Abstract:
A counterbalanced decklid hinge assembly for rotatably supporting a decklid relative to a vehicle includes a torque rod extending between a first hinge box and a second hinge box. A support member is rotatably supported by each of the first and second hinge boxes. A linkage system interconnects one axial end of the torque rod to one of the support members. A lever is attached to and rotatable with the other axial end of the torque rod. A clamping block attaches the torque rod to one of the lever and the linkage system, and is configured to provide an infinite degree of rotational adjustment therebetween to infinitely adjust the pre-loaded torque rod.

Description:
TECHNICAL FIELD 
     The invention generally relates to a hinge assembly for rotatably supporting a decklid of a vehicle, and more specifically to a counterbalanced hinge assembly having a twisted torque rod extending between a pair of hinge boxes for applying an opening force to the decklid. 
     BACKGROUND 
     Counterbalanced decklid hinge assemblies typically include at least one torque rod that extends between a pair of hinge boxes. A support member is rotatably attached to and supported by each of the hinge boxes. One end of the torque rod is bent to define a wind-up end that engages one of the hinge boxes, and the other end of the torque rod is bent to define a looped end that engages one of the support members. The torque rod is twisted during assembly and secured in a position relative to the hinge box to pre-load the torque rod. The pre-loaded torque rod acts as a spring to untwist, thereby applying a torque to the support member to assist in opening the decklid. 
     The amount of torque that the torque rod is capable of storing is dependent upon the length of the torque rod, with the bent ends of the torque rod reducing the overall effective length of the torque rod. Furthermore, the bent ends of the torque rod induce bending stresses into the torque rod, which decreases the durability of the torque rod. Additionally, such a configuration of the torque rod only allows for a single torque wind up position, thereby limiting the amount of torque that may be pre-loaded into the torque rod. A limited amount of variability may be built into the system by adding different attachment positions to the hinge box to which the wind-up end of the torque rod is attached. However, due to packaging constraints, these variable wind up positions are only able to provide a range of between 3° and 4° of torque rod rotation. 
     SUMMARY 
     A decklid hinge assembly for a vehicle is provided. The decklid hinge assembly includes a first hinge box and a second hinge box. The second hinge box is spaced from the first hinge box, with each of the first hinge box and the second hinge box being configured for attachment to the vehicle. A first support member is rotatably attached to the first hinge box, and a second support member is rotatably attached to the second hinge box. The first support member and the second support member are configured for simultaneous rotation about a rotation axis between a closed position and an open position. The decklid hinge assembly further includes a torque mechanism. The torque mechanism includes a torque rod extending between and rotatably supported by the first hinge box and the second hinge box. The torque rod includes a first axial end and a second axial end. The second axial end is pre-loaded with a twisting moment relative to the first axial end to generate a twisting torque. A lever is attached to and rotatable with the first axial end of the torque rod, and is secured in a position relative to the first hinge box. A linkage system interconnects the second axial end of the torque rod and the second support member. The linkage system is configured for transferring the torque from the torque rod to the second support member to assist the simultaneous movement of the first support member and second support member from the closed position into the open position. A clamping block is fixedly attached to one of the lever and the linkage system. The clamping block is configured to positionally secure the torque rod to the one of the lever and the linkage system at any relative rotational position therebetween. 
     A vehicle is also provided. The vehicle includes a body that extends along a longitudinal axis. The body defines an opening. A decklid is coupled to the body and is configured for sealing the opening. A decklid hinge assembly rotatably attaches the decklid to the body for rotation about a rotation axis between a closed position and an open position. The decklid hinge assembly includes a first hinge box and a second hinge box. The second hinge box is laterally spaced from the first hinge box across the longitudinal axis of the body. Each of the first hinge box and the second hinge box are attached to the body. A first support member is rotatably attached to the first hinge box. A second support member is rotatably attached to the second hinge box. The first support member and the second support member are configured for simultaneous rotation about the rotation axis between the closed position and the open position. The decklid hinge assembly includes a torque mechanism that is configured for applying a torque to the first support member and the second support member. The torque assists the simultaneous movement of the first support member and the second support member from the closed position into the open position. 
