Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
As amended by the Patents (Amendment) Act, 2005
&
The Patents Rules, 2003
As amended by the Patents (Amendment) Rules, 2016
COMPLETE SPECIFICATION
(See section 10 and rule 13)

TITLE OF INVENTION
A hinge assembly for mounting a door on a vehicle body

APPLICANT
MAHINDRA ELECTRIC AUTOMOBILE LIMITED, an Indian company, having its address at Mahindra Tower, Pandurang Budhkar Marg, Nr. Doordarshan Kendra, Worli, Mumbai, Mumbai City, Maharashtra 400018, India.

PREAMBLE TO THE DESCRIPTION
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.
FIELD OF THE INVENTION
[001] The present invention relates to a hinge assembly for mounting a door on a vehicle body and more particularly, to a hinge assembly having a reinforcement member for reinforcing the mounting of the door on the vehicle body and provide stiffness thereof.

BACKGROUND OF THE INVENTION
[002] In automotive industry, the Body in White (BIW) manufacturing process involves several steps, including stamping, welding, and sometimes bonding of various sheet metal parts to create a basic structure of the vehicle. Layer manufacturing, in the realm of the Body in White (BIW) manufacturing process, refers to the sequential assembly of various layers of stamped and formed sheet metal components. These layers are joined together using welding techniques such as spot welding, arc welding, or laser welding, as well as adhesives or other joining methods.
[003] In the production of the Body-in-White (BIW) layer for automobiles, maintaining proper design clearances between each panel layer is crucial for ensuring seamless attachment. However, notable challenges arise due to mounting of the door hinge assemblies on a vehicle body. This complexity arises as the clearances maintained for the layer build process make it more challenging to transfer loads from one layer of panels to other layers.
[004] Further, it has also been observed that mounting the lift door at locations encompassing adjoining portions of roof and the rear most pillars of the vehicle, through the hinge assemblies becomes more complex, time consuming and a cumbersome task. In such instances, achieving the necessary stiffness for mounting the lift door becomes extremely difficult.
[005] It has been observed that it is essential to attain sufficient stiffness in mounting the liftgate hinge assemblies to achieve the requisite functioning of the liftgate while preventing deformation to the portion of the vehicle body on which the hinge assembly is mounted. Owing to the existing mounting arrangement, the hinge assemblies fail to effectively transfer the load.
[006] Hence there is a need in the art for a hinge assembly for mounting a door on a vehicle body which addresses at least the aforementioned problems/ drawbacks.

