening of the vehicle door 2 by applying an opening force to the door support memberS.

The hollow central legion of the tubular member 21 could be used as a pathway for a wiring loom to the vehicle door 2. Alternatively, or in addition, the tubular member 21 could be used as a fluid pathway for conveying air (for example from an air conditioning unit) into the vehicle door 2 for distribution into the cabin or for demisting a window.

It will be appreciated that various changes and modifications can be made to the embodiment described herein without departing from the spirit and scope of the present invention. Although the hinge assembly 1 has been described with reference to a single pivot hinge for a dihedral vehicle door 2, the present invention is not limited to this application. In particular, the hinge assembly can be used on its own, or in combination with other hinge assemblies.

Also, the hinge assembly can be used for vehicle doors which open horizontally and for other access panels, such as a bonnet (hood) cover and boot (trunk) cover. The hinge assembly could also be used as part of a convertible hood or folding hardtop application.

The hinge assembly could provide a more complex articulation, for example as part of a four (4) bar hinge.

Claims

CLAIMS: 1. A hinge member comprising: a tubular support member having a cross section with a minor cross section dimension along a first axis and a major cross section dimension along a second axis, and having a generally centrally disposed longitudinal axis; and a first coupling defining a first pivot axis, the first coupling being located at a first end of the tubular support member; wherein at least a portion of the tubular support member is twisted about said longitudinal axis.
2. A hinge member as claimed in claim 1, wherein, at said first end of the tubular support member, the second axis and the first pivot axis are arranged at least substantially in the same plane.
3. A hinge member as claimed in claim 1 or claim 2, wherein a second coupling is provided at a second end of the tubular support member.
4. A hinge member as claimed in claim 3, wherein the second axis and a longitudinal axis of the second coupling are arranged at least substantially in the same plane.
5. A hinge member as claimed in any one of claims 1 to 4, wherein the cross-sectional profile of the tubular support member is symmetrical about said first axis and/or said second axis; and/or the cross-sectional profile of the tubular support member is oval or elliptical.
6. A hinge member as claimed in any one of the preceding claims, wherein the longitudinal axis of the tubular support member is curved.
7. A hinge member as claimed in claim 6, wherein the curvature of the longitudinal axis is substantially constant along the length of the tubular support member; or the curvature of the longitudinal axis increases or decreases in a direction extending away from the first coupling.
8. A hinge member as claimed in any one of the preceding claims, wherein the second axis of the tubular support member is inclined at an acute angle relative to said first pivot axis at said first end of the tubular support member.
9. A hinge member as claimed in any one of the preceding claims, wherein a stop member is provided on the first coupling for inhibiting rotation of the hinge member about said first pivot axis.
10. A hinge member as claimed in any one of the preceding claims comprising a third coupling for attaching a biasing mechanism.
11. A hinge member as claimed in any one of the preceding claims, wherein the tubular support member is made of a composite material, such as carbon fibre reinforced resin.
12. A hinge member comprising: a support member having a first end and a second end; and a first coupling defining a first pivot axis, the first coupling being located at the first end of the tubular support member; wherein the support member is a hollow tubular support member.
13. A hinge comprising a hinge member as claimed in any one of the preceding claims pivotally coupled to a hinge mount.
14. A vehicle or a vehicle door comprising a hinge member as claimed in claim 14.
15. A method of manufacturing a hinge member comprising a tubular support member, the method comprising forming first and second sections of the tubular support member separately and then joining the first and second sections together.
16. A hinge member, a vehicle or a method constructed and/or arranged substantially as as described herein with reference to one or more of the accompanying drawings.