     The torque mechanism includes a first torque rod and a second torque rod. The first torque rod extends between and is rotatably supported by the first hinge box and the second hinge box. The first torque rod includes a first axial end that is disposed adjacent the first hinge box, and a second axial end that is disposed adjacent the second hinge box. The first axial end and the second axial end of the first torque rod are twisted relative to each other to generate a torque. A first lever is attached to and is rotatable with the first axial end of the first torque rod, and is secured in a position relative to the first hinge box. A first linkage system interconnects the second axial end of the first torque rod and the second support member. The first linkage system is configured for transferring the torque from the first torque rod to the second support member. A first clamping block is fixedly attached to one of the first lever and the first linkage system. The first clamping block is configured for positionally securing the first torque rod to the one of the first lever and the first linkage system at any relative rotational position therebetween. The second torque rod extends between and is rotatably supported by the first hinge box and the second hinge box. The second torque rod includes a first axial end disposed adjacent the second hinge box, and a second axial end disposed adjacent the first hinge box. The first axial end and the second axial end of the second torque rod are twisted relative to each other to generate a torque. A second lever is attached to and is rotatable with the first axial end of the second torque rod, and is secured in a position relative to the second hinge box. A second linkage system interconnects the second axial end of the second torque rod and the first support member. The second linkage system is configured for transferring the torque from the second torque rod to the first support member. A second clamping block is fixedly attached to one of the second lever and the second linkage system. The second clamping block is configured for positionally securing the second torque rod to the one of the second lever and the second linkage system at any relative rotational position therebetween. 
     Accordingly, no bends in the torque rods are required to connect the torque rods to either the hinge boxes or the support members. More specifically, the levers connect one axial end of each of the torque rods to one of the hinge boxes, and the linkage systems connect the other axial end of each of the torque rods to one of the support members. The lever and the linkage systems are attached to the torque rods in a manner that eliminates any bends in the torque rod, thereby reducing and/or eliminating any bending stresses in the torque rods. Additionally, because no bends are required to secure the axial ends of the torque rods to the hinge boxes and/or the support members, the overall length of the torque rods may be maximized to fit within the cross vehicle packaging restraints of the vehicle. Furthermore, the first torque rod and/or the second torque rod may be positioned in any desirable rotational position relative to the first clamping block and the second clamping block respectively and secured in place, thereby providing an infinite degree of rotational adjustment to pre-load the first torque rod and/or the second torque rod respectively. 
     The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic cross sectional view from a side of the vehicle showing the hinge assembly. 
         FIG. 2  is a schematic perspective view from a first angle of a hinge assembly for rotatably supporting a decklid of a vehicle. 
         FIG. 3  is a schematic perspective view from a second angle of the hinge assembly. 
         FIG. 4  is a schematic perspective view of a lever of the hinge assembly. 
         FIG. 5  is a schematic exploded fragmentary perspective view of a clamping block configured for attaching a torque rod to linkage system. 
         FIG. 6  is a schematic partial perspective view of the clamping block attaching the torque rod to the linkage system. 
         FIG. 7  is a schematic cross sectional view of the clamping block. 
     
    
    
     DETAILED DESCRIPTION 
     Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the invention, as defined by the appended claims. 
     Referring to the Figures, wherein like numerals indicate like parts throughout the several views, a decklid hinge assembly, hereinafter referred to as the hinge assembly, is generally shown at  20 . Referring to  FIG. 1 , the hinge assembly  20  is for a vehicle  22 , and rotatably couples a decklid  24  to a body  26  of the vehicle  22 . The decklid  24  seals an opening  28  defined by the body  26 , such as for example, a trunk or cargo area of the vehicle  22 . 
