Power drive unit driveshaft with wobble connection

Patent metadata

Field	Value
Publication number	US-12320394-B2
Application number	US-202217980750-A
Country	US
Kind code	B2
Filing date	Nov 4, 2022
Priority date	Nov 4, 2022
Publication date	Jun 3, 2025
Grant date	Jun 3, 2025

Abstract

A drive system for a tailgate and including a drive unit having a first coupler supported for rotation about a first longitudinal axis and defining a receptacle. A second coupler including a first side and a second side configured to engage with a hinge component of a vehicle and defining a second longitudinal axis. A driveshaft extends between the first and second couplers at an angled orientation relative to the first and second axes via wobble connections formed between a first end of the driveshaft and the first coupler and between a second end of the driveshaft and the first side of the second coupler.

First claim

What is claimed is:

1. A drive system for use in a tailgate of a pickup truck, the drive system comprising:
a drive unit disposed in an interior cavity defined by the tailgate and including a motor operatively connected to a first coupler having a first longitudinal axis, the first coupler defining a polygon-shaped receptacle having a plurality of first inner walls circumferentially interconnected to form a plurality of inside corners extending parallel to and radially spaced apart from the first longitudinal axis;
a driveshaft having a second longitudinal axis that is angled relative to the first longitudinal axis, the driveshaft including a central portion and a first bulbous end, the first bulbous end arranged along the second longitudinal axis, the first bulbous end having a tip and a neck, wherein the neck is joined to the central portion, and the first bulbous end defines a first plurality of engaging surfaces that are arcuate in a direction parallel to the second longitudinal axis and are circumferentially arranged around the second axis such that the first plurality of engaging surfaces are joined to each other at arcuate edges that extend between the neck and the tip, the driveshaft having a second bulbous end formed on the driveshaft opposite the first bulbous end and being coaxial with the second longitudinal axis,
wherein the first bulbous end is received in the receptacle in which the inside corners receive the arcuate edges to rotationally fix the driveshaft to the first coupler;
each engaging surface of the first plurality of engaging surfaces includes at least a first portion and a second portion that are longitudinally spaced from each other such that, when the second axis of the driveshaft is in a first angled position relative to the first longitudinal axis, the first portion of a first engaging surface of the first plurality of engaging surfaces contacts a corresponding inner wall of the plurality of first inner walls, while the second portion of the first engaging surface of the first plurality of engaging surfaces is not in contact with the corresponding inner wall; and
wherein the drive unit includes a motor having a longitudinal axis arranged orthogonal to at least one of the first and second longitudinal axes.

2. The drive system of claim 1 , wherein, when the second axis of the driveshaft is in a second angled position relative to the first longitudinal axis, the second portion of the first engaging surface of the first plurality of engaging surfaces is in contact with the corresponding inner wall while the first portion of the first engaging surface of the first plurality of engaging surfaces is not in contact with the corresponding inner wall.

3. The drive system of claim 1 , further comprising a retainer connected between the first end and the coupler to retain the first bulbous end in the receptacle.

4. The drive system of claim 3 , wherein the retainer is a C-clip.

5. The drive system of claim 1 , wherein the plurality of first inner walls of the receptacle are in equal number to the first plurality of engaging surfaces of the first bulbous end.

6. The drive system of claim 5 , further comprising:
a second coupler defining a second polygon-shaped receptacle having a plurality of second inner walls circumferentially interconnected to form a plurality of second inside corners extending parallel to and radially spaced apart from a third longitudinal axis of the second coupler,
wherein the second bulbous end includes a second tip and a second neck, wherein the second neck is joined to the central portion, and the second bulbous end defines a second plurality of engaging surfaces that are arcuate in a direction parallel to the second longitudinal axis and are circumferentially arranged around the second longitudinal axis such that the second plurality of engaging surfaces are joined to each other at second arcuate edges extending between the second neck and the second tip,
wherein the second bulbous end is received in the second receptacle, and the second inside corners receive the second arcuate edges to rotationally fix the driveshaft to the second coupler.

7. The drive system of claim 6 , wherein each engaging surface of the second plurality of engaging surfaces of the second bulbous end includes a first portion and a second portion longitudinally spaced from each other such that, when the second axis of the driveshaft is in the first angled position, the first portion of at least one of the second plurality of engaging surfaces contacts a corresponding second inner wall of the plurality of second inner walls while the second portion of the at least one of the second plurality of engaging surfaces is not in contact with the corresponding second inner wall.

8. A drive system for use in a tailgate of a pickup truck, the drive system comprising:
a drive unit disposed in an interior cavity defined by the tailgate and including a first coupler supported for rotation about a first longitudinal axis, the first coupler defining a first receptacle;
a motor operatively connected to the first coupler;
a second coupler disposed in a sidewall of the tailgate and including a first side and a second side, the second side configured to engage with a hinge component of the pickup truck, the second coupler supported for rotation about a second longitudinal axis that is parallel to and offset from the first axis, wherein the sidewall of the tailgate partially defines the interior cavity; and
a driveshaft extending between the first and second couplers at an angled orientation relative to the first and second axes, the driveshaft including a first end connected to the first coupler and a second end connected to the first side of the second coupler, the first end defining a first plurality of engaging surfaces, the first plurality of engaging surfaces being arcuate in a direction parallel to a third longitudinal axis of the driveshaft and circumferentially arranged around the third axis such that the engaging surfaces are joined to each other at edges that are arcuate in the direction parallel to the third axis,
wherein the first end is received in the receptacle of the first coupler in which at least some engaging surfaces of the first plurality of engaging surfaces are disposed against first inner walls of the first receptacle such that the first plurality of engaging surfaces are configured rock with respect to the first inner walls to permit the third axis of the driveshaft to be angled relative to the first axis of the first coupler, and a longitudinal axis of the motor is arranged orthogonal to at least one of the first and second longitudinal axes.

9. The drive system of claim 8 , wherein the first side of the second coupler defines a second receptacle, and wherein the second end of the driveshaft defines a second plurality of engaging surfaces that are arcuate in the direction parallel to the third longitudinal axis of the driveshaft and are circumferentially arranged around the third axis such that the second plurality of engaging surfaces are joined to each other at second edges that are arcuate in the direction parallel to the third axis,
wherein the second end is received in the second receptacle of the second coupler in which the second engaging surfaces are disposed against second inner walls of the second receptacle such that the second engaging surfaces rock with respect to the second inner walls to permit rotation of the driveshaft and the second coupler while the third axis of the drive shaft is angled relative to the second axis of the second coupler.

10. The drive system of claim 8 further comprising a retainer connected between the first end and the first coupler to retain the first end in

Assignees

• Brose Fahrzeugteile Se & Co Kg Bamberg

Inventors

• Alexander Shane
• Kidd Michael
• Lakerdas Andrew

Classifications

• E05F15/611 Primary

  for swinging wings · CPC title

• E05Y2201/706

  Shafts · CPC title

• E05Y2900/542

  Roof panels · CPC title

• F16D3/20 Primary

  one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members (F16D3/18, F16D3/24 take precedence) · CPC title

• E05Y2201/636

  Universal or ball joints · CPC title