Patent Publication Number: US-6666497-B2

Title: Door hinge mounting structure

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a door hinge mounting structure, and more particularly to a door hinge mounting structure for a door panel or a door mounting portion of a vehicle body, that positions the door hinge on the vehicle body side or the door side on an assembly line of automobiles when the door is remounted on the vehicle body after the door has been temporarily mounted on the vehicle body for painting and also pieces of equipment have been mounted on the vehicle side and the door side while the door being removed. 
     In assembling processes of automotive vehicles, painting is performed after door panels are temporarily mounted on the vehicle body. After the painting work has been completed, the door panels are removed from the vehicle body in such a manner that seats can be assembled to the vehicle body and window glass can be assembled to the door panels. Thereafter, the door panels are remounted on the vehicle body at their original positions. 
     Consequently, in order to reassemble the door panels to the vehicle body, door hinges need to be positioned on the vehicle body side or the door side. Proposed as a door hinge positioning structure as has just been described above is a technology which is described in, for example, JP-B-6-49798U. 
     The prior art will be described with reference to FIG.  10 . 
     In the prior art, a positioning bolt passable hole  103  for a positioning bolt  102  is pierced through a pillar outer panel  101 , and the positioning bolt  102  is screwed through a threaded hole  105  formed in a retaining plate  104  provided in the interior of the pillar outer panel  101 , whereby the positioning bolt  102  is positioned in the pillar outer panel  101 . A door hinge  106  is positioned based on this positioning bolt  102 . 
     In addition, the door hinge  106  comprises a moving side bracket  107  and a fixed side bracket  108  which are rotatably assembled together with a connecting pin  109 . In addition, reference numeral  110  denotes a door panel. 
     Incidentally, in the prior art, when the positioning bolt  102  is screwed through the retaining plate  104  provided within the pillar outer panel  101 , the positioning bolt passable hole  103  formed in the pillar outer panel  101  deviates largely from the threaded hole  105  in the retaining plate  104  in normal conditions. 
     Consequently, since the positioning bolt  102  needs to be passed through the positioning bolt passable hole  103  and the threaded hole  105  by matching the positioning bolt passable hole  103  and the threaded hole  105  while holding the retaining plate  104  with a hand, there is caused a problem that the working efficiency is deteriorated. 
     In addition, in the prior art, in order to improve the efficiency in passing the positioning bolt  102  through the holes, since an inserting portion  111  of a small outside diameter needs to be provided at a distal end of the positioning bolt  102  to facilitate the ingress of the distal end portion of the positioning bolt  102  into the positioning bolt passable hole  103 , a general-purpose bolt cannot be used as the positioning bolt, causing a problem that the component costs are increased. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is a main object of the invention to provide a door hinge mounting structure which allows the positioning bolt to be passed through the holes without supporting the retaining plate with the hand so that the working efficiency can be improved and which also allows a normal general-purpose bolt to be used as the positioning bolt without using any particular positioning bolt so that the component costs can be reduced. 
     With a view to attaining the main object, according to a first aspect of the invention, there is provided a door hinge mounting structure in which a retaining member having a threaded hole formed therein is provided in the interior of a door panel or a door mounting portion on a vehicle body and in which a positioning bolt is threadedly engaged with the threaded hole in the retaining member via a positioning bolt passable hole formed in the door panel or the door mounting portion, whereby a door hinge is positioned based on the position of the positioning bolt so mounted, the door hinge mounting structure being characterized in that the positioning bolt passable hole is formed larger than the threaded hole in the retaining member, and in that restrictive wall portions are provided in the interior of the door panel or the door mounting portion on the vehicle body for restricting the movement of the retaining member within a range in which the positioning bolt passable hole and the threaded hole in the retaining member substantially coincide in position with each other. 
     With this structure, according to the door hinge mounting structure according to the first aspect of the invention, since the movement of the retaining member is limited within a predetermined range by the restrictive wall portions for restricting the moving range of the retaining member, the positioning bolt passable hole and the threaded hole can be matched substantially, whereby the positioning bolt can be passed through the holes without supporting the retaining member with the hand. 
