Cable-less end door for vehicle

Abstract

A container for a pickup truck includes a base portion including a first end defining the container, a second end, and an intermediate portion, a first side wall extending from the first end toward the second end on a first side of the container, a second side wall including a first end portion extending from the first end toward the second end on a second side of the container, a second sidewall extends from the first end toward the second end, the second sidewall including a second end portion. The container further includes an end door pivotally mounted at the second end of the base portion by a pair of adjustable hinges, the end door disposed in one of a closed position, a first intermediate position, and a fully open position. The pair of adjustable hinges is configured to selectively hold the end door in one of a first intermediate position and a fully open position.

Description

Technical Field

[0001] The exemplary embodiments relate to the field of vehicles, and more particularly, to a cable-free end gate for a pickup truck bed. Background Art

[0002] Many vehicles, such as pickup trucks, include a cargo box for transporting various goods, tools, materials, etc. The cargo box includes end doors that can be opened and closed to selectively provide access to the cargo box. Traditionally, the end doors are pivotally mounted to the cargo box and secured to the cargo box using cables that limit the range of motion of the end doors. These end doors are configured to be used in only one of a closed position and an open position. Summary of the invention

[0003] In one exemplary embodiment, a cargo box for a pickup truck is provided. The cargo box includes a base portion, a first side wall and a second side wall, the base portion including a first end, a second end and a middle portion defining the cargo box, the first side wall extending from the first end toward the second end on a first side of the cargo box, the first side wall including a first end portion, the second side wall extending from the first end toward the second end on a second side of the cargo box, and the second side wall including a second end portion. The cargo box also includes an end door, the end door having a first side portion, a second side portion, a surface extending between the first side portion and the second side portion, and an end portion, the end door being pivotally mounted at the second end of the base portion by a pair of adjustable hinges, the end door being arranged in one of a closed position, a first middle position and a fully open position, in the closed position, the end door is linked to the first side wall and the second side wall, in the first middle position, the end door is arranged at a first angle relative to the base portion, and in the fully open position, the end door is arranged at a second angle greater than the first angle relative to the base portion. The pair of adjustable hinges is configured to selectively maintain the end door in one of the first middle position and the fully open position.

[0004] In addition to one or more features described herein, the end door can be further disposed in a second intermediate position in which the end door is disposed at a third angle relative to the base portion that is greater than the first angle and less than the second angle.

[0005] In addition to one or more of the features described herein, the cargo box also includes a release activation configured to allow the end door to transition directly from the closed position to the fully open position.

[0006] In addition to one or more of the features described herein, the release activator is further configured to allow the end door to transition from the first intermediate position to the closed position or the fully open position.

[0007] In addition to one or more features described herein, the release activator is an end door handle disposed on the second surface of the end door.

[0008] In addition to one or more features described herein, the release activator is a button disposed on one of the first side wall and the second side wall.

[0009] In addition to one or more of the features described herein, in the fully open position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred seventy-seven degrees, in the closed position, the angle between the base portion of the cargo box and the first surface of the end door is approximately ninety degrees, in a first intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred fifty degrees, and in a second intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately 120 degrees.

[0010] In addition to one or more of the features described herein, each of the pair of adjustable hinges includes a hinge pin fixed to one of the first side wall and the second side wall, a positioning cam fixed to the hinge pin, and a pawl configured to selectively engage the positioning cam.

[0011] In addition to one or more of the features described herein, the cargo box also includes a release activation member configured to selectively engage the pawl with the detent cam.

[0012] In addition to one or more of the features described herein, each of the pair of adjustable hinges further includes a control disk configured to prevent the pawl from engaging the detent cam when the end door transitions from the closed position to the fully open position.