     The body  26  extends along a longitudinal axis  30  between a forward end of the body  26  and a rearward end of the body  26 . The hinge assembly  20  rotatably attaches the decklid  24  to the body  26  for rotation about a rotation axis  32 . As shown, the rotation axis  32  is perpendicular relative to the longitudinal axis  30  of the vehicle  22 . However, the relative positions between the rotation axis  32  and the longitudinal axis  30  of the vehicle  22  may differ from that shown and described herein. The decklid  24  is rotatable between a closed position for sealing the opening  28 , and an open position for allowing access to the opening  28 . 
     Referring to  FIGS. 2 and 3 , the hinge assembly  20  includes a first hinge box  34  and a second hinge box  36 . The second hinge box  36  is laterally spaced from the first hinge box  34  across the longitudinal axis  30  of the body  26 . Accordingly, the first hinge box  34  and the second hinge box  36  are disposed on opposing lateral sides of the longitudinal axis  30 . Each of the first hinge box  34  and the second hinge box  36  are attached to the body  26 . The first hinge box  34  and the second hinge box  36  may be attached to the body  26  in any suitable fashion, such as for example, with fasteners such as bolts and/or screws. 
     A first support member  38  is rotatably attached to the first hinge box  34 . A second support member  40  is rotatably attached to the second hinge box  36 . The first support member  38  and the second support member  40  are attached to and support the decklid  24  relative to the body  26 . The first support member  38  and the second support member  40  are configured for simultaneous rotation about the rotation axis  32  between the closed position and the open position to rotate the decklid  24  between the closed position and the open position. The first support member  38  and the second support member  40  may be shaped in any suitable manner, such as but not limited to the gooseneck configuration shown in the Figures. 
     A torque mechanism  42  interconnects the first hinge box  34  and the second hinge box  36  with the first support member  38  and the second support member  40 . The torque mechanism  42  is pre-loaded to assist in opening the decklid  24 . The torque mechanism  42  is configured for applying a torque to at least one of the first support member  38  and the second support member  40  to assist the simultaneous movement of the first support member  38  and the second support member  40  from the closed position into the open position. 
     The torque mechanism  42  includes a first torque rod  44  and a second torque rod  46 . The first torque rod  44  extends between and is rotatably supported by the first hinge box  34  and the second hinge box  36 . The first torque rod  44  includes a first axial end  48  that is disposed adjacent the first hinge box  34 , and a second axial end  50  that is disposed adjacent the second hinge box  36 . The first torque rod  44  extends along a first rod axis  52 . The first rod axis  52  is disposed along the longitudinal center of the first torque rod  44 . The first axial end  48  and the second axial end  50  of the first torque rod  44  are linearly disposed and extend along the first rod axis  52 , with each of the first axial end  48  and the second axial end  50  of the first torque rod  44  extending linearly outboard away from the longitudinal axis  30  beyond a respective one of the first hinge box  34  and the second hinge box  36 . As used herein, the term outboard is defined as disposed farther from. Accordingly, the first axial end  48  and the second axial end  50  are disposed farther from the longitudinal axis  30  than the first hinge box  34  and/or the second hinge box  36 . As shown and described herein, the first axial end  48  of the first torque rod  44  is disposed adjacent and outboard of the first hinge box  34  and the second axial end  50  of the first torque rod  44  is disposed adjacent and outboard of the second hinge box  36 . 
     A first lever  54  is attached to and rotatable with one of the first axial end  48  and the second axial end  50  of the first torque rod  44 . The first lever  54  is secured in a position relative to one of the first hinge box  34  and the second hinge box  36 . As shown, the first lever  54  is attached to and rotatable with the first axial end  48  of the first torque rod  44 , and secured in a position relative to the first hinge box  34 . The first lever  54  is rotationally fixed relative to the first axial end  48  of the first torque rod  44  such that rotation of the first lever  54  rotates the first torque rod  44 . 
