Patent Publication Number: US-11021897-B2

Title: Overtravel hinge

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a divisional application of U.S. patent application Ser. No. 15/792,907, now U.S. Pat. No. 10,676,974, filed Oct. 25, 2017, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/416,246, having the title “Overtravel Hinge” filed Nov. 2, 2016, the disclosures of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     The present application relates to a passenger vehicle for transporting one or more passengers, and more particularly to a modified passenger vehicle which is configured to provide access to the vehicle for a physically limited passenger. 
     BACKGROUND 
     Automobile manufacturers do not currently mass-produce passenger motor vehicles specifically designed to transport passengers having physical limitations, either as a driver or as a non-driving passenger. Consequently, mass-produced passenger vehicles are modified, or retrofitted, by a number of aftermarket companies dedicated to supplying vehicles to physically limited passengers. Such vehicles can be modified by removing certain parts or structures within a vehicle and replacing those parts with parts specifically designed to accommodate the physically limited passenger. For example in one configuration, a van is retrofitted with a ramp to enable a physically limited individual using a wheelchair to enter and exit the vehicle without the assistance of another individual. 
     Other known products for retrofitting a vehicle, such as a van, include wheel chair lifts, lift platforms, and lowered floor surfaces. In some instances, a door of an original equipment manufacturer (OEM) van is enlarged or otherwise modified to permit entry and exit of the physically limited individual through what is known as the assisted entrance. Once inside the van, individual who uses the assisted entrance is located in a rear passenger compartment of the van adjacent to or behind the assisted entrance. 
     In one known retrofitted van, the sliding side door moves toward the back of the vehicle to open a passenger entrance as well as to provide access to a ramp located beneath the floor. In some vehicles, which are considered as viable candidates for retrofitting, the construction of the OEM vehicle requires significant modification to accommodate the addition of a ramp. Not only must a subfloor be added, but the door opening needs to be widened to provide access to a wheelchair. Consequently, what is needed is a modification to an OEM vehicle which reduces the amount of changes required to retrofit the OEM vehicle to provide access to individuals confined to a wheelchair or other mobility alternatives to wheelchairs. 
     SUMMARY 
     In one embodiment, there is provided a motor vehicle having a body. The motor vehicle includes a track mounted to the body wherein the track includes a first end and a second end. A door is adapted to move from a closed position to an open position. An extendable hinge is slidingly mounted to the track and is fixedly mounted to the door. The extendable hinge includes a collapsed first condition in the closed position of the door, a partially deployed condition between the first end and the second end of the track, and a fully deployed condition in the open position of the door. At the fully deployed condition, the position of the door is adjusted with respect to the body without further sliding movement of the hinge along the track. 
     In another embodiment, there is provided an extendable hinge for a door operatively coupled to a sliding mechanism configured to slide along a track of a passenger vehicle. The extendable hinge includes a first bracket adapted to couple to the door. A second bracket pivotably coupled to the first bracket. A third bracket pivotably coupled to the second bracket and an arm pivotably coupled to the first bracket and to the third bracket. The pivotable movement of the arm controls movement of the extendable hinge from a collapsed condition, a partially deployed condition, and a fully deployed condition. 
     In an additional embodiment, there is provided a vehicle door hinge for a door of a motor vehicle having a track configured to accept the door hinge for sliding movement of the door along the track. The door hinge includes an extendable hinge configured to slidingly mount to the track and fixedly mount to the door, wherein the extendable hinge includes: i) a collapsed condition at a first end of the track, ii) a partially deployed condition between the first end and a second end of the track, and iii) a fully deployed condition at the second end of the track. When the vehicle door hinge is in the fully deployed condition, the fully deployed condition further adjusts the position of the door with respect to the track without further sliding movement of the hinge along the track. 
     In still another embodiment, there is provided a method of opening a vehicle door moving along a track located along a side of the vehicle, wherein the track includes a first end at which the door is in a closed position and a second end at which the door is in an open position. The method includes: adjusting the position of the door by sliding the door along the track from the closed position at the first end of the track toward the second end of the track; and continuing to adjust the position of the door with respect to the track without further sliding movement of the door along the track at the second end of the track. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned aspects of the present invention and the manner of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention, taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  illustrates an elevational side view of a passenger vehicle including an access ramp. 
         FIG. 2  illustrates an elevational side view of a passenger vehicle having a first, second, and third track adapted to provide for sliding movement of a door from a closed position to an open position. 
         FIG. 3  illustrates a perspective view of a prior art door hinge. 
         FIG. 4  illustrates a perspective view of an extendable hinge in a first, second, and third position with respect to door track. 
