Tailgate Hinge Locking Wedge Resolves Rattle
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Solution Overview
Problem
Existing tailgate hinges for vehicles experience rattling when driving over rough roads due to clearance requirements that allow for tool-free removal, leading to manufacturing tolerances and pivot binding issues.
Innovation Solution
A hinge design featuring a tailgate leaf, a body leaf with chambers, a slider, and a locking mechanism that includes a locking wedge and cam lever, allowing for tool-free removal and assembly while minimizing clearance and reducing rattling through tapered surfaces and alignment springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If larger clearance is provided within the pivot to allow off-axis manipulation for tool-free removal, then ease of operation is improved, but audible rattling occurs when driving over rough surfaces
Solution Approach 1:
The hinge transitions from a static clearance-based design to a dynamic locking mechanism. The locking mechanism dynamically adjusts the clearance state - providing larger clearance when unlocked for easy removal, and minimizing clearance when locked to eliminate rattling. This dynamic adaptation resolves the contradiction between ease of operation and elimination of harmful rattling.
Solution Approach 2:
The invention changes the clearance parameter dynamically through the locking mechanism. When locked, the mechanism minimizes clearance between pivot components to eliminate rattling. When unlocked, it allows larger clearance for off-axis manipulation and tool-free removal. This parameter change approach enables the system to satisfy both contradictory requirements at different operational states.
2Reliability
If larger clearance is provided within the pivot to accommodate manufacturing tolerances and prevent pivot binding, then reliability is improved, but audible rattling occurs when driving over rough surfaces
Solution Approach 1:
The locking mechanism dynamically controls the clearance state based on operational requirements. When locked, it maintains minimal clearance to prevent pivot binding and eliminate rattling. When unlocked, it provides larger clearance for easy removal. This dynamic control resolves the contradiction between reliability and elimination of harmful rattling.
Solution Approach 2:
The invention extracts the clearance requirement from the continuous operational state and applies it only when needed for removal. The locking mechanism separates the clearance function from the normal operational state, providing clearance only during the unlocking/removal phase, while maintaining minimal clearance during normal operation to prevent binding and eliminate rattling.
3Object-affected harmful factors
If a locking mechanism is added to minimize clearance and reduce rattling, then object-generated harmful factors are reduced, but device complexity increases
Solution Approach 1:
The locking mechanism is designed to be self-operating through the cam lever system. The user simply operates the cam lever to lock or unlock the hinge, and the mechanism automatically adjusts the clearance and secures the tailgate. This self-service approach minimizes the need for additional control systems or complex actuation mechanisms, reducing overall device complexity while still achieving the goal of eliminating rattling.
Solution Approach 2:
The locking mechanism is segmented into functional components (cam lever, locking surfaces, pivot elements) that can be manufactured and assembled separately. This segmentation allows for simpler manufacturing and assembly of each component, reducing overall device complexity while achieving the goal of minimizing clearance to eliminate rattling.
4Reliability
If a locking mechanism with multiple components is used to enable secure locking and unlocking, then reliability is improved, but ease of manufacture worsens
Solution Approach 1:
The locking mechanism combines multiple functions into integrated components. The cam lever simultaneously controls the locking action, adjusts clearance, and secures the tailgate position. The locking surfaces are integrated with the existing pivot structure rather than being separate add-on components. This merging approach maintains reliable locking capability while simplifying manufacturing and assembly.
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 design enables secure locking and unlocking of the tailgate without tools, reducing rattling and assembly complexity, allowing for easy removal and installation by a single user without additional support, while maintaining structural integrity.
Implementation Method 1
an alignment spring, and the alignment spring may include a loop sheet disposed on the second surface and a tongue at a free end. The free end of the alignment spring may be bent toward the front surface of the slider and the tongue may extend at a direction opposing the free end.
Implementation Method 2
The locking mechanism may include a locking wedge received in the second chamber, a shaft connected to the locking wedge and a cam lever pivotally connected to the shaft. The slider is locked when the locking wedge is moved by the cam lever to a locked position at which the locking wedge applies a force to the body of the slider.
Data Source
AI summary
A hinge to removably mount a tailgate to a vehicle is provided. The hinge comprises a tailgate leaf connected to a tailgate and a body leaf connected to the box of the vehicle. The tailgate leaf is attached to the slider through a hinge pivot. The body leaf has a first chamber in which a slider can be locked and unlocked through a locking mechanism in the second chamber. The locking mechanism comprises a locking wedge, a threaded shaft, and a cam lever to operate the locking wedge without the requirement of a tool.