CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 62/824,426, filed March 28, 2019, the entirety of which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention relates generally to a hinge for an overhead bin, and more particularly to a hinge for an overhead bin that can be made via three-dimensional printing.

BACKGROUND OF THE INVENTION

[0003] The need has arisen to develop a three-dimensional (3D) printed overhead bin hinge.

Typical passenger aircraft include overhead storage bins where the passengers are able to store their carry-on luggage. These bins are assembled from a wide range of materials and parts each manufactured individually and then assembled into a whole overhead storage bin assembly. This method requires many different materials to be used and individual parts to be manufactured and assembled into a final assembled unit. Alternatively, using 3D printing technology allows for an overhead stowage bin to be manufactured in a single step. This reduces assembly cost and complexity resulting in a less expensive product. However, certain portions of the bin, such as the hinge, are difficult to manufacture with 3D printing because they contain multiple pieces that are held, or locked, together into position and yet still must be able to move relative to each other and to other portions of the hinge. Therefore, being able to create a 3D printed hinge as part of a 3D printed overhead storage bin is advantageous.

SUMMARY OF THE PREFERRED EMBODIMENTS

[0004] In accordance with a first aspect of the present invention there is provided a hinge assembly that includes an outer race that includes an outer surface and an inner annular ridge that defines an inner bearing surface, an inner race that includes an inner surface, an outer annular ridge that defines an outer bearing surface and defines a central opening, and a plurality of bearings disposed between the outer race and the inner race. Each bearing includes an annular groove defined therein. The inner annular ridge and the outer annular ridge are received in the annular grooves of each of the plurality of bearings.

[0005] In accordance with another aspect of the invention there is provided a pivot bin assembly that includes an upper housing that includes a top and first and second housing side walls that each include a lower edge, a bucket that cooperates with the upper housing to define a bin interior, and first and second hinge systems. The bucket includes a bottom and first and second bucket side walls that each include an upper edge and pivots with respect to the upper housing between an open position and a closed position. The first hinge system includes a hinge assembly having an outer race, an inner race, and a plurality of bearings disposed between the outer race and the inner race. The inner race includes a central opening, an inner cover having an inner surface and an outer surface, and an outer cover having an inner surface and an outer surface. An inner pivot member extends inwardly from the inner surface of the inner cover and an outer pivot member extends inwardly from the inner surface of the outer cover. The inner and outer pivot members are positioned in the central opening of the inner race to form a pivot axle. The second hinge system includes a hinge assembly having an outer race, an inner race, and a plurality of bearings disposed between the outer race and the inner race. The inner race includes a central opening, an inner cover having an inner surface and an outer surface, and an outer cover having an inner surface and an outer surface. An inner pivot member extends inwardly from the inner surface of the inner cover. An outer pivot member extends inwardly from the inner surface of the outer cover. The inner and outer pivot members are positioned in the central opening of the inner race to form a pivot axle. [0006] In accordance with another aspect of the invention there is provided a pivot bin assembly that includes an upper housing that includes a top and first and second housing side walls that each include a lower edge, a bucket that cooperates with the upper housing to define a bin interior, and a first compression member. The bucket includes a bottom and first and second bucket side walls that each include an upper edge and pivots with respect to the upper housing between an open position and a closed position. The first housing side wall and the first bucket side wall cooperate to define a first compression member opening. The first compression member is positioned in the first compression member opening and includes a main body portion that includes a plurality of cells that are defined by a plurality of sidewalls. The plurality of cells are comprised of a compliant material that compresses as the bucket moves to the open position to provide dampening and expands as the bucket moves to the closed position to provide lift assist.

[0007] The present invention is directed to a hinge assembly, and to a 3D printed hinge assembly that is part of a 3D printed overhead storage bin assembly. In a preferred embodiment, the hinge assembly is printed in a single print. This single print may or may not be part of a greater single overhead storage bin print. In another embodiment, the hinge assembly can be manufactured using a method that does not include 3D printing. The use of 3D printing technology is not a limitation on the present invention.

[0008] In a preferred embodiment, the hinge assembly includes a hinge that is preferably printed in one print with a tightening mechanism or capability, load carrying capacity and motion capacity. The motion capacity and load carrying capacity allow the lower portion or bucket of the storage bin to rotate relative to the upper portion of the storage bin.