     In addition, since the positioning bolt passable hole formed in the door panel or the door mounting portion is made larger than the threaded hole in the retaining member, it becomes easier for the positioning bolt to be inserted into the positioning bolt passable hole than in a case where the positioning bolt passable hole is identical in size to the threaded hole. Consequently, no inserting portion of a small outside diameter needs to be additionally formed at the distal end portion of the positioning bolt so as to improve the working efficiency, whereby a general-purpose bolt can be used as the positioning bolt. 
     According to a second aspect of the invention, there is provided a door hinge mounting structure as set forth in the first aspect of the invention, wherein the retaining member is provided with a projection which protrudes radially outwardly of the threaded hole, and wherein an opening is formed between the restrictive wall portions for passage of the projection. 
     With this structure, according to the door hinge mounting structure as set forth in the second aspect of the invention, when the positioning bolt is passed through the holes, the retaining member can be prevented from rotating around the threaded hole by the projection on the retaining member and the opening between the restrictive wall portions. Consequently, the rotation of the retaining member can be restricted at positions disposed away from the rotational center of the retaining member without constructing the retaining member itself larger. 
     Furthermore, according to a third aspect of the invention, there is provided a door hinge mounting structure as set forth in the first or second aspect of the invention, wherein the restrictive wall portions each form a portion which faces the opening along directions in which the retaining member rotates around the threaded hole. 
     With this structure, according to the door hinge mounting structure as set forth in the third aspect of the invention, since the restrictive wall portions are formed in such a manner as to extend along orientations which are opposite to the rotating directions of the retaining member, the prevention of the rotation of the retaining member can be ensured further. 
     According to a fourth aspect of the invention, there is provided a door hinge mounting structure as set forth in any of the first, second and third aspects of the invention, wherein the restrictive wall portions are provided in a recessed portion formed on the door panel or the door mounting portion. 
     With this structure, according to the door hinge mounting structure as set forth in the fourth aspect of the invention, the retaining member is also accommodated in the recessed portion formed on the door panel or the door mounting portion, whereby the door hinge mounting structure can be formed compact. In addition, a great mounting strength can be secured at the door hinge mounting structure. 
     According to a fifth aspect of the invention, there is provided a door hinge mounting portion as set forth in any of the first to fourth aspects of the invention, wherein the retaining member is provided with a pair of left and right symmetrical projections. 
     With this structure, according to the door hinge mounting structure as set forth in the fifth aspect of the invention, when inserting the positioning bolt in the threaded hole to screw (threadedly engage) it therethrough forces are exerted on the left and right projections equally, and the forces are dispersed relative to the restrictive wall portions, whereby the projections themselves and the restrictive wall portions may not have to be formed sturdier and larger than required. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front view of a tail door of an automobile according to an embodiment of the invention which is being assembled on an assembly line; 
     FIG. 2 is a horizontal cross-sectional view taken along the line II—II in FIG. 1; 
     FIG. 3 is a right side view of the tail door; 
     FIG. 4A is a perspective view showing a piece of an upper hinge which is fixed to the vehicle body side, and FIG. 4B is a perspective view, similar to FIG. 4A, showing a piece of the upper hinge which is fixed to the door panel side; 
     FIG. 5 is a perspective view showing a retaining member for positioning the upper hinge relative to the tail door panel; 
     FIG. 6A is a view showing a state in which the retaining member is disposed in a recessed portion on the tail door panel, and FIG. 6B is a vertical sectional view showing a state in which the upper hinge is mounted on the tail door panel; 
     FIG. 7 is a side view of a positioning bolt; 
     FIGS. 8A,  8 B,  8 C,  8 D are view showing the transition of the position of the retaining member due to scattering generated when the upper hinge is applied to the retaining member provided in the interior of the door frame; 
     FIG. 9 is a view showing adjustment margins when the retaining member is positioned in the recessed portion on the door frame with the positioning bolt; 
     FIG. 10 is a partially cutaway side view describing a main portion of a conventional door hinge mounting structure. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     An embodiment of a door hinge mounting structure according to the invention will be described below with reference to the accompanying drawings. 
