CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/392,322, filed July 26, 2022, the disclosures of which are incorporated by reference herein.

TECHNICAL FIELD

[0002] The present invention is generally related to a towbar with an electrical hitch and, more specifically a high capacity towbar with an electrically retractable hitch and adaptor system.

BACKGROUND

[0003] A towbar with a hitch is often used by a towing vehicle to tow other vehicles, such as trailers. The hitch may include a hitch ball. On some towing vehicles, the hitch rotates between a stowed position in which the hitch ball is not accessible and a towing position in which the hitch ball is accessible (sometimes referred to as a “retractable hitch”). For example, vehicles where there is a demand for both aesthetics as well as functional towing may include a retractable hitch to hide the hitch when not in use. The towed vehicle generally includes a coupler that operatively engages with the hitch ball of the towbar when the hitch is in the towing position. Generally, the hitch ball is securely mounted to the rear of the tow vehicle and the coupler is mounted on the trailer tongue. Traditionally, retractable hitches have a lower towing capacity compared to fixed and removeable heavy duty hitches. SUMMARY

[0004] A towbar with an electrically retractable hitch adaptor system is described below. The electrically retractable hitch adaptor system is configured to provide a relatively higher towing capacity for a retractable hitch system. The hitch of the retractable hitch adaptor system includes a primary connector body and a secondary connector body that together stabilizes the hitch and resists axial or twisting movement of the retractable hitch adaptor system due to forces applied to the hitch while a towing vehicle is towing a trailer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Operation of the present disclosure may be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:

[0006] FIGS. 1A and IB illustrate a high capacity towbar with an electrically retractable mount system with a primary and secondary connection to the towbar, in accordance with the teachings of the disclosure.

[0007] FIG. 2 illustrates a high capacity towbar with an electrically retractable mount system with a reinforced connection to the towbar, in accordance with the teachings of the disclosure.

[0008] FIG. 3 illustrates a side cross-sectional view of a portion of the electrically retractable mount system of FIGS. 1A, IB, and 2, in accordance with the teachings of the disclosure.

[0009] FIG. 4 illustrates a partial rear perspective view of the portion of the electrically retractable mount system of FIGS. 1A, IB, and 2, in accordance with the teachings of the disclosure.

[0010] FIGS. 5A and 5B illustrate a partial rear perspective view of the portion of the electrically retractable mount system of FIGS. 1A, IB, and 2 in the holding and freeing positions, in accordance with the teachings of the disclosure. [0011] FIG. 6 illustrates a partial side view of the portion of the electrically retractable mount system of FIGS. 1 A, IB, and 2 with a secondary locking mechanism, in accordance with the teachings of the disclosure.

[0012] FIG. 7 illustrates a perspective view of the corresponding locking parts of a hitch and a connector plate, in accordance with the teachings of the disclosure.

[0013] FIGS. 8A, 8B, 8C, 8D, and 8E HE illustrate examples configurations of the positive locking parts of a hitch, in accordance with the teachings of the disclosure.

DETAILED DESCRIPTION

[0014] Reference will now be made in detail to exemplary embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized, and structural and functional changes may be made without departing from the respective scope of the present disclosure. Moreover, features of the various embodiments may be combined or altered without departing from the scope of the present disclosure. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the present disclosure.

[0015] As used herein, the words “example” and “exemplary” mean an instance, or illustration. The words “example” or “exemplary” do not indicate a key or preferred aspect or embodiment. The word “or” is intended to be inclusive rather an exclusive, unless context suggests otherwise As an example, the phrase “A employs B or C,” includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggests otherwise. [0016] Towbars with retractable hitches (sometimes collectively referred to as “retractable towbars”) are generally stowed in a position behind the rear bumper when not in use. When in the towing position, the retractable hitch is available to couple with a coupler of a trailer. Retractable towbars offer towing capability while having a discreet appearance when not in use and not interfering with other activities, such as loading the towing vehicle, etc. However, generally, retractable towbars have a lower towing capacity than a fixed towbar. In some locations, such as Europe, sport utility vehicle (“SUVs”) are generally capable of towing around 2500 kg (approx. 5500 lbs), which is comparable to the maximum towing capacity of the retractable towbars of around 2400 kg (approx. 5300 lbs). In other locations however, such as the United States, many SUVs are capable of towing between 3700 and 4200 kg (approx. 8200 and 93001bs). As a result, in some locations, retractable towbars do not have a capacity that matches the performance of the towing vehicle. Therefore, there is a need for an improved electrically retractable towbar with an increased towing capacity.