Components are printed with a single print, thus not requiring labor to connect components at a later step. In a preferred embodiment, the present invention includes barbell style bearings with a tightening feature. The bearings are ready to tighten. The self-tightening feature allows for load transfer while minimizing rattle and loading maintenance susceptibility. The hinge assembly is preferably a smooth rolling hinge.

[0009] In another preferred embodiment, the above described individual 3D printed

overhead storage bin hinge can be manufactured in a single print concurrent with the complete 3D printed overhead storage bin.

[0010] The hinge assembly includes roller bearings that are printed in place, or printed simultaneously with the other parts of the hinge. Because of the hourglass shape of the roller bearings and the hinge being a print-in-place design, all the internal parts of the hinge are locked in to prevent the hinge from falling apart (i.e., the hinge assembly can withstand thrust load). The design of the roller bearing hinge minimizes vibration and noise while retaining a smooth rotating motion. In a preferred embodiment, the outer track or race of the hinge and the bottom bin are joined together as a single printed part. The inner track or race can be connected using panels that attach to the top bin. These hinge panels can include a keystone or truncated cone shaped pivot member that inserts into the center of the hinge. This keystone panel provides support to keep the hinge intact and applies pressure to roller bearings to reduce vibration and noise. The panels are preferably optimized for thickness so that when attached to the hinge, the full weight of the bottom half of the bin and luggage is supported and rotation is not inhibited. The hinge connects the top and bottom halves of the bin (upper housing and bucket), allowing the bin to open and close. In a preferred embodiment, the side panel/key was designed to integrate the hinge to the top bin while the hinge is printed as a part of the bottom bin. Incorporating panels on both sides of the hinge increases the structural integrity of the bin, decreases the bending moment, and decreases the overall thickness of the panel. As a result, strength is maximized while minimizing volume. In a preferred embodiment, the roller bearing hinge is printed as a part of the bottom bucket and the sidepanel/keys are attached to the top bin. The inside panel is printed as part of the top bin and the outside panel is glued to the outer wall of the bin (this is due to the assembly steps required for the hinge and key or tightening feature).

[0011] Also, a lift-assist system is provided that uses compliant mechanisms or materials.

This compliant mechanism or compression member helps the user close the bin and prevent the bin from abruptly dropping open upon unlatching. As the bucket moves to the open position, the lift-assist is compressed, cushioning the downward force of the bottom bin. The bin-closing behavior of the compression member applies a force on the bucket such that less force is required from the user as they close the bin. To achieve the desired properties for the compression member, the compliant mechanism can be printed using a strong, flexible plastic material, such as“Ninja-flex.” During design, the desired spring constant was determined by calculating how much force the compression member needed to contribute for the user to input only 15 lbs. on the inboard portion of the bucket.

[0012] In a preferred embodiment, the compression member is a generally triangular shaped compliant mechanism that fits within the slot defined between the back end of the upper housing of the bin and the bucket. The lift assist or compression member compresses when the bucket opens (preventing the bucket from slamming open) and provides a pushback force that assists a user closing the bucket. Side covers enclose the compression member between the bucket and upper housing and maintain the compression member in the proper position. These can be the same side covers used for the hinge assembly or they can be separate.

[0013] The present invention can be used in different types of aircraft including, but not limited to, commercial, business and/or military. The present invention can be further used in scenarios other than an aircraft. For example, the invention can be used in other modes of transportation including but not limited to trains, cars, buses and vertical take-off and landing autonomous vehicles.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The invention may be more readily understood by referring to the accompanying drawings in which:

[0015] FIG. 1 is a perspective view of a pivot bin assembly in accordance with a preferred embodiment of the present invention;

[0016] FIG. 2 is an exploded perspective view of the pivot bin assembly showing the hinge assembly and compression member;

[0017] FIG. 3 is perspective view of the hinge assembly;

[0018] FIG. 4 is an exploded perspective view of the hinge assembly;

[0019] FIG. 5 is an elevational view of a bearing;

[0020] FIG. 6 is a cross-sectional elevation of the outer race;

[0021] FIG. 7A is a top plan view of one inner race member of the inner race;

[0022] FIG. 7B is a rear elevational view of one inner race member of the inner race;

[0023] FIG. 7C is a side elevational view of one inner race member of the inner race;

[0024] FIG. 7D is a front elevational view of one inner race member of the inner race;

[0025] FIG. 7E is a bottom plan view of one inner race member of the inner race;

[0026] FIG. 8 is a cross-sectional view through the hinge system;

[0027] FIG. 9 is a perspective view of the inner cover;

[0028] FIG. 10 is a perspective view of the outer cover;

[0029] FIG. 11 is a side elevational view of the compression member; and

[0030] FIG. 12 is a side elevational view of the pivot bin assembly with the inner and outer covers removed to show the compression member.

