Door hinge repair apparatus and method

• US 20050138773A1
• Filed: 02/23/2005
• Published: 06/30/2005
• Est. Priority Date: 06/04/2003
• Status: Active Grant

• Current Assignee: Total Automotive Incorporated
• Original Assignee: Ronald F. Lehner
• Inventors: Lehner, Ronald F.
• Granted Patent: US 7,003,859 B2
• Time in Patent Office: Days
• US Class Current: 16/334
• CPC Class Codes: B23P 6/00 Restoring or reconditioning objects straightening or restoring form of sheet metal, metal rods, metal tubes, metal profiles, or specific articles made therefrom B21D1/00, B21D3/00; repairing defective or damaged objects by casting techniques B22D19/10
• CPC Class Codes: B25B 27/14 for assembling objects other than by press fit or detaching same
• CPC Class Codes: E05D 11/00 Additional features or accessories of hinges edge protecting devices E06B3/88
• CPC Class Codes: E05D 5/121 Screw-threaded pins
• CPC Class Codes: E05D 5/127 by forcing the pin into the socket E05D5/125 takes precedence
• CPC Class Codes: E05Y 2800/00 Details, accessories and auxiliary operations not otherwise provided for
• CPC Class Codes: E05Y 2800/70 Retrofitting of elements
• CPC Class Codes: E05Y 2900/531 Doors
• CPC Class Codes: Y10T 29/24 Hinge making or assembling
• CPC Class Codes: Y10T 29/49718 Repairing
• CPC Class Codes: Y10T 29/49721 with disassembling
• CPC Class Codes: Y10T 29/4973 Replacing of defective part
• CPC Class Codes: Y10T 29/49732 by attaching repair preform, e.g., remaking, restoring, or patching
• CPC Class Codes: Y10T 29/5343 Means to drive self-piercing work part

Abstract

Apparatus for use in repairing, and methods of repairing, a door hinge of a vehicle includes use of a substitute hinge bracket and at least one pin configured to be received through at least one opening of a vehicle frame bracket. A locking portion of the at least one pin and a locking surface that defines an opening in the hinge bracket are configured such that the at least one pin is locked in a fixed position relative to the hinge bracket when assembled. Further, another repair apparatus includes a substitute pin having an interference portion for forming an interference fit with one or more surfaces defining an opening of a factory hinge bracket.

Claims

1. An apparatus for use in repairing a door hinge of a vehicle, the door hinge comprising at least a vehicle frame bracket attached to a portion of a vehicle frame of the vehicle, wherein the vehicle frame bracket comprises at least one opening defined therein, the apparatus comprising:

at least one pin configured to be received through the at least one opening of the vehicle frame bracket, the at least one pin comprising a locking portion; and

a hinge bracket, wherein the hinge bracket comprises at least one opening corresponding to the at least one opening of the vehicle frame bracket, and further wherein the at least one opening of the hinge bracket is defined by a locking surface configured as a function of the locking portion of the at least one pin such that the at least one pin is locked in a fixed position relative to the hinge bracket when at least a part of the locking portion of the pin is positioned in at least part of the at least one opening of the hinge bracket.

2. The apparatus of claim 1, wherein the locking portion of the pin comprises a threaded region, and further wherein at least a portion of the locking surface of the hinge bracket is threaded for receiving the threaded region of the pin.

3. The apparatus of claim 1, wherein the locking portion of the pin comprises one or more flat surfaces, and further wherein the locking surface of the hinge bracket comprises at least one flat surface configured to correspond to the one or more flat surfaces of the locking portion of the pin.

4. The apparatus of claim 1, wherein the at least one pin further comprises a threaded end portion configured to be inserted through the at least one opening defined in the vehicle frame bracket and the at least one opening defined in the hinge bracket, and further wherein the apparatus comprises a nut for coupling to the threaded end portion.

5. The apparatus of claim 4, wherein the at least one pin comprises an elongated pin end portion extending along a pin axis at an end opposite the threaded end portion of the at least one pin, and further wherein the at least one pin comprises an engagement element extending orthogonal to the pin axis at a position between the threaded end portion and the pin end portion to maintain the pin end portion at a position to receive a door bracket of the vehicle when a nut is coupled to the threaded end portion.

6. The apparatus of claim 5, wherein the engagement element is configured with one or more grasping surfaces such that a tool corresponding to such grasping surfaces can be used to hold and/or turn the engagement element.

7. The apparatus of claim 4, wherein the apparatus further comprises a bushing configured for insertion through the at least one opening defined in the vehicle frame bracket, wherein an opening is defined by the bushing, and further wherein the at least one pin is configured for insertion through the opening defined by the bushing.

8. The apparatus of claim 7, wherein the pin or the bushing is configured such that an engagement surface thereof exists a distance below and outside of the at least one opening defined in the vehicle frame bracket when the pin or bushing is inserted through the at least one opening defined in the vehicle frame bracket, and wherein the engagement surface is configured such that when the nut for coupling to the threaded portion is tightened on the threaded portion that the nut is tightened against the engagement surface.

9. The apparatus of claim 1, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the at least one pin comprises a first pin configured to be received through the first opening of the vehicle frame bracket and a second pin configured to be received through the second opening of the vehicle frame bracket, wherein each of the first and second pins comprises a locking portion.

10. The apparatus of claim 9, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to a hinge bracket axis, wherein the hinge bracket axis and the frame bracket axis coincide and the first and second openings of the hinge bracket axis lie adjacent to the first and second openings of the vehicle frame bracket, respectively, when the apparatus is assembled with the vehicle frame bracket, and further wherein each of the first and second openings of the hinge bracket are defined by a locking surface configured as a function of the locking portion of the respective first and second pins such that the first pin is locked in a fixed position relative to the hinge bracket when at least a part of the locking portion of the first pin is positioned in the first opening of the hinge bracket and such that the second pin is locked in a fixed position relative to the hinge bracket when at least a part of the locking portion of the second pin is positioned in the second opening of the hinge bracket.

