Automobile hinges

A hinge for pivotably mounting a panel to a vehicle body includes a panel attachment plate securable to the panel, a body attachment plate securable to the vehicle body, and an intermediate member pivotably attached between the body and panel attachment plates. The intermediate member has opposite sidewalls and a center flange extending between the sidewalls. The sidewalls engage the body attachment plate with the center flange spaced from the body attachment plate when the intermediate member is pivoted such that the sidewalls are positioned generally along the body attachment plate. The intermediate member may include a stop member for limiting pivotal movement of the panel attachment plate. The stop member may limit such pivotal movement at different positions by being cut to different sizes during manufacture of the hinge. The body attachment plate may provide a hinge portion that provides enhanced structural rigidity to the hinge.

FIELD OF THE INVENTION

The present invention relates to hinges, and more particularly to hinges used on vehicles, such as automobiles, such as vans, min-vans, sport utility vehicles, cars, sedans, hatch-backs, coupes and the like.

BACKGROUND OF THE INVENTION

Modern automobiles include a number of different types of hinges. Some hinges are used to mount the doors to the body of the vehicle, others to mount the trunk lid or deck lid to the vehicle body, others to pivotably support the rear door or gate of a vehicle at the rear of the vehicle body (such as, for example, the body of a minivan or sport utility vehicle or the like), and others are used to mount the hood to the vehicle body. In many cases, different models of vehicles require different hinges because of the different constructions of the different vehicle models. One of these differences relates to the stopping position of the hinge. For example, the hinges used to support the rear gate of a vehicle often include stops built into the hinge to stop the rear gate from pivoting upwardly past a certain point. While the vehicle will often include gas struts on the upwardly pivoting rear gate that stop the rear door from pivoting beyond a given angle of opening, it is typically the case that the gate hinge includes upward stops that limit or positively stop the extent to which the gate can be lifted before the gas struts are mounted to the gate and vehicle. The stops may thus prevent the gate or door from rolling over onto the top of the vehicle during initial assembly of the vehicle in the vehicle assembly plant. The gate is typically installed on the vehicle body in the “body in white” area of the vehicle assembly plant before the vehicle body and doors and other components are moved to the paint area. After the vehicle is painted, the gate is raised and the gas struts are installed. The gas struts then provide the stops for the gate to limit the upward pivotal movement of the gate.

The stops on the hinges thus may control the degree of opening, depending on where they are located, and may prevent the gate from rolling over onto the top of the vehicle body. For different models of vehicles, the angular position of the respective hinge when it has reached its upward limit will desirably be different, due to different rear door constructions and different overall vehicle constructions and different desired opening angles.

Typically, in order to accommodate the different stop positions for the hinge, it has often been necessary to construct different hinges, with each particular hinge being used with a specific vehicle model. The construction of different hinges for each vehicle, however, is typically relatively expensive. Automobile manufacturers are increasingly looking to use common parts on different vehicle models in order to reduce the costs associated with manufacturing so many separate parts. The desirability of an automobile hinge that can easily accommodate different stopping positions can therefore be seen.

Automobile manufactures are also looking to decrease the manufacturing costs of virtually all automobile components, including vehicle hinges. Some automobile hinges have included relatively expensive components, such as extruded aluminum parts that are cut and further processed after the extrusion process takes place. The aluminum parts typically require strengthening ribs or flanges or the like formed thereon to make the parts strong enough to withstand the forces typically encountered during opening and closing of the pivotable components. The use of aluminum is often desirably avoided due to its relatively expensive nature as compared with other metals. Other hinge parts have been made out of bent tubular steel in order to provide suitable strength. Bent tubular steel, however, is also typically relatively expensive as compared to other manufacturing materials and techniques.

The desire thus exists for automobile hinges that have reduced manufacturing costs as compared to present hinges and techniques. Furthermore, it is desirable to reduce the weight of automobile hinges while still retaining the necessary structural strength. Therefore, there is a need in the art for an automobile hinge that overcomes the shortcomings of the prior art.

SUMMARY OF THE INVENTION

The present invention provides several hinge types that are easier and less expensive to manufacture than conventional hinges. In one embodiment of the present invention, a hinge construction is provided that can accommodate different stopping positions. The basic hinge construction may thus be used or implemented in different vehicle models that require different stopping positions, thereby reducing manufacturing and tooling costs of the hinges. The hinge includes an intermediate member that may be stamped from a single piece of metal, such as steel or the like, and which may be lighter and less expensive to manufacture than comparable parts, such as aluminum extruded components or bent tubular steel or the like. The intermediate member is formed in a manner that enhances the strength of the intermediate member to limit or substantially preclude bending or twisting of the intermediate member under loads typically encountered during opening and closing of the pivotable door, gate or panel or the like. The body attachment plate of the hinge may be formed to substantially enhance the structural rigidity of the plate to resist or limit or substantially preclude flexing or bending or twisting of the plate during use of the hinge.

