1. Technical field

The present invention relates to a hinge with integrated stay mechanism, particularly for a door hinge for the door of a motor vehicle with integrated door check. The stay mechanism prevents an undesired opening or closing of the door.

2. Prior art

The prior art provides different solutions for door hinges of motor vehicles. Mostly the doors of a motor vehicle are mounted to the car body by means of common hinges and a separate stay mechanism is provided, by means of which the door at particular fixed predetermined stay positions can be locked. The door then locks in the predetermined positions such that in normal circumstances it does not undesired closes or opens any further.

Such separate stay mechanisms have the disadvantage, that they are an additional component, which must be mounted to the door or the car body in addition to the common hinges, whereby an increased assembly effort results. Further, such stay mechanisms have to be costly integrated into the door or the car body and must be costly sealed.

In this respect door hinges are an improvement which comprise an integrated stay mechanism. Such a door hinge is for example disclosed in the EP 1 067 267 Al . In this door hinge, a plurality of needles of a needle bearing are radially pressed in direction to a hinge axis which comprises axially oriented recesses, by means of a spring force. At a particular angular position the cylindrical needles latch within

spring force. At a particular angular position the cylindrical needles latch within the recesses and provide in that way a locking of the door at a predetermined stay position.

A further door hinge with integrated stay mechanism is disclosed in the DE 199 53 077 B4. At this door hinge a pressure tappet is pressed against a profiled circumference section of a hinge shaft which comprises three predetermined stay positions. With such a hinge it is possible to hold the motor vehicle door at three predetermined stay positions.

From the prior art, therefore, the problem underlying the present invention relates to provide a hinge comprising an integrated stay mechanism, which allows to reliably hold for example a door in each arbitrary angular position. Further, this hinge should be as simple in construction as possible, be cost efficiently produc- ible and should reliably function over the complete life span of the motor vehicle. It is further desirable, that the hinge comprises a relation between holding torque and opening torque as high as possible. Further, the stay mechanism should be as invisible as possible which leads to an aesthetically pleasing hinge.

3. Summary of the invention

The present invention solves this problem by a hinge according to the independent patent claim 1.

Particularly this problem is solved by a hinge, particularly for the door of a motor vehicle, comprising a first hinge part, a second hinge part, a hinge shaft, which defines the pivot axis of the hinge, around which the first hinge part is pivotable with respect to the second hinge part, and an integrated stay mechanism for a stepless locking of the first hinge part with respect to the second hinge part at an arbitrary fixing position, wherein the stay mechanism comprises a first fixing element which is selectively rotatably fixed at the first hinge part and selectively

rotatable around the pivot axis by means of the second hinge part, to set the stay position, and a second fixing element which is pivotable together with the second hinge part and latches with the first fixing element at the respective stay position.

Therefore, a hinge is provided which automatically can be securely locked in any arbitrary stay position. The locking of the hinge can be done at each angular position and is not dependent on particular predetermined stay positions. The locking therefore can for example be done at each arbitrary opening angle of the door. It is done automatically in a mechanical way, and without any further manual actua- tion actions needed. Further, a hinge according to the invention comprises a high holding torque at a low adjusting torque. Therefore, for example the door of a motor vehicle can be opened or closed without high force effort and with a low adjusting torque and can be released in any arbitrary position and will securely be held there at a high holding torque.

Preferably the first fixing element is provided such that it is not rotatably arranged around the pivot axis during a comparably small pivoting movement of the first hinge part with respect to the second hinge part and rotatably arranged around the pivot axis during a comparably large pivoting movement. By changing the angular position of the hinge by a small pivoting movement, the first fixing element is held in place and provides together with the second fixing element a high holding torque or stay torque. If this is exceeded, to pass over the stay position, the first fixing element rotates together with the second hinge part, whereby at a low adjusting torque a new stay position is set. In that way a door can easily be opened or closed and is securely held in this position after releasing.

In a preferred embodiment the first fixing element comprises a contoured guiding surface having exactly one portion for the defined stay position. By this arrangement of the contoured guiding surface the desired holding torque as well as the angular range can be set in which the high holding torque should be effective.

- A -

In a further preferred embodiment the second fixing element comprises a tappet which is urged in direction of the guiding surface by means of a spring element. The tappet of the second fixing element therefore presses against the contoured guiding surface of the first fixing element and therefore provides the desired hold- ing torque of the hinge.

