GB2560739A

GB2560739A - Vehicle door hinge

Info

Publication number: GB2560739A
Application number: GB1704585.7A
Authority: GB
Inventors: Dean Nigel
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-03-23
Filing date: 2017-03-23
Publication date: 2018-09-26
Also published as: GB201704585D0

Abstract

A vehicle hinge comprises a first hinge element 20 for mounting to a vehicle body structure and a second hinge element 30 for mounting to a door. According to a first claim the first hinge element 20 is formed of aluminium and includes a single aperture in which a single fastener 50 mounts the hinge. Also claimed is a hinge where the first hinge has an attachment portion in which is an aperture/socket extends into an upstanding post 24 portion of the hinge; a single fastener 50 extends into the aperture and reinforces the post portion. The hinge may be of aluminium or magnesium and the threaded fastener may be steel. Preferably the fastener is a double ended stud threaded at both ends with a radial flange/collar 53 that locates flush within an annular recess 26 surrounding the aperture. Also claimed is a method of visually inspecting the hinge assembly. The vehicle support structure may be a box section pillar wherein the fastener extends between first and second spaced surfaces.

Description

(71) Applicant(s):

Jaguar Land Rover Limited (Incorporated in the United Kingdom)

Abbey Road, Whitley, Coventry, Warwickshire, CV3 4LF, United Kingdom

1704585.7 |_NT ci_:

E05D 5/02 (2006.01) E05D 9/00 (2006.01)

23.03.2017 (56) Documents Cited:

GB 2490391 A GB 0315600 A

EP 0435490 A2 DE 102009058956 A1

DE 102007010090 A1 JP 2001151152 A (58) Field of Search:

INT CL E05D

Other: EPODOC, WPI, Patents Fulltext (72) Inventor(s):

Nigel Dean (74) Agent and/or Address for Service:

Jaguar Land Rover

Patents Department W/1/073, Abbey Road, Whitley, COVENTRY, CV3 4LF, United Kingdom (54) Title of the Invention: Vehicle door hinge Abstract Title: Vehicle door hinge (57) A vehicle hinge comprises a first hinge element 20 for mounting to a vehicle body structure and a second hinge element 30 for mounting to a door. According to a first claim the first hinge element 20 is formed of aluminium and includes a single aperture in which a single fastener 50 mounts the hinge. Also claimed is a hinge where the first hinge has an attachment portion in which is an aperture/socket extends into an upstanding post 24 portion of the hinge; a single fastener 50 extends into the aperture and reinforces the post portion. The hinge may be of aluminium or magnesium and the threaded fastener may be steel. Preferably the fastener is a double ended stud threaded at both ends with a radial flange/collar 53 that locates flush within an annular recess 26 surrounding the aperture. Also claimed is a method of visually inspecting the hinge assembly. The vehicle support structure may be a box section pillar wherein the fastener extends between first and second spaced surfaces.

FIG. 3

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

1/4

FIG. 1

06 18

FIG. 2

2/4

06 18

FIG. 3

FIG. 4

3/4

06 18

FIG. 5

FIG. 6

4/4

06 18

FIG. Ί

FIG. 8

VEHICLE DOOR HINGE

TECHNICAL FIELD

The present disclosure relates to a hinge and particularly, but not exclusively, to a hinge for an automotive vehicle door. Aspects of the invention relate to a hinge, to a hinge assembly comprising a hinge and a vehicle body structure and/or a vehicle door, to a vehicle, to a method of mounting a vehicle door to a vehicle body structure, and to a method of inspecting a hinge assembly.

BACKGROUND

Vehicle side doors are typically attached to a vehicle body using a pair of hinges. Each hinge typically includes a body-side hinge element that is attached to the vehicle body and a door-side hinge element that is attached to the door. The body-side hinge element is typically formed of steel and includes a substantially planar attachment portion including a pair of through holes for receiving a pair of bolts for attaching the hinge to the vehicle body. The body-side hinge element also typically includes a hinge connection portion that receives a hinge pin used to pivotally couple the body-side hinge element to the door-side hinge element. The hinge connection portion of the body-side hinge element is typically connected to the attachment portion by a post portion extending outwardly from the attachment portion at a location offset from the bolt-receiving holes.

Known vehicle door hinges suffer from several disadvantages. For example, vehicle door hinges may be prone to bending, for example in the post portion and/or the attachment portion, and may also tend to peel away from and/or dig into the attachment portion of the vehicle body under loading. For these reasons it is generally necessary to use a stiff material such as steel in the construction of door hinges, and to employ a relatively bulky design for both the vehicle hinge and the attachment portion of the vehicle body, which leads to increased vehicle weight and packaging problems around the doors.