     In the drawings to be referred to, FIG. 1 is a front view of a tail door of an automobile according to an embodiment of the invention which is being assembled on an assembly line. 
     Note that in this front view portions on a side of a vehicle body at the rear thereof where door hinges are assembled are cutaway so that the door hinges so assemble become visible. 
     In assembling processes of automobiles, when vehicle bodies are, assembled on a vehicle body assembling line door panels are temporarily mounted on the vehicle bodies, and thereafter the vehicle bodies so assembled are then painted on a painting line. Then, after completion of the painting work on the painting line, the door panels are removed from the vehicle bodies, and on an equipment mounting line seats and so on are assembled to the vehicle bodies, and also window glasses are assembled to the door panels. Then, after all the work has been completed, the door panels are then re-assembled to their original positions on the vehicle bodies. 
     Consequently, as shown in FIG. 1, the door hinge mounting structure according to the embodiment of the invention is applied to an automobile  1  which is being assembled on the vehicle body assembling line, and more particularly is applied to an upper hinge  5  and a lower hinge  6  which are constructed to mount a tail door panel  2  of the automobile  1  to a door mounting portion  4  on a right side portion of a vehicle body  3 . Reference numeral  7  denotes a door handle. Since an identical mounting structure to that applied to the upper hinge  5  is applied to the lower hinge  6 , in this embodiment, the door hinge structure will be described only with reference to the upper hinge  5 . 
     FIG. 2 is a horizontal cross-sectional view taken along the line II—II shown in FIG. 1, and FIG. 3 is a right side view of the tail door. 
     In the figures, the upper hinge  5  fixed to a door frame  8  of the door panel  2  with bolts  9  is also fixed to the door mounting portion  4  of the vehicle body  3  with bolts  10 , and the door panel  2  is mounted rotatably through rotations of this upper hinge  5  (and the lower hinge  6 ). Reference numeral  11  denotes a positioning bolt, which will be described in detail later. 
     Note that reference numeral  12  denoted a thin plate-like door skin. 
     FIG. 4A is a perspective view showing a piece of the upper hinge which is fixed to the vehicle body side, and similarly, FIG. 4B is a perspective view showing a piece of the upper hinge which is fixed to the door panel side. 
     As shown in FIG. 4A, the upper hinge  5  is constituted by the vehicle body-side fixed piece  13  and the door panel-side fixed piece  14  which are constructed to be rotatable via pin  15 . The vehicle body-side fixed piece  13  is substantially formed into an L-shape and comprises a substantially rectangular positioning bolt passable portion  16  which faces the door panel-side fixed piece  14  and a substantially isosceles triangular fixed portion  17  one of whose-corners or vertexes which is fixed to the vehicle body  3  side is rounded. 
     Formed in the positioning bolt passable portion  16  is a recessed portion  18  having a difference in level at a central portion thereof. A position bolt passable hole  19  is formed within the recessed portion  18  through which a positioning bolt is passed when the upper hinge  5  is positioned relative to the door frame  8  with a positioning bolt  11 , which will be described later. The positioning bolt passable hole  19  become visible by being provided within the recessed portion  18 . 
     Fixed portion  17  constitutes, as described above, substantially an isosceles triangle adopting a side facing the bolt passable portion  16  as a base, and mount holes  20 ,  21 ,  21  are formed at positions corresponding to the respective vertexes of the triangle for fixing the upper hinge  5  to the door mounting portion  4  of the vehicle body  3 . 
     Wall portions  22 ,  22  are formed at positions corresponding to the upper and lower vertexes in such a manner as to partly surround the mount holes  21 ,  21 , respectively, on the bolt passable portion  16  side. In addition, a wider wall portion  23  is formed in such a manner as to separate the mount holes  21 ,  21  from each other and to extend to a position facing the mount hole  20 . A strength is imparted to the upper hinge  5  by these wall portions  22 ,  23 . 
