Insert molded torsion bar hinge

A method of forming an insert molded torsion bar hinge comprising:

• placing a cylindrical metal torsion bar into a mold cavity, the torsion bar comprising a main bar body, portion of which extends along a torsion bar axis, a first contoured bar end and a second contoured bar end on opposite ends of the main bar body, and the mold cavity comprising first and second mold cavity parts;
• wherein the first contoured bar end is contained exclusively within the first mold cavity part, the second contoured bar end is contained exclusively within the second mold cavity part, and wherein portions of the main bar body are contained within both the first and second mold cavity parts;
• injection molding a flowable plastic into the first mold cavity part and directly over and fully encompassing the first contoured bar end and directly over and fully encompassing at least a portion of the main bar body;
• allowing the flowable plastic in the first mold cavity part to freeze, thereby forming a first hinged element of molded plastic containing the first contoured bar end and comprising a first knuckle containing at least a portion of the main bar body;
• injection molding a flowable plastic into the second mold cavity part and directly over and fully encompassing the second contoured bar end and directly over and fully encompassing at least a portion of the main bar body;
• and
• allowing the flowable plastic in the second mold cavity part to freeze, thereby forming a second hinged element of molded plastic containing the second contoured bar end and comprising a second knuckle containing at least a portion of the main bar body;
• wherein the first and second hinged elements are configured to rotate relative to each other along the torsion bar axis.

A fold down system comprising:

• a base;
• a folding member hinged to the base such that it is foldable relative to the base;
• and
• an insert molded torsion bar hinge comprising a fixed hinge side and a spring loaded side, the fixed hinge side fixed to the base and the spring loaded side rotatable with the folding member;
• wherein the insert molded torsion bar hinge comprises:
• a cylindrical metal torsion bar comprising a main bar body, a portion of which extends along a torsion bar axis, a first contoured bar end and a second contoured bar end on opposite ends of the main bar body;
• wherein the fixed hinge side comprises a molded plastic and comprising a first knuckle, the fixed hinge side molded directly over and encompassing the first contoured bar end such that the first contoured bar end is fixed within and not rotatable relative to the fixed hinge side, and the first knuckle molded directly over and encompassing a portion of the main bar body;
• and
• wherein the spring loaded side comprises a molded plastic and comprising a second knuckle, the spring loaded side molded directly over and encompassing the second contoured bar end such that the second contoured bar end is fixed within and not rotatable relative to the spring loaded side, and the second knuckle molded directly over and encompassing a portion of the main bar body;
• wherein the fixed hinge side and the spring loaded side are configured to rotate relative to each other along the torsion bar axis, the torsion bar producing a torsional spring torque with the relative rotation of the fixed hinge side and the spring loaded side.

An insert molded torsion bar hinge comprising:

• a first hinged element;
• a second hinged element;
• a cylindrical metal torsion bar comprising a main bar body, a portion of which extends along a torsion bar axis, a first contoured bar end and a second contoured bar end on opposite ends of the main bar body;
• wherein the first hinged element comprises a molded plastic and a first knuckle, the first hinged element molded directly over and encompassing the first contoured bar end such that the first contoured bar end is fixed within and not rotatable relative to the first hinged element, and the first knuckle molded directly over and encompassing a portion of the main bar body;
• and
• wherein the second hinged element comprises a molded plastic and a second knuckle, the second hinged element molded directly over and encompassing the second contoured bar end such that the second contoured bar end is fixed within and not rotatable relative to the second hinged element, and the second knuckle molded directly over and encompassing a portion of the main bar body;
• wherein the first hinged element and the second hinged element are aligned coaxially on the torsion bar axis and are configured to rotate relative to each other along the torsion bar axis, the torsion bar producing a torsional spring torque with the relative rotation.