According to an aspect of the present invention, an automobile hinge for pivotally mounting a pivotable component or panel to a vehicle body includes a panel attachment plate adapted to be secured to the pivotable panel of the vehicle, a body attachment plate adapted to be secured to the vehicle body, and an intermediate member pivotably attached to the body attachment plate and the panel attachment plate. The intermediate member comprises opposite sidewalls and a center flange extending between the sidewalls. The sidewalls engage the body attachment plate with the center flange being spaced from the body attachment plate when the intermediate member is pivoted toward a first position where a first portion of the intermediate member is positioned generally along the body attachment plate. The center flange may include a fastener portion extending toward the body attachment plate when the intermediate member is positioned or pivoted toward the first position. The intermediate member may be fixedly securable to the body attachment plate via a fastener at least partially through the body attachment plate and the fastener receiving portion.

The intermediate member may comprise first and second portions that are arranged at an angle relative to one another. The intermediate member may be pivotably attached to the body attachment plate at a junction of the first and second portions. The panel attachment plate may be pivotably attached to the intermediate member at an end of the second portion opposite the junction of the first and second portions.

The intermediate member may include a panel stop member configured to engage a portion of the panel attachment plate to limit pivotal movement of the panel attachment plate relative to the intermediate member. The stop member may be adaptable to limit pivotal movement of the panel attachment plate at different positions by being cut or formed to different sizes during the manufacturing of the automobile hinge.

The intermediate member may include a body plate stop member that is configured to engage a portion of the body attachment plate to limit pivotal movement of the intermediate member away from the first position. The body plate stop member may comprise at least one flange protruding from the first portion of the intermediate member and configured to engage a corresponding flange extending from the body attachment plate.

According to another aspect of the present invention, an automobile hinge for pivotably mounting a pivotable component or panel to a vehicle body comprises a panel attachment plate adapted to be secured to a pivotable panel or component of a vehicle, a body attachment plate adapted to be secured to a vehicle body, and an intermediate member pivotably attached to the body attachment plate and the panel attachment plate. The intermediate member includes at least one stop that is adapted to limit the range of pivotal movement of the panel attachment plate relative to the intermediate member. The at least one stop limits pivotal movement of the panel attachment plate at different positions by being cut or adjusted or formed to different sizes during manufacturing of the automobile hinge.

The intermediate member may be stamped out of a metallic material. The intermediate member may include opposite sidewalls and a center flange extending between the sidewalls. The panel stop member or members may comprise a pair of panel stop members extending from respective ones of the sidewalls at an end of the intermediate member. The panel attachment plate may be pivotably mounted generally at the end of the intermediate member and generally adjacent to the stop members, such that the stop members engage the panel attachment plate to limit pivotal movement of the panel attachment plate in one direction.

According to another aspect of the present invention, a method for making an automobile hinge comprises providing a panel attachment plate adapted to be secured to a pivotable panel component vehicle, providing a body attachment plate adapted to be secured to a body of a vehicle, and providing an intermediate member that has a stop portion formed thereon. The intermediate member is pivotably attached to the body attachment plate and the panel attachment plate is pivotably attached to the intermediate member. The stop portion of the intermediate member is trimmed or adjusted to define a stop, which is configured to limit the range of pivotal movement of the panel attachment plate relative to the intermediate member. The degree of the trimming process adapts the stop to define the stopping position of the panel attachment plate relative to the intermediate member. A greater portion may be trimmed from the intermediate member to create a greater range of pivotal motion of the panel attachment plate relative to the intermediate member. Optionally, a lesser portion may be trimmed from the intermediate member to create a lesser range of pivotal motion of the panel attachment plate relative to the intermediate member.

According to another aspect of the present invention, an automobile hinge for pivotably mounting a pivotable panel component to a vehicle body comprises a panel attachment plate adapted to be secured to a pivotable panel of a vehicle, an intermediate member and a body attachment plate. The intermediate member comprises first and second leg portions angularly disposed relative to one another. The panel attachment plate is pivotably attached at or near an end of the first leg portion of the intermediate member opposite a junction of the first and second leg portions. The body attachment plate includes a plate portion adapted to be secured to a vehicle body and at least one generally vertical raised flange or wall. The flange includes a first flange portion extending at least partially along an edge or edge portion of the plate portion (such as along a rear portion of the plate) and a second flange portion extending at an angle to the first flange portion to define a hinge portion of the body attachment plate. The at least one raised flange provides structural support to the plate portion. The intermediate member is pivotably attached to the body attachment plate at the hinge portion via a pivot member extending through the second flange portion of the at least one raised flange portion and through the intermediate member.