     As shown in FIG. 4B, the door panel-side fixed piece  14  constitutes substantially an elongate isosceles triangular shape whose corners or vertexes are rounded, and formed at positions corresponding to the respective vertexes of the triangle are fixing holes  24 ,  24 ,  24  for fixing the upper hinge  5  to the tail door panel  2 . The door panel-side fixed piece  14  has two wall portions  25 ,  25  formed in parallel to each other for reinforcement thereof. Formed in a central portion of the door panel-side fixed piece  14  which is so isolated by the wall portions  25 ,  25  is a positioning hole  26  for positioning the upper hinge  5  relative to the door panel  2 . 
     FIG. 5 is a perspective view showing a retaining member for positioning the upper hinge relative to the tail door panel. 
     A reinforcement recessed portion  27  is formed on the tail door panel  2 . A retaining member  28  is disposed substantially horizontally in this recessed portion  27  for positioning the upper hinge  5  relative to the tail door panel  2 . The door hinge mounting structure can be made compact by accommodating the retaining member  28  in the recessed portion  27 , and the mounting strength can also be increased. 
     In the retaining member  28 , a threaded hole  30  is formed in a central portion of a slightly laterally elongate hexagonal main body  29 . Internal threads are formed in the threaded hole  30 . The threaded hole  30  is a hole into which the positioning bolt shown in FIG. 2 is screwed when the upper hinge  5  is positioned relative to the tail door panel  2 . A pair of left and right symmetrical rectangular projections  31 ,  31  are formed in such a manner as to protrude radially outwardly from the main body  29 . 
     Restrictive wall portions  32 ,  32  and  33 ,  33  and  36 ,  36  are formed within the recessed portion  27  in such a manner as to surround the projections  31 ,  31  of the retaining member  28 . The movable range of the retaining member  28  is restricted by the restrictive wall portions  32 ,  32  and  33 ,  33  and  36 ,  36 , whereby the retaining member  28  is allowed to move only within a predetermined range. Since this allows the passable hole and the threaded hole  30  to be substantially matched with each other in terms of position, the positioning bolt  11  can be passed through the holes without supporting the retaining member  28  with the hand. 
     Openings  34  and  35  are formed between the restrictive wall portions  32 ,  32  and  33 ,  33  through which the projections  31  are allowed to pass. In addition, the restrictive wall portions  32 ,  32  (and  33 ,  33 ) form portions facing the opening  34  (and  35 ) along directions in which the retaining member  28  rotates around the threaded hole  30 . As this occurs, the restrictive wall portions  32 ,  32  becomes substantially parallel with inclined side portions  29   a ,  29   a  of the hexagonal main body  29 . 
     Thus, since the restrictive wall portions  32 ,  32  are formed in such a manner as to extend along orientations which are opposite to the rotating directions of the retaining member  28 , so that the restrictive wall portions  32 ,  32  and the inclined side portions  29   a ,  29   a  of the main body  29  of the retaining member  28  become substantially parallel with each other, the pair of left and right projections  31 ,  31  of the retaining member  28  are securely received by the respective wall portions  32 ,  32  when they try to rotate when the positioning bolt  11  shown in FIG. 2 is screwed into the retaining member  28 , whereby the rotation of the retaining member  28  around the threaded hole  30  can be prevented. Consequently, the rotation of the retaining member  28  can be restricted from positions disposed away from the rotational center (the threaded hole  30 ) of the retaining member  28  without constructing the retaining member  28  itself larger. 
     In addition, the movement of the retaining member  28  is also restricted by the pair of upper and lower post-like restrictive members  36 ,  36  provided in the recessed portion  27  on both sides of the main body  29 . 