SUMMARY OF THE INVENTION
[007] Accordingly, the present invention in one aspect provides a hinge assembly for mounting a door on a vehicle body. The hinge assembly includes a first hinge member and a second hinge member. The first hinge member is configured to be attached to the door and the second hinge member is pivotally attached to the first hinge member. Further, the second hinge member is configured to be attached to the vehicle body. The vehicle body is having an outer panel and an inner panel. The inner panel is spaced apart from the outer panel. Each of the outer panel and the inner panel include one or more mounting holes aligned with each other. Further, the hinge assembly includes a reinforcement member. The reinforcement member includes a base plate and one or more sleeves. The one or more sleeves extend away from the base plate. The base plate is mounted on the outer panel and the one or more sleeves are configured to be passed through the one or more mounting holes of the outer panel. Further, the one or more sleeves are configured to be aligned with the one or more mounting holes of the inner panel. The second hinge member is configured to be mounted on the base plate of the reinforcement member and attached to the inner panel through one or more fasteners passing through the one or more sleeves.
[008] In an embodiment of the invention, the one or more sleeves is of a length corresponding to the space between the outer panel and the inner panel.
[009] In another embodiment of the invention, the one or more fasteners includes abutment portions.
[010] In another embodiment of the invention, each of the base plate and the one or more sleeves of the reinforcement member is having a thickness ranging from 0.8 mm to 2 mm.
[011] In another embodiment of the invention, the reinforcement member is made of steel.
[012] In another embodiment of the invention, the hinge assembly is mounted on an upper portion of a rear pillar of the vehicle.
[013] In another embodiment of the invention, the door is a liftgate of the vehicle. Further, the door is configured to be opened vertically.
BRIEF DESCRIPTION OF THE DRAWINGS
[014] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a rear portion of a vehicle body, in accordance with an embodiment of the invention.
Figure 2 illustrates a cross-sectional view of a hinge assembly mounted on the region (X) of the vehicle body shown in Figure 1, in accordance with an embodiment of the invention.
Figure 3 illustrates a first hinge member and a second hinge member of the hinge assembly, in accordance with an embodiment of the invention.
Figure 4 illustrates a perspective view of a reinforcement member, in accordance with an embodiment of the invention.
Figures 5a-5d illustrate a perspective, front, top and side views of the reinforcement member respectively, in accordance with an embodiment of the invention.
Figures 6a-6d illustrate a perspective, front, top and side views of the reinforcement member respectively, in accordance with an embodiment of the invention.
Figures 7a-7d illustrate a perspective, front, top and side views of the reinforcement member respectively, in accordance with an embodiment of the invention.
Figure 8 illustrates an exploded view of the hinge assembly, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[015] The present invention is directed towards a hinge assembly for mounting a door on a vehicle body. The hinge assembly includes a reinforcement member which ensures that sufficient stiffness is maintained for the hinge assembly mounting.
[016] Figure 1 shows a rear portion of a vehicle body 100 in an embodiment of the invention. In a non-limiting example, the vehicle body 100 being a hatch back body. The vehicle body 100 includes a structure 101. The structure 101 includes vertical and horizontal structural members. The horizontal structural members include a roof panel (R) and a vehicle under body (not shown). The vertical structural members are disposed between the roof panel (R) and the vehicle under body. The vertical structure members include A-pillar positioned at a front portion of the vehicle body 100, a B-pillar disposed at a middle portion of the vehicle body 100 and a C-pillar (C). The C-pillar (C) being a rear pillar is located at a rear portion of the vehicle body 100.
[017] In an embodiment, the rear portion of the vehicle body 100 includes an opening (O) formed between the C-pillars (C), the roof panel (R) and the vehicle under body. The opening (O) is configured to receive a door (not shown). In a non-limiting example, the door is a liftgate of the vehicle and configured to be opened vertically. The door is mounted on each side of an upper portion of the C-pillar (C) and in regions (X) through hinge assemblies. Each of the regions (X) encompasses adjoining portions of the roof panel (R) and the upper portion of each of the C-pillar (C).
[018] In an embodiment, each of structural members of the vehicle body 100 comprises of several layers of sheet metal panels which are attached to each other. As shown in Figure 1, the layers of the vehicle body 100 include an outer panel 102 and an inner panel 104. The outer panel 102 being the panel visible from an exterior of the vehicle.