It is an aim of the invention to address disadvantages associated with the prior art.

SUMMARY OF THE INVENTION

According to a first aspect of the invention there is provided a hinge for an automotive vehicle door; the hinge comprising a first hinge element configured to be attached to a vehicle body structure and a second hinge element configured to be attached to a vehicle door; wherein the first hinge element is formed of aluminium and comprises an aperture that is configured to receive a single fastener for attaching the first hinge element to the vehicle body structure, wherein the first hinge element is configured to be attached to the vehicle body structure by a single fastener received in the aperture.

It will be appreciated that the first hinge element is configured to be attached to the vehicle body structure by the single fastener alone when the first hinge element is fully mounted to the vehicle body structure, that is without any further fasteners extending between the first hinge element and the vehicle body structure. The first hinge element preferably does not include any further apertures for receiving fasteners for mounting the first hinge element to the vehicle body structure.

By providing a vehicle door hinge in which the vehicle-side hinge element is formed of aluminium and configured to be attached to the vehicle body structure by a single fastener it is possible to reduce the size and weight of the hinge compared to hinges known in the art.

The hinge may be an upper hinge or a lower hinge for a front or rear side door. Alternatively the hinge may be a hinge for a tailgate, including for a split tailgate. The hinge may be configured to be attached to any suitable structural portion of the vehicle body, for example a structural post adjacent to a door aperture.

It will be appreciated that the term aluminium covers aluminium alloys, for example alloys formed at least 95% by weight of aluminium. The second hinge element may also be formed of aluminium.

The first hinge element may comprise: an attachment portion that is configured to engage the vehicle body structure; a hinge connection portion via which the first hinge element is coupled to the second hinge element; and a post portion connecting the attachment portion to the hinge connection portion. The attachment portion may be substantially planar. The post portion may extend outwardly from a central region of the attachment portion, and may extend in a direction substantially perpendicular to the plane of the attachment portion.

The aperture may have an axis that passes through or close to a pivot axis of the hinge connection portion, for example within 4mm or 8mm or 12mm of the pivot axis. By arranging the axis of the aperture (and therefore a fastener used to attach the first hinge element to the vehicle body structure once the hinge has been installed) to pass through or close to the pivot axis, the first hinge element becomes less prone to bending and peeling away from the vehicle body structure in use. In this way reliability of the hinge may be improved, and the size and weight of the first hinge element may be reduced. It will be appreciated that the pivot axis is an axis about which the second hinge element is configured to pivot relative to the first hinge element. The axis of the aperture may be at least substantially orthogonal to the pivot axis.

The aperture may be aligned with the post portion of the first hinge element. The aperture may be aligned with the post portion such that the axis of the aperture passes through the post portion at least at an inboard section of the post portion adjacent to the attachment portion. By aligning the aperture (and therefore a fastener used to attach the first hinge element to the vehicle body structure once the hinge has been installed) with the post portion, the first hinge element becomes less prone to bending and peeling away from the vehicle body structure in use. In this way reliability of the hinge may be improved, and the size and weight of the first hinge element may be reduced.

The aperture may extend into the post portion of the first hinge element.

The aperture may be configured to receive the fastener such that the fastener extends into the post portion of the first hinge element to thereby provide reinforcement to the post portion. By arranging the fastener to reinforce the post portion it is possible to distribute forces more efficiently and to reduce the localised stress experienced by the post portion of the first hinge element in use. Since the fastener is able to transfer forces directly from the post portion to a vehicle body structure, it is also possible to reduce the stress experienced by the attachment portion of the first hinge element.

The aperture may be configured to receive the fastener such that the fastener extends into the post portion by a distance of at least 6mm or at least 12mm or at least 20mm and/or by a distance equal to or greater than the diameter of the fastener. The first hinge element may be configured to be engaged by the fastener over a distance of at least 6mm or at least 12mm or at least 20mm and/or a distance equal to or greater than the diameter of the fastener within the post portion.

The aperture may be configured to receive the fastener such that the fastener extends from a body-facing surface of the attachment portion at least 25% or at least 30% or at least 50% of the distance towards a pivot axis of the hinge connection portion. The first hinge element may be configured to be engaged by the fastener up to a point at least 25% or at least 30% or at least 50% of the distance from the body-facing surface of the attachment portion towards the pivot axis of the hinge connection portion.

