Dual Torque Rod Tailgate Hinge Assembly
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Solution Overview
Problem
Existing hinge mechanisms for vehicle tailgates, particularly those using a single torque rod, are time-consuming and costly to install, can block access to the bottom edge, and are difficult to manufacture due to high strength requirements, especially when compared to the dual torque rod design which offers easier installation and reduced weight while maintaining support.
Innovation Solution
A hinge assembly featuring a dual torque rod design where one torque rod is fixed to a connector body and the other to a hinge bracket, with their free ends anchored together within the closure member, allowing for torsional deflection to assist in opening and closing the tailgate, reducing assembly complexity and weight while providing necessary torque support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single torque rod is used in the tailgate hinge mechanism, then the structural simplicity is maintained, but the installation time and complexity increase, and access to the bottom edge is blocked
Solution Approach 1:
The single torque rod is divided into two separate torque rods. This segmentation allows each rod to be installed independently through separate access points, eliminating the need to block the bottom edge for installation and reducing overall installation time while maintaining structural functionality
2Strength
If a single torque rod extends through the entire tailgate, then the torque support is provided, but access to the bottom edge for wiring is blocked
Solution Approach 1:
Dividing the single through-extending torque rod into two separate rods allows wiring access at the bottom edge while maintaining torque support functionality. Each rod can be positioned to provide necessary structural support without obstructing access paths for wiring and other operations
3Device complexity
If a bent U-shaped torque rod is used, then the single rod structure is maintained, but manufacturing difficulty increases due to high strength requirements
Solution Approach 1:
Splitting the bent U-shaped rod into two straight or simpler-shaped rods significantly reduces manufacturing complexity. Each segment can be produced using standard straight rod manufacturing processes without requiring complex bending operations, while the dual-rod configuration maintains the necessary mechanical strength and torque characteristics
4Device complexity
If a single torque rod design is used, then the component count is reduced, but the overall weight of the tailgate assembly increases
Solution Approach 1:
The dual torque rod design with strategic positioning and connector optimization distributes the load more efficiently, allowing for lighter individual rod sections. The overall weight is reduced compared to a single heavy-duty torque rod while maintaining sufficient structural support through the distributed configuration
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dual torque rod design facilitates quicker and easier installation, reduces the weight of the tailgate, and provides effective torque assistance for opening and closing, while allowing for easier access to wiring and reducing manufacturing complexity compared to single torque rod designs.
Implementation Method 1
The torque rods are configured to deflect when the closure member is pivoted between the at least open and closed positions to produce a biasing torque towards an opposite position
Data Source
AI summary
This disclosure relates to a hinge assembly for mounting a closure member or tailgate to a vehicle. It includes a hinge bracket and connector body for connection to one side of the tailgate. The connector body provides a fixed connection to the vehicle and enables the hinge bracket to rotate about a pivot axis, so that the tailgate rotates. Also included are a first torque rod having one end fixed to the connector body and an opposite, free end, and a second torque rod spaced from the first torque rod and pivot axis. The second torque rod has one end fixed to the hinge bracket and an opposite, free end. A connector device anchors the free ends of the torque rods together within the tailgate, so that the rods deflect when the tailgate is pivoted between its opened and closed positions to produce a biasing torque towards an opposite position.