Preferably the spring force of the spring element is adjustable. By means of the adjustable spring force again the desired holding torque can be set.

In a further preferred embodiment the tappet comprises an end which is adapted to the portion for the defined stay position and which is preferably hemispherical or half cylindrically shaped. The tappet is pressed by means of the spring into a correspondingly shaped notch in the contoured guiding surface, which defines the defined stay position. During a following movement of the second hinge part with respect to the first hinge part the tappet is urged out of the notch of the contoured guiding surface against the spring force, which causes a resetting torque in direction of the stay position.

In a further preferred embodiment the hinge comprises at least one clutch element, which is provided to prevent or to allow a rotation of the first fixing element around the pivot axis. If the hinge is displaced around a small angle and is located in the range of the holding torque, the clutch element prevents a rotation of the first fixing element with respect to the pivot axis. If this angular portion is exceeded, for example by further opening or closing the door of the motor vehicle, the clutch element allows a rotation of the first fixing element with respect to the pivot axis. Therefore, the first fixing element can rotate and can take a new stay position.

In a further preferred embodiment the clutch element is actuated by means of a pivoting movement of the second hinge part to prevent or to allow the rotation of the first fixing element around the pivoting axis. Therefore, the pivoting move-

ment of the second hinge part selectively controls the rotation of the first fixing element around the pivoting axis.

Preferably the first fixing element is shaped in form of a bushing or in shape of a tube and further preferred it is arranged around the hinge shaft. By this bushing or tube shaped design, the stay mechanism can be immediately integrated into the hinge and is therefore almost invisible.

Preferably the clutch element comprises at least one clutch pin, which is arranged in parallel to the pivoting axis between the first fixing element and the hinge shaft, and which selectively prevents or allows a rotation of the first fixing element with respect to the hinge shaft. This clutch pin forms together with the first fixing element and the hinge shaft a particularly simple and reliable friction clutch, which prevents or allows a rotation of the first fixing element around the pivoting axis.

Preferably the clutch element comprises two axis parallel clutch pins which are pressed away from each other by means of a spring element. In this embodiment a particularly reliable clutching or releasing of the clutch pins of the friction clutch is achieved.

Preferably the hinge shaft is provided with a flattened portion, such that the first fixing element is free to rotate along a defined angular range. In a further preferred embodiment the first fixing element is provided with a portion having an increased inner diameter, such that the first fixing element is free to rotate along a defined angular range. If the hinge is in that range no resistance torque is applied, such that for example a door can be closed with minimized force.

In another preferred embodiment the clutch element comprises at least one torsion spring clutch which is simultaneously wrapped around the hinge shaft and the first fixing element. Instead of the friction clutch with pins also a torsion spring clutch

can be used, which is able to transmit particularly high clutch torques and comprises a particularly high reliability compared to clutch pins.

Preferably the clutch element comprises two torsion spring clutches and two sepa- rate parts of the hinge shaft, wherein the torsion spring clutches each are simultaneously wrapped around a part of the hinge shaft and the first fixing element. In this embodiment for each rotation direction of the first fixing element a torsion spring clutch is used.

Furthermore preferred embodiments result from the subclaims.

4. Short description of the drawing

In the following the preferred embodiments of the present invention are described v'ith reference to the drawing. Therein it shows:

Fig. 1 a three-dimensional view of a first embodiment of the hinge according to the invention;

Fig. 2 a three-dimensional view of the hinge of Fig. 1 from the top;

Fig. 3 a three-dimensional, partially sectional view of the hinge of Fig. 1 , to show the components of the stay mechanism;

Fig. 4 a three-dimensional view of the hinge of Fig. 1 during the pivoting movement;

Fig. 5 a three-dimensional, partially sectional view of a stay mechanism of a hinge according to Fig. 1 during the pivoting movement;

Fig. 6 an elongational view of parts of the stay mechanism of a hinge according to Fig. 1 ;

Fig. 7 a three-dimensional view of a further embodiment of a hinge ac- cording to the invention;

Fig. 8 a partially sectional, three-dimensional view of a hinge according to Fig. 7;