The second flange portion may comprise spaced apart and opposed flange portions that cooperatively define the hinge portion. The at least one raised flange may comprise two flanges along opposite portions of the edge portion of the plate portion. Each of the flanges may extend at an angle to or generally transverse to the edge portion and may comprise a respective one of the spaced apart and opposed second flange portions to cooperatively define the hinge portion. The second leg portion of the intermediate member may include at least one stop extending therefrom for engaging a raised projection extending from the at least one raised flange to limit pivotal movement of the intermediate member about the pivot member.

In another embodiment of the present invention, a hinge component is provided that is adapted to be attached to a pivotable portion or panel of a vehicle, such as an automobile hood or deck lid or the like. The hinge component is made from a single piece of metal that is stamped into a U-shaped channel and includes one end adapted to be attached to the hood or pivotable panel, and another end adapted to be pivotably attached to the vehicle body. The end adapted to be attached to the vehicle body includes a thickened region which can be net pierced for accommodating a pivot pin or axis. The construction of the hinge component may be less costly than comparable components, such as those made from metal tubing or the like.

According to another aspect of the present invention, a hinge component for pivotably mounting a pivotable component or panel to a vehicle body comprises a first wall, a second wall and a third wall constructed from a single piece of material and joined together to form a generally U-shaped elongated member. Each of the walls defines one of the sidewalls and bottom walls of the U-shaped member. The elongated U-shaped member includes a least one bend along its length and has first and second ends. The first end is adapted to be secured to a pivotable automobile component or panel, such as a hood, deck lid or the like. The second end is adapted to be pivotably attached to a pivot pin at the vehicle body. The second end is defined by the sidewalls of the U-shape being compressed together. At least one of the sidewalls includes an extension that is folded onto the compressed sidewalls to form a planar wall region having at least three layers of walls in planar contact with one another. The hole may be created by net piercing during the manufacturing and assembly of the vehicle. The pivotable component may be aligned with the vehicle body prior to creating the hole in the hinge component, whereby the hole may be created in a manner that ensures that the pivotable component is properly aligned with the vehicle body when the hinge component is attached to the vehicle body.

Therefore, the present invention provides a hinge or hinge component for a vehicle or automobile that may limit pivotal movement of a pivotable panel or component at a desired location. The intermediate member of the hinge provides enhanced structural rigidity, while providing common hinge parts for multiple vehicles or vehicle lines. The stop portions of the intermediate member may be selectively trimmed to trim the stop portions to set a desired stop location for positively stopping the pivotal movement of the pivotable component relative to the intermediate member and the vehicle body. The present invention also provides for enhanced structural rigidity of the body attachment plate via a raised rib or flange extending along the rear portion of the body attachment plate that also extends rearward to define the hinge portion of the body attachment plate. The present invention also provides for a hinge component that provides an increased wall thickness at a mounting end of the hinge component to enhance the structural rigidity of the hinge component, while manufacturing the hinge component out of a single stamped piece of metal.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described with reference to the accompanying figures, wherein the numbered elements in the following written description correspond to like-numbered elements in the figures. A hinge20according to a first embodiment of the invention is depicted inFIGS. 1–13. Hinge20includes a gate or panel attachment plate or portion22and a vehicle body attachment plate or portion24. Gate attachment plate22is attached to a pivotable panel or gate14(such as a rear door or gate or hatch-back or other pivotable panel or the like, such as a window or door or deck lid or hood or the like) of a vehicle12, while body attachment plate24is attached to a body or roof portion16of vehicle12(FIG. 1). Both gate attachment plate22and vehicle body attachment plate24are pivotably attached to an intermediate member32, which allows the gate attachment plate22to pivot relative to the intermediate member32, while also allowing the intermediate member to pivot relative to the body attachment plate24. Intermediate member32may be configured to limit pivotal movement of the intermediate member relative to body attachment plate24and to limit pivotal movement of gate attachment plate22relative to intermediate member32, as discussed below.