[0013] In another exemplary embodiment, a vehicle is provided, the vehicle having a body and a cargo box mechanically connected to the body. The cargo box includes a base portion, a first side wall and a second side wall, the base portion including a first end, a second end and a middle portion defining the cargo box, the first side wall extending from the first end toward the second end on a first side of the cargo box, the first side wall including a first end portion, the second side wall extending from the first end toward the second end on a second side of the cargo box, and the second side wall including a second end portion. The cargo box also includes an end door, the end door having a first side portion, a second side portion, a surface extending between the first side portion and the second side portion, and an end portion, the end door being pivotally mounted at the second end of the base portion by a pair of adjustable hinges, the end door being disposed in one of a closed position, a first middle position, and a fully open position, in which the end door is linked to the first side wall and the second side wall, in the first middle position, the end door is arranged at a first angle relative to the base portion, and in the fully open position, the end door is arranged at a second angle greater than the first angle relative to the base portion. The pair of adjustable hinges are configured to selectively retain the end door in one of a first intermediate position and a fully open position.

[0014] In addition to one or more features described herein, the end door can be further disposed in a second intermediate position in which the end door is disposed at a third angle relative to the base portion that is greater than the first angle and less than the second angle.

[0015] In addition to one or more of the features described herein, the cargo box also includes a release activation member configured to allow the end door to transition directly from the closed position to the fully open position.

[0016] In addition to one or more of the features described herein, the release activator is further configured to allow the end door to transition from the first intermediate position to the closed position or the fully open position.

[0017] In addition to one or more features described herein, the release activator is an end door handle disposed on the second surface of the end door.

[0018] In addition to one or more features described herein, the release activator is a button disposed on one of the first side wall and the second side wall.

[0019] In addition to one or more of the features described herein, in the fully open position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred seventy-seven degrees, in the closed position, the angle between the base portion of the cargo box and the first surface of the end door is approximately ninety degrees, in a first intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred fifty degrees, and in a second intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately 120 degrees.

[0020] In addition to one or more of the features described herein, each of the pair of adjustable hinges includes a hinge pin fixed to one of the first side wall and the second side wall, a positioning cam fixed to the hinge pin, and a pawl configured to selectively engage the positioning cam.

[0021] In addition to one or more of the features described herein, the cargo box also includes a release activation member configured to selectively engage the pawl with the detent cam.

[0022] In addition to one or more of the features described herein, each of the pair of adjustable hinges further includes a control disk configured to prevent the pawl from engaging the detent cam when the end door transitions from the closed position to the fully open position.

[0023] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Other features, advantages and details appear, by way of example only, in the following detailed description, which refers to the accompanying drawings, in which:

[0025] Figure 1A is a perspective view of a vehicle having an end door, depicted in a closed configuration, according to an exemplary embodiment;

[0026] Figure 1B According to an exemplary embodiment Figure 1A a perspective view of a vehicle of , depicting the end door in a fully open configuration;

[0027] Figure 2A and 2B is a side view of an example hinge assembly according to an exemplary embodiment;

[0028] Figure 2C is an exploded view of an example hinge assembly according to an exemplary embodiment;

[0029] Figure 3A , 3B, 3C and 3D are side views of an example hinge assembly in a closed position, a first intermediate position, a second intermediate position, and a fully open position, respectively, according to an exemplary embodiment; and

[0030] Figure 4A is a side view of an example hinge assembly in a closed position according to an exemplary embodiment;

[0031] Figure 4B is a side view of an example hinge assembly transitioning from a closed position to a fully open position according to an exemplary embodiment;

[0032] Figure 4C is a side view of an example hinge assembly in a fully open position according to an exemplary embodiment;

[0033] Figure 4D is a side view of an example hinge assembly in a first intermediate position according to an exemplary embodiment; and

[0034] Figure 4E is a side view of an example hinge assembly in a second intermediate position according to an exemplary embodiment. DETAILED DESCRIPTION

[0035] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0036] According to an exemplary embodiment, a cable-free end door for a cargo box of a vehicle is provided. The cable-free end door is pivotally mounted to the cargo box of a vehicle (e.g., a pickup truck) via a hinge assembly that controls the relative position of the end door to the cargo box. Notably, the hinge assembly is configured to selectively secure the end door to one of a plurality of positions relative to the cargo box without the use of cables. In addition, the hinge assembly allows the end door to be securely placed in an intermediate position between a fully open position and a fully closed position.