     A first linkage system  56  interconnects another of the first axial end  48  and the second axial end  50  of the first torque rod  44 , and one of the first support member  38  and the second support member  40 . As shown, the first linkage system  56  interconnects the second axial end  50  of the first torque rod  44  with the second support member  40 . The first linkage system  56  transfers a torque from the first torque rod  44  to the one of the first support member  38  and the second support member  40 . The torque applied to the first support member  38  and/or the second support member  40  assists the simultaneous movement of the first support member  38  and/or the second support member  40  from the closed position into the open position. As shown, the first linkage system  56  transfers the torque from the first torque rod  44  to the second support member  40 . 
     The first axial end  48  and the second axial end  50  of the first torque rod  44  are twisted relative to each other to generate the torque that is stored within the first torque rod  44 . During assembly, the first lever  54  is rotated into position and secured in that position relative to the first hinge box  34 . This rotation, about the first rod axis  52 , twists the first torque rod  44  between the first axial end  48 , secured to the first lever  54 , and the second axial end  50 , secured to the first linkage system  56 , thereby generating the torque used to assist in opening the decklid  24 . The first hinge box  34  includes a retention feature  58  that is configured for securing the first lever  54  in position relative to the first hinge box  34 . The retention feature  58  prevents the rotation of the first lever  54  in a direction that would allow the first torque rod  44  to untwist, and also resists lateral movement away from the longitudinal axis  30  to prevent unintentional disengagement of the first lever  54  from the retention feature  58 . 
     The second torque rod  46  extends between and is rotatably supported by the first hinge box  34  and the second hinge box  36 . The second torque rod  46  includes a first axial end  60  that is disposed adjacent the second hinge box  36 , and a second axial end  62  that is disposed adjacent the first hinge box  34 . As such, the relative positions of the first axial end  60  and the second axial end  62  of the second torque rod  46  are reversed from those of the first torque rod  44 . The second torque rod  46  extends along a second rod axis  64 . The second rod axis  64  is disposed along the longitudinal center of the second torque rod  46 . The first axial end  60  and the second axial end  62  of the second torque rod  46  are linearly disposed and extend along the second rod axis  64 , with each of the first axial end  60  and the second axial end  62  of the second torque rod  46  extending linearly outboard away from the longitudinal axis  30  beyond a respective one of the first hinge box  34  and the second hinge box  36 . Accordingly, the first axial end  60  and the second axial end  62  of the second torque rod  46  are disposed farther from the longitudinal axis  30  than the first hinge box  34  and/or the second hinge box  36 . As shown and described herein, the first axial end  60  of the second torque rod  46  is disposed adjacent and outboard of the second hinge box  36  and the second axial end  62  of the second torque rod  46  is disposed adjacent and outboard of the first hinge box  34 . 
     A second lever  66  is attached to and rotatable with one of the first axial end  60  and the second axial end  62  of the second torque rod  46 . The second lever  66  is secured in a position relative to one of the first hinge box  34  and the second hinge box  36 . As shown, the second lever  66  is attached to and rotatable with the first axial end  60  of the second torque rod  46 , and secured in a position relative to the second hinge box  36 . The second lever  66  is rotationally fixed relative to the first axial end  60  of the second torque rod  46  such that rotation of the second lever  66  rotates the second torque rod  46 . 
     A second linkage system  68  interconnects another of the first axial end  60  and the second axial end  62  of the second torque rod  46 , and one of the first support member  38  and the second support member  40 . As shown, the second linkage system  68  interconnects the second axial end  62  of the second torque rod  46  with the first support member  38 . The second linkage system  68  transfers a torque from the second torque rod  46  to the one of the first support member  38  and the second support member  40 . The torque applied to the first support member  38  and/or the second support member  40  assists the simultaneous movement of the first support member  38  and/or the second support member  40  from the closed position into the open position. As shown, the second linkage system  68  transfers the torque from the second torque rod  46  to the first support member  38 . 