The aperture may be configured to receive the fastener such that the fastener extends into the first hinge element by a distance of at least 12mm or at least 20mm or at least 25mm. The first hinge element may be configured to be engaged by the fastener over a distance of at least 12mm or at least 20mm or at least 25mm.

The aperture may comprise a threaded bore configured to engage threading provided on the fastener. However, other means of engagement are also possible.

The first hinge element may be provided with a recess surrounding an opening of the aperture that is configured to receive a collar or flange of a fastener when received in the aperture. The recess may be configured to receive the collar or flange such that the collar or flange does not protrude outwardly from the first hinge element when the fastener is assembled correctly together with the first hinge element, but such that the collar or flange protrudes outwardly from the first hinge element if the fastener is not assembled correctly together with the first hinge element. In this case the hinge cannot be fully installed with the first hinge element sitting correctly against a surface of the vehicle body structure if the fastener is not assembled correctly together with the first hinge element, such that installation of the hinge is prevented in the case that the fastener has not been received correctly within the aperture.

The hinge may be provided with a fastener for attaching the hinge to a vehicle body structure, the fastener extending into and being secured within the aperture of the first hinge element. The fastener may extend into the post portion of the first hinge element, and may be configured to reinforce the post portion of the first hinge element. The fastener may extend into the first hinge element and/or engage the first hinge element over a distance of at least 12mm or at least 20mm or at least 25mm; and may extend into the post portion and/or engage the post portion over a distance of at least 6mm or at least 12mm or at least 20mm and/or a distance equal to or greater than the diameter of the fastener. The fastener may comprise a stud including a threaded shaft portion that is engaged with threading provided in the aperture to thereby securely locate the fastener with respect to the first hinge element.

The fastener may be formed of a material that is stronger and/or stiffer than the material of the first hinge element.

The fastener may be formed of steel.

According to a further aspect of the invention there is provided a hinge assembly comprising a hinge as described above and an automotive vehicle body structure, wherein the first hinge element is attached to the vehicle body structure by the fastener. The vehicle body structure may comprise, for example, a structural post to which the first hinge element is attached. The first hinge element may be attached to the vehicle body structure by the single fastener alone when fully installed with respect to the vehicle body structure.

The vehicle body structure may comprise a first structural element and a second structural element spaced apart from the first structural element, wherein the fastener extends through and between the first and second structural elements and is configured to transfer forces from the first hinge element into the first and second structural elements. The first structural element may be an outer structural element, and may be engaged by the first hinge element, either directly or indirectly via an intervening spacer or covering component such as an outer skin. The second structural element may be an inner diaphragm, and may be configured to reinforce the first structural element. The second structural element may be attached to the first structural element to form a box section. Advantageously, by arranging the fastener to extend through and between spaced apart first and second structural elements it is possible to improve the transfer of forces between the hinge and the vehicle body structure. In particular, the fastener arrangement is able to transfer shear forces into the first and second structural elements, which reduces the bending stresses experienced by the hinge and the vehicle body structure in use of the hinge. Such an arrangement is particularly advantageous in combination with a fastener that extends into the post portion of the first hinge element and provides reinforcement to the post portion because the fastener is able to both reinforce the post portion and transfer forces directly from the post portion into the first and second structural elements as shear forces, thereby minimising bending forces experienced by the first hinge element and the portion of the vehicle body structure to which the first hinge element is attached.

The hinge assembly may further include a spacer located between the first and second structural elements. The spacer may take the form of an open or closed wall tube or collar surrounding the fastener, and may extend between and engage the first and second structural elements. The provision of a spacer may assist with the transfer of forces between the hinge and the vehicle body structure, and between the first and second structural elements of the vehicle body structure.

According to a further aspect of the invention there is provided a hinge assembly comprising a hinge as described above and a vehicle door, wherein the second hinge element is attached to the vehicle door. The door may be, for example, a front or rear side door. The door may be provided with a pair of the hinges, for example upper and lower hinges both in accordance with the invention. Alternatively the door may be provided with a hinge in accordance with the invention in combination with a second hinge that is not in accordance with the invention, depending on space constraints around the hinges.

However, it will be appreciated that the hinge may be supplied separately to the door and the vehicle body structure to which it is to be fitted.

According to a further aspect of the invention there is provided an automotive vehicle comprising at least one hinge as described above or at least one hinge assembly as described above. The vehicle may be a road vehicle or an off road vehicle, for example a car.