[0037] In one embodiment, the hinge assembly is configured to allow the end door to transition directly from the closed position to the fully open position without stopping at any intermediate position between the closed position and the fully open position. In addition, the hinge assembly is configured to allow the end door to transition from the closed position to one of the first intermediate position, the second intermediate position, and the closed position. In addition, the hinge assembly is configured to allow the end door to transition from the first intermediate position to one of the second intermediate position, the fully open position, and the closed position. Likewise, the hinge assembly is configured to allow the end door to transition from the second intermediate position to one of the first intermediate position, the fully open position, and the closed position.

[0038] Reference Figure 1A and Figure 1B, a motor vehicle such as a pickup truck according to an exemplary embodiment is generally indicated at 4. The motor vehicle 4 includes a body 6 including a passenger compartment or cab 9. In the exemplary embodiment shown, the motor vehicle 4 includes a cargo box 12 having a first end 15 disposed adjacent the cab 9, a second end 17, and a base portion 20 extending between the first end 15 and the second end 17. The cargo box 12 also includes a first side wall 22 and an opposing second side wall 23. The first side wall 22 and the second side wall 23 extend between the first end 15 and the second end 17.

[0039] The cargo box 12 includes an end door 30 pivotally mounted between the first side wall 22 and the second side wall 23 at the second end 17. The end door 30 includes a body 36 having a first surface 38, an opposing second surface 40, and an end portion 42. The end door 30 also includes a first side portion 44 and a second side portion 46. The end portion 42 extends between the first side portion 44 and the second side portion 46. The end door 30 is pivotally mounted to both the first side wall 22 and the second side wall 23 via hinge assemblies 60 disposed on the first side portion 44 and the second side portion 46 of the end door 30.

[0040] The end door 30 includes a release mechanism 90 configured to interact with the hinge assembly 60. Figure 1A As shown, the release mechanism 90 includes an end door handle 50 disposed on the second surface 40 of the end door 30. In another embodiment, as shown in FIG. Figure 1B As shown, the release mechanism 90 includes a button 52 disposed on the end door 30. For example, on the first surface 38 or the side portions 44, 46 of the end door 30. The release mechanism 90 selectively activates the hinge assembly 60 to allow movement of the end door 30. The release mechanism 90 is partially enclosed within the end door 30 and includes an actuator or release element extending from within the end door 30 through the first side portion 44 and the second side portion 46. The release mechanism 90 also includes a pawl that can selectively protrude through the hinge assembly 60.

[0041] Reference now Figure 2A , 2B2C, various views of an example hinge assembly 100 according to an exemplary embodiment are shown. As shown, the hinge assembly 100 includes an attachment portion 110, which is configured to secure the hinge assembly 100 to the end door. The attachment portion 110 includes a side member 112 and a bottom member 114, each of which includes a hole 116, and the hole 116 is configured to secure the attachment portion 110 to the end door. The hinge assembly 100 includes a hinge body 118 connected to the attachment portion 110. In one embodiment, the hinge body 118 is integrally formed with the attachment portion 110. In another embodiment, the hinge assembly 100 may include the attachment portion 110, the side member 112, the bottom member and the hinge body 118 that have been welded together. The hinge body 118 includes an opening 115 configured to receive the positioning cam 124. The opening 115 includes an inner surface 113 that is configured to interact with the positioning cam 124 to limit rotational movement of the positioning cam 124 within the opening 115 .

[0042] The hinge assembly 100 also includes a hinge pin 120 connected to a positioning cam 124. In one embodiment, the hinge pin 120 is integrally formed with the positioning cam 124. The hinge pin 120 is configured to be fixed to one of the side walls of the cargo box. In one embodiment, the hinge pin 120 includes a hole 122 configured to receive a pin or a bolt to fix the hinge pin 120 to the side wall of the cargo box. The hinge assembly 100 may also include a cover 150 that is configured to surround the hinge body 118 and only allow the hinge pin 120 to protrude through the cover 150.

[0043] In one embodiment, the hinge assembly 100 further includes a control disk (not shown) disposed in the opening 115 of the hinge body 118. In one embodiment, the control disk is configured to rotate about the hinge pin 120. In one embodiment, the positioning cam 124 of the hinge assembly 100 is configured to facilitate the end door to transition directly from the closed position to the fully open position without stopping at any intermediate position between the closed position and the fully open position.

