Patent ID: 8171606

Claim:
A method of manufacturing a hinge assembly including a rail bracket having first and second portions each with inner and outer bushings, a step bracket having first and second parts each with inner and outer bushings, an inner arm having upper and lower pivot shafts, and an outer arm having upper and lower pivot shafts utilizing a THIXOMOLDING™ process and a die, the method comprising the steps of: locating a plurality of the inner and outer bushings in the die; locating a plurality of the upper and lower pivot shafts in the die; molding, utilizing the THIXOMOLDING ™ process, the first and second portions of the rail bracket with the inner and outer bushings insert molded therein, the first and second parts of the step bracket with the inner and outer bushings insert molded therein, the inner arm with the upper and lower pivot shafts insert molded therein, and the outer arm with the upper and lower pivot shafts insert molded therein in the die; removing the first and second portions of the rail bracket, the first and second parts of the step bracket, and the inner and outer arms from the die; and assembling the first and second portions of the rail bracket, the first and second parts of the step bracket, and the inner and outer arms to form the hinge assembly.