Multi-Hinge Tonneau Cover for Flush Sealing and Panel Clearance
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Solution Overview
Problem
Current tonneau covers lack efficient mechanisms to prevent fluid penetration through hinge joints, restrict movement without hindrance, and securely connect to vehicles, while maintaining a flush closure and preventing longitudinal movement.
Innovation Solution
A tonneau cover system featuring expansion links, covers that extend over hinges, standing hinges, connectors that move within tracks, and rotary locks to ensure fluid prevention, unhindered movement, and secure vehicle attachment, maintaining a flush closure and preventing longitudinal movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single cover extends over the hinge to prevent fluid penetration and hold the hinge together, then fluid sealing and hinge integrity are improved, but the cover must disconnect from the hinge or panel to facilitate hinge movement
Solution Approach 1:
The cover connection mechanism transitions from a static permanent attachment to a dynamic reversible connection. The cover is designed to connect to the hinge assembly during installation/movement phases and disconnect during normal operation, allowing the system to adapt its connection state based on operational requirements.
Solution Approach 2:
The cover system is divided into separate functional components: a sealing portion that prevents fluid penetration and a connection portion that facilitates hinge assembly/disassembly. This segmentation allows the cover to perform multiple functions while maintaining simplicity in each individual function.
2Length of moving object
If expansion caps extend the hinge to a location proximate to or over a rail cap and support rail, then the hinge reaches the required position, but additional components increase device complexity
Solution Approach 1:
The expansion cap integrates multiple functions into a single component: it extends the hinge assembly, provides structural support, and positions the hinge relative to the rail cap and support rail. This merging reduces the number of separate components needed while achieving the required hinge extension.
Solution Approach 2:
The expansion cap serves multiple purposes within the hinge assembly: it acts as an extension element, a support element, and a positioning element. This multi-functionality allows a single component to address several requirements simultaneously, reducing overall system complexity.
3Shape
If standing hinges lift panels from the rail cap and header panel to space them away, then panel clearance is improved, but the lifting mechanism increases hinge complexity
Solution Approach 1:
The standing hinge utilizes an arcuate or curved path to lift the panel from its initial position to the spaced position. This curved mechanism provides smooth motion transition and maintains structural efficiency while achieving the required panel clearance, avoiding complex linear actuation systems.
4Adaptability or versatility
If connectors are movably locked within a track to allow transverse movement while preventing longitudinal movement, then connector versatility is improved, but the locking mechanism increases complexity
Solution Approach 1:
The connector employs a dynamic locking mechanism that transitions between locked and unlocked states based on movement direction. The connector allows free movement in the transverse direction while automatically engaging the locking mechanism to prevent longitudinal movement, adapting its constraint level based on operational requirements.
5Reliability
If rotary locks prevent hinges from being vertically moved when the tonneau cover is closed, then security and stability are improved, but the locking mechanism increases complexity
Solution Approach 1:
The rotary lock mechanism replaces complex multi-component locking systems with a simpler rotational engagement system. A single rotary element engages with corresponding features on the hinge assembly to prevent vertical movement, providing secure locking with minimal components.
Data Source
AI summary
A tonneau cover that includes a first panel and a second panel; a hinge located between the first panel and the second panel, the hinge includes a first link and a second link, the first link includes a pocket; the second link includes a projection that is configured to engage the pocket of the first link to connect the first link and the second link; and one or more covers extending over all or a portion of the first panel, the second panel, the first link, and the second link; the second link has a structure that is substantially similar to a structure of the first link and/or the one or more covers provide an indirect connection between the first panel and the first link.