Fig. 9 a partially sectional, three-dimensional view of a hinge according to Fig. 7, wherein parts of the hinge are not shown;

Fig. 10 a three-dimensional detailed view of single components of the stay mechanism of the hinge according to Fig. 7;

Fig. 1 1 a three-dimensional explosionary view of the single components of the hinge according to Fig. 7;

Fig. 12 a diagram which shows the course of the torque T with respect to the opening angle co;

Fig. 13 a sectional view of a further embodiment of a clutch mechanism of a hinge according Fig. 1 ;

Fig. 14 a sectional view of a further embodiment of a clutch mechanism of a hinge according Fig. 1 having a free rotation zone;

Fig. 15 a sectional view of a further embodiment of a clutch mechanism of a hinge according Fig. 1 having an other free rotation zone; and

Fig. 16 a three-dimensional view of an end portion of a second hinge part.

5. Detailed description of the preferred embodiments

In the following with respect to the drawing different embodiments of the present invention is described.

Figures 1 and 2 show the basic arrangement of a hinge 1 having a first hinge part 10, a second hinge part 20 and a hinge shaft 30, which defines the pivoting axis of hinge 1. The second hinge part 20 is pivotable with respect to the first hinge part 10 around the hinge shaft 30.

If hinge 1 is used for fixing the door or a motor vehicle (not shown) the second part 20 is mounted to the car body of the motor vehicle by means of ordinary screws (not shown), which are inserted into mounting openings 24 of a mounting plate 22. The first hinge part 10 also comprises a mounting plate 12 with mount- ing openings 14, to mount the first hinge part 10 by means of ordinary screws (not shown) to the door of a motor vehicle.

Fig. 1 also shows a first fixing element 40, which is shaped like a bushing and which is arranged around the hinge shaft 30. The further components of the stay mechanism integrated into hinge 1 are almost not visible from the outside. Therefore, the hinge 1 shown in Fig. 1 is particularly preferably under esthetic aspects. Further it is comparably small. Therefore, only little space is needed, to integrate hinge 1 into a motor vehicle door.

Figs. 3 and 6 show the inner components of the stay mechanism of hinge 1. Hinge 1 comprises a hollow prismatic or cylindrical portion 21 which was cut in Fig. 3 to show the inner components. Within the hollow prismatic/cylindrical portion 21 a spring element 70 is arranged, which pushes a second fixing element 50 in direction of a guiding surface 42 of the first fixing element 40. In the shown em- bodiment the second fixing element 50 is a tappet 50 which is biased by means of a spring 70 in direction of the hinge shaft 30 as indicated by arrow 51 in Fig. 6.

The hollow prismatic/cylindrical portion 21 is closed by means of a set screw at the side opposite to the tappet 50 (not shown), which acts as a stop for the spring element 70. The spring force of the spring element 70 can be adjusted by screwing the (not shown) set screw into or out of the hollow prismatic/cylindrical portion 21. In this case the spring element 70 is pre-biased stronger or weaker.

Fig. 3 shows further the first fixing element 40, which is formed as an essentially cylindrical bushing 40. The bushing 40 is rotatably supported onto the cylindrical hinge shaft 30 and therefore around the pivoting axis of the hinge 1, as it is indicated by arrow 41 in fig. 6. This rotation is selectively prevented or allowed by means of a friction clutch 60, 62 in form of a first 60 and a second clutch pin 62. The way of operation of the friction clutch in cooperation with the other components of the stay mechanism is explained in detailed further below.

For increasing the clutching behavior the two axis parallel clutch pins 60, 62 are preferably pressed away from each other by means of one or a plurality of spring elements (not shown) perpendicular to its longitudinal axis. The spring elements can be normal springs or elastic elements for example rubber blocks or bands. The clutch pins 60, 62 are arranged between the first fixing element 40 and the pivot shaft 30 and selectively prevent or allow a rotation of the first fixing element 40 with respect to the hinge shaft 30 rigidly connected to the first hinge part 10.

The clutch pins 60, 62 are located within a preferably sickle shaped portion 45 of the inner bore 46 of the first fixing element 40, as shown in figs. 5 and 6. The portion 45 is therefore provided as a preferably sickle shaped pocket 45, which inner diameter decreases in direction of the ends 48 of the sickle. Therefore, the clutch pins 60, 62 seize if they are pressed in direction of the ends 48, and prevent in one movement direction respectively rotation of the first fixing element 40 around the hinge shaft 30.