11. The apparatus of claim 1, wherein the at least one pin comprises a material that has a hardness that is greater than about 80 Rockwell B Hardness (HRB).

12. A method for repairing a door hinge, wherein the door hinge comprises at least a vehicle frame bracket attached to a portion of a vehicle frame and a hinge bracket, wherein the vehicle frame bracket comprises a first and second opening aligned along and lying orthogonal to a frame bracket axis, wherein the hinge bracket comprises a first and second opening aligned along and lying orthogonal to the frame bracket axis, wherein the vehicle frame bracket and the hinge bracket are coupled using a first pin positioned in the first opening of the vehicle frame bracket and the first opening of the hinge bracket and using a second pin positioned in the second opening of the vehicle frame bracket and the second opening of the hinge bracket, wherein the method comprises:

removing the first and second pins to release the hinge bracket from the vehicle frame bracket;

providing a first substitute pin configured to be received through the first opening of the vehicle frame bracket and a second substitute pin configured to be received through the second opening of the vehicle frame bracket, wherein each of the first and second substitute pins comprise a locking portion;

providing a substitute hinge bracket comprising a first and second opening aligned orthogonal on a substitute hinge bracket axis, wherein each of the first and second openings of the substitute hinge bracket are-defined by a locking surface configured as a function of the locking portion of the respective first and second substitute pins such that the first substitute pin is locked in a fixed position relative to the substitute hinge bracket when at least a part of the locking portion of the first substitute pin is positioned in the first opening of the substitute hinge bracket and such that the second substitute pin is locked in a fixed position relative to the substitute hinge bracket when at least a part of the locking portion of the second substitute pin is positioned in the second opening of the substitute hinge bracket;

aligning the substitute hinge bracket axis and the vehicle frame bracket axis; and

coupling the vehicle frame bracket and the substitute hinge bracket using the first and second substitute pins.

13. The method of claim 12, wherein the locking portion of each of the first and second substitute pins comprise a threaded region, and further wherein each locking surface defining the first and second openings of the substitute hinge bracket is threaded for receiving the threaded region of the respective first and second substitute pins.

14. The method of claim 12, wherein the locking portion of each of the first and second substitute pins comprises one or more flat surfaces, and further wherein each locking surface defining the first and second openings of the substitute hinge bracket comprises at least one flat surface configured to correspond to the flat surface of the locking portion of the respective first and second substitute pins.

15. The method of claim 12, wherein each of the first and second substitute pins comprises a threaded end portion, and further wherein the method comprises coupling a first nut on the threaded end portion of the first substitute pin after the first substitute pin is inserted through the first opening of the vehicle frame bracket and the first opening of the substitute hinge bracket and coupling a second nut on the threaded end portion of the second substitute pin after the second substitute pin is inserted through the second opening of the vehicle frame bracket and the second opening of the substitute hinge bracket.

16. The method of claim 15, wherein the method further comprises providing a first bushing in the first opening of the vehicle frame bracket and providing a second bushing in the second opening of the vehicle frame bracket, wherein the first bushing defines an opening through which the first substitute pin is inserted and the second bushing defines an opening through which the second substitute pin is inserted.

17. The method of claim 16, wherein coupling the first nut on the threaded end portion of the first substitute pin comprises tightening the first nut against an engagement surface of the first substitute pin or first bushing existing at a distance below and outside of the first opening defined in the vehicle frame bracket so as to prevent over-tightening of the first nut against the vehicle frame bracket or wherein coupling the second nut on the threaded end portion of the second substitute pin comprises tightening the second nut against an engagement surface of the second substitute pin or second bushing existing at a distance below and outside of the second opening defined in the vehicle frame bracket so as to prevent over-tightening of the second nut against the vehicle frame bracket.

18. The method of claim 15, wherein each of the first substitute pin and second substitute pin comprises an elongated pin end portion extending along a pin axis at an end opposite the threaded end portion of the first substitute pin, and further wherein each of the first substitute pin and second substitute pin comprises an engagement element extending orthogonal to the pin axis at a position between the threaded end portion and the pin end portion to maintain the pin end portion at a position to receive a door bracket, wherein the door bracket comprises a first opening to be positioned on the pin end portion of the first substitute pin and a second opening to be positioned on the pin end portion of the second substitute pin after the vehicle frame bracket and the substitute hinge bracket are coupled using the first and second substitute pins.

19. The method of claim 18, wherein the engagement element of each of the first substitute pin and second substitute pin is configured with one or more grasping surfaces, and wherein coupling the vehicle frame bracket and the substitute hinge bracket using the first and second substitute pins comprises holding and/or turning at least one of the first substitute pin and second substitute pin using a tool corresponding to such grasping surfaces.

20. The method of claim 12, wherein removing the first and second pins to release the hinge bracket from the vehicle frame bracket comprises:

removing ends of the first and second pins holding the first and second pins in the openings of the hinge bracket and vehicle frame bracket;

pushing the first and second pins out of the openings of the hinge bracket and vehicle frame bracket using a punch tool, wherein the punch tool comprises;

a body portion; and

first and second spaced apart portions extending from the body portion to define a bracket receiving region therebetween configured to receive a portion of the vehicle frame bracket and the hinge bracket when the tool is used to remove one of the first and second pins, wherein one of the first and second spaced apart portions defines a pin receiving region configured to receive one of the first and second pins when the tool is used to remove the pin and the other of the first and second spaced apart portions defines a threaded opening configured to receive a threaded punch screw operable to engage the pin when the tool is being used to remove the pin.

21. -28. (canceled)