According to a further aspect of the invention there is provided a hinge; the hinge comprising a first hinge element and a second hinge element; wherein the first hinge element comprises:

an attachment portion that is configured to engage a structure to which the hinge may be mounted in use, a hinge connection portion via which the first hinge element is coupled to the second hinge element, a post portion connecting the attachment portion to the hinge connection portion, and an aperture provided in the attachment portion that is configured to receive a fastener for mounting the hinge;

wherein the aperture extends into the post portion of the first hinge element and is configured to receive a fastener extending into the post portion to thereby provide reinforcement to the post portion.

The hinge may be a hinge for a door, for example for an automotive vehicle door. The first hinge element may be a body-side hinge element, and may be configured to be attached to a fixed structure, for example a vehicle body structure. The second hinge element may be a door-side hinge element, and may be configured to be attached to a door, for example a vehicle door.

The hinge may include any features described above in connection with earlier aspects of the invention. In particular, the first hinge element may optionally be formed of aluminium (including aluminium alloys), may optionally be configured to be attached to the vehicle body structure (or other fixed structure) by a single fastener received in the aperture, and may optionally not include any further apertures for receiving fasteners in its attachment portion. However, in other embodiments the first hinge element may be formed of another material and/or may include one or more additional apertures for receiving additional fasteners for attaching the first hinge element to the vehicle body structure (or other fixed structure).

According to a further aspect of the invention, there is provided a hinge assembly comprising a hinge as described above and a door, wherein the second hinge element is attached to the door. The door may be provided with a pair of the hinges, for example upper and lower hinges both in accordance with the invention. Alternatively the door may be provided with a hinge in accordance with the invention in combination with a second hinge that is not in accordance with the invention, depending on space constraints around the hinges.

However, it will be appreciated that the hinge may be supplied separately to the door and structure to which it is to be fitted.

According to a further aspect of the invention there is provided a method of mounting a vehicle door to a vehicle body structure, the method comprising providing a hinge as described above, mounting the vehicle door to the second hinge element, securing a fastener within the recess in the first hinge element, and mounting the hinge to the vehicle body structure using the fastener. It will be appreciated that the step of mounting the vehicle door to the second hinge element may be performed either before or after the hinge is mounted to the vehicle body structure.

According to a further aspect of the invention there is provided a method of inspecting a hinge for an automotive vehicle door that is provided with a fastener for mounting the hinge; wherein the hinge comprises a hinge element including an aperture within which the fastener is received and a recess surrounding an opening of the aperture that is configured to receive a collar or flange of the fastener; the method comprising determining that the fastener has not been assembled correctly together with the hinge if the collar or flange is not located correctly within the recess. The hinge may be a hinge as described above. The method may be performed while mounting a vehicle door to a vehicle body structure as described above.

The hinge element may be a body-side hinge element, and the fastener may be a fastener for attaching the hinge to a vehicle body structure.

The method may comprise a step of inspecting the collar or flange of the fastener and determining that the collar or flange is not located correctly within the recess if the collar or flange protrudes outwardly from the surface of the hinge in which the recess is provided. This step may be performed before the hinge has been attached to a vehicle body structure.

The method may comprise a step of inspecting an interface between the hinge and a vehicle body structure to which the hinge has been attached or is being attached, and determining that the collar or flange is not located correctly within the recess if the hinge is prevented from adopting a correct installed position with respect to the vehicle body structure. The vehicle body structure may be, for example, a structural post. The correct installed position may be a position in which a surface of the hinge sits directly against the vehicle body structure.

The method may comprise a step of attempting to close a door that is mounted to a vehicle body structure by the hinge, and determining that the collar or flange is not located correctly within the recess if the door is prevented from adopting a correct fully closed position.

The method may further include taking action to prevent installation a hinge with an incorrectly installed fastener in a vehicle if it is determined that the fastener has not been assembled correctly together with the hinge. For example, the fastener may be adjusted with respect to the hinge, or the fastener and/or hinge may be discarded.

According to a further aspect of the invention there is provided a method of mounting a door to a structure, the method comprising providing a hinge as described above, mounting the door to the second hinge element, securing a fastener within the recess in the first hinge element, and mounting the hinge to the structure using the fastener. It will be appreciated that the step of mounting the door to the second hinge element may be performed either before or after the hinge is mounted to the structure.

According to a further aspect of the invention there is provided a method of inspecting a hinge for a door that is provided with a fastener for mounting the hinge; wherein the hinge comprises a hinge element including an aperture within which the fastener is received and a recess surrounding an opening of the aperture that is configured to receive a collar or flange of the fastener; the method comprising determining that the fastener has not been assembled correctly together with the hinge if the collar or flange is not located correctly within the recess.