[0031] Like numerals refer to like parts throughout the several views of the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] The following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details are not described in order to avoid obscuring the description. References to one or an embodiment in the present disclosure can be, but not necessarily are references to the same

embodiment; and, such references mean at least one of the embodiments.

[0033] Reference in this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the-disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other

embodiments.

[0034] The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks: The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. [0035] It will be appreciated that the same thing can be said in more than one way.

Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein. No special significance is to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification.

[0036] Without intent to further limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

In the case of conflict, the present document, including definitions, will control.

[0037] It will be appreciated that terms such as "front," "back,"“top,”“bottom,” "side," "short," "long," "up," "down," "aft," "forward," "inboard," "outboard" and "below" used herein are merely for ease of description and refer to the orientation of the components as shown in the figures. It should be understood that any orientation of the components described herein is within the scope of the present invention.

[0038] Referring now to the drawings, which are for purposes of illustrating the present invention and not for purposes of limiting the same, the drawings show an aircraft pivot bin assembly 10 that is configured to be installed or used in a commercial passenger aircraft. As shown in FIGS. 1-2, the pivot bin assembly 10 generally includes an upper housing 12 that includes a top 14 and first and second housing side walls 16, a bucket 18 that cooperates with the upper housing 12 to define a bin interior 20, at least one hinge assembly 22, and at least one compression member 24. In a preferred embodiment, a hinge assembly 22 and compression member 24 are included on each side of the bin. However, in another embodiment, only one hinge assembly 22 and compression member 24 can be used.

[0039] The hinge assemblies 22 are included to allow the bucket to move or pivot (with respect to the upper housing) between an open position and a closed position. The compression members 24 are included to provide one or more of dampening when the bucket 18 moves to the open position or lift assist when the bucket 18 is moved by a user to the closed position.

[0040] In a preferred embodiment, the first and second housing side walls 16 each include a lower edge 26, and the bucket 18 includes a bottom 28 and first and second bucket side walls 30 that each include an upper edge 32. The first housing side wall 16 and the first bucket side wall 30 cooperate to define a first hinge assembly opening 34 and a first compression member opening 36. It will be appreciated that in an embodiment with hinge assemblies and/or compression members on both sides, that all description that applies to the first side, which is shown in FIGS. 1 and 2, equally applies to the opposite second side, which cannot be seen in the drawings.

[0041] As shown in FIGS. 3-10, the hinge assembly 22 generally includes an outer race 38 that includes an outer surface 40 and an inner annular ridge 42 that defines an inner bearing surface 44, an inner race 46 that includes an inner surface 48 and an outer annular ridge 50 that defines an outer bearing surface 52, and a plurality of rollers or bearings 54 disposed between the outer race 38 and the inner race 46. The hinge assembly 22 combines with the inner cover 25 and the outer cover 27 to form a hinge system 23. The outer race 38 and inner race 46 are ring shaped and the bearings 54 fit between the races. As shown in FIGS. 4 and 5, each bearing 54 includes an annular race or groove 56 defined therein. The inner annular ridge 42 and the outer annular ridge 50 are received in the annular grooves 56 of each of the plurality of bearings 24 (see FIG. 8). In use, the outer race 38 remains stationary and the inner race 46 and bearings 24 rotate as the bucket 18 pivots. In another embodiment, the inner race remains stationary and the outer race and bearings rotate.