Another configuration to achieve this clutch effect is shown in Fig. 13. In this alternative embodiment the hinge shaft 30 comprises a flattened portion 32 and the inner bore 46 of the first fixing element 40 is round and has a constant diameter. This configuration provides also two ends 34 at which the clutch pins 60, 62 seize if they are pressed in direction of the ends 34. Again, the clutch pins 60, 62 prevent rotation of the first fixing element 40 around the hinge shaft 30 in one movement direction, respectively.

The first fixing element 40 comprises at the outside a contoured guiding surface 42 which exactly has one portion 44 that defines a stay position. In the shown embodiment the portion 44 is preferably shaped as a notch or groove 44, which is recessed in parallel to the hinge axis 30 into the essentially cylindrical guiding surface 42.

Figure 3 and Fig'ire 6 show hinge 1 while the second hinge part 20 is located ?X the stay position with respect to the first hinge part 10. Thereby, the spring element 70 presses the tappet 50 in direction of the first fixing element 40. The tappet 50 comprises an end 52 which faces the first fixing element 40 and which is preferably half cylindrically shaped and preferably comprises a pin 52 which can be made of a different material than the tappet 50. In the shown position the end 52 respectively the pin 52 engages the notch 44 for the stay position.

If now the first hinge part 10 with respect to the second hinge part 20 (or the other way round) should be pivoted, initially the end 52 has to move out of the portion 44 against the spring force of the spring element 70. Thereby a defined holding torque Tp has to be overcome, as shown in Fig. 12. The holding torque T _P can be adjusted by means of the shape of the end 52, the shape of the portion 44 and the spring force of spring element 70. It should be at least that high, that for example an undesired closing or opening of a motor vehicle door is reliably prevented. On the other hand it should also not be excessively high, such that elderly persons or children can close a motor vehicle door without problems.

During an increasing pivoting ω ₀ to eoi the holding torque T increases from 0 to Tp, as the first angular section 202 of the diagram 200 of Fig. 12 schematically shows. If the pivoting movement co of the hinge parts 10, 20 to each other is con- tinued after exceeding the holding torque T _P via cθ|, the clutch pins 60, 62 disengage and the first fixing element 40 can rotate together with the pivoting movement of the second hinge part 20 around the hinge shaft 30. Thereby the holding torque decreases from Tp to T _L ι- as the second angular section 204 shows and thereafter the hinge 1 can easily be pivoted with a low resistance torque T _LF , as it is shown in the third angular section 206 of Fig. 12.

The disengagement of clutch pins 60, 62 happens automatically, by supporting them within two curve shaped slots 28 in opposite sides of the prismatic/cylindrical portion 21, as shown in Fig. 2 and Fig. 16. During a displace- ment of the second hinge part 20, one of the clutch pins 60, 62 is pressed to the center of the sickle shaped portion 48 by one end of the slots 28, as indicated by the aiτows 64 in fig. 6, whereby the seizing of the clutch pin 60, 62 is revoked.

This condition is shown in Figs. 4 and 5 as an example. By pivoting the second hinge part 20 in direction 23 the clutch pin 60 is pressed by the upper and lower ends 29 of the slots 28 to the centre of the sickle shaped portion 45 and thereby disengaged.

As shown in Fig. 16 the second hinge part 20 comprises two slots 28 which are arranged at the prismatic/cylindrical portion 21 adjacent to two bores 26 which support the hinge shaft 30. The slots 28 may form a common opening with the bores 26 like it is shown.

In other embodiments (not shown) the pins 60, 62 may be actuated in another way than with slots 28. It is however important, that the actuation of the pins 60, 62 is

related to the relative pivoting movement of the second hinge part 20 with respect to the first fixing element 40.

Then the first fixing element 40 is moved respectively pivoted together with the second hinge part 20 in direction 23, as indicated by arrow 41 in Fig. 6, by means of the friction of the end 52 of the tappet 50 at the guiding surface 42 of the first fixing element 40. The first fixing element 40 thus rotates with respect to the hinge shaft 30, such that its portion 44, which defines the stay position, is also moved further, to define a new stay position.