         FIG. 5  illustrates a top view of an extendable hinge in a collapsed configuration located in a recess of a vehicle pillar. 
         FIG. 6  illustrates a perspective view of a portion of an extendable hinge operatively connected to an inside of a vehicle door. 
         FIGS. 7A, 7B, 7C, and 7D  illustrate perspective views of the front and back of an extendable hinge in different states of operation. 
         FIG. 8  illustrates an exploded view of an extendable hinge. 
         FIG. 9  illustrates a diagrammatic top view of a prior art door hinge located an end of travel of a door track. 
         FIG. 10  illustrates a diagrammatic top view of an overtravel door hinge located at an end of travel of a door track. 
         FIG. 11  illustrates a perspective view of an extendable hinge in a first, second, and third position with respect to a door track. 
         FIG. 12  illustrates a perspective view of a portion of a door hinge configured to engage a door track having a door track support. 
         FIG. 13  illustrates a perspective view of a portion of a door hinge including a retaining block and a door track including a retention flange. 
         FIG. 14  illustrates a perspective view of a door hinge including a latch. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention. 
       FIG. 1  illustrates a vehicle  10 , commonly identified as a passenger van, available from any number of United States and foreign manufacturers. In the illustrated embodiment, the vehicle  10  includes a unibody construction, but other vehicles having a frame on body construction, are also included in the present disclosure. Consequently the use of vehicle herein includes all types and kinds of vehicles with a body on frame construction, a unibody construction, or other constructions. In addition, while the passenger van  10  is illustrated in  FIG. 1 , the present disclosure is directed to all passenger vehicles carrying one or more passengers. 
     The vehicle  10  includes a body  12  operatively coupled to front wheels  14  and rear wheels  16 . The vehicle  10  includes a unibody construction. A first passenger side door  18  is located between the front wheels  14  and rear wheels  16  and provides access to a passenger for sitting in a front seat of the vehicle adjacent to the driver. 
     The vehicle  10  includes a second passenger side door  20  coupled to the unibody frame through a sliding mechanism including three tracks. Other numbers of tracks are possible. The sliding mechanism is modified to slide along the tracks to increase the size of an opening  22  to the interior. The widened opening  22  provides improved access to a passenger seated in a wheelchair. The opening is defined on the sides thereof by an edge  19  of a B-pillar  23  and the edge  21  of the door  20 . The vehicle is further modified to include a ramp assembly  24  which provides rolling access of a wheelchair from pavement  26  into an interior  28  of the vehicle  10 . The ramp assembly  24  is installed at the opening  22  and is movable between the interior of the vehicle, where it is stored in some embodiments, and to the exterior for wheelchair access. 
     In known modified vehicles, such as the modified van, the middle row of seats is removed from the manufacturer supplied vehicle to enable access to a wheelchair supporting a passenger. Once the wheelchaired passenger moves into the interior of the vehicle, the passenger or caregiver locates the wheelchair in the middle portion of the interior behind the driver and passenger seats of the front row. As used herein, a wheelchaired passenger is used to indicate that the individual is making use of a wheelchair, whether that use is temporary or permanent. 
     As can be seen in  FIG. 2 , the vehicle  10  includes a first track  30 , a second track  32 , and a third track  34 , each of which is adapted to provide sliding movement of the door  20  from a closed position to an open position and back to a closed position as is understood by those skilled in the art. In one embodiment, an upper portion of the body  12  supports the track  30  and a lower portion of the body  12  supports the track  34 . The track  32  is supported by the body but is located, in one embodiment, at a bottom portion of a side window. 
     In an OEM door, a sliding door hinge  36 , such as the prior art sliding door hinge  36  of  FIG. 3 , is coupled to an interior of the door  20  and is slidingly coupled to one or more of the first track  30 , the second track  32 , and the third track  34 . The sliding door hinge  36  includes sliding member  38  having a first part  40  which engages a track with a plurality of roller bearings  42 . The sliding member  38  includes a bracket support  44 , coupled to the first part  40 , to locate the door  20  at an appropriate distance from the body  12  of the vehicle  10 . A door bracket  46  is rotatably coupled to the bracket support  44  at a pin  48  which enables pivotable movement of the bracket  46  about an axis defined by the pin  48  with the bracket support  44 . A spring  50  provides a predetermined amount of tension between the bracket support  44  and the door bracket  46  to reduce play between the two brackets. The door bracket  46  includes a plurality of apertures which provides openings for connectors to engage the sliding door hinge  36  to an inside of the door  20 . 