[0042] In a preferred embodiment, the inner race 46 includes a plurality of inner race

members 58 that cooperate to define a ring shape. FIGS. 7A-7E show a plurality of views of one of the inner race member 58. As shown, each inner race member 58 is curved and includes first and second inner tightening surfaces 60 (which together form the inner surface 48), a wedge 62 on one end and a wedge receiver 64 on the opposite end. Each inner race member 58 also includes the inner annular ridge 42 (with a peak surface and two angled surfaces extending away from the peak surface), which defines the inner bearing surface 44. The wedge 62 of one inner race member 58 is received in the wedge receiver 64 of the adjacent inner race member 58 to form the complete inner race 46. In a preferred embodiment, the entire hinge assembly 22 is 3D printed together or otherwise

manufactured as a unit. As shown in FIG. 7D, the inner race (a single inner race member 58 is shown in FIG. 7D) is bifurcated by a plane PI. The first and second inner tightening surfaces 60 form an angle A1 with the plane. In a preferred embodiment, angle A1 is between 91° and 179°, in a more preferred embodiment, angle A1 is between 95° and 140°, and in a most preferred embodiment, angle A1 is between 100° and 130°.

[0043] With reference to FIGS. 9 and 10, the inner cover 25 includes an inner surface 25a and an outer surface 25 b and the outer cover 27 includes an inner surface 27a and an outer surface 27b. In a preferred embodiment, the inner and outer covers each include a pivot member 66. The inner and outer pivot members 66 extend inwardly from the inner and outer covers 25 and 27 and extend into the center opening 22a of the hinge assembly 22 (which is the center opening of the inner race). The inner and outer pivot members 66 cooperate to form a pivot axle about which the inner race and bearings rotate. In a preferred embodiment, the pivot members 66 are shaped as a truncated cone that include tightening surfaces 66a. As shown in FIG. 8, the tightening surfaces 66a of the pivot members 66 press against the tightening surfaces 60 of the inner race members 58. As a result of the interaction of these surfaces, and because the inner race members 58 are separate components of the inner race, the inner race members 58 are moved, pushed or expanded radially outwardly to tighten them against the bearings 54. This helps prevent vibration and rattling of the bearings within the hinge assembly. In another embodiment, the pivot members 66 can be cylindrical and the inner surface of the inner race can be a flat surface (e.g., parallel to the pivot axis) that engages the outer surfaces of the pivot members 66. In another embodiment, only one pivot member 66 can form the entire pivot axle and extend through the center opening of the inner race 46.

[0044] As shown in FIGS. 9 and 10, in a preferred embodiment, the inner and outer covers

25 and 27 both include a hinge portion 68 that covers the hinge assembly 22 and a lift assist portion 70 that covers the compression member 24. In a preferred embodiment, the inner and outer covers 25 and 27 include connection members for connecting the inner panel to the outer panel. For example, one of the inner or outer cover can include some type of male attachment and the other of the inner or outer cover can include the complementary female attachment. In the embodiment shown in the drawings, the inner cover 25 includes holes 29 and the outer cover 27 includes mating tabs 31 that allow the covers to snap fit together. In another embodiment, the covers can be adhered or welded together. In another embodiment, the inner and outer covers can be part of or unitary with one or both of the upper housing or bucket (e.g., they can be 3D printed or otherwise manufactured as a unit). Furthermore, the outside race 38 of the hinge assembly 22 can be 3D printed or otherwise manufactured as a unit with one or both of the inner and/or outer covers 25 and 27.

[0045] With reference to FIGS. 11 and 12, the compression member 24 is made of a

compliant material that provides one or more of dampening when the bucket 18 opens and/or lift assist when the bucket 18 closes. The compression member 24 is essentially a spring (or plurality of springs) that is positioned in the compression member opening 36. The compression member opening 36 is defined between the upper surface 32 of the first bucket side wall 30 and the lower surface 26 of the first housing side wall 16.

[0046] In a preferred embodiment, the compression member 24 includes a main body

portion 72 that includes a plurality of cells 74 that are defined by a plurality of sidewalls 76. The plurality of cells 74 can all have the same shape or some of the plurality of cells can have different shapes. For example, a first set of cells can have a first shape (e.g., octagonal in FIG. 11) and a second set of cells can have a second shape (e.g., square in FIG. 11). Exemplary shapes are hexagon, pentagon, octagon, square, diamond, triangle, circular, ovular, etc. Any shape is within the scope of the present invention. The cells can take on“organic” and/or any polygon, curved side or combination thereof shape and the density of cells and their distribution contributes to the different and changing spring forces or constants throughout the compression member.

