Tonneau Cover Flexible Hinge Reduces Assembly Complexity

Solution Overview

Problem

Current panelized tonneau cover hinge systems are complex, time-consuming, and costly to assemble due to their multi-component nature, which includes seals, perimeter channels, and adhesives.

Innovation Solution

A tonneau cover system with a single piece spanning multiple panels, featuring a core panel with bonded upper and lower films and a flexible hinge that is foldable between deployed and folded arrangements, where the flexible hinge has a reduced thickness and includes a channel formed in the core panel with the films overlaying it, allowing for simplified assembly and reduced component count.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If multiple component hinge systems are used, then the tonneau cover can articulate between open and closed positions, but the assembly becomes complex, time-consuming, and costly

Engineering Contradiction:

Improvearticulation capabilityVSAvoidhinge system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines multiple separate hinge components (seals, perimeter channels, adhesives) into a single integrated flexible hinge piece made of elastomeric material. This single piece spans multiple panels and provides all necessary articulation functions through its inherent flexibility and integrated structure, eliminating the need for separate sealing components and adhesive applications.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible hinge is constructed as an elastomeric piece that functions as a flexible shell, allowing articulation between panels through its inherent elasticity and flexibility. This flexible structure replaces rigid multi-component hinge systems while maintaining the articulation capability between open and closed positions.

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of operation

If multiple component hinge systems are used, then the tonneau cover can articulate between open and closed positions, but the assembly time and cost increase

Engineering Contradiction:

Improvearticulation capabilityVSAvoidassembly efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent combines multiple separate hinge components (seals, perimeter channels, adhesives) into a single integrated flexible hinge piece made of elastomeric material. This single piece spans multiple panels and provides all necessary articulation functions through its inherent flexibility and integrated structure, eliminating the need for separate sealing components and adhesive applications.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible hinge is pre-formed as a complete integrated component with all articulation and sealing functions built-in during manufacturing. This preliminary formation of the complete hinge assembly eliminates the need for complex on-site assembly operations, significantly reducing assembly time and labor requirements.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If multiple component hinge systems are used, then the tonneau cover can articulate between open and closed positions, but the manufacturing cost increases

Engineering Contradiction:

Improvearticulation capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate hinge components (seals, perimeter channels, adhesives) into a single integrated flexible hinge piece made of elastomeric material. This single piece spans multiple panels and provides all necessary articulation functions through its inherent flexibility and integrated structure, eliminating the need for separate sealing components and adhesive applications.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible hinge is constructed as an elastomeric piece that functions as a flexible shell, allowing articulation between panels through its inherent elasticity and flexibility. This flexible structure replaces rigid multi-component hinge systems while maintaining the articulation capability between open and closed positions.

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS9895963B1Tonneau cover system with single piece spanning multiple panels

Publication Date: 2018.02.20 TRUXEDO

AI summary

A tonneau cover including a core panel having a first panel surface, a second panel surface, and a perimeter. An upper film is bonded to the first panel surface. A lower film is bonded to the second panel surface. The tonneau cover has a first section, a second section, and a flexible hinge separating the first and second sections. The tonneau cover is foldable between a deployed arrangement where the first section and the second section are generally planar for covering the cargo box, and a folded arrangement where the first section and the second section are stacked for allowing access to the cargo box. The tonneau cover has a first thickness at the first section and the second section, and a second thickness at the flexible hinge. The second thickness is less than the first thickness.