Integrated Hinge Assembly for Power Tailgate Systems

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Solution Overview

Problem

Existing power tailgate systems for vehicles face challenges in simplifying construction, improving reliability, and enhancing manufacturability, design soundness, and cost-effectiveness while maintaining efficient pivotal movement of tailgates between open and closed positions.

Innovation Solution

A hinge assembly and tailgate actuator system that includes a torque shaft, crank, and ball-and-socket connections, with a load arm and embossed rib design, which supports axial rotation and pivotal movement of the tailgate, and a motor-driven spindle drive for powered operation, reducing the need for additional components like struts and dampers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional power tailgate systems use multiple separate components (struts, dampers, hinge mechanisms), then the tailgate can achieve pivotal movement, but the construction complexity increases and reliability decreases

Engineering Contradiction:

Improvesystem reliabilityVSAvoidconstruction complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (struts, dampers, hinge mechanisms) into a single integrated hinge assembly. The hinge assembly includes a housing, torque shaft, crank mechanism, and damping elements all merged into one unified structure that performs both support and damping functions, thereby reducing construction complexity while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hinge assembly is designed as a multi-functional component that simultaneously provides mechanical support, damping, and pivotal movement control. The single hinge assembly performs functions that traditionally required separate struts and dampers, making the system more reliable by reducing the number of potential failure points

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If traditional power tailgate systems use multiple separate components, then the tailgate can achieve pivotal movement, but the manufacturing cost and production complexity increase

Engineering Contradiction:

ImprovemanufacturabilityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple manufacturable components into a single integrated hinge assembly that can be produced as one unit or pre-assembled module. This reduces the number of separate manufacturing processes and assembly steps required, improving ease of manufacture while reducing the total number of components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hinge assembly is designed with modular segmentation where the housing, torque shaft, crank mechanism, and damping elements are structured as distinct but integrated sub-components. This allows for efficient manufacturing of individual parts that can be precisely assembled, improving overall manufacturability

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If the hinge assembly uses a torque shaft with head-and-socket connection, then the tailgate achieves smooth pivotal movement, but the structural complexity increases

Engineering Contradiction:

Improvepivotal movement smoothnessVSAvoidstructural complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The hinge assembly uses spherical ball-and-socket connections at critical joints (torque shaft to housing, crank to housing). These spherical interfaces enable smooth multi-directional pivotal movement while maintaining simple geometric forms that are easy to manufacture and assemble

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Reliability

If the hinge assembly integrates damping and support functions, then the system becomes more reliable, but the design complexity increases

Engineering Contradiction:

Improvesystem reliabilityVSAvoiddesign complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hinge assembly merges damping elements and support structures into a single integrated design. The damping components are positioned within the housing to work in conjunction with the torque shaft and crank mechanism, providing both support and damping functions through a unified structural design rather than separate assemblies

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11535309B2Hinge assembly for a power tailgate system

Publication Date: 2022.12.27 AISIN TECHNICAL CENTER OF AMERICA INC

AI summary

A hinge assembly includes a tailgate bracket securable to a vehicular tailgate, a support bracket securable to a vehicular bed, a torque shaft, and a crank. The tailgate bracket includes a socket. The support bracket includes a support. The torque shaft is supported by the support for axial rotation. The torque shaft includes a tailgate-side head and a crank-side head. The tailgate-side head and the socket are configured to make a head-and-socket connection with one another. The crank-side head includes an external profile. The crank includes a shaft-side base and an actuator-side base, a load arm extending therebetween, and at least one of a dogleg along the shaft-side base, the load arm and the actuator-side base, and an embossed rib extending along the load arm. The shaft-side base includes an internal profile. The external profile and the internal profile are configured to make a shaft-and-hub connection with one another.