[0047] In a preferred embodiment, the plurality of cells 74 can all be the same size (i.e., include the same dimensions) or some of the plurality of cells can be a different size. For example, the cells may all be a first shape (i.e., a square shape), however, a first set of cells can have sidewalls 76 with a first length and a second set of cells can have sidewalls 76 with a second length. [0048] In a preferred embodiment, the plurality of cells 74 can all be comprised of sidewalls that are the same density (i.e., include the same thickness sidewalls or include the same material throughout) or some of plurality of cells can have a different density (i.e., include the sidewalls or differing thickness or include a different material therein to provide a different desired characteristic). The compression member can include variable density throughout, which can be based on the type of material used. For example, the material can be half rubber and half plastic. Generally, it is preferred to use a polymer or different polymers that are semi rigid and can withstand repeatable deformations. For example, nylon can be used. Furthermore, fibers can be added in certain locations to provide some areas that are stiffer than others. The change in material can be provided during the 3D printing operation.

[0049] It will be appreciated that any of the differing characteristics discussed above can be included in a single compression member 24. For example, the size, shape, density, type of material and/or thickness of the sidewalls can be varied throughout the main body portion 72 of the compression member. Therefore, the spring capabilities of the compression member 24 can be customized based on the shapes, sizes and other characteristics of the cells 74 discussed herein. The changing of the characteristics of the cells allows the spring force to differ throughout the main body portion so the bucket can open and close as desired (e.g., open fast and then slow down near the end). It should be understood that each characteristic can be changed in more than two sets of cells ("first and second sets" are discussed above). For example, there can be two or more sets of different shaped cells, two or more sets of different sized cells, two or more sets of different material density cells, two or more sets of different wall thickness cells, two or more different types of cells that are made of different materials, etc. [0050] As a result of changing the characteristics, the main body portion 72 can include one or more sections that include different spring constants. In other words, a first section can include a first spring constant and a second section can include a second spring constant. In another embodiment, there can be more than two sections and each further section can include a different spring constant.

[0051] In a preferred embodiment, the compression member 24 has a generally triangular or wedge shape. By "generally," it should be understood that the compression member 24 may have sides that are not completely straight. For example, see the open cells in FIG. 2 that cause the sides to not be straight. Furthermore, the compression member 24 may have a curved surface, for example, to match the curved surface shown in the back of the compression member opening 36, as shown in FIG. 12. In another embodiment, the compression member 24 may be another shaped polygon, such as a quadrilateral or generally a quadrilateral. The compression member 24 has a front 78 and a back 80.

Preferably, the back 80 is taller or has a greater length dimension that the front 78.

[0052] In use, in a preferred embodiment, the compression member 24 collapses and flattens almost completely, which provides dampening as the bucket 18 opens. As the bucket 18 is pushed closed, the compression member 24 expands to help the user.

[0053] Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to." As used herein, the terms "connected," "coupled," or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words "herein," "above," "below," and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description of the Preferred Embodiments using the singular or plural number may also include the plural or singular number respectively. The word "or" in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

[0054] The above-detailed description of embodiments of the disclosure is not intended to be exhaustive or to limit the teachings to the precise form disclosed above. While specific embodiments of and examples for the disclosure are described above for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize. Further, any specific numbers noted herein are only examples: alternative implementations may employ differing values, measurements or ranges.

[0055] The teachings of the disclosure provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments. Any measurements described or used herein are merely exemplary and not a limitation on the present invention. Other measurements can be used. Further, any specific materials noted herein are only examples: alternative implementations may employ differing materials.

[0056] Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference in their entirety. Aspects of the disclosure can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the disclosure. [0057] These and other changes can be made to the disclosure in light of the above Detailed Description of the Preferred Embodiments. While the above description describes certain embodiments of the disclosure, and describes the best mode contemplated, no matter how detailed the above appears in text, the teachings can be practiced in many ways. Details of the system may vary considerably in its implementation details, while still being encompassed by the subject matter disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the disclosure should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features or aspects of the disclosure with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the disclosures to the specific embodiments disclosed in the specification unless the above Detailed Description of the Preferred Embodiments section explicitly defines such terms. Accordingly, the actual scope of the disclosure encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the disclosure under the claims.

[0058] Accordingly, although exemplary embodiments of the invention have been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.