The hinge may include any features described above in connection with earlier aspects of the invention. The method may include any features above in combination with earlier aspects of the invention.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 schematically illustrates a vehicle;

Figures 2 and 3 schematically illustrate a hinge according to one possible embodiment of the invention;

Figures 4 and 5 schematically illustrate a portion of the hinge; and

Figures 6 to 8 schematically illustrate portions of hinges according to other possible embodiments of the invention.

DETAILED DESCRIPTION

Figure 1 illustrates a car 1 comprising a pair of front side doors 2 and a pair of rear side doors 3. Each door 2, 3 is attached to a body or chassis of the vehicle 1 by an upper hinge and a lower hinge (described below but not visible in Figure 1). The hinges are in accordance with the present invention.

Figures 2 and 3 illustrate the upper hinge 10 used to attach one of the front doors 2 to the vehicle chassis. The hinge 10 comprises a first hinge element or body-side hinge element 20 that is attached to a mounting post 100 of the vehicle chassis adjacent to a door aperture, and a second hinge element or door-side hinge element 30 that is attached to a front door 2.

The body-side hinge element 20 comprises a substantially planar, rectangular attachment portion 21 that is configured to engage the mounting post 100. The bodyside hinge element 20 further comprises a hinge connection portion 22 including a vertically-extending through-hole 23 that is configured to receive a multi-part pivot pin 40 in order to pivotally attach the body-side hinge element 20 to the door-side hinge element 30. The hinge connection portion 22 is connected to the attachment portion 21 by an elongate post portion 24 that extends outwardly from a central region of the attachment portion 21, the hinge connection portion 22 being provided at a distal end of the post portion 24. The post portion 24 extends substantially the full height of the attachment portion 21 (in the vertical direction) between the attachment portion 21 and the hinge connection portion 22, but has a width (in a horizontal direction) that is substantially smaller than the width of the attachment portion 21. The post portion 24 extends in a direction perpendicular to the plane of the attachment portion 21 over its inboard section (closest to the attachment portion 21), but curves slightly rearwardly with respect to the longitudinal direction of the vehicle towards its distal end. The attachment portion 21, post portion 24 and hinge connection portion 22 of the bodyside hinge element 20 are integrally formed together as a single component of cast aluminium.

The body-side hinge element 20 includes a single aperture 25 that is configured to receive a single fastener for attaching the body-side hinge element 20 to the body of the vehicle 1. The aperture 25 takes the form of a circular section bore with internal threading that extends from a body-facing surface of the attachment portion 21, through the attachment portion 21, and into the post portion 24. Interaction between the aperture 25 and the fastener is described in detail below. The body-side hinge element 20 is further provided with a circular recess 26 surrounding the opening of the aperture 25 at the body facing surface of the attachment portion 21. The recess 26 is configured to receive a flange or collar of the fastener, as also described in more detail below.

By forming the body-side hinge element 20 of aluminium and configuring the body-side hinge element 20 to be attached to the body of the vehicle 1 by a single fastener it is possible to reduce the size and weight of the hinge 10 compared to prior art hinges, in which the body-side hinge element is generally formed of steel and configured to be attached to a vehicle body by a plurality of bolts. The use of aluminium in combination with a single fastener attachment to the body of the vehicle 1 is further enhanced by the specific design of the body-side hinge element 20, and in particular the arrangement of the fastener 50 with respect to the body-side hinge element 20, as described in more detail below.

The door-side hinge element 30 comprises a substantially planar attachment portion 31 including a single through-hole 31 for receiving a single bolt 45 for attaching the door-side hinge element 30 to the front door 2. The door-side hinge element 30 further comprises a hinge connection portion 32 including a vertically-extending through-hole that is connected directly to the attachment portion 31. The door-side hinge element 30 is pivotally coupled to the body-side hinge element 20 by the pivot pin 40, which extends though the hinge attachment portions of the body-side and door-side hinge elements to thereby securely attach the body-side and door-side hinge elements while allowing pivotal movement about a pivot axis P. The door-side hinge element 30 further comprises a stop formation 33 extending outwardly from the hinge connection portion 32 that is configured to engage the post portion 24 of the body-side hinge element 20 as the door 2 is opened in order to limit the extent of opening of the door 2.

The door-side hinge element 30 is also an integrally formed component of cast aluminium.

Attachment of the hinge 10 to the vehicle body will now be described with reference to Figure 4, in which the door-side hinge element 30 and the front door 2 have been omitted for clarity.