     The first axial end  60  and the second axial end  62  of the second torque rod  46  are twisted relative to each other to generate the torque that is stored within the second torque rod  46 . During assembly, the second lever  66  is rotated into position and secured in that position relative to the second hinge box  36 . This rotation, about the second rod axis  64 , twists the second torque rod  46  between the first axial end  60 , secured to the second lever  66 , and the second axial end  62 , secured to the second linkage system  68 , thereby generating the torque used to assist in opening the decklid  24 . The second hinge box  36  includes a retention feature  58  that is configured for securing the second lever  66  in position relative to the second hinge box  36 . The retention feature  58  prevents the rotation of the second lever  66  in a direction that would allow the second torque rod  46  to untwist, and also resists lateral movement away from the longitudinal axis  30  to prevent unintentional disengagement of the second lever  66  from the retention feature  58 . 
     The first lever  54  and the second lever  66  each include a rotational locking mechanism  70  rotationally securing the first lever  54  to the first torque rod  44  and the second lever  66  to the second torque rod  46 . The rotational locking mechanism  70  may include any mechanism capable of rotationally securing the first lever  54  and the second lever  66  to the first torque rod  44  and the second torque rod  46  respectively, while maintaining the straight axial orientation of the first torque rod  44  and the second torque rod  46  respectively. In other words, the rotational locking mechanism  70  rotationally secures the first lever  54  and the second lever  66  to the first torque rod  44  and the second torque rod  46  respectively without bending the respective axial ends of the first torque rod  44  and/or the second torque rod  46 . For example, referring to  FIG. 4 , the rotational locking mechanism  70  may include a lever aperture  72  having a non-annular shape defined by the first lever  54  and/or the second lever  66 . As shown, a lever barrel portion  74  is welded or otherwise securely attached to the first lever  54  and/or the second lever  66 , with the lever barrel portion  74  defining the lever aperture  72 . As shown in  FIGS. 2 and 3 , the lever aperture  72  is in mated engagement with a lever extension  76  of the first torque rod  44  and/or the second torque rod  46 . The lever extension  76  includes a non-annular shape that corresponds to the non-annular shape of the lever aperture  72 . As shown, the non-annular shape of the lever aperture  72  and the non-annular shape of the lever extension  76  define a D-shaped configuration. However, it should be appreciated that other non-annular shapes may alternatively be used. 
     Referring to  FIGS. 2 and 3 , the first linkage system  56  and the second linkage system  68  are identical, with each including a wind-up link  78  that is attached to and rotatable with the first torque rod  44  and the second torque rod  46  respectively. The wind-up link  78  extends radially away from the first rod axis  52  or the second rod axis  64  respectively to a distal pivot point  80 , which is laterally spaced from the first rod axis  52  and the second rod axis  64  respectively. The first linkage system  56  and the second linkage system  68  further include a driven link  82  having a first end rotatable coupled to the wind-up link  78  at the pivot point  80  and a second end rotatably coupled to the second support member  40  and the first support member  38  respectively. 
     A first clamping block  90  is fixedly attached to the first linkage system  56  and positionally and rotationally secures the first torque rod  44  to the first linkage system  56  at any relative rotational position therebetween. A second clamping block  92  is fixedly attached to the second linkage system  68  and positionally and rotationally secures the second torque rod  46  to the second linkage system  68  at any relative rotational position therebetween. While the torque mechanism  42  is shown herein with the first clamping block  90  interconnecting the first torque rod  44  and the first linkage system  56 , and the first lever  54  coupled to the first torque rod  44  via the retention feature  58  interlocking the first lever  54  and the first torque rod  44 , it should be appreciated that the torque mechanism  42  may alternatively employ another clamping block to connect the first lever  54  to the first torque rod  44  in place of the retention feature  58 . As such, the torque mechanism  42  may include one clamping block interconnecting either the first lever  54  or the first linkage system  56  to the first torque rod  44 , or may include two clamping blocks, with one connecting the first lever  54  to the first torque rod  44  and another connecting the first linkage system  56  to the first torque rod  44 . Similarly, While the torque mechanism  42  is shown herein with the second clamping block  92  interconnecting the second torque rod  46  and the second linkage system  68 , and the second lever  66  coupled to the second torque rod  46  via the retention feature  58  interlocking the second lever  66  and the second torque rod  46 , it should be appreciated that the torque mechanism  42  may alternatively employ another clamping block to connect the second lever  66  to the second torque rod  46  in place of the retention feature  58 . As such, the torque mechanism  42  may include one clamping block interconnecting either the second lever  66  or the second linkage system  68  to the second torque rod  46 , or may include two clamping blocks, with one connecting the second lever  66  to the second torque rod  46  and another connecting the second linkage system  68  to the second torque rod  46 . 