[0044] The hinge assembly 100 also includes a pawl 106 disposed within the opening 115 of the hinge body 118. The pawl 106 is connected to a release element 102, which is configured to control the movement of the pawl 106. In an exemplary embodiment, the release element 102 is part of the release mechanism 90 shown in FIG. 1. In an exemplary embodiment, the pawl 106 is configured to interact with one or both of the positioning cam 124 and the control disk to control the rotation of the hinge body 118 about the hinge pin 120. In one embodiment, the button 52 of the release mechanism 90 selectively disengages the pawl 106 from the positioning cam 124 when the end door 30 is in one of the intermediate positions.

[0045] The hinge assembly is configured to allow the end door to transition from the closed position to one of the first intermediate position, the second intermediate position, and the open position. In addition, the hinge assembly is configured to allow the end door to transition from the first intermediate position to one of the second intermediate position, the fully open position, and the closed position. In one embodiment, in order to transition the end door from the first intermediate position to the fully open position, the button 52 of the release mechanism 90 must be activated. Similarly, the hinge assembly is configured to allow the end door to transition from the second intermediate position to one of the first intermediate position, the fully open position, and the closed position. In one embodiment, in order to transition the end door from the second intermediate position to the first intermediate position or the fully open position, the button 52 of the release mechanism 90 must be activated. That is, the end door can be raised without activating the button 52 of the release mechanism 90, but in order to lower the end door from the first intermediate position or the second intermediate position, the button 52 of the release mechanism 90 must be activated.

[0046] Reference now Figure 3A , 3B 3C and 3D respectively show side views of an example hinge assembly 100 in a closed position, a first intermediate position, a second intermediate position, and a fully open position according to an exemplary embodiment. Figure 3A As shown, when the hinge assembly 100 is in the closed position, the pawl 106 is not engaged with the positioning cam 124, and the positioning cam 124 has clearance to the inner surface 113 of the hinge body. Figure 3D As shown, when the hinge assembly 100 is in the fully open position, the pawl 106 is not engaged with the positioning cam 124, and the positioning cam 124 is in contact with the inner surface 113 of the hinge body. Figure 3B As shown, when the hinge assembly 100 is in the first intermediate position, the pawl 106 is engaged with the positioning cam 124, and the positioning cam 124 is not in contact with the inner surface 113 of the hinge body. Figure 3C As shown, when the hinge assembly 100 is in the second intermediate position, the pawl 106 is engaged with the positioning cam 124, and the positioning cam 124 is not in contact with the inner surface 113 of the hinge body.

[0047] In one embodiment, Figure 3D In the fully open position shown, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred and seventy-seven degrees. Figure 3A As shown, the angle between the base portion of the container and the first surface of the end door is approximately 90 degrees. Figure 3B As shown, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred and fifty degrees. Figure 3CAs shown, the angle between the base portion of the cargo box and the first surface of the end door is approximately 120 degrees. In some embodiments, the hinge assembly can be configured to have additional intermediate positions and alternative opening angle stops, not limited to the angles disclosed herein.

[0048] Reference now Figure 4A , 4B , 4C, 4D and 4E, side views of an example hinge body 218 in various positions are shown according to an exemplary embodiment. As shown, the hinge body 218 includes a stop 217 disposed on an inner surface of the hinge body 218. The hinge body 218 also includes a pawl 206 pivotally mounted to the hinge body 218. The hinge body 218 further includes a positioning cam 224 and a control disk 230 configured to rotate within the hinge body 218. In one embodiment, the positioning cam 224 is fixed to a hinge pin 220 protruding from the hinge body 218 or is formed internally with a hinge pin 220 protruding from the hinge body 218. The hinge pin 220 is configured to be fixed to a side wall of a cargo box of a vehicle.

[0049] In one embodiment, the positioning cam 224 includes one or more recesses 227, 229, each recess 227, 229 corresponding to an intermediate position of the hinge body 218. When the positioning cam 224 rotates within the hinge body 218, the pawl 206 selectively engages the recess to fix the relative position of the hinge body 218 and the hinge pin 220, and by extension, fixes the relative position of the cargo box and the end door. The positioning cam 224 includes an end portion 225, which is configured to contact the stop portion 217 of the hinge body 218 when the hinge body 218 is in the fully open position, as shown in FIG. Figure 4C shown.