     In an OEM vehicle, three sliding door hinges are coupled to the inside of the door  20  and each engage one of the tracks  30 ,  32 , and  34 . The sliding door hinge  36  is typically located at the middle track  32 . Different types of sliding door hinges are configured to engage the tracks  30  and  34 . When the described hinges are used in the OEM vehicle, however, the size of the opening  22  is established between the edge  19  of the B-pillar  23  and the edge  21  of the door  20  which can open no further than a location  54  as illustrated by the dotted line in  FIG. 2 . In this OEM configuration the size of the door opening  22  is insufficient to provide adequate access to a wheelchaired individual. In one embodiment, the door  22  is opened manually by an individual. In another embodiment, the door  22  is a powered sliding door which moves along the track powered by sliding door motor (not shown) located in the door. 
     To provide an increased access area of the door opening  22 , an extendable hinge  60 , as illustrated in  FIG. 4 , slidingly engages one, some, or all of the tracks  30 ,  32 , and  34 . For purposes of the present disclosure, the track  32  is discussed. In other embodiments, a single extendable hinge  60  is used at the middle track  32  and other hinges, not necessarily the prior art hinge of  FIG. 3 , are used. 
       FIG. 4  illustrates the extendable hinge  60  at different locations of the track  32  as the door is moved from the closed position to the open position. In a first position  62  at a terminating end of the track  32 , the hinge  60  is in a collapsed condition, or fully closed condition. At this position, the door is closed. In a second position  64 , the hinge  60  is in a partially deployed condition, or partially open condition. In a third position  66 , the hinge is in a fully deployed condition, or fully open condition. At this position, the door is fully open. A stop  67  is located at the end of the track  32  to stop the extendable hinge from traveling further along the rail  32 . This stop defines the extent of the open position of the door, which is increased by the extendable hinge. In this embodiment, the extendable hinge  60  is operatively connected to the bracket support  44  which is coupled to the first part  40 , which engages the track  32 . In other embodiments, one or both of the first part  40  and the bracket support  44  are not an OEM part, but are parts specifically adapted to mate with the extendable hinge  60 . 
     In the first position  62 , the extendable hinge  60  is located in a cavity  70  defined by a body pillar  72  of the body  12  as illustrated in  FIG. 5 . In one embodiment, the cavity  70  is located in what is generally known as a C pillar. As seen in this top view and in  FIG. 4 , the extendable hinge  60  includes a first bracket  74  formed to attach to an inside of the door  20  as illustrated in  FIG. 6 . The bracket  74  includes a plate  76  having terminating sides  78  and  80  inclined with respect to the plate  76  to provide a relatively rigid structure. The plate  76  includes a plurality of apertures  82  adapted to receive fasteners or connectors to couple the extendable hinge  60  to the door  20 . 
     An end  84  of the bracket  74  includes first and second apertures  86  disposed in the terminating sides  78  and  80  which capture a pin  88 . The pin  88  extends through the apertures  86  and into a second bracket  90  to pivotably couple the second bracket  90  to the fixed first bracket  74 . While not apparent from  FIG. 6 , the first bracket  74  includes a finger or extending portion  92 , which extends past the pin  88 . See also  FIGS. 7A-7D . While the side  78  includes the finger  92 , the other side  80  does not. 
     An arm  94  extends along the extendable hinge  60  when the hinge is in the collapsed condition. As seen in both  FIG. 5  and in  FIG. 7A , a first end  96  of the arm  94  is pivotably coupled to the finger  92  with a connector  98 . A second end  100  of the arm  94  is pivotably coupled to a third bracket  102  with a connector  104 . The pivotable coupling of the arm  94  at the end  100  is located between a first end  106  and a second end  108  of the third bracket  102 . The third bracket  102  is pivotably coupled to the bracket support  44  with a pin  110 . The pin  110  extends through a spring  111 , a terminating end  112  of the bracket support  44 , and through a first side  114  and a second side  116  of the third bracket  102 . The first side  114  and the second side  116  are coupled to an intermediate plate  118 . In one embodiment, the first side  114 , the second side  116 , and the intermediated plate  118  are all one casting. In another embodiment, the first side  114 , the second side  116 , and the intermediated plate  118  are separate components fixedly coupled together. 
     The first end of the bracket  102  is pivotably coupled to the bracket  90  with a pin  120 . The pin  120  extends through a spring  121 , the first and second sides  114  and  116  of the third bracket  102 , and a first side  122  and a second side  124  of the second bracket  90 . The first side  122  and second side  124  are separated by and coupled to a plate  125 . In one embodiment, the first side  122 , the second side  124 , and the plate  125  are all one casting. In another embodiment, the first side  122 , the second side  124 , and the plate  125  are separate components fixedly coupled together. 