In practice, intermediate member32may be made from stamped metal, preferably stamped steel or the like, and may be stamped from a single piece of sheet metal. Because intermediate member32(and the attachment plates22,24) may be made from stamped metal, as opposed to extruded aluminum or other types of materials, the hinge20may have reduced costs associated with manufacturing of the intermediate member and the attachment plates, as well as reduced weight (because the steel component may be formed from a thinner sheet or plate than an aluminum component), all while still retaining sufficient structural strength. It will, however, be understood that intermediate member32can be made from other metals besides steel, and that it can be created by methods other than stamping, such as by molding or the like, or other techniques, without affecting the scope of the present invention.

Body attachment plate24comprises a plate portion24aand a hinge portion24bextending along a portion or edge of the plate portion24a. Plate portion24aincludes a pair of mounting apertures or holes25afor fasteners to extend therethrough for mounting the plate to the body of the vehicle. Although shown as threaded nuts30that may engage a bolt or stud extending through the openings25a, the fasteners may otherwise comprise other types of fasteners, such as studs pressed through the openings25afor extending through corresponding openings in the body portion of the vehicle or the like, for mounting or securing or attaching body attachment plate24to the vehicle body16. Plate portion24aalso includes an aperture or opening25btherethrough for receiving a fastener (not shown) therethrough for securing intermediate member32relative to body attachment plate24, as discussed below. The plate portion24aof body attachment plate24may also include a strengthening rib or gusset or the like to strengthen or enhance the structural rigidity of the body attachment plate24.

Hinge portion24bof body attachment plate24extends along a portion or edge of the plate portion24aand may include one or more cylindrical hinge members or stamped curled portions for receiving a pivot pin35which defines a pivot axis35aalong hinge portion24b. Pin35extends through the hinge portions24band also through openings in intermediate member32to pivotably mount or secure or attach intermediate member32to body attachment plate24. Body attachment plate24may further include a stop portion24c(FIG. 6) positioned generally between the spaced apart hinge portions24bfor engaging a corresponding stop portion36on intermediate member32to limit pivotal movement of intermediate member32relative to body attachment plate24, as discussed below.

Panel attachment plate22may comprise a bent plate having a panel mounting portion22aand a hinge mounting portion22b. Panel mounting portion22amay include holes or apertures26therethrough for mounting or attaching or securing the pivotable panel or gate14to mounting portion22avia fasteners28(FIG. 3), such as studs or bolts or the like extending through openings26and secured to the panel attachment plate22and the gate or pivotable panel14. For example, mounting portion22aof gate attachment plate22may be secured to the gate or panel by studs or bolts secured to the gate or panel and having a threaded end protruding through holes26in gate attachment plate22for receiving a threaded fastener or nut thereon, or by studs pressed through the openings26for extending through corresponding openings in the gate or panel or the like, for mounting or securing or attaching gate attachment plate22to the gate or panel14, or other types of fasteners, without affecting the scope of the present invention.

The hinge mounting portion22bincludes a hinge portion22ccomprising a pair of generally cylindrical hinge portions or stamped curled portions which receive a pivot pin37therethrough to define a pivot axis37abetween gate attachment plate22and intermediate member32. The pin37extends through the hinge portions22cand through corresponding openings or holes in intermediate member32to pivotably attach the gate attachment plate22to intermediate member32. Hinge mounting portion22bmay include a stop portion22dgenerally between the hinge portions22cfor engaging the stop members38a,38bof intermediate member32, as discussed below. Gate attachment plate22may further include a rib or gusset or the like to strengthen or enhance the structural rigidity of the gate attachment plate to limit or resist twisting and bending of the plate during opening and closing of the gate of the vehicle.

Intermediate member32comprises an angled or bent member having a first or body plate leg or portion33aand a second or gate plate leg or portion33barranged at an angle to one another. Intermediate member32is pivotably mounted at hinge portion24bof body attachment plate24at the junction33cof the legs33a,33bvia pivot pin35. Gate attachment plate22is similarly pivotably mounted to an outer end portion of leg33bvia pivot pin37extending through hinge portions22cof gate attachment plate22and through the corresponding openings in or at or near the end of leg33bof intermediate member32. Intermediate member32may also include a stop member or members36(FIGS. 3–6) at or near the junction of the leg portions33a,33bfor limiting pivotal movement of intermediate member32relative to body attachment plate24, as discussed below. Likewise, intermediate member32may include a stop member or members38a,38bat an end of leg portion33bto limit pivotal movement of gate attachment plate22relative to intermediate member32, as also discussed below.