The body-side hinge element 20 is attached to a mounting post 100 forming part of the vehicle chassis that extends along a front edge of a door aperture. The mounting post 100 comprises a substantially vertical outer post element 101 having a U shaped cross section, with the base of the U section defining an outer surface of the mounting post 100 that is engaged by the body-side hinge element 20. The mounting post 100 further comprises an inner diaphragm 102 that is located within the U shaped cross section of the outer post element 101. The diaphragm 102 is spaced apart from and arranged substantially parallel to the base of the outer post element 101, and is attached to the respective sides of the outer post element 101 along its side edges. The outer post element 101 and the diaphragm 102 together form a box section that acts to reinforce the mounting post 100.

The body-side hinge element 20 is attached to the mounting post 100 by a single fastener 50 that is received in the aperture 25. The fastener 50 comprises a steel stud 51 including a first threaded portion 52 that extends into the aperture 25 of the bodyside hinge element 20 and engages the internal threading of the aperture 25. The stud 51 includes an annular flange or collar 53 that is integrally formed with the main body of the stud 51 and that sits within the recess 26 provided around the opening of the aperture 25, the purpose of which is explained below.

The stud 51 extends outwardly from the body-facing surface of the body-side hinge element 20 and through a pair of aligned holes formed in the outer post element 101 and the diaphragm 102. The stud 51 is secured relative to the mounting post 100 by a nut 55 that is coupled to a second threaded portion 54 thereof and bears against the diaphragm 102 via a washer. The body-side hinge element 20 is configured to be attached to the body of the vehicle 1 by the single fastener 50 alone (without any additional fasteners) when the body-side hinge element 20 is fully mounted and installed with respect to the vehicle body, and does not include any additional fastener receiving apertures in its attachment portion 21.

The fastener 50 is provided with a spacer 56 in the form of a sleeve or collar that extends around the stud 51 between the outer post element 101 and the diaphragm 102. The spacer 56 includes enlarged flanges at its axial ends for engaging the outer post element 101 and the diaphragm 102, and may be arranged to be in compression between the outer post element 101 and the diaphragm 102.

As illustrated in Figure 4, the stud 51 extends into the post portion 24 of the body-side hinge element 20 and engages the threaded inner surface of the aperture 25, thereby providing reinforcement to the body-side hinge element 20, and in particular to the post portion 24 of the body-side hinge element 20. In the present embodiment the stud 51 extends into the body-side hinge element 20 and engages the body-side hinge element 20 over a distance of 20mm, and over a distance of 15mm within the post portion 24. In the present embodiment the stud 51 extends into the body-side hinge element 20 and engages the body-side hinge element 20 up to a point 40% of the distance from the body-facing surface of the attachment portion 21 towards the pivot axis P of the hinge connection portion 22. This extent of engagement helps to provide effective reinforcement of the body-side hinge element 20, although in other embodiments the stud 51 may extend into the body-side hinge element 20 by a shorter distance and/or engage the body-side hinge element 20 over a shorter distance.

As illustrated in Figure 4, the aperture 25 and the reinforcing stud 51 located within the aperture 25 are generally aligned with the pivot axis P such that the longitudinal axes of the aperture 25 and the stud 51 pass close to the pivot axis P of the hinge 10 (within 8mm in the present embodiment) in a direction substantially orthogonal to the pivot axis P. The arrangement of the reinforcing stud in this manner helps to reduce bending stress experienced by the body-side hinge element 20 in use, and in particular makes the body-side hinge element 20 less prone to peeling away from the mounting post 100 in use.

Since the stud 51 extends into and engages the post portion 24 of the body-side hinge element 20 and also engages both the outer post element 101 and the diaphragm 102 of the mounting post 100, the stud 51 is able to transfer forces from the post portion 24 directly into the outer post element 101 and the diaphragm 102 as shear forces. This reduces the bending stresses experienced by the body-side hinge element 20 and the mounting post 100 in use. The spacer 56 also assists with the transfer of forces to the outer post portion 101 and the diaphragm 102.

Assembly of the hinge 10 together with the mounting post 100 will now be described.