       FIG. 7B  illustrates a back view of the extendable hinge  60  in the fully deployed condition. The spring  111  includes a first terminating end  130  which engages the plate  118  and a second terminating end  132  which engages a portion of the bracket support  44 . See  FIG. 7A . The spring  121  includes a first terminating end  134  which engages a notch in the plate  125 . A second terminating end  136  engages a notch located in a sidewall  138  of the third bracket  102 . Each of the springs  111  and  121  provides a predetermined amount of spring tension to the respective first, second, and third brackets  74 ,  90 , and  102  to reduce or prevent the appearance of play or slop when the extendable hinge  60  moves from the collapsed condition to the fully deployed condition and back to the collapsed condition. 
     As seen in both  FIGS. 7A and 7B , a latch  140  is mounted on the pin  110  on one side of the spring  111 . The latch  140  is spring biased about the pin  110  by a spring  142  which includes a first terminating end  144  operatively connected to the bracket support  44 . A second end  146  of the spring  142  is coupled to an end of the latch  140  with a connector  141 . The latch  140  is therefore biased in a counterclockwise direction as shown in  FIG. 7A . The latch  140  includes a notch  150  having a predetermined size which is sufficient to capture the pin  88  as further illustrated in  FIG. 7C . 
       FIG. 7C  illustrates the partially deployed condition  64  of  FIG. 4  and  FIG. 7D  illustrates a back view of the partially deployed condition  64 . In this condition, the each of the brackets  74 ,  90 , and  102  are aligned substantially in parallel just prior to being fully collapsed in the collapsed condition  62 . In this partially deployed condition, the latch  140  is positioned such that the notch  150  is located at a position just before engaging the pin  88 . As the door  20  is moved toward the closed position, the latch  140  fully engages the pin  88  and pulls the pin  88  toward the car body  12  and into a fully latched position which seals the door to the body  12 . The finally engaged position of the latch  140  with the pin  88  can be seen in  FIG. 4  at the collapsed position  62 . 
     As more clearly seen in  FIG. 7A , the second bracket  90  includes a rib  160  which is coupled to the top wall  122  and the bottom wall  124 . The rib  160  is inclined with respect to the planes of each of the walls  122  and  124  and extends from each to provide structural support for the second bracket  90 . To provide for the substantially parallel orientation for each of the first, second, and third brackets  74 ,  90 , and  102 , the third bracket  102  includes an inclined recess  162 , which is configured to receive the rib  160  when the extendable latch  60  is in the collapsed condition. Not only does this enable each of the brackets to collapse and to fit within the cavity  70  of the pillar  72 , but it also provides for a nesting of parts such that a close fit between parts is provided to reduce any noise that could result if the parts were not so aligned. 
     As is also illustrated in  FIG. 7D , each of the first, second, and third brackets  74 ,  90 , and  120  include plates of different heights such that the top and bottom walls of each bracket nest without interfering with another bracket when collapsed. For instance, the bottom wall  116  of the third bracket  102  is disposed adjacently to the bottom wall  124  of the second bracket  90 . The bottom wall  124  of the second bracket  90  is disposed adjacently to the bottom wall  80  of the first bracket  74 . Top walls of each of the brackets are similarly adjacently disposed. 
     As is also illustrated in  FIG. 7D , a standoff  158  is located between the end  100  of the arm  94  and the top plate  114  of the third bracket  102 . To enable the second bracket  90  to nest with the third bracket  102 , the top wall  122  of the second bracket  90  includes a cutout  157  shown in  FIG. 5 . The arm  94  is also configured to nest with a nut  159 , one of the parts used to hold the pin  110  in place. To enable nesting of the arm  94  with the nut  159 , the arm  94  includes a first section  161 , coupled to the connector  104 , and a second section  163  which extends from the first section at an angel of other than 180 degrees to interface with the nut  149 . The second section  163  also includes a cutout  165  which is configured to interface with the pin  88 . 
     The arm  94  provides one link of a four bar linkage which includes as the other links: a) the finger  92 , between the pin  88  and the connector  98 ; b) the second bracket  90 , between the pin  88  and the pin  120 , and c) a portion of the third bracket  102 , between the pin  120  and the connector  104 . The arm  94  is used to control movement of the overtravel hinge  60  between the collapsed condition and the fully deployed condition. 
       FIG. 8  illustrates an exploded view of the bracket support  44  and the extendable hinge  60 . Additional parts, including washer, inserts, standoffs, and nuts are shown to complete the assembly of the bracket support  44  and extendable hinge  60 . 