[0050] In one embodiment, the positioning cam 224 includes a protrusion 226 configured to extend through a slot 232 of the control disk 230. The protrusion 226 and the slot 232 are configured to control the position of the control disk 230 through the cycle of the hinge. Figure 4B As shown, the positioning cam / gear 224 includes a first surface 231 that is configured to initially lift the pawl 206 when the door is closed. The control disk 230 will then engage the pin on the pawl 206, which prevents the pawl 206 from being moved on the hinge body 218 as shown. Figure 4A The closed position shown is changed to Figure 4CThe fully open position shown engages with the recesses 227, 229 of the positioning cam / gear 224. As the door approaches fully open, the protrusion 226 of the positioning cam / gear 224 reaches the end portion of the slot 232 of the control disk 230. As a result, the control disk 230 stops rotating. As the hinge body 218 and the pawl 206 continue to the fully open position, the pawl pin slides off the surface of the control disk 230 and engages the positioning cam / gear 224.

[0051] Once the hinge body 218 reaches the fully open position, Figure 4C As shown, the end portion 225 is configured to contact the stop 217 of the hinge body 218 to stop the rotation of the positioning cam 224 within the hinge body 218, thereby maintaining the end door in the open position. When the positioning cam 224 rotates back toward the closed position, the control disk 230 remains in a fixed position relative to the positioning cam / gear 224. When the door is closed, the pawl 206 is allowed to engage with the recesses 227, 229 corresponding to the intermediate position, as shown in FIG. Figure 4D and 4E shown.

[0052] The terms "a" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0053] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0054] Unless stated to the contrary herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0055] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0056] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A cargo box for a pickup truck, comprising: a base portion including a first end, a second end, and a middle portion defining the cargo box; a first side wall extending from the first end toward the second end on a first side of the container, the first side wall including a first end portion; a second side wall extending from the first end toward the second end on a second side of the container, the second side wall including a second end portion; as well as an end door having a first side portion, a second side portion, a surface extending between the first side portion and the second side portion, and an end portion, the end door being pivotally mounted at the second end of the base portion by a pair of adjustable hinges, the end door being disposed in one of a closed position, in which the end door is linked to the first side wall and the second side wall, a first intermediate position in which the end door is disposed at a first angle relative to the base portion, and a fully open position in which the end door is disposed at a second angle relative to the base portion that is greater than the first angle, Wherein the pair of adjustable hinges is configured to selectively retain the end door in one of a first intermediate position and the fully open position.

2. The container of claim 1, wherein the end door is further positionable in a second intermediate position, in which the end door is arranged at a third angle relative to the base portion that is greater than the first angle and less than the second angle.

3. The cargo box of claim 2, further comprising a release activation member configured to allow the end door to transition directly from the closed position to the fully open position.

4. The cargo box of claim 3, wherein the release activator is further configured to allow the end door to transition from a first intermediate position to the closed position or the fully open position.

5. The cargo box of claim 3, wherein the release activator is an end door handle disposed on the second surface of the end door.

6. The cargo box of claim 3, wherein the release activator is a button disposed on one of the first side wall and the second side wall.

7. The cargo box of claim 3, wherein in the fully open position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred and seventy-seven degrees, in the closed position, the angle between the base portion of the cargo box and the first surface of the end door is approximately ninety degrees, in a first intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately one hundred and fifty degrees, and in a second intermediate position, the angle between the base portion of the cargo box and the first surface of the end door is approximately 120 degrees.

8. The cargo box of claim 1, wherein each of the pair of adjustable hinges includes a hinge pin secured to one of the first side wall and the second side wall, a detent cam secured to the hinge pin, and a pawl configured to selectively engage the detent cam.

9. The cargo box of claim 8, further comprising a release activation member configured to selectively engage the pawl with the detent cam.

10. The cargo box of claim 9, wherein each of the pair of adjustable hinges further comprises a control disk configured to prevent the pawl from engaging the detent cam when the end door transitions from the closed position to the fully open position.

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