     Thus, as has been described heretofore, since the pair of left and right projections  31 ,  31  and the main body  29  of the retaining member  28  are restricted by the restrictive wall portions  32 ,  32 ,  33 ,  33  and the restrictive members  36 ,  36 , forces are exerted on the left and right projections  31 ,  31  equally when the positioning bolt  11  is passed and screwed through the threaded hole  30  in the retaining member  28 . Moreover, since the main body  29  is restricted by the restrictive members  36 ,  36 , the forces are dispersed to the restrictive wall portions  32 ,  32 ,  33 ,  33  and the restrictive members  36 ,  36 . Therefore, the restrictive wall portions  32 ,  32 ,  33 ,  33  and the restrictive members  36 ,  36  do not have to be formed sturdier than required. 
     FIG. 6A is a view showing a state in which the retaining member  28  is disposed in a recessed portion on the tail door panel, and FIG. 6B is a vertical sectional view showing a state in which the upper hinge is mounted on the tail door panel. 
     As shown in FIG. 6A, the retaining member  28  is disposed in the recessed portion  27  for positioning the upper hinge  5  on the door frame  8 . 
     In addition, as shown in FIG. 6B, a bolt passable hole  41  is formed in the door frame  8  and the door skin  12 . This bolt passable hole  41  is formed larger than the threaded hole  30  formed in the retaining member  28 . Since the movement of the retaining member  28  disposed in the recessed portion  27  is restricted to a range where the threaded hole  30  substantially matches the passable hole  41  in position by the restrictive wall portions  32 ,  32 ,  33 ,  33  and the restrictive members  36 ,  36  (FIG.  5 ), the positioning bolt  11  can be screwed into the threaded hole  30  via the passable hole  41  without supporting the retaining member with the hand, whereby an extremely good working efficiency can be obtained. 
     In addition, since the positioning bolt  11  is allowed to be inserted so easily, there is no need to form additionally an inserting portion of a smaller outside diameter at a distal end portion of the positioning bolt  11  in order to increase the working efficiency, and therefore, a general-purpose bolt, which will be described later, can eventually be used as the positioning bolt. 
     In addition, since the retaining member  28  mounted in the recessed portion  27  is covered with the door frame  8  and the door skin  12 , the retaining member  28  is set in the interior of the tail door panel  2 , whereby it can be invisible from the outside, resulting in a good external appearance. 
     FIG. 7 is a side view of the positioning bolt. 
     The positioning bolt  11  is a socket bolt with a general-purpose washer  50 , and a hexagonal hole  52  is formed in a head portion  51  with a threaded portion  53  having the same diameter along the full length thereof from the head portion  53  side to a distal end thereof. 
     Since the socket bolt with the general-purpose washer can be used as the positioning bolt  11 , there is no need to prepare a special positioning bolt provided with an inserting portion of a small diameter at a distal end thereof, whereby the number of components can be reduced, and therefore the components costs can be in turn reduced. 
     After having been positioned with the positioning bolt  11  being passed through the positioning hole  26 , the upper hinge  5  is temporarily mounted by screwing bolts into the fixing holes  24  to the tail door panel  2  and the mount holes  20 ,  21  to the door mounting portion  4  of the vehicle body  3 . Next, the door panel is transferred to a sub-line (such as an equipment mounting line) where a window glass is fitted with the upper hinge  5  being kept temporarily fastened thereto. After the fitment of equipment has been completed, the tail door panel is assembled again to the vehicle body on the body assembly line by fastening the upper hinge after the upper hinge has been positioned as has been described above. 
     Next, the function of the door hinge mounting structure of the invention will be described which is constructed as has been described heretofore. 
     FIGS. 8A,  8 B,  8 C,  8 D are views showing the transition of the position of the retaining member provided in the interior of the door frame due to scattering generated when the upper hinge is applied to the retaining member. 
     FIG. 8A shows a state in which the retaining member  28  deviates 1.5 mm downwardly and 3 mm leftward relative to its reference set position (denoted by reference numeral  41  in the figure: corresponding the passable hole  41  in the door frame  8  and the door skin  12 ), whereby the left-hand projection  31  abuts with the lower restrictive wall portion  32  (shown by broken lines). 
     Note that the in the state shown in the figure the upper hinge  5  is removed (this is also true hereinafter). 