       FIG. 9  illustrates the prior art hinge of  FIG. 3  located at the stop  67  of the rail  32 . This is a top view of the hinge  46  and shows the location of the edge  22  of the door  20  aligned with the location  54 , also illustrated in  FIG. 2 .  FIG. 10 , in contrast, illustrates the extendable hinge  60  of the present disclosure and the additional travel distance of the door  20  provided along the track  32 . While the bracket support  44  is prevented from moving further along the rail by the stop  67 , the extendable hinge  60  in the fully deployed condition provides additional movement of the door  20  along the body  12  of the vehicle  10 . The edge of the door  21  is therefore moved away from the location  54  to provide an additional space  164 . The opening  22  is thereby increased in size to provide additional room for entry into and out of the vehicle  10 . 
       FIG. 11  illustrates a perspective view of another embodiment of an extendable hinge  170  in a first, second, and third position with respect to a door track  172 . In this embodiment, the door track includes a track flange  174  which is operatively connected to the door track  172  at an end  176  at which the hinge  170  is fully extended. The track flange  174  provides increased strength to the OEM track and provides additional stability of the door. In this embodiment, the hinge  170  includes a bracket support  178  which has been modified to engage the door track  172  and in particular to engage the flange  174 . The bracket support  178  includes a first part  179  configured to engage the track flange  174 . 
     The hinge  170  includes a first bracket  180  coupled to a second bracket  182  which is in turn coupled to a third bracket  184 . An arm  186  is pivotably coupled to and extends between the second bracket  182  and the third bracket  184 . The arm  186  has been modified when compared to the arm  94  of the prior configurations to accommodate a connector  188  which is supported by the third bracket  184 . In this embodiment, the arm  186  includes a relatively straight configuration between the connector  188  and a connector  190  located on the second bracket  182 . A latch  192  is located at a pin  194  which couples the third bracket  184  to the bracket support  178 . 
     As seen in  FIG. 12 , the flange  174  includes a first end  196  and a second end  198  each of which are fixedly coupled to the track  172 . A center section of the flange  174  includes an upstanding portion  200  which extends upwardly away from a bottom  202  of the track  176 . A retention block  204  is fixedly coupled to the first part  179  with a first fastener  206  and a second fastener  208 . 
     As further illustrated in  FIG. 13 , the retention block  204  includes a channel  210  which extends from a first side  212  to a second side (not shown) of the retention block  204 . The channel  210  includes a dimension sufficient to accommodate the width of the upstanding portion  200 , such that the retention block  204 , and therefore the hinge  170 , moves along the track flange  174 . The internal dimension of the channel  210  is sufficiently sized to permit movement of the block  204  along the portion  200  without excessive binding, while not being too loose. The retention block  204 , in combination with the flange  174 , reduces an amount of deformation to the track  172  which can result from the weight of the door as it travels along the track  172 . 
       FIG. 14  illustrates a perspective view of a portion of the door hinge  170  including the latch  192 . The latch  192  is spring biased about the pin  194  by a spring  214 . The latch  192  is biased in a counterclockwise direction as shown in  FIG. 14 . The latch  192  includes a notch  216  having a predetermined size which is sufficient to capture a pin  218  when the hinge  170  is in the closed position. The latch  192  further includes a leg  220 , which is spaced from the notch  216 , and which extends away from the pin  194 . 
     When the hinge  170  is in the closed position and the door of the vehicle is completely closed, the pin  218  is located within the notch  216  of the latch  192 . In this position, the leg  220  extends toward the door and provides additional leverage for opening the door from the closed position and moving the door to a partially open state. The leg  220  contacts the original equipment door upon rotation of the hinge  170  and pushes the hinge  170  to disengage the notch  216  from the pin  218 . As the leg  220  continues to contact the door, the hinge  170  is forced open by a small amount which reduces the force necessary to move the door from the closed position to the open position. 
     As further illustrated in  FIG. 14 , the second bracket  182  includes a rib  222  which is inclined with respect to the top wall and the bottom wall of the bracket  182 . In this embodiment, however, the rib  222  includes a centrally located cutout  224 . The third bracket  184  includes an inclined recess  226  having a crosspiece  228 , which extends across the inclined recess  226 . As the hinge  170  is moved to close the door, the cutout  224  moves into close proximity with the crosspiece  228 . Once the door is completely closed, the crosspiece  228  provides support for the rib  222  and consequently reduces any flex of the hinge  170  which can result from movement of the vehicle while the door is closed. 
     While exemplary embodiments incorporating the principles of the present invention have been disclosed herein, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. For instance, the present disclosure is not limited to the modification of a purchased OEM vehicle, but can be incorporated into the OEM vehicle when manufactured. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.