[019] In a non-limiting example, the vehicle body 100 is manufactured through a layer build process. The design clearance/space between the outer panel 102 and the inner panel 104, depending upon the vehicle design requirements, needs to be maintained to avoid the interference between the panels during the Body in White (BIW) layer build process.
[020] In an embodiment, the vehicle body 100 provides support for other structural and functional elements of the vehicle. Additional members such as the doors are attached to the vehicle body 100 through attachment means such as brackets or the hinge assemblies. When hinge assemblies are used to mount the doors on the vehicle body 100, sufficient strength and stiffness must be ensured for the mounting. The necessary space between the outer panel 102 and the inner panel 104 for the layer build process prevents the hinge assemblies from being attached to both the outer panel 102 and the inner panel 104 of the vehicle body 100. Ordinarily, the hinge assemblies are attached only to the outer panel 102 which limits the stiffness and strength of the mounting. To overcome the problem of reduced stiffness of the hinge assemblies being mounted only to the outer panel 102 of the vehicle body 100, the present invention provides a hinge assembly 110 (shown in Figure 2) being supportably attached to each of the outer panel 102 and the inner panel 104.
[021] Referring to figures 2 and 3, the hinge assembly 110 includes a first hinge member 112 and a second hinge member 114. The second hinge member 114 being pivotably attached to the first hinge member 112 through a pivot pin 113. The first hinge member 112 is configured to be attached to the door of the vehicle 100. The second hinge member 114 is configured to be attached to the vehicle body 100.
[022] In an embodiment, depending upon the vehicle design and/or vehicle body configuration in the Body in White (BIW) layer build process, the outer panel 102 and the inner panel 104 are spaced apart from each other at least at portions of the vehicle body 100 to maintain the necessary design clearance/space therebetween for the layer build process. Each of the outer panel 102 and the inner panel 104 includes one or more mounting holes 103, 106, respectively. The one or more mounting holes 103, 106 being aligned with each other.
[023] In an embodiment, the hinge assembly 110 includes a reinforcement member 120. The reinforcement member 120 includes a base plate 122 and one or more sleeves 124. The one or more sleeves 124 extend away from the base plate 122. The one or more sleeves 124 has a length (L) corresponding to the space between the outer panel 102 and the inner panel 104.
[024] In an embodiment of the invention, the one or more sleeves 124 are formed as circular sleeves with an internal recess. In another embodiment of the invention, the base plate 122 and the one or more sleeves 124 of the reinforcement member 120 are having a thickness ranging from 0.8 mm to 2 mm. In a non-limiting example, the reinforcement member 120 is made of steel.
[025] As shown in figure 4 and figures 5a-5d, in accordance with an embodiment of the present invention, the reinforcement member 120 has three sleeves 124 and is having a triangular base plate 122. The three sleeves 124 are extending outwardly away from one side of the triangular base plate 122 and are disposed adjacent to the three vertices of the triangular base plate 122.
[026] In another embodiment of the invention as shown in figures 6a-6d, a reinforcement member 220 is having only two sleeves 224 extending from one side of a base plate 222. The base plate 222 is having a rectangular shape with rounded sides. The two sleeves 224 are having a length (L) equal to the space between the outer panel 102 and the inner panel 104. The length (L) depends on the design and/or mounting requirements of the vehicle body 100 (shown in Figure 1).
[027] In another embodiment of the invention, as shown in figures 7a-7d, a reinforcement member 320 is having a sleeve 324 extending from one side of a base plate 322. The base plate 322 is having a square shape with rounded peripheral edges. The sleeve 324 is having a length (L) corresponding to the space between the outer panel 102 and the inner panel 104.
[028] As shown in figure 8, the one or more sleeves 124 are configured to pass through the one or more mounting holes 103 provided on the outer panel 102. The one or more sleeves 124 are aligned with the one or more mounting holes 106 of the inner panel 104.
[029] In an embodiment of the invention, the distal ends of the one or more sleeves 124 are configured to abut against the inner panel 104. The second hinge member 114 is mounted on the base plate 122 on a side opposite to the one or more sleeves 124. The second hinge member 114 is attached to the inner panel 104 through one or more fasteners 130 passing through the one or more sleeves 124.