     FIG. 8B shows a state in which the retaining member  28  deviates 1.5 mm downwardly and 3 mm rightward relative to its reference set position (denoted by reference numeral  41  in the figure: corresponding the passable hole  41  in the door frame  8  and the door skin  12 ), whereby the left-hand projection  31  abuts with the lower restrictive wall portion  32  whereas the right-hand projection  31  abuts with the lower restrictive wall portion  33  (shown by broken lines). 
     FIG. 8C shows a state in which the retaining member  28  deviates a maximum distance downwardly relative to the reference set position (denoted by reference numeral  41  in the figure: corresponding the passable hole  41  in the door frame  8  and the door skin  12 ) and the main body  29  abuts with the lower restrictive member  36 . Thus, the main body  29  abuts with the lower restrictive member  36  (as illustrated by broken lines). Note that although not shown, when the main body  20  deviates similarly a maximum distance but upwardly, conversely, the main body  29  abuts with the upper restrictive member  36 . 
     FIG. 8D shows a state in which the retaining member  28  does not deviate relative to the reference set position (denoted by reference numeral  41  in the figure: corresponding the passable hole  41  in the door frame  8  and the door skin  12 ), whereby the retaining member  28  remains at the reference set position. 
     FIG. 9 is a view showing adjustment margins that are taken into consideration when the retaining member is positioned in the recessed portion using the positioning bolt. 
     The above various deviations occurring when the upper hinge  5  is applied to the door frame  8  are corrected by assembling the upper hinge  5  by screwing the positioning bolt into the positioning bolt passable hole therein. 
     As shown in the figures, the assembling errors occurring when the retaining member  28  is assembled to the recessed portion  27  of the door frame  8  with the positioning bolt  11  can guarantee adjustment margins upto +/−0.5 mm in vertical directions and +/−2 mm in the transverse directions. 
     In addition, while the retaining member  28  having the threaded hole  30  is described as being provided in the interior of the tail door panel  2  in this embodiment, it goes without saying that the same effect can be provided even if the retaining member  28  is provided in the interior of the door mounting portion  4  of the vehicle body  3 . 
     As has been described heretofore, with the door hinge mounting structure according to the first aspect of the invention, since the movement of the retaining member is limited within the predetermined range by the restrictive wall portions for restricting the movable range of the retaining member, the positioning bolt passable hole and the threaded hole can be matched substantially, whereby the positioning bolt can be passed through the holes without supporting the retaining member with a hand. 
     In addition, since the positioning bolt passable hole formed in the door panel or the door mounting portion is made larger than the threaded hole in the retaining member, it becomes easier for the positioning bolt to be inserted into the positioning bolt passable hole than in a case where the positioning bolt passable hole is identical in size to the threaded hole. Consequently, no inserting portion of a small outside diameter needs to be additionally formed at the distal end portion of the positioning bolt so as to improve the working efficiency, whereby a general-purpose bolt can be used as the positioning bolt. 
     According to the door hinge mounting structure as set forth in the second aspect of the invention, when the positioning bolt is passed through the holes, the retaining member can be prevented from rotating around the threaded hole by the projection on the retaining member and the opening between the restrictive wall portions. Consequently, the rotation of the retaining member can be restricted at positions disposed away from the rotational center of the retaining member without constructing the retaining member itself larger. 
     According to the door hinge mounting structure as set forth in the third aspect of the invention, since the restrictive wall portions are formed in such a manner as to extend along orientations which are opposite to the rotating directions of the retaining member, the prevention of the rotation of the retaining member can be ensured further. 
     According to the door hinge mounting structure as set forth in the fourth aspect of the invention, the retaining member is also accommodated in the recessed portion formed on the door panel or the door mounting portion, whereby the door hinge mounting structure can be formed compact. 
     According to the door hinge mounting structure as set forth in the fifth aspect of the invention, when inserting the positioning bolt in the threaded hole to screw it therethrough forces are exerted on the left and right projections equally, and the forces are dispersed relative to the restrictive wall portions, whereby the projections themselves and the restrictive wall portions may not have to be formed sturdier and larger than required, the door hinge mounting structure being thereby made compact. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.