Intermediate member32includes a pair of opposite sidewalls32aand a central flange portion32bextending along and generally between the sidewalls. The arrangement of the central flange32band sidewalls32aprovides enhanced structural rigidity and strength to intermediate member32, in order limit or substantially preclude twisting or bending of the intermediate member during use of hinge20. As can be seen inFIGS. 10 and 12, body plate leg33adefines a generally inverted U-shaped member relative to plate portion24aof body attachment plate24. Accordingly, when intermediate member32is pivoted relative to body attachment plate24such that body plate leg33ais positioned generally along and adjacent to and in engagement with plate portion24a, the opposite sidewalls32aalong leg or portion33aengage the surface of plate portion24a, with the central flange32bspaced from the plate portion24a(as best shown inFIG. 12).

A fastener portion34of intermediate member32may extend partially between the central flange32band plate portion24awhen intermediate member32is pivoted to the retracted position relative to body attachment plate24. Fastener portion34is adapted to receive a fastener (not shown) that secures intermediate member32to vehicle body attachment plate24in a non-pivoting manner. For example, fastener portion34may comprise a threaded hole or opening or passageway34aextending at least partially therethrough, such that a fastener may be inserted through hole25bin body attachment plate24and threadedly engage threaded opening34aof fastener portion34of intermediate member32. As the fastener is tightened and secured in fastener portion34, the leg33aof intermediate member32is tightly secured to plate portion24aof body attachment plate24. The inverted U-shape arrangement of the leg33aalong plate portion24asubstantially enhances the strength and structural rigidity of the hinge20and substantially resists twisting and/or bending of the intermediate member32during use of the hinge. The inverted U-shaped arrangement of the present invention thus provides a hinge member having enhanced strength, while allowing the hinge member to be formed from a stamped piece of sheet metal or the like.

Second leg or portion33bof intermediate member32is pivotably mounted to gate attachment plate22via pivot pin37. Second leg33bincludes a pair of stop portions38a,38bfor engaging stop portions22dof gate attachment plate22to limit pivotal movement of the gate attachment plate22relative to intermediate member32. Stop members38a,38bextend from the sidewalls32aof leg portion33band extend beyond the openings or holes in the leg portion33bfor receiving pivot pin37. The stop portions38a,38bmay be formed to initially extend substantially rearwardly toward the gate attachment plate22, and may then be adjusted or cut or trimmed to adjust the stop portions to accommodate different degrees of pivotal movement of gate attachment plate22relative to intermediate member32. The stop members38a,38bthus may limit how far the vehicle gate can be opened by engaging the stop portions22dof gate attachment plate22as the gate attachment plate (and the gate) pivot to the desired fully opened position.

The stop members38a,38bmay limit pivotal movement of the gate attachment plate22via engagement of edges40of stop members38a,38bwith stop portion22dof gate attachment plate22, and may limit the pivotal movement at different positions by having the stop members38a,38bcut or trimmed to different sizes during the manufacture of the hinge20. For example, a greater amount or portion of material may be trimmed from the stop members38a,38bto create a greater pivotal range of motion of the gate attachment plate22relative to the intermediate member32, or a lesser amount or portion of material may be trimmed from the stop members38a,38bto create a lesser pivotal range of motion of the gate attachment plate22relative to the intermediate member32. For example,FIG. 13illustrates an alternative position for edges40a(shown in dashed lines). When edges40aare trimmed in this manner, gate attachment plate22will contact edges40alater than it would if the edges were trimmed to the level shown inFIG. 5, and therefore will limit the upward pivoting of gate attachment plate22at a greater range of pivotal movement. Intermediate member32thus may comprise a common part or common parts for different vehicles or vehicle lines, whereby the stop members38a,38bmay be adjusted or trimmed a desired amount to adapt the intermediate member to each particular application, depending on the desired amount of pivotal movement of the gate or/and gate attachment plate.

During use of hinge20, body attachment plate24may be mounted or secured to the body portion16of a vehicle12, such as a rear portion of a roof of the vehicle, via the mounting fasteners (such as studs or bolts and nuts30or other fasteners or the like) as shown inFIG. 1. The gate attachment plate22may be mounted or secured to the lift gate or tail gate14of the vehicle12, such that the gate14may be pivotably mounted to the rear portion of the vehicle and pivotable about the generally horizontal pivot axis37abetween gate attachment plate22and intermediate member32. Although shown and described as pivotably mounting a lift gate or tail gate to a vehicle body, the hinge of the present invention may be equally suitable for mounting other pivotable doors or panels (such as, for example, a window, a deck lid, a hood, a door or the like) to a vehicle body, without affecting the scope of the present invention.

