Segmented Tonneau Cover Hinge Structure for Secure Folding
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Solution Overview
Problem
Existing tonneau cover systems for pickup trucks face challenges in providing a secure, flexible, and easy-to-use solution for covering cargo boxes, particularly in terms of attachment mechanisms and panel flexibility.
Innovation Solution
A tonneau cover apparatus featuring a support frame assembly attachable to the cargo box and a cover assembly with multiple rigid panels and a flexible hinge, allowing for folding and unfolding, and secure attachment to the support frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid panels are used for the cover assembly, then structural strength and stability are improved, but flexibility and ease of folding are worsened
Solution Approach 1:
The cover assembly is divided into multiple rigid panels that are connected by flexible hinges, allowing each panel to maintain its structural strength while the overall assembly gains flexibility through the segmented configuration
Solution Approach 2:
Flexible hinges serve as intermediary elements between rigid panels, mediating the connection to allow relative movement and folding while maintaining structural integrity of the individual panels
2Ease of operation
If flexible hinge is used to connect panels, then ease of operation and folding capability are improved, but attachment security and stability are worsened
Solution Approach 1:
The flexible hinge design merges rigid connection points with flexible intermediate sections, combining the security of rigid attachment with the flexibility needed for easy operation and folding
Solution Approach 2:
Different portions of the hinge assembly have different properties - the side portions provide rigid attachment security while the intermediate portions provide flexible movement capability, creating local quality variations within the single component
3Reliability
If complex attachment mechanisms are used, then attachment security is improved, but device complexity and ease of manufacture are worsened
Solution Approach 1:
The flexible hinge serves multiple functions simultaneously - it provides attachment security, enables folding operation, and simplifies the overall attachment mechanism, reducing device complexity while maintaining reliability
Solution Approach 2:
The hinge design allows the cover assembly to self-secure through the interlocking of side portions with panel features, eliminating the need for complex additional attachment mechanisms
Data Source
AI summary
A folding tonneau cover apparatus including a cover assembly and a support frame assembly. The cover assembly having a plurality of rigid panels interconnected in series by a series of flexible hinges. Elongated support members having hinge support flanges help to secure the flexible hinges to the rigid panels. In preferred embodiments, the support flanges of the elongated support members cooperate with the underside of the respective rigid panels to which the support members are secured, to form a partial enclosure within which a side portion of the respective flexible hinge is secured. The cover assembly is secured to the support frame assembly to cover a cargo box of a pickup truck by a plurality of locking members when the support frame assembly is secured to sidewalls of the cargo box. Methods of making a tonneau cover apparatus and methods of folding and unfolding the cover assembly are also disclosed.