[030] In an embodiment of the invention, the one or more fasteners 130 (shown in Figure 2) includes abutment portions 130a which abut against the inner panel 104 for reinforcing the inner panel 104 with the outer panel 102 and/or the second hinge member 114. In an embodiment of the invention, the one or more fasteners 130 include a nut and a bolt. The bolt is inserted into the one or more sleeves 124 and fastened with the nut either at the inner panel 104 side or the outer panel 102 side. In a non-limiting example, the bolt head forms the abutment portion 130a.
[031] In an embodiment of the invention, the mounting of the hinge assembly 110 at the upper portion of the rear pillar of the vehicle provides more geometric stability to the door of the vehicle. As shown in figure 8, the outer panel 102 of the upper portion of the rear pillar (C) is provided with three mounting holes 103. Further, corresponding mounting holes 106 are provided on the inner panel 104 (shown in Figure 2). The sleeves 124 of the reinforcement member 120 are inserted into the mounting holes 103 of the outer panel 102 and the sleeves 124 of the reinforcement member 120 are aligned with the mounting holes 106 on the inner panel 104. The second hinge member 114 is mounted on the base plate 122 of the reinforcement member 120. The fasteners 130 (shown in Figure 2) are inserted to pass through the second hinge member 114, the mounting holes 103 of the outer panel 102 and the reinforcement member 120. The fasteners 130 are abutted on both ends to fix the hinge assembly 110 to the vehicle body 100.
[032] In an embodiment of the invention, the load transfer happens from the liftgate to the hinge assembly 110 and further to the base plate 122 and sleeves 124. During operation, the load gets transferred from the sleeves 124 to the inner panel 104. The sleeves 124 increases the sectional stiffness between the outer panel 102 and the inner panel 104 and thereby increases the stiffness of the joinery of the hinge mounting. In a non-limiting example, the hinge assembly 110 of the present invention provides substantial increment in sectional stiffness for the liftgate mounting as compared to prior art systems (approximately six times) for attaching the hinge assembly 110 to the outer panel 102 without the reinforcement member 120.
[033] Advantageously, the present invention enables mounting of the door of the vehicle at regions of the vehicle body where clearances are to be maintained between the inner panel and the outer panel of the vehicle body. The hinge assembly of the present invention ensures that load from the door is transferred between the inner panel and the outer panel and that the overall stiffness of the hinge assembly for mounting the door on the vehicle body is increased.
[034] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
, Claims:We claim:
1. A hinge assembly (110) for mounting a door on a vehicle body (100), the hinge assembly (110) comprising:
a first hinge member (112) configured to be attached to the door;
a second hinge member (114) being pivotally attached to the first hinge member (112) and configured to be attached to the vehicle body (100);
the vehicle body (100) having an outer panel (102) and an inner panel (104) being spaced apart from the outer panel (102), each of the outer panel (102) and the inner panel (104) comprises one or more mounting holes (103, 106) aligned with each other; and
a reinforcement member (120) comprising a base plate (122) and one or more of sleeves (124) extending away from the base plate (122), the base plate (122) being mounted on the outer panel (102) and the one or more sleeves (124) configured to be passed through the one or more mounting holes (103) of the outer panel (102),the one or more sleeves (124) configured to be aligned with the one or more mounting holes (106) of the inner panel (104), the second hinge member (114) configured to be mounted on the base plate (122) of the reinforcement member (120) and attached to the inner panel (104) through one or more fasteners (130) passing through the one or more sleeves (124).

2. The hinge assembly (110) as claimed in claim 1, wherein the one or more sleeves (124) is of a length (L) corresponding to the space between the outer panel (102) and the inner panel (104).

3. The hinge assembly (110) as claimed in claim 1, wherein the one or more fasteners (130) comprises abutment portions (130a).

4. The hinge assembly (110) as claimed in claim 1, wherein each of the base plate (122) and the one or more sleeves (124) of the reinforcement member (120) is having a thickness ranging from 0.8 mm to 2 mm.

5. The hinge assembly (110) as claimed in claim 1, wherein the reinforcement member (120) is made of steel.

6. The hinge assembly (110) as claimed in claim 1, wherein the hinge assembly (110) is mounted on an upper portion of a rear pillar of the vehicle.

7. The hinge assembly (110) as claimed in claim 1, wherein the door is a liftgate of the vehicle and configured to be opened vertically.

Dated this 28th day of March 2024

MAHINDRA ELECTRIC AUTOMOBILE LIMITED
By their Agent & Attorney

(Janaksinh Jhala)
of Khaitan & Co
Reg No IN/PA-2193