After the gate14and hinge20are installed to the vehicle body16, intermediate member32(and gate attachment plate22and gate14) may pivot about the pivot axis35awith respect to body attachment plate24into an extended position (FIGS. 2 and 10). Such pivotal movement of the hinge may be desired during the manufacture of the vehicle, such as during the painting of the vehicle on the vehicle assembly line. In the extended position, more clearance is provided to ensure that paint is received over all of the components of hinge20, as well as over all of the external surfaces of the vehicle body16and gate14. First stop member or members36(FIG. 6) limits the pivoting of the intermediate member32with respect to vehicle body attachment plate24by abutting against a stop portion24cof body attachment plate24.

After painting, intermediate member32may be pivoted back, such that sidewalls32bof leg portion33aare in contact with the plate portion24aof vehicle body attachment plate24. Intermediate member32may then be permanently or fixedly secured to body attachment plate24via insertion of the fastener through the aligned hole24bin body attachment plate24and at least partially through fastener portion34of center wall or flange32aof intermediate member32. Thereafter, hinge20may pivot only about pivot axis37aat the junction between intermediate member32and gate attachment plate22.

Intermediate member32also includes at least one second stop, which, in the illustrated embodiment, is made up of a right stop38band a left stop38a. Second stop or stops38a,38blimits the upward pivoting of gate attachment plate22with respect to intermediate member32. Second stop38a,38bthus limits how far a vehicle gate can be opened before the gas struts are mounted to the vehicle. Second stop38a,38blimits the pivotal movement of gate attachment plate22by way of edges40that abut against gate attachment plate22when it is pivoted to it upward-most position (FIG. 4). Second stop38a,38bcan be manufactured to limit the angle of this upward-most position at different angular positions by trimming edges40in different manners.

The trimming of edges40at different positions may be readily accomplished during the manufacturing process by simply changing one or more punches. The punches are aligned generally parallel to the axis37aabout which gate attachment plate22pivots. By cutting away more material from intermediate member32adjacent to stops38a,38b, the stops38a,38bare made smaller (as shown inFIG. 13), and more range is given to the pivotal movement of the vehicle gate about pivot axis37a. By cutting away less material, stops38a,38bare made larger and contact gate attachment plate22sooner, thereby providing a more limited range of pivotal movement of the vehicle gate. Regardless of the desired size of stops38a,38b, intermediate member32can be manufactured starting from the same single piece of sheet metal or from the same stamped member. All of the same tooling can be used to create the intermediate members for multiple hinges with the exception of simply changing the punch used to trim or size stops38a,38b. The manufacturing of hinges to accommodate different vehicle models is therefore greatly simplified. The same starting materials and virtually the same tooling is used to create a variety of different types of hinges. Although shown and described as having an adjustable or trimmable intermediate member, it is envisioned that the range of pivotal movement of the gate attachment plate relative to the intermediate member may be adjusted via trimming or modifying the stop portion of the gate attachment plate, such as by cutting or forming grooves of different depths for receiving the stop tabs or members of the intermediate member, without affecting the scope of the present invention.

Referring now toFIGS. 14–16, a hinge120includes a body attachment plate124and a gate or panel attachment plate122and an intermediate member132pivotably mounted to body attachment plate124and gate attachment plate122. Hinge120is substantially similar to hinge20, discussed above, such that a detailed discussion of the hinge will not be repeated herein. The similar or common components or features of the hinge120are referenced with similar reference numbers inFIGS. 14–16, but with 100 added to each reference number. As described above with respect to hinge20(and as shown generally inFIG. 1), the gate attachment plate122of hinge120is attached to a pivotable panel or gate (such as a rear door or gate or hatch-back or other pivotable panel or the like, such as a window or door or deck lid or hood or the like) of a vehicle, while the body attachment plate124is attached to a body or roof portion of the vehicle. Body attachment plate124may be positioned at a rearward end of the body or roof portion of the vehicle such that a rearward or hinge portion124bof body attachment plate124may overhang or extend from the rearward end of the body or roof portion and, thus, may be unsupported by the body or roof portion of the vehicle.

Body attachment plate124includes a plate portion124aand hinge portions124bfor pivotably mounting intermediate member132to body attachment plate124. Body attachment plate124comprises at least one raised wall or flange131extending generally vertically upwardly from and at least partially along an edge or portion of plate portion124a. Flange131extends along the rear edge portion and extends at an angle to (such as generally orthogonal or transverse to) the rear edge or edge portion of the plate portion and generally rearwardly to define spaced apart and opposed hinge portions124b. The hinge portions124binclude openings or apertures131a(FIG. 16) for receiving a pivot pin or member135therethrough to pivotably mount the intermediate member to the body attachment plate.