When it is desired to mount the body-side hinge element 20 to the mounting post 100, the stud 51 is first screwed into the threaded aperture 25 of the body-side hinge element 20. When the stud 51 has been fully screwed into the threaded aperture 25, the flange or collar 53 of the stud 51 is received within the recess 26 surrounding the aperture and sits with its outer face (with respect to the body-side hinge element 20) either flush with or slightly recessed relative to the body-facing surface of the mounting portion 21, as illustrated in Figure 3. It is then possible to feed the protruding end of the stud 51 through the holes formed in the outer post element 101 and the diaphragm 102 (with the spacer 56 already located between the outer post element 101 and the diaphragm 102), and then thread the nut 55 onto the second threaded portion 54 of the stud 51 to thereby secure the stud 51 and the body-side hinge element 20 relative to the mounting post 100. The door 2 may then be mounted to the door-side hinge element 30 (which may already have been assembled together with the body-side hinge element 20 prior to installation of the body-side hinge element 20 with respect to the mounting post 100).

If the stud 51 is not correctly received within the aperture 25 in the manner illustrated in Figure 3 then the flange or collar 53 of the stud 51 will not be fully received within the recess 26 and will instead stand proud and extend outwardly from the body-facing surface of the mounting portion 21 of the body-side hinge element 20, as illustrated in Figure 5. This provides a clear visual indication that the stud 51 has not been assembled correctly together with the body-side hinge element 20, so that it is possible to avoid installing the hinge 10 if the stud 51 is not correctly installed. In addition, since the flange or collar 53 of the stud extends outwardly from the body-facing surface of the body-side hinge element 20, if assembly of the hinge is attempted it will not be possible to install the hinge 10 with the attachment portion 21 of the body-side hinge element 20 sitting correctly against the mounting post 100. This provides a further visual cue that the stud 51 has been installed incorrectly, and may prevent the door 2 from closing correctly once installed with respect to the body of the vehicle 1, thereby providing a further cue if the stud 51 has been installed incorrectly. In this way the probability of the hinge being installed incorrectly with respect to the vehicle body is minimised.

In some embodiments the stud 51 may include a plain shank portion (that is a portion that is not threaded) that is configured to be located outside the body-side hinge element. For example, the plain shank portion may extend between the flange or collar 53 and the second threaded portion 54. The plain shank portion may act to prevent the hinge 10 and fastener 50 from being mounted to a mounting post or other vehicle structure having a significantly different design to that described above, for example without spaced apart first and second post elements 101, 102, which may prevent use of the hinge 10 and fastener 50 in other applications without a design review being performed.

An embodiment of the invention has been described with respect to an upper hinge for one of the front doors 2. However, as described above, the remaining side door hinges are also in accordance with the invention. Figure 6 illustrates the body-side hinge element of one of the lower front door hinges as attached to a mounting post and Figure 7 illustrates the body side hinge element of one of the upper rear door hinges as attached to a mounting post. (Elements equivalent to those described above are labelled using the same reference numbers.) These hinges are generally similar to the upper front door hinge 10 described above and so will not be described any further. Figure 8 illustrates the body side hinge element of one of the lower rear door hinges as attached to a mounting post. The body side hinge element is still formed of aluminium and configured to be attached to a mounting post by a single fastener. However, due to space constraints in the area of this hinge an alternative hinge shape is used in which the fastener does not extend into the post portion of the body side hinge element.

Many modifications may be made to the above examples without departing from the scope of the invention as defined in the accompanying claims. For example, in another embodiment the body side hinge element could be formed of a material other than aluminium, for example magnesium (including magnesium alloys). In addition, the body-side hinge element could include a second fastener receiving aperture for receiving an additional fastener for attaching the body side hinge element to a vehicle body. For example, a pair of threaded fastener receiving apertures could be provided in a vertically offset arrangement such that the body side hinge element may be mounted to a vehicle body by a pair of reinforcing studs that each extend into and reinforce the post portion of the body side hinge element. Alternatively the body side hinge element illustrated in Figures 2 to 4 could simply be modified to include a second fastener-receiving hole extending through the attachment portion at a location offset from the post portion. Other variations and modifications will also be apparent to the skilled person.

Claims

1. A hinge for an automotive vehicle door; the hinge comprising a first hinge element configured to be attached to a vehicle body structure and a second hinge element configured to be attached to a vehicle door; wherein the first hinge element is formed of aluminium and comprises an aperture that is configured to receive a single fastener for attaching the first hinge element to the vehicle body structure, wherein the first hinge element is configured to be attached to the vehicle body structure by a single fastener received in the aperture.

2. A hinge according to claim 1, wherein the first hinge element comprises: an attachment portion that is configured to engage the vehicle body structure; a hinge connection portion via which the first hinge element is coupled to the second hinge element; and a post portion connecting the attachment portion to the hinge connection portion.

3. A hinge according to claim 2, wherein the aperture has an axis that passes through or close to a pivot axis of the hinge connection portion.