     Referring to  FIGS. 5 through 7 , the first clamping block  90  is identical to the second clamping block  92 . The clamping blocks  90 ,  92  each include a first portion  94  and a second portion  96 . The first portion  94  is attached to one of the levers  54 ,  66  or the linkage systems  56 ,  68 . As shown, the first portion  94  of each of the first clamping block  90  and the second clamping block  92  are attached to the wind-up link  78  of the first linkage system  56  and the second linkage system  68  respectively. However, if the clamping blocks  90 ,  92  were configured to connect the first lever  54  and the second lever  66  to the first torque rod  44  and the second torque rod  46  respectively, then the first portions  94  of the first clamping block  90  and the second clamping block  92  would be attached to the first lever  54  and the second lever  66  respectively. The second portions  96  of the clamping blocks  90 ,  92  are removably attached to the first portions  94 . 
     The clamping blocks  90 ,  92  include a fastening mechanism  98  that is configured for attaching the second portion  96  to the first portion  94 . The fastening mechanism  98  may include any device capable of securing the second portion  96  to the first portion  94  with enough clamping force therebetween to positionally secure one of the torque rods  44 ,  46  therebetween. For example, the fastening mechanism  98  may include at least one fastener  100  extending through the first portion  94  and into threaded engagement with the second portion  96 . Two fasteners  100  are shown in the Figures. Alternatively, it is contemplated that some other fastening mechanism not shown or described herein may be employed, such as, for example, a cam and lever system. 
     The first portion  94  and the second portion  96  cooperate to define an annular passage  102  therebetween. As shown, each of the first portion  94  and the second portion  96  define a semi-circular recess, that when joined together, form the annular passage  102 . The annular passage  102  receives one of the torque rods  44 ,  46  therethrough, with the first portion  94  and the second portion  96  drawn together by the fastening mechanism  98  to provide a clamping force against the torque rod  44 ,  46  to secure the torque rod  44 ,  46  in place relative to the clamping block  90 ,  92 . 
     The annular passage  102  includes an anti-rotation feature  104  for frictionally engaging the torque rod  44 ,  46 . The anti-rotation feature  104  engages the torque rod  44 ,  46  disposed within the annular passage  102  to prevent rotation of the torque rod  44 ,  46  relative to the clamping block  90 ,  92  when the second portion  96  is attached to and clamped against the first portion  94 . The anti-rotation feature  104  may include, for example, a plurality of deformations  106 , such as but not limited to a plurality of ridges extending along a central axis parallel to the torque rod  44 ,  46  disposed within the annular passage  102 , and extending radially inward toward the torque rod  44 ,  46 . The anti-rotation feature  104  engages the torque rod  44 ,  46  and increases the friction therebetween when the first portion  94  is clamped against the second portion  96 , to prevent rotation of the torque rod  44 ,  46  relative to the clamping block  90 ,  92 . Accordingly, the torque rod  44 ,  46  may be angularly positioned relative to the clamping block in any angular position about the rod axis  52 ,  64 , and secured in place by fastening the second portion  96  of the clamping block  90 ,  92  to the first portion  94  to clamp the torque rod  44 ,  46  between the first portion  94  and the second portion  96 . As such, the pre-load torque in the torque rod  44 ,  46  may be adjusted during installation to any desired torque value suitable for the application. 
     The detailed description and the drawings or figures are supportive and descriptive of the invention, but the scope of the invention is defined solely by the claims. While some of the best modes and other embodiments for carrying out the claimed invention have been described in detail, various alternative designs and embodiments exist for practicing the invention defined in the appended claims.