In the illustrated embodiment ofFIGS. 14–16, the at least one wall or flange comprises two flange portions131along opposite portions of the rear edge of the body attachment plate. Each of the flange portions curves generally rearwardly near the center region of the plate to define a respective one of the spaced apart and opposed hinge portions124bof body attachment plate124. The generally rearwardly extending raised hinge portions124bprovide enhanced structural rigidity to the body attachment plate to limit or substantially preclude downward flexing or bending of the hinge portion and/or plate portion during pivotal movement of the intermediate member132(and the gate attachment plate and gate) relative to the body attachment plate124and/or pivotal movement of the gate attachment plate (and gate) relative to the intermediate member132. This enhanced structural rigidity or support is especially beneficial/desired for applications where the hinge portion124bof body attachment plate124may extend rearward of the vehicle body or roof portion16and may thus be substantially non-supported by the vehicle body. Because the hinge portions124bare spaced apart, the body attachment plate of the present invention also provides clearance or room for a ridge or gusset125cor the like to be formed in plate portion124ato further enhance the strength and overhang rigidity of the body attachment plate124. Although shown and described as extending along the rear edge of the plate portion, the flange or wall portions of the body attachment plate may extend along the plate portion inward of the edge (such as generally along the rear portion or region of the plate) and then extend at an angle to or generally transverse to the rear portion to define the hinge portions124b, without affecting the scope of the present invention.

The flange portion131thus may have a portion or wall that extends generally along the rear edge or portion of the plate portion124ato provide enhanced strength and structural rigidity to the body attachment plate124, and may have a hinge portion124bthat extends or curves at an angle to or in a direction generally transverse to the edge portion to provide further rigidity and resistance to flexing or bending or twisting of the body attachment plate during opening and closing of the lift gate of the vehicle. The angularly disposed portions of the flanges131may thus provide resistance to flexing or bending of the plate in multiple directions to enhance the structural rigidity of the body attachment plate. The generally vertical walls or flanges131and hinge portions124balso may provide structural support for the cross car location of the intermediate member sidewalls133band may provide enhanced rigidity to the body attachment plate for the overhang of the hinge portions for applications where the hinge portion is not supported by a vehicle body portion. The hinge portions124bof flanges131may further include upwardly extending protrusions or stop portions131bgenerally at or adjacent to openings131a. The stop portions131bfunction to limit pivotal movement of intermediate member132relative to body attachment plate124, as discussed below.

Intermediate member132may be substantially similar to intermediate member32, discussed above, and includes angularly disposed legs or portions133a,133b, and a central flange portion132bextending along and between opposite sidewalls or side portions132a. Leg portion133bis pivotably mounted to body attachment plate124, such as via a pivot pin135extending through holes131ain the spaced apart and opposed hinge portions124bof the flanges131of body attachment plate124and through holes133d(FIG. 15) in intermediate member132. Leg portion133amay include a pair of stop members136which extend outwardly from sidewalls132a. The stop members136may engage the stop members131bof body attachment plate124to limit pivotal movement of intermediate member132relative to body attachment plate124(such as when the intermediate member is pivoted relative to the body attachment plate for the paint process at the vehicle assembly plant, and before the intermediate member is secured to the body attachment plate, such as via a fastener or bolt or the like).

As best shown inFIG. 15, a fastener portion134may extend downwardly from central flange portion132b, such that when the fastener is inserted through the opening125b(FIG. 16) in body attachment plate124and threadedly engages the threaded opening134aof mounting portion134, the fastener may pull downward on the mounting portion134and central flange132bto pull the sidewalls132ainto engagement with the surface of the plate portion124aof body attachment plate124. The body attachment plate may have an upwardly protruding portion125daround the opening125b, such that the fastener portion134may contact the upwardly extending portion125dto substantially positively position the intermediate member132relative to body attachment plate124and to substantially secure the fastener in position within the threaded opening134a.

The other leg portion133bof intermediate member132pivotably receives or is mounted to gate attachment plate122, such as via a pivot pin or member137extending through holes133c(FIG. 15) in leg portion133b. Leg portion133bincludes a pair of stop members138a,138bextending from the sidewalls132aof leg portion133bfor engaging the stop portion122dof the gate attachment plate122, such as in a similar manner as described above. As also described above with respect to hinge20ofFIGS. 2–13, the stop members138a,138bof hinge120may be adjusted or trimmed to adjust the range of pivotal movement of gate attachment plate122relative to intermediate member132, and thus of the gate or panel or pivotable component relative to the vehicle body. For example, the edges140of stops138a,138bmay be trimmed or adjusted to adjust the stopping position of the gate attachment plate122relative to intermediate member132. The hinge120thus may provide for adjustment of the pivotal range of the hinge during manufacturing of the hinge, and particularly during manufacturing of the intermediate member.