[0017] As illustrated in FIGS. 1A, IB, 2A and 2B, a towbar 100 includes an electrically retractable hitch adaptor system 102. The electrically retractable hitch adaptor system 102 includes a hitch 104, a swivel/locking assembly 106, an actuator 108, a primary connector body 110, and a secondary connector body 112. The hitch 104 includes a coupling head 114 to which a hitch arm 116 with a hitch adaptor 118 is formed on an outer end thereof. Examples of the hitch adaptor 118 are described in, for example, U.S. Patent No. 10,953,713 entitled “Towbar with a Hitch Adaptor System,” which is incorporated herein by reference in its entirety. While the hitch adaptor 118 is illustrated in FIGS. 1A, IB, 2A and 2B, any permanent, detachable, or interchangeable hitch may be used (such as, a swan neck hitch, etc ).

[0018] The coupling head 114 is axially displaceable along and rotatable about axis A, with respect to the primary connector body 110, to permit the hitch 104 to rotate between (i) an operable position (sometimes referred to as a “towing position”) (shown in FIGS. 1A and 2A), in which the hitch arm 1 16 and hitch adaptor 1 18 extend from underneath of the vehicle to facilitate connecting a hitch ball or other coupler to the hitch adaptor 118 and coupling the hitch 104 to a towed vehicle, and (ii) a retracted position (sometimes referred to as a “stowed position”), such that the hitch arm 116 and hitch adaptor 118 are stored under the vehicle and substantially hidden. In some examples, the hitch 104 rotates approximately 180 degrees between the operable position and the retracted position.

[0019] The swivel/locking assembly 106 operates to move the hitch 104 between the operable and retracted positions and lock the hitch 104 in either the operable position or retracted position. The actuator 108 electrically drives the swivel/locking assembly 106. The swivel/locking assembly 106 and actuator 108 may be enclosed in a cover to prevent wear and contamination from environmental elements such as water, salt and dirt that may negatively affect performance and longevity of the mechanical and electrical components. In the illustrated example, the hitch 104 and actuator 108 are positioned on opposite sides of the primary connector body 110.

[0020] Both primary connector body 110, the secondary connector body 112, and the coupling head 114 each define a through hole coaxial with axis A to accept a hollow shaft therein. An outer end of the coupling head 114 is covered with a cap 120 to (i) seal a hollow shaft (e.g., hollow shafted 304 below) and (ii) to provide an interface to connect the secondary connector body 112 to the hitch 104. A seal (e.g. seal 330 of FIG. 3) may be positioned between the coupling head 114 and the primary connector body 110 to prevent moisture or dirt from entering between these movable elements.

[0021] As best illustrated in FIG. 3, a locking pin 302 is axially displaceable along axis

A within hollow shaft 304. The locking pin 302 includes collar 306 and a shoulder 308 having opposing cam surfaces, with a reduced diameter section 310 there between. In a holding position, the locking pin 302 is positioned such that the shoulder radially displaces one or more locking balls 312 through corresponding inner holes 314 defined in the hollow shaft 304, such that the locking balls are locked against a bearing seat 316 of a bearing ring 318 disposed between the hollow shaft 304 and the coupling head 114. In this position, unlocking balls 315 are not engaged and rest in the reduced diameter section 310 of the locking pin 302. In some examples, the swivel/locking mechanism 106 includes three locking balls 312 and three unlocking balls 315. A spring 322 within the hollow shaft 304 urges locking pin 302 axially outward to maintain it in the holding position with the coupling head 114 abutting the primary connector body 110.

[0022] In the holding position, positive locking elements 324 provided on an inner surface of coupling head 114 are seated in a corresponding plurality of negative locking elements 326 of the primary connector body 110. Thus, rotation of the coupling head 114 with respect to the primary connector body 110 is prohibited. In some examples, the positive locking elements 324 may be protrusions and the negative locking elements 326 may be recesses defined by the primary connector body 110. Alternatively, in some examples, the positive locking elements 324 may be defined by the coupling head 114 as recesses and the negative locking elements 326 may be protrusions on the primary connector body 110. In some examples, the protrusions 324 and corresponding recesses 326 may be semi-circular or bullet shaped and may be provided in various numbers and configurations.

[0023] When locking pin 302 is inwardly axially displaced within the hollow shaft 304, the locking balls 312 disengage from the bearing seat 306 to rest in the reduced diameter section 310, while the collar 306 forces the unlocking balls 315 through outer holes 328 against the bearing seat 306. This inward axial displacement of locking pin 304 into a freeing position causes corresponding outward axial displacement of coupling head 114 with respect to the primary connector body 110. The inner portion of the coupling head 1 14 is outwardly displaced such that positive locking elements 324 disengage from negative locking elements 326, thereby permitting rotation of the coupling head 114, hollow shaft 306 and locking pin 304 about axis A with respect to the primary connector body 110. The swiveling/locking mechanism 106 is configured such that the locking pin 304 is oriented in a holding position when the hitch 104 is fully extended in an operable position and when hitch 104 is rotated 180 degrees in the retracted position.

