Nested Foam Hitch Inserts for Multi-Size Receiver Fit
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Solution Overview
Problem
Hitch covers often do not fit properly with different sized hitch receivers, requiring owners to purchase new covers that match the specific size, which can be undesirable due to aesthetic differences.
Innovation Solution
A hitch insert set, comprising foam inserts that nest within each other to adapt a hitch cover to fit variously sized receivers, ensuring a snug fit through their deformability and high coefficient of friction, allowing a single hitch cover to be used across different receiver sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hitch cover is designed for a specific receiver size, then it provides a proper fit for that size, but it cannot be used with other receiver sizes
Solution Approach 1:
The adapter system is segmented into multiple nested foam inserts of different sizes (1.25-inch, 2-inch, 2.5-inch, 3-inch receivers). Each insert can be independently selected and installed within the hitch cover tube to match the specific receiver size, allowing the same hitch cover to adapt to multiple receiver dimensions while maintaining a precise fit.
Solution Approach 2:
The foam inserts are designed to nest within each other, with smaller inserts fitting inside larger ones. This nesting arrangement allows multiple size adapters to be stored compactly within the hitch cover tube, enabling a single hitch cover to accommodate various receiver sizes by selecting and installing the appropriate insert size.
2Manufacturing precision
If multiple hitch covers are purchased for different receiver sizes, then each cover fits its designated size properly, but the device complexity and cost increase
Solution Approach 1:
The hitch cover is designed with universal adaptability through the inclusion of multiple foam inserts representing different receiver sizes (1.25-inch, 2-inch, 2.5-inch, 3-inch). By selecting and installing the appropriate insert size, a single hitch cover can function with multiple receiver sizes, eliminating the need to purchase and maintain multiple different hitch covers.
Solution Approach 2:
The internal diameter of the hitch cover tube is designed to accommodate variable insert sizes. By changing the parameter of the insert diameter rather than the entire hitch cover structure, the system allows a single cover to adapt to different receiver sizes, reducing the need for multiple covers.
3Adaptability or versatility
If foam inserts are used to fill gaps between receiver and tube portion, then adaptability to various sizes is achieved, but the insert material must have specific properties
Solution Approach 1:
The foam inserts are designed with specific material parameters including density (15-30 pounds per cubic foot), compressive strength (5-15 percent compression at 50 psi), and coefficient of friction (0.5-1.0). These parameter specifications ensure the foam provides adequate structural support, friction for retention, and deformability to fill gaps between the receiver and tube portion effectively.
Solution Approach 2:
The system uses foam material with specific composite properties combining adequate compressive strength, deformability, and high coefficient of friction. This composite material selection allows the inserts to simultaneously provide structural support, gap-filling capability, and retention through friction against the tube portion.
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
Enables a hitch cover to be easily adapted and securely fitted to hitch receivers of different sizes, facilitating the swapping of hitch covers between vehicles without the need for multiple decorative covers.
Implementation Method 1
the foam material having a high coefficient of friction to prevent the tube portion from rotating or slipping
Implementation Method 2
the foam inserts being deformable to ensure a snug fit
Data Source
AI summary
A hitch insert set, hitch system, and method of coupling a hitch cover to a hitch receiver are generally disclosed herein. The hitch system includes a hitch receiver designed to couple to a vehicle, with the hitch receiver defining a receiver opening. The hitch system further includes a hitch cover comprising a tube portion and a cover portion that substantially covers the receiver opening. At least one hitch insert from a hitch insert set couples to the hitch receiver and the tub portion, in use, with the at least one hitch insert filling a gap between the hitch receiver and the tube portion of the hitch cover. The tube portion coupled coupled within the receiver opening such that the tube portion is at least partially retained in place by the at least one hitch insert.