Referring now toFIGS. 17–23, a hinge component42may be especially adapted to be attached to a hood or trunk of a vehicle (not shown inFIGS. 17–23). Hinge component42is preferably made from a single, stamped piece of metal, such as steel or the like. Hinge component42includes three walls44a,44b,44c, which are arranged to form a generally U-shaped channel. The U-shape provides comparable strength to a tubular product, yet allows hinge component42to be stamped, thereby reduces the manufacturing cost of the hinge component42. One end of hinge component42includes one or more fastener holes46which receive fasteners used to secure component42to a vehicle pivotable panel, such as a hood of the vehicle or the like. The other end of hinge component42is crimped such that the two sidewalls44aand44cof the U-shaped channels are in planar contact with each other. This region of planar contact forms a thickened region48, as best shown inFIG. 23.

The thickened region48may define a pivot axis50of the hinge component42for the hood or deck lid and hinge component42to pivot about when the hood or deck lid and hinge component42are mounted to the vehicle body. A hole52can be net pierced in thickened region48to receive a bushing, which in turn receives a pivot pin that defines a pivot axis about which hinge component42will pivot. This net piercing may take place on the vehicle assembly line after hinge component42has been attached to a hood, trunk cover or deck lid, or other pivotable panel or component or item. After attachment to the pivotable component, the pivotable component can be placed in proper alignment on the vehicle body and the hole net pierced so that proper alignment of the pivotable component is ensured with respect to the vehicle body.

For example, hinge component42may be attached to a hood. The hood may then be aligned properly with the vehicle body so that when it is closed, it is aligned and evenly spaced about the vehicle body. The hole52in hinge component42may then be pierced while the hood is properly aligned. A bushing54may then be put in the hole, and a pivot pin (not shown) on the body of the vehicle may be inserted through the bushing and hole to pivotably mount the hinge component42(and the hood) to the vehicle body. Two hinge components42may be used with a single hood to provide hinged support on both sides of the hood (or other pivotal component or item, such as a deck lid or the like).

Thickened region48of hinge component42is preferably thick enough to provide sufficient structural strength and resistance to wear over the life of the vehicle. If the thickness of sidewalls44a,44care less than one half of the desired thickness of thickened region48, then thickened region48may not be thick enough in the illustrated embodiment. In order to accommodate a desired greater thickness in thickened region48, one of sidewalls44aor44c(such as44ainFIG. 23) may be designed to initially extend beyond the terminus of the other sidewall (as shown in phantom at44a′ inFIG. 23). This extended portion of the sidewall can then be folded back over onto the two sidewalls in thickened region48, thereby creating a thickened region having a thickness equal to the thickness of three sidewalls44a,44cand44a′ Additional foldings can be made to provide even thicker regions48, if desired.

Therefore, the present invention provides a hinge for an automobile that may be formed from stamped metal components, yet may be substantially strong and structurally rigid to withstand the forces encountered in opening and closing a pivotable panel, such as a tailgate or lift gate or hatchback or deck lid or the like of a vehicle. The hinge of the present invention may be used on different vehicles where a desired range of pivotal movement of the pivotable panel may be different between the different vehicles or vehicle lines. The intermediate member or gate attachment plate may be adjusted or trimmed to provide different stop locations of the gate relative to the body portion of the vehicle. The intermediate members (and attachment plates) thus may be common parts across different vehicles or vehicle lines and may be adjusted to adapt the particular hinge to the particular application of that hinge. Also, the generally inverted U-shaped design of the intermediate member provides for enhanced structural rigidity of the intermediate member and thus of the hinge over conventional designs. Also, the body attachment plate of the hinge of the present invention may be formed to substantially enhance the structural rigidity of the plate to resist or limit or substantially preclude flexing or bending or twisting of the plate and hinge during use of the hinge.

It is to be understood that the foregoing is a description of the preferred embodiments only. One skilled in the art will recognize that variations, modifications and improvements may be made without departing from the spirit and scope of the invention disclosed herein. The scope of protection is to be measured by the claims which follow and the breadth of interpretation which the law allows, including the doctrine of equivalents.