Overmolded component reinforcement bracket

Abstract

A lift gate (28) formed of thermoplastic overmolded around preselected reinforcements at stress points such as corner areas, the lift gate including a pair of spaced reinforcement panels (14, 18) and wherein a three-dimensional reinforcement panel (12) is connected between the pair of spaced reinforcements (14, 18). Preferably, the three-dimensional reinforcement panel is connected to three reinforcements.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 864,685 filed on June 21, 2019, U.S. Provisional Patent Application No. 62 / 864,691 filed on June 21, 2019, U.S. Provisional Patent Application No. 62 / 864,785 filed on June 21, 2019, U.S. Provisional Patent Application No. 62 / 864,878 filed on June 21, 2019, and U.S. Provisional Patent Application No. 62 / 864,981 filed on June 21, 2019. The disclosures of the above applications are incorporated herein by reference. Technical Field

[0003] The present invention relates to an overmolded assembly reinforcement bracket and a method of increasing the rigidity of an overmolded lift gate assembly. Background Art

[0004] Many lift gates in the past have used stamped sheet metal components. This provides a very strong lift gate. However, the interior trim always typically requires some type of padded or molded Class A interior surface panel. These lift gates are very heavy and require strong hinges and lift assemblies that are expensive and complicated.

[0005] It has been proposed to use lift gates made strictly of polymer materials to save weight and cost. However, such lift gates sometimes suffer from less strength and flexibility and are therefore not useful in some applications.

[0006] Polymer doors often require reinforcements in stress areas such as hinge points, tailgate lift support points, and latch points. Therefore, steel reinforcements are often provided at each of these areas to help support the loads applied in these areas on the door.

[0007] There remains a need in the art to provide a stiffer, more powerful and lightweight overmolded liftgate for SUV vehicles. Summary of the invention

[0008] A lift gate is provided that is formed of a thermoplastic that is overmolded around preselected reinforcements at stress points such as corner areas, the lift gate including a pair of spaced reinforcement panels, and wherein a three-dimensional reinforcement panel is connected between the pair of spaced reinforcements.

[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter.It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention will be more fully understood from the detailed description and accompanying drawings, in which:

[0011] Figure 1 is a perspective view of an overmold assembly reinforcement of the present invention shown from the interior of a vehicle according to the present invention;

[0012] Figure 2 yes Figure 1 An external view of the area shown in;

[0013] Figure 3 is a perspective view of a ball joint bracket assembly reinforcement of the present invention shown from the interior of a vehicle according to an alternative embodiment of the present invention; and

[0014] Figure 4 yes Figure 3 External view of the area. DETAILED DESCRIPTION

[0015] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0016] Overall reference Figure 1 and Figure 2 , a reinforcement bracket assembly suitable for use with a lift gate 28 of a vehicle is provided, the reinforcement bracket assembly being generally shown at 10. According to aspects of the present invention, a 3D assembly reinforcement bracket is provided after an overmolding process.

[0017] To gain additional stiffness in situations where three-dimensional (3D) overmolding is not possible or does not provide the desired properties, the 3D formed bracket 12 is assembled after the overmolding process.

[0018] The 3D formed bracket 12 is connected to the hinge reinforcement 14 at the ball joint reinforcement 18 and to the ball joint reinforcement 18. For maximum performance, a third connection to the overmolded metal bracket is required to span the triangular shaped geometry.

[0019] The connection points preferably utilize existing connection points for ball joint bracket and hinge bracket installations.

[0020] The 3D formed bracket 12 is preferably operably connected, for example with fasteners, in at least three attachment locations 16 (to the hinge reinforcement 14), 20 (to the ball joint reinforcement 18), and 24 (e.g., to the panel 28 or reinforcement). The ball joint reinforcement 18 is preferably attached to at least the attachment location 22 (e.g., to the liftgate panel or reinforcement). Figure 2A view of the outer surface 26 of a spherical joint 26, such as a metal stamped bracket, is depicted.

[0021] exist Figure 3 and Figure 4 In an alternative embodiment of the present invention generally shown in FIG. 1 , the ball joint bracket 26 is expanded from its standard use as a ball joint connection bracket 26 relative to a lift gate 28 to an additional reinforcement plate function. This is accomplished by enlarging the size of the bracket 26 for connecting the hinge reinforcement 14 and the ball joint reinforcement 18 in a 3D shape.