[0024] The axial and rotational movement of the coupling head 114, hollow shaft 306 and/or locking pin 304 are driven by drive elements 332 and 334. The drive elements 332 and 334 may be adjacent gears rotatable about axis A. In some examples, a first drive element 332 is configured to axially displace the locking pin 304 between its holding position and freeing position and a second drive element 334 is configured to rotate the coupling head 114 about axis A between the operable position and retracted position.

[0025] As best illustrated in FIG. 4, an inner end of the locking pin 304 includes at least one fin 402 disposed within a corresponding axial channel 404 at an inner end of hollow shaft 306. In some examples, the locking pm 304 includes two opposing fins 402, approximately 180 degrees apart, and hollow shaft 306 includes two corresponding channels 404. The fin(s) 402 is/are sized such that it extends radially out of channel 404 to engage with a stationary locking ring 336 that is not rotatable about axis A. Thus, when the locking pin 304 is in a holding position as shown in Fig. 4, the fin 402 is positioned within a locking slot 406 of locking ring 336, thereby preventing rotation of the locking pin 304 and the hollow shaft 306 about the axis A. Inward axial displacement of the locking pin 304 (towards the left in Fig. 4) moves fin 402 out of locking slot 406, but still within axial channel 404. In this freeing position, locking pin 304 and hollow shaft 306 can freely rotate about the axis A. Fig. 5A illustrates locking pin 304 in the holding position with fin 402 seated in the locking slot 406 Fig. 5B illustrates locking pin 304 in the freeing position with fin 401 axially extending beyond the locking slot 406.

[0026] The co-axial and compact arrangement of first drive element 332 and second drive element 334 may provide several advantages including, but not limited to, a more compact design of swivel/locking assembly 104 and the overall retractable hitch system 100, and also the ability to be driven by a simple and compact electrical actuator. In some examples, the actuator 108 includes mating elements 408 for engaging first drive element 332 and second drive element 334.

[0027] As best shown in FIG. 6, the actuator 108 may also include a secondary locking mechanism 602 including a bolt 604 having a head 606 sized to be at least partially disposed within the locking slot 406 of locking ring 336. Bolt 604 is slidably disposed within a chamber in a housing and is radially biased with a spring towards axis A. A curved arm connects bolt 604 to a stationary post about which the arm is pivotable. The spring maintains engagement of curved arm against an axle, having a larger diameter portion and a smaller diameter portion. Engagement of the larger diameter portion of the axle with the curved arm causes the arm to radially pivot outward (away from axis A) and engagement of the smaller diameter portion of the axle with the curved arm causes the arm to radially pivot inward (toward axis A). Rotation of the axle will cause the arm to sequentially engage with the larger diameter portion the smaller diameter portion of the axle. The mating elements are also operably connected to the axle and, thus, rotation of the axle causes rotation of mating elements.

[0028] In an embodiment in accordance with the present disclosure, the head 606 of bolt 602 engages the fin 402, thereby preventing outward axial displacement of locking pin 304. Pivoting the arm radially outward draws the bolt 604 radially outward from axis A and out of engagement with fin 402, thereby permitting outward axial displacement of locking pin 304 into a freeing position. Once in the freeing position, fin 402 of locking pin 304 may axially extend past the locking slot 406, permitting rotation of locking pin 304 and hollow shaft 306.

[0029] Returning to FIGS. 1A, IB, and 2, the primary connector body 110 and the secondary connector body 112 provide interfaces to connect the hitch 104 to the towbar 100. In the illustrated examples of FIG. 2, the primary connector body 110 is fastened or otherwise affixed to the towbar 100 at a primary connection point 122. The primary connector body 110 includes one or more flanges 124 to affix the primary connector body 110 with, for example, one or more bolts. The secondary connector body 112 surrounds the towbar 100 on at least three sides at a secondary connection point 126. In the illustrated example, the secondary connector body 112 defines a first bend 128 to accommodate the hitch adaptor 118 when the hitch 104 is in the retracted position (e.g., as shown in FIG. IB). The secondary connector body 112 defines a second bend 130 to accommodate the towbar 100 and/or affix the secondary connector body 112 to the towbar 100. The secondary connector body 112 is directly or indirectly affixed or otherwise attached to the primary connector body 110 (e.g., via the hollow shaft described above) such that the secondary' connector body 112 does not rotate with respect to the primary connector body 110. In some examples, the secondary connector body 112 is removable from the hollow shaft when the cap 120 is removed to facilitate removing the hitch 104 as described above. The secondary connector body 112 facilitates distributing force applied to the hitch 104 to the towbar 100 and resisting axial movement of the retractable hitch adaptor system 102.