4. A hinge according to claim 2 or claim 3, wherein the aperture is aligned with the post portion of the first hinge element.

5. A hinge according to any of claims 2 to 4, wherein the aperture extends into the post portion of the first hinge element.

6. A hinge according to claim 5, wherein the aperture is configured to receive the fastener such that the fastener extends into the post portion of the first hinge element to thereby provide reinforcement to the post portion.

7. A hinge according to claim 5 or claim 6, wherein the aperture is configured to receive the fastener such that the fastener extends into the post portion by a distance of at least 6mm or at least 12mm or at least 20mm and/or by a distance equal to or greater than the diameter of the fastener.

8. A hinge according to any of claims 2 to 7, wherein the aperture is configured to receive the fastener such that the fastener extends from a body-facing surface of the attachment portion at least 25% or at least 30% or at least 50% of the distance towards a pivot axis of the hinge connection portion.

9. A hinge according to any preceding claim, wherein the aperture is configured to receive the fastener such that the fastener extends into the first hinge element by a distance of at least 12mm or at least 20mm or at least 25mm.

10. A hinge according to any preceding claim, wherein the aperture comprises a threaded bore configured to engage threading provided on the fastener.

11. A hinge according to any preceding claim, wherein the first hinge element is provided with a recess surrounding an opening of the aperture that is configured to receive a collar or flange of a fastener when received in the aperture.

12. A hinge according to any preceding claim, wherein the hinge is provided with a fastener for attaching the hinge to a vehicle body structure, the fastener extending into and being secured within the aperture of the first hinge element.

13. A hinge according to claim 12, wherein the fastener is formed of a material that is stronger and/or stiffer than the material of the first hinge element.

14. A hinge according to claim 13, wherein the fastener is formed of steel.

15. A hinge assembly comprising a hinge according to any of claims 12 to 14 and an automotive vehicle body structure, wherein the first hinge element is attached to the vehicle body structure by the fastener.

16. A hinge assembly according to claim 15, wherein the vehicle body structure comprises a first structural element and a second structural element spaced apart from the first structural element, wherein the fastener extends through and between the first and second structural elements and is configured to transfer forces from the first hinge element into the first and second structural elements.

17. A hinge assembly comprising a hinge according to any preceding claim and a vehicle door, wherein the second hinge element is attached to the vehicle door.

18. An automotive vehicle comprising a hinge according to any of claims 1 to 14 or a hinge assembly according to any of claims 15 to 17.

19. A hinge for an automotive vehicle door, the hinge comprising a first hinge element configured to be attached to a vehicle body structure and a second hinge element configured to be attached to a vehicle door; wherein the first hinge element comprises:

an attachment portion that is configured to engage the vehicle body structure;

a hinge connection portion via which the first hinge element is coupled to the second hinge element;

a post portion connecting the attachment portion to the hinge connection portion;

and an aperture provided in the attachment portion that is configured to receive a fastener for attaching the first hinge element to the vehicle body structure;

20. A method of mounting a vehicle door to a vehicle body structure, the method comprising providing a hinge according to claim 1 or claim 19, mounting the vehicle door to the second hinge element, securing a fastener within the aperture in the first hinge element, and mounting the hinge to the vehicle body structure using the fastener.

21. A method of inspecting a hinge for an automotive vehicle door that is provided with a fastener for mounting the hinge; wherein the hinge comprises a hinge element including an aperture within which the fastener is received and a recess surrounding an opening of the aperture that is configured to receive a collar or flange of the fastener; the method comprising determining that the fastener has not been assembled correctly together with the hinge if the collar or flange is not located correctly within the recess.

22. A method according to claim 21, wherein the hinge element is a body-side hinge element and the fastener is a fastener for attaching the hinge to a vehicle body structure.

23. A method according to claim 21 or claim 22, comprising a step of inspecting the collar or flange of the fastener and determining that the collar or flange is not located correctly within the recess if the collar or flange protrudes outwardly from the surface of the hinge in which the recess is provided.

24. A method according to any of claims 21 to 23, comprising a step of inspecting an interface between the hinge and a vehicle body structure to which the hinge has been attached or is being attached, and determining that the collar or flange is not located correctly within the recess if the hinge is prevented from adopting a correct installed position with respect to the vehicle body structure.

25. A method according to any of claims 21 to 24, comprising a step of attempting to close a door that is mounted to a vehicle body structure by the hinge, and determining that the collar or flange is not located correctly within the recess if the door is prevented from adopting a correct fully closed position.

Intellectual

Property

Office

Application No: GB1704585.7 Examiner: Ben Munns