innovations CASTING
Diecast Hinge Reduces Assembly, Parts and Cost
design of the common hinge includes interlocking collars through which a straight pin is fed. T e emerging, patented method for producing hinges instead creates multi-joint couplings with one casting operation. T e pivot bearing insert (PBI) al-
A
lows movable linkages, such as hinges or joints, to be produced in a single di- ecasting step. Nearly any molten metal can be injected into the die around the PBI, which is composed of two pre- fabricated cap-like parts inserted into one another. No pin is required. T e inserts are placed into one
new method for pro- ducing hinges and other joints can signifi cantly reduce weight and fab- rication costs. T e basic
half of the die mold along the axis of rotation. When the molten metal fi lls the mold, it fuses to the pivot bear- ing insert caps, creating freely moving fl anges. T e caps act as permanently lubricated pivots. T e fi nished hinges and joints are aligned with all moveable parts, need no lubrication and require minimal mainte- nance. No heat treating is required. T e pivot bearing insert has been
in the prototype stage for fi ve years while the inventor, Joachim Janz, has worked with his partner’s tool and die shop to develop and test the method for producing multi-joint rotor cou- plings in a single metal (or nonmetal) casting operation. Approximately 6,000 hinges in various sizes and confi gurations have been produced,
including a rear deck lid hinge for several Volkswagen models. In this application, the pivot bearing insert could replace an estimated 10 mil- lion pieces per year for a $30 million savings. Each hinge or rotor coupling produced has undergone testing by the automotive industry. An aluminum version of the pivot
bearing insert was recognized in the annual casting competition held by the North American Die Casting Asso- ciation, Wheeling, Ill., for best entry in the aluminum under 1 lb. category. Testing has shown that an aluminum hinge produced with a pivot bearing insert does not show signs of wear after 30,000 movements under a load.
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The pivot bearing insert eliminates the need for a straight pin in hinges, allowing the moving joint to be produced in a single casting step. Nov/Dec 2011 | METAL CASTING DESIGN & PURCHASING | 49
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