[0030] In the illustrated examples of FIGS. 2A and 2B, the secondary connector body 112 is integrally formed with the primary connector body 110. The stiffness provided by the secondary connector body 112 at the distal end 132 of the coupling head 114 resists axial movement of the retractable hitch adaptor system 102 to force applied to the hitch 102 by towing a vehicle. In the illustrated examples, the secondary connector body 112 is curved to accommodate the hitch adaptor 118 when the hitch 104 is in the retracted position (e.g., as shown in FIG. 2B). That is, the secondary connector body 112 is configured to interfere with the hitch 104 as it transitions between the operable position and the retracted position.

[0031] The actuator 108 drives the aforementioned axial and rotational movements. The actuator 108 may be coupled to the first drive element configured to axially displace the locking pin between its holding position and freeing position and a second element configured to rotate the hollow shaft and the coupling head about the axis between the operable position and retracted position. In some examples, the first and second drive elements are gears that are rotatable about the axis A. The actuator 108 may be positioned on the inside of the primary connector body 110, such that the entire actuator mechanism may remain affixed to the towbar 100, while the 102 can be changed depending on the needs of the user or location. In the illustrated examples, the hitch 104 includes the hitch adaptor 118 that is integrally formed with the hitch arm 116 and the outer cover of the coupling head 114.

[0032] The towing vehicle to which the retractable hitch system 102 is affixed includes an electrical system with a digital bus, for example a CAN bus, to which various motor vehicle bus modules are connected. In some examples, the actuator 108 and a trailer socket (in which a plug of the trailer or towed vehicle is inserted) of the retractable hitch system 102, are electrically connected to a coupling control module. The coupling control module controls the functions of the retractable hitch system 102 via the actuator 108. Accordingly, in such examples, the swivel/locking assembly 106 is controlled using the coupling control module to release the locking elements and/or and the actuator 108 is controlled to drive the drive elements to pivot or adjust the hitch 104 between operable and retracted positions. The coupling control module may include one or more control programs, for example, to control the actuator 108. Thus, for example, when the motor vehicle is traveling, if for example a minimum speed has been exceeded, the function of the actuator 108 may be deactivated. Thus, for example, the hitch 104 cannot be adjusted between the operable and retracted positions during driving operation of the motor vehicle. The coupling control module also reacts with its control program to the respective operating state of the motor vehicle.

[0033] As discussed above, the retractable hitch system 100 is capable of accommodating a European-style swan neck hitch or a US-style receiver sleeve hitch system. Increased towing needs and capacities between the US and European markets may, in some instances, require a stronger connection between the coupling head of the hitch and the connector plate. Performance of the retractable hitch system 100 is dictated, in part, by the locking parts 324 and 336 between the hitch 104 and the primary connector body 110. FIG. 7 illustrates an example of the hitch 104 being seperate from the primary connector body 110. A stronger connection is achieved, in some examples, by adjusting the sizing, number and/or position of the positive locking elements 324 provided on an inner surface of coupling head 114 and corresponding negative locking elements 326 on the primary connector body 110. FIG. 8 A illustrates a known configuration of the corresponding locking elements operable in the present disclosure. In an example illustrated in FIG. 8B, increased strength of the connection is achieved by increasing the radius of the circle on which the locking elements 324 and 326 lie, thereby increasing the lever action. Increased connection strength may also be achieved by providing additional locking elements. For example, as shown in FIG. 8C, the number of locking elements 324 and 326 is increased from six to eight. This provides increased surface contact, but less contact pressure at each connection point In some examples, shown in FIG 8D, less surface pressure is achieved by increasing the size of the locking elements 324 and 326. Reduced forces, achieved by providing locking elements with steeper angles (greater pitch), as shown in FIG. 8E, also increases performance of the locking parts. In some examples, the retractable hitch system 100 includes the locking elements 324 and 326 with any combination of an increased radius of the circle on which the locking elements 324 and 326 lie, an increase number of the locking elements 324 and 326, and/or a change in the pitch one of the circle on which the locking elements 324 and 326 he.

[0034] Although the embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present disclosure is not to be limited to just the embodiments disclosed, but that the disclosure described herein is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the claims hereafter. The terms “includes,” “including,” and “include” are inclusive and have the same scope as “comprises,” “comprising,” and “comprise” respectively. The claims as follows are intended to include all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof.

[0035] Having thus described the invention, the following is claimed: