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US-12617478-B2 - Tailgate assembly

US12617478B2US 12617478 B2US12617478 B2US 12617478B2US-12617478-B2

Abstract

A tailgate assembly including a first gate and a second gate. The first gate configured to rotate with respect to a vehicle body and the second gate configured to rotate with respect to the first gate. The second gate includes an outer panel, an injection molded carrier plate, and a drive mechanism. The injection molded carrier plate is configured to be fixed the outer panel to form a cavity. And the injection molded carrier plate is configured to carry a number of functional components. The drive mechanism is fixed to the carrier plate and operably connected to at least one functional component of the number of functional components. Drive mechanism is configured to actuate and move the at least one functional component with respect to the second gate between the number of positions.

Inventors

  • Kim TAYLOR
  • Mark FARRUGIA
  • Ehren Mroczek

Assignees

  • BROSE FAHRZEUGTEILE SE & CO. KOMMANDITGESELLSCHAFT, BAMBERG

Dates

Publication Date
20260505
Application Date
20230726

Claims (20)

  1. 1 . A tailgate assembly comprising: a first gate configured to rotate with respect to a vehicle body; and a second gate configured to rotate with respect to the first gate, the second gate including: an outer panel, an injection-molded carrier plate configured to be fixed to the outer panel to form a cavity, the injection-molded carrier plate configured to carry a number of functional components, and a drive mechanism fixed to the carrier plate and operably connected to at least one functional component of the number of functional components, the drive mechanism configured to actuate and move the at least one functional component with respect to the second gate between a number of positions.
  2. 2 . The tailgate assembly of claim 1 , wherein the number of functional components includes a deployable member coupled to and configured to move with respect to the second gate between a non-use position and a deployed position of the number of positions.
  3. 3 . The tailgate assembly of claim 2 , wherein the deployable member includes a platform configured to form a step to support a user.
  4. 4 . The tailgate assembly of claim 3 , wherein the injection-molded carrier plate includes a main body, the main body including a first end region, a second end region, and a central region, the central region disposed between the first and second end regions, wherein at least one of the first end region, the second end region, and the central region has a first wall thickness and other regions of the main body has a second wall thickness, the second wall thickness different than the first wall thickness.
  5. 5 . The tailgate assembly of claim 4 , wherein the second wall thickness is less than the first wall thickness.
  6. 6 . The tailgate assembly of claim 5 , further comprising: a number of hinges fixed to a first side of the injection-molded carrier plate, a first hinge of the number of hinges disposed within the first end region of the main body, a second hinge of the number of hinges disposed within the first end region of the main body, the number of hinges configured to be connected to either the first gate or the deployable member.
  7. 7 . The tailgate assembly of claim 1 , further comprising: a drive mounting bracket configured to carry the drive mechanism and including a main portion, a first end portion, and a second end portion, the first and second end portions each extending from the main portion, the injection-molded carrier plate including a main body, the main body including a first end region, a second end region, and a central region, the central region disposed between the first and second end regions, wherein at least one of the first end region, the second end region, and the central region has a first wall thickness and other regions of the main body has a second wall thickness, the second wall thickness different than the first wall thickness, and wherein the first end portion is fixed to the central region of the injection-molded carrier plate.
  8. 8 . The tailgate assembly of claim 7 , wherein the injection-molded carrier plate includes a number of accessory apertures each configured to receive a vehicle accessory, and the drive mounting bracket extends over and covers at least some of the number of accessory apertures.
  9. 9 . The tailgate assembly of claim 8 , wherein the number of functional components includes a latch assembly and a platform, the platform coupled to and configured to move with respect to the second gate between a non-use position and a deployed position of the number of positions, the latch assembly provided with, a latch including at least one striker and at least one catch, the at least one striker fixed to one of the injection-molded carrier plate and the platform and the catch fixed to the other of the carrier plate and the platform, the latch operable between a locked state, in which the striker engages the catch, and an unlocked state in which the striker is disengaged from the catch, and a lost-motion mechanism operably connected to the latch and the drive mechanism so that as the drive mechanism actuates in the first direction, the lost-motion mechanism is actuated to change the state of the latch from the locked state to the unlocked state prior to moving the platform from the non-use position towards the deployed position.
  10. 10 . The tailgate assembly of claim 9 , wherein the lost-motion mechanism includes a fixed member and a translating member, the fixed member and the second end region of the injection-molded carrier plate sandwiching at least a portion of the second end portion of the drive mounting bracket.
  11. 11 . An assembly module configured for use in a tailgate assembly provided with a major gate and a minor gate, the major gate configured to rotate with respect to a vehicle body and the minor gate configured to rotate with respect the major gate, the assembly module comprising: a carrier plate configured to be fixed to an outer panel of the minor gate, the carrier plate including a main body having a first surface and a second surface, the first surface opposing the second surface; a deployable member pivotally coupled to the first surface of the carrier plate configured to rotate with respect to the carrier plate between a deployed position and a non-use position; a linear actuator fixed to the second surface of the carrier plate; a force-transmission member including a first end and a second end, the first end fixed to the deployable member; and a pivot bracket pivotally coupled to the second surface of the carrier plate and including a first leg and a second leg, the first leg connected to the force-transmission member and the second leg connected to the linear actuator.
  12. 12 . The assembly module of claim 11 , further comprising: a number of minor gate hinges fixed to the carrier plate, each minor gate hinge of the number of minor gate hinges including an attachment portion and a hinge portion, the attachment portion fixed to the second surface of the carrier plate and the hinge portion configured to be connected to the major gate, the force-transmission member substantially equidistantly spaced apart from a first minor gate hinge of the number of minor gate hinges and a second minor gate hinge of the number of minor gate hinges.
  13. 13 . The assembly module of claim 11 , further comprising: a latch including a striker and a catch, the striker fixed to one of the carrier plate and the deployable member and the catch fixed to the other of the carrier plate and the deployable member, the latch operable between a locked state, in which the striker engages the catch, and an unlocked state in which the striker is disengaged from the catch, wherein the latch is operatively connected to the linear actuator so that in response to actuation of the linear actuator, the latch changes from the locked state to the unlocked state.
  14. 14 . The assembly module of claim 13 , further comprising: a lost-motion mechanism disposed in a cavity formed by the carrier plate and the outer panel of the minor gate, the lost-motion mechanism operably connected to the latch and the linear actuator so that as the linear actuator actuates in the first direction, the linear actuator actuates the lost-motion mechanism to change the state of the latch from the locked state to the unlocked state substantially prior to moving the deployable member from the non-use position towards the deployed position.
  15. 15 . The assembly module of claim 14 , wherein the lost-motion mechanism includes a fixed member and a translating member, the fixed member fixed to the second surface of the carrier plate, the translating member coupled to the linear actuator and configured to move along the fixed member in response to actuation of the linear actuator.
  16. 16 . The assembly module of claim 15 , wherein the deployable member is configured to rotate about a rotational axis, and the translating member of the lost-motion mechanism is configured to move in a direction substantially parallel to the rotational axis.
  17. 17 . The assembly module of claim 11 , further comprising: an actuator mounting bracket including a main body, a first end portion, and a second end portion, the first and second end portions respectively extending from first and second end regions of the main body, a section of the first end portion sandwiched between the second surface of the carrier plate and at least a portion of the pivot bracket.
  18. 18 . The assembly module of claim 17 , wherein the carrier plate includes a first peripheral panel extending from the main body in a direction substantially transverse to the main body of the carrier plate, the second end portion including a flange fixed to the first peripheral panel.
  19. 19 . A method of assembling a minor gate for use in a tailgate assembly, the tailgate assembly provided with a major gate and the minor gate, the major gate configured to rotate with respect to a vehicle body and the minor gate configured to rotate with respect to the major gate, the method comprising: forming a carrier plate configured to be fixed to an outer panel of the minor gate, the carrier plate including a main body having a first side and a second side, the first side opposing the second side; attaching at least one minor gate hinge to a first side of the carrier plate, the at least one minor gate hinge configured to be rotationally connected to the major gate; attaching at least one tailgate step assembly to the second side of the carrier plate, the tailgate step assembly including a tailgate step hinge and a platform configured to rotate with respect to the tailgate step hinge; inserting at least one vehicle accessory into one of a number of vehicle accessory apertures; attaching at least one drive mounting bracket to the first side of the carrier plate so that at least a portion of the drive mounting bracket covers the at least one vehicle accessory; attaching a pivot bracket to the at least one drive mounting bracket, the pivot bracket configured to pivot with respect to the at least one drive mounting bracket; attaching a spindle drive assembly to the drive mounting bracket and the pivot bracket; and operatively coupling the pivot bracket to the tailgate step assembly so that in response to actuation of the spindle drive assembly, the platform of the tailgate step assembly rotates about the tailgate step hinge.
  20. 20 . The method of claim 19 , further comprising: placing the at least one minor gate hinge in an end region of the carrier plate, wherein the forming step includes injection molding the carrier plate, the carrier plate including the end region the end region having a first wall thickness and other regions of the carrier plate having a second wall thickness, the second wall thickness less than the first wall thickness.

Description

TECHNICAL FIELD The present disclosure relates to vehicle closures such as a tailgate for a truck. BACKGROUND Vehicles such as trucks may include a truck bed and a tailgate that may be rotated from a closed position to an open position to facilitate loading and unloading of items within the truck bed. Certain tailgates may be powered so that the tailgate may be actuated remotely or without assistance from a user. As another example, certain tailgates may include one or more deployable accessories such as a secondary gate that may be moved with respect to a main portion of the tailgate. SUMMARY According to one aspect of the present disclosure, a tailgate assembly is provided. The tailgate assembly may include a first gate and a second gate. The first gate may be configured to rotate with respect to a vehicle body and the second gate may be configured to rotate with respect to the first gate. The second gate may include an outer panel, an injection molded carrier plate, and a drive mechanism. The injection molded carrier plate may be configured to be fixed the outer panel to form a cavity. And the injection molded carrier plate may be configured to carry a number of functional components. The drive mechanism may be fixed to the carrier plate and operably connected to at least one functional component of the number of functional components. Drive mechanism may be configured to actuate and move the at least one functional component with respect to the second gate between the number of positions. According to another aspect, an assembly module configured for use in a tailgate assembly is provided. The tailgate assembly may include a major gate and a minor gate. The major gate may be configured to rotate with respect to a vehicle body and the minor gate may be configured to rotate with respect to the major gate. The assembly module may include a carrier plate, a deployable member, a linear actuator, a force-transmission member, and a pivot bracket. The carrier plate may be configured to be fixed to an outer panel of a minor gate and may include a main body having a first surface and a second surface, the first surface opposing the second surface. The carrier plate may also include a number of flanges extending from the first surface. The deployable member may be operably couple to the number of flanges and configured to rotate with respect to the carrier plate about the number of flanges between a deployed position and a non-use position. Linear actuator may be fixed to the second surface of the carrier plate. The force-transmission member may include a first end and a second end, the first end may be fixed to the deployable member. Pivot bracket may be pivotally coupled to the second surface of the carrier plate and may include the first leg and a second leg, the first leg may be connected to the force transmission member and the second leg may be fixed to the linear actuator. According to yet another embodiment, a method of assembling a minor gate for use in a tailgate assembly is provided. The tailgate assembly may be provided with a major gate and a minor gate, the major gate may be configured to rotate with respect to a vehicle body and the minor gate may be configured to rotate with respect to the major gate. The method may include forming a carrier plate that may be configured to be fixed to an outer panel of minor gate. The carrier plate may include a main body having a first side and a second side, the first side opposing the second side. The method may also include: attaching at least one minor gate hinge to a first side of the carrier plate, the at least one minor gate hinge may be configured to be rotationally fixed to the major gate; attaching at least one tailgate step assembly to the second side of the carrier plate, the tailgate step assembly may include a tailgate step hinge and a platform configured to rotate with respect to the tailgate step hinge; inserting at least one vehicle accessory into one of a number of vehicle accessory apertures; attaching at least one drive mounting bracket to the first side of the carrier plate so that at least a portion of the drive mounting bracket covers the at least one vehicle accessory; BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a rear view of an exemplary truck provided with an exemplary tailgate assembly provided with major gate and minor gate. FIG. 2 illustrates a rear-perspective view of the exemplary tailgate assembly in an open position and deployed position. FIG. 3 illustrates a rear-perspective view of a portion of the exemplary tailgate assembly. FIG. 4 illustrates another rear-perspective view of a portion of the exemplary tailgate assembly. FIG. 5 illustrates a partial-rear-plan view of a portion of the exemplary tailgate assembly. FIG. 5A illustrates a detail view of a portion of a drive mechanism disposed in the exemplary tailgate assembly taken along the lines A-A in FIG. 5 in which the tailgate assembly is in a non-use position. FIG.