[0022] One benefit of this enlargement is additional rigidity in the most critical hinge area of ​​the lift door.

[0023] By adding functionality to the ball joint bracket, the amount of material and components can be reduced, thereby reducing weight and cost.

[0024] According to aspects of the present invention, there is provided overmolding of steel reinforcements in place for corner hinge points and cylinder auxiliary mounts.

[0025] According to aspects of the invention, a reinforcement member is located on the inside of the lift gate and includes a ball joint connection for attaching a gas strut.

[0026] According to a preferred aspect of the invention, the 3D reinforcement panel is connected to a third separate overmoulded reinforcement panel for providing a triangular reinforcement.

[0027] According to aspects of the present invention, the support portion provides connection between the hinge plate and the lifting strut.

[0028] According to aspects of the present invention, a 3D reinforcement is attached to the exterior of the lift gate.

[0029] The description of the present invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the present invention are intended to be within the scope of the present invention. Such variations should not be regarded as a departure from the spirit and scope of the present invention.

Claims

1. A lifting door for an SUV vehicle, comprising: A lift gate formed of a thermoplastic that is overmolded at stress points around a preselected reinforcement member that includes at least a pair of separate reinforcement panels and a three-dimensional reinforcement bracket that is assembled and connected between the pair of separate reinforcement panels after the overmolding process.

2. The lift gate for an SUV vehicle according to claim 1, wherein: The three-dimensional reinforcement bracket is attached to an exterior of the lift gate.

3. The lift gate for an SUV vehicle according to claim 1, wherein: The three-dimensional reinforcement bracket is located on the inner side of the lift gate and includes a ball joint connection for attaching a gas strut.

4. The lift gate for an SUV vehicle according to claim 1, wherein: The three-dimensional reinforcement bracket is connected to a third separate overmolded reinforcement panel for providing a triangular reinforcement member.

5. A three-dimensional reinforcement assembly adapted to be secured to a liftgate of a sport utility vehicle, comprising: At least one pair of separate reinforcement panels, and wherein the three-dimensional reinforcement bracket is connected between the pair of separate reinforcement panels after the overmolding process.

6. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is attached to the exterior of the lift gate.

7. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is located on the inside of the lift gate and includes a ball joint connection for attaching a gas strut.

8. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is connected to a third separate overmolded reinforcement panel for providing a triangular reinforcement member.

9. The three-dimensional reinforcement assembly according to claim 5, wherein: One of the pair of separate reinforcement panels is a hinge reinforcement member, and the three-dimensional reinforcement bracket is connected to the hinge reinforcement member.

10. The three-dimensional reinforcement assembly according to claim 5, wherein: One of the pair of separate reinforcement plates is a ball joint reinforcement, and the three-dimensional reinforcement bracket is connected to the ball joint reinforcement.

11. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is connected to the hinge reinforcement and the ball joint reinforcement.

12. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is connected to the hinge reinforcement and the ball joint reinforcement, and the three-dimensional reinforcement assembly also includes a third connector connected to the overmolded metal bracket for allowing the three-dimensional reinforcement bracket to span the triangular shape geometry for increased strength.

13. The three-dimensional reinforcement assembly according to claim 5, wherein: The pair of separate reinforcement panels include a hinge reinforcement and a ball joint reinforcement and utilize existing connection points for hinge reinforcement installation and ball joint reinforcement installation.

14. The three-dimensional reinforcement assembly of claim 5, further comprising an enlarged ball joint bracket, wherein the enlarged ball joint bracket is a ball joint connector and reinforcement member that connects the hinge reinforcement member and the ball joint reinforcement member in a 3D shape geometry.

15. The three-dimensional reinforcement assembly according to claim 5, wherein: The three-dimensional reinforcement bracket is connected to the 3D shaped enlarged ball joint bracket.

16. The three-dimensional reinforcement assembly of claim 5, further comprising a ball joint connection bracket that is enlarged in a hinge area for additional rigidity of the lift gate.

Images