# US 9,038,241 B2 · Hinge in composite material and process for its manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,038,241 B2 - Document ID: US9038241B2 - Status: Granted - Kind: B2 - Application number: 14/386,202 - Filed: 2013-04-10 - Published: 2015-02-19 - Granted: 2015-05-26 - Earliest claimed: 2012-04-13 - Assignees: Automobili Lamborghini S.P.A. - Applicants: Automobili Lamborghini S.P.A - Inventors: Attilio Masini - Web page: https://patentgrep.com/patent/US9038241B2 ## CPC - E05D 1/02: made of one piece - B29C 65/70: by moulding (using a particular moulding technique, see the relevant technique {, e.g. by injection B29C45/14467}) - B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination} - B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding} - B29K 2061/04: Phenoplasts - B29K 2105/089: {fabric} - B29L 2031/22: Hinges {, pivots} - E05Y 2800/68: Combinations of materials creating distinct article parts - E05D: HINGES OR SUSPENSION DEVICES FOR DOORS, WINDOWS OR WINGS (pivotal connections in general F16C11/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - E05Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES E05D AND E05F, RELATING TO CONSTRUCTION ELEMENTS, ELECTRIC CONTROL, POWER SUPPLY, POWER SIGNAL OR TRANSMISSION, USER INTERFACES, MOUNTING OR COUPLING, DETAILS, ACCESSORIES, AUXILIARY OPERATIONS NOT OTHERWISE PROVIDED FOR, APPLICATION THEREOF ## Abstract Disclosed is a hinge having a rigid portion integral with a flexible portion suitable to be bent with respect to the rigid portion, wherein the rigid portion has a substrate in a rigid composite material and the flexible portion has a first flexible sheet, wherein a first portion of the first flexible sheet is joined at least partially to the substrate by means of at least one first layer of resin for composite materials, wherein the flexible portion also has a second flexible sheet joined at least partially by means of at least one second layer of resin for composite materials both to the first portion of the first flexible sheet and to at least one second portion of the first flexible sheet which is not joined to the substrate. ## Claims ### Claim 1 Hinge comprising a rigid portion integral with a flexible portion suitable to be bent with respect to the rigid portion, wherein said rigid portion comprises a substrate in a rigid composite material and said flexible portion comprises a first flexible sheet, wherein a first portion of the first flexible sheet is joined at least partially to the substrate by means of at least one first layer of resin for composite materials, wherein said flexible portion also comprises a second flexible sheet joined at least partially by means of at least one second layer of resin for composite materials both to said first portion of the first flexible sheet and to at least one second portion of the first flexible sheet which is not joined to the substrate. ### Claim 2 (depends on 1) Hinge according to claim 1, wherein a portion of the second flexible sheet is joined to a portion of the substrate by means of at least one layer of resin for composite materials. ### Claim 3 (depends on 1) Hinge according to claim 1, wherein said at least one second portion of the first flexible sheet protrudes beyond an edge of the substrate. ### Claim 4 (depends on 3) Hinge according to claim 3, wherein a portion of the second flexible sheet is joined by means of at least one layer of resin for composite materials to said at least one second portion of the first flexible sheet. ### Claim 5 (depends on 3) Hinge according to claim 3, wherein the first flexible sheet is joined at least partially to a bevel made on said edge of the substrate. ### Claim 6 (depends on 5) Hinge according to claim 5, wherein the bevel forms an angle between 1° and 45° with the surface of the edge of the substrate opposite to the bevel, the width of the bevel is between 5 and 60 mm, and/or the height of the bevel is between 50% and 100% of the thickness of the substrate. ### Claim 7 (depends on 5) Hinge according to claim 5, wherein the end of the edge provided with the bevel comprises a non-beveled portion that has a height comprised between 0.3 and 0.7 mm, in particular 0.5 mm. ### Claim 8 (depends on 3) Hinge according to claim 3, further comprising a slit of the first flexible sheet and a portion adjacent the end of said edge of the substrate. ### Claim 9 (depends on 1) Hinge according to claim 1, wherein one or more further flexible sheets are arranged one on the other on the first flexible sheet, on the second flexible sheet and/or on the substrate, at least one layer of resin for composite materials being applied between two adjacent flexible sheets. ### Claim 10 (depends on 1) Hinge according to claim 1, wherein one or more of said flexible sheets are provided with one or more holes leading to the substrate. ### Claim 11 (depends on 1) Hinge according to claim 1, wherein said rigid portion comprises one or more layers of fibers which are joined in a single piece by means of cured resin to the substrate, to the first flexible sheet, to the second flexible sheet and/or to further flexible sheets, if any, arranged on the first flexible sheet and/or on the second flexible sheet, wherein the first flexible sheet and the second flexible sheet are comprised between the substrate and the layers of fibers. ### Claim 12 (depends on 11) Hinge according to claim 11, wherein one or more of said layers of fibers cover holes made in the first flexible sheet and/or in the second flexible sheet. ### Claim 13 (depends on 11) Hinge according to claim 11, wherein a sealing tape is applied on an edge of the upper layer of fibers and on the upper flexible sheet. ### Claim 14 (depends on 1) Hinge according to claim 1, wherein the flexural rigidity in a section of the flexible portion is inversely proportional to its distance from the rigid portion. ### Claim 15 (depends on 1) Hinge according to claim 1, wherein one or more of said layers of resin comprise a thermosetting resin. ### Claim 16 (depends on 1) Hinge according to claim 1, wherein one or more of said flexible sheets comprise a fabric of carbon fiber. ### Claim 17 (depends on 16) Hinge according to claim 16, wherein said carbon fiber fabric is laminated with a polyurethane or acrylic film and/or is impregnated with a silicone or acrylic emulsion. ### Claim 18 Process for manufacturing a hinge, comprising the following steps: arranging a substrate of composite material on at least one functional surface of a mold; arranging a first flexible sheet on the substrate, wherein at least one first layer of resin for composite materials is arranged between a first portion of the first flexible sheet and the substrate; arranging a second flexible sheet both on said first portion of the first flexible sheet and on a second portion of the first flexible sheet, wherein at least one second layer of resin for composite materials is arranged between the second flexible sheet and said portions of the first flexible sheet and curing said layers of resin in order to obtain a rigid portion integral with a flexible portion suitable to be bent with respect to the rigid portion, wherein said rigid portion comprises the substrate and said flexible portion comprises the first flexible sheet and the second flexible sheet. ### Claim 19 (depends on 18) Process according to claim 18, wherein the first flexible sheet protrudes on the mold from an edge of the substrate. ### Claim 20 (depends on 18) Process according to claim 18, wherein at least one edge of the substrate is arranged beside a rib protruding from the functional surface of the mold. ### Claim 21 (depends on 20) Process according to claim 20, wherein the first flexible sheet protrudes from the edge of the substrate, overcomes the rib and continues on the functional surface of the mold. ### Claim 22 (depends on 20) Process according to claim 20, wherein the height of the rib is greater than the thickness of the substrate. ### Claim 23 (depends on 18) Process according to claim 18, wherein the first layer of resin and/or the second layer of resin are applied onto the first flexible sheet and/or the second flexible sheet, respectively, when the latter are already arranged on the substrate and/or onto the first flexible sheet arranged on the mold, respectively. ### Claim 24 (depends on 18) Process according to claim 18, wherein the first flexible sheet and/or the second flexible sheet are provided with one or more holes before they are arranged onto the substrate and/or onto the first flexible sheet arranged on the mold, respectively.