With a small back movement of the second hinge part 20 the clutch pin 60 again clutches and prevents a rotation of the first fixing element 40 with respect to the hinge shaft 30. Simultaneously the end 52 of the tappet 50 again latches within the portion 44 of the first fixing element 40 and therefore locks the hinge 1 at the new stay position:

The stay mechanism is effective in both pivoting directions. For the other pivoting direction the clutch pin 62 is provided, which clutches and disengages in the above described way.

Figures 14 and 15 show a further embodiment, wherein the hinge shaft 30 or the first fixing element was modified to provide a hinge 1 which comprises a defined angular range where no locking effect occurs. If the hinge pivots through this angular range it does not apply any resistance torque T. This effect is used near the closing position of the hinge 1 to facilitate the closing movement of an automotive door.

Fig. 14 shows a configuration according Figs. 3 -5 wherein the first fixing element 40 comprises a sickle shaped pocket 45, which inner diameter decreases in direc- tion of the ends 48 of the sickle. The shaft 30 in addition comprises a flattened portion 36 to provide the non-locking range.

If the hinge 1 rotates, such that the flattened portion 36 and the pocket 45 face each other, the pins 60, 62 disengage or can not engage, such that the first fixing element 40 is free to rotate along a defined angular range. This angular range is defined by the shape an size of the flattened portion 36.

Fig. 15 shows a configuration according Figs. 13 wherein the hinge shaft 30 comprises a flattened portion 32 and the inner bore 46 of the first fixing element 40 is substantially round. In addition to the Fig. 13 embodiment the bore 46 comprises a portion 49 having a constant larger diameter than the remainder of the bore 46 to provide the non-locking range.

If the hinge 1 rotates, such that the portion 49 and flattened portion 32 of the hinge shaft 30 face each other, the pins 60, 62 disengage or can not engage, such that the first fixing element 40 h free to rotate along a defined angular range. This angular range is defined by the shape an size of the portion 49 with the increased diameter.

Figures 7 - 11 show a further embodiment of the hinge.

Figure 7 shows a hinge 100 having first hinge part 110 which comprises of two parts 110 which are rigidly connected to each other in an arbitrary way, for example by fixing them to the car body of a motor vehicle (not shown). The hinge 100 comprises a second hinge part 120 which for example for assembly comprises a plate 128. The plate 128 of the hinge part 120 could for example be mounted to a door of a motor vehicle (not shown).

The second hinge part 120 is pivotable with respect to the first hinge part 110 around a pivot axis of the hinge 100. To this end a hinge shaft 130 is connected at the first hinge part 110. In the shown embodiment the hinge shaft 130 comprises

of two stationary hollow cylindrical shaft parts 130 and 131 which are axis parallel aligned to each other and which face each other.

The second hinge part 120 comprises a cylindrically shaped inner-shaft 124 which extends into the bore of the hinge shafts 130, 131 and which is there rotatably supported.

The hinge 100 further comprises an integrated stay mechanism to hold the first hinge part 1 10 with respect to the second hinge part 120 at an arbitrary stay posi- tion.

The stay mechanism comprises a first fixing element 140, which is connected to the first hinge part 110 by means of an inner shaft 124 and which is selectively rotatable around the pivot axis of the hinge 100 for adjusting the stay position. The first fixing element 140 comprises a tube shaped respectively bushing shaped bushing part 145 which is arranged around the inner shaft 124. The outer and inner diameter of the bushing part 145 corresponds to the outer and inner diameter of the shaft parts 130, 131.

The plate 128 of the second hinge part 120 is connected to the inner shaft 124 by means of two strips 126 which extend through a rectangular window 146 within the bushing part 145. It is important for the function of the stay mechanism, that the second hinge part 120 is independently rotatable with respect to the first fixing element 140.

The first fixing element 140 further comprises a contoured guiding surface 142, which comprises two radially extending cams 147, which, as shown in Figure 10, define a non-extending portion 144 for a defined stay position in-between them. The contoured guiding surface 142 is provided in the shown embodiment by a cam element 143, which is rigidly arranged at the outer cylinder surface of the bushing part 145.

The stay mechanism further comprises a second fixing element 150, which is connected at the second hinge part 120 and which is pivotable with the same and which ledges with the first fixing element 140 at the corresponding stay position.

For generating a holding torque the second fixing element 150 comprises a tappet 150, which is axially moveable supported within a guiding 122. The tappet 150 is spring-biased by a spring element 170, which is arranged in the guiding 122, and the tappet 150 is pressed in direction to the guiding surface 142, see Figure 10. The tappet 150 comprises a rounded, preferably hemispherical end 152 which is adapted to the portion 144 for the stay position.

Like in the first embodiment here the first fixing element 140 is also selectively prevented from a rotation around the hinge shafts 130, 131 by means of two clutch elements 160, 162. In the shown embodiment the clutch elements 160, 162 comprise of two torsion spring clutches 160, 162 which are wrapped around portions of the hinge shafts 130, 131 as well as around parts of the first fixing element 140. The torsion spring clutches 160, 162 are pre-biased wrap springs 160, 162 which initially prevent a rotation of the first fixing element 140 in one direc- tion respectively.

The stay mechanism functions as follows: Initially it is started from the position shown in Figures 7 to 10, which show the locked condition of the hinge 100. In this condition the end 152 of the tappet 150 is located at the deepest position of the portion 144. The torsion spring clutches 160, 162 prevent a rotation of the first fixing element 140. Therefore, the hinge 100 is held in its actual position.

If now the second hinge part 120 is pivoted with respect to the first hinge part

1 10, the tappet 150 is pressed into the guiding 122 by means of the cams 147 of the contoured guiding surface 142 against the spring force of the spring element

170. To this end a particular force is needed, which results to a holding moment T.

Like in the first embodiment the holding moment T increases with increasing pivoting movement ωo to cθ| from 0 to Tp, as the angular section 202 of Figure 12 schematically shows. If the hinge 100 respectively the door is released in this sec- tion, it moves back to the stay position ω ₀ .

If the pivoting movement ω of the hinge parts 1 10, 120 to each other is continued exceeding the holding torque Tp below coi, the second hinge part 120 pushes on the respective ends 164, 166 (see Figs. 9 and 1 1) of one of the torsion spring clutches 160, 162 and causes that the respective torsion spring clutch 160, 162 is disengaged. Then, the first fixing element 140 can rotate together with the pivoting movement of the second hinge part 120 with respect to the hinge shaft 130.

Thereby the holding torque decreases from T _P to T _LF , as it is shown by angular section 204 (cøi to ω ₂ ) and the second hinge parfc-120 can easily be pivoted with a small resistance torque T _LF as shown in section 206.

After the desired end position is reached, the corresponding torsion spring clutch 160, 162 again clutches and with a small back movement of the second hinge part 120 the tappet 150 again ledges with the portion 144 of the first fixing element 150. Thereby, the hinge 100 or the door is held in this new position.

The stay mechanism of the second embodiment functions in both pivoting directions. For the other pivoting direction the other torsion spring 160, 162 is provided which clutches or disengages in the above described way.

List of reference signs 1 hinge

10 first hinge part 12 mounting plate

14 mounting openings

20 second hinge part

21 hollow, prismatic/cylindrical portion

22 mounting plate

23 pivoting movement

24 mounting openings

26 bores

28 curved slot

30 hinge shaft

32 flattened portion

34 end of flattened portion

36 flattened portion

40 first fixing element

41 rotational movement

42 guiding surface

44 portion of stay position, notch-, groove

45 sickle-shaped portion

46 inner bore

48 ends of the sickle-shaped portion

49 portion with increased diameter

50 second fixing element, tappet

51 spring pre-tension

52 end of the tappet

60 first clutch pin

62 second clutch pin

64 disengagement direction

70 spring

100 hinge

110 first hinge part

120 second hinge part

122 support

124 inner shaft

126 strips

128 plate

130 hinge shaft, first part

131 hinge shaft, second part 140 first fixing element

142 guiding surface

143 cam element

144 non-extending portion

145 bushing part 146 window

147 cam

150 second fixing element, tappet

152 end

160 first clutch element, torsion spring clutch 162 second clutch element, torsion spring clutch

164 end of torsion spring clutch

166 end of torsion spring clutch

170 spring element

200 torsion-rotation angle-diagram 202 first angular portion

204 second angular portion

206 third angular portion