Lightweight tailgate for a pickup truck

Abstract

Tailgate (12) for a pickup truck (10), comprising: an external cladding (28); an inner paneling (16) which is attached to the outer paneling (28); a reinforcement extending in a transverse direction (30) comprising a U-shaped body (76) with a rounded surface (78) between an upper leg (80) having an upper flange (82) and a lower leg (84) having a lower flange (86), a lower reinforcement (32) extending in a transverse direction, which is attached between the inner and outer sheathing (16, 28) and arranged under the reinforcement (30) extending in a transverse direction; a locking retainer (48) which is connected to the upper leg (80) of the reinforcement (30) and extends upwards from it and is designed to support a locking arrangement (50) for locking the tailgate (12) in a closed position; and a handle reinforcement (52) which is attached at a lower end of the handle reinforcement (52) to the locking holder (48), extends to the outer paneling (28) and is attached at an upper end of the handle reinforcement (52) to the outer paneling (28), characterized by the fact that the rounded surface (78) is connected to an inner surface of the outer sheathing (28) with a structural adhesive (90) and the upper and lower flanges (82, 86) are connected to the inner sheathing (16) by fasteners (88).

Description

TECHNICAL AREA

[0001] The invention relates to tailgates for pickup trucks made of lightweight panels which are less ductile than conventional panels made of mild steel. BACKGROUND

[0002] The use of lightweight materials, including aluminum body panels, is increasing due to the need to meet stringent fuel economy targets. Lightweight materials include aluminum, fiber-reinforced composites, magnesium components, and the like. These materials present challenges due to reduced ductility and formability. Furthermore, aluminum panels, reinforcements, and brackets have reduced tensile strength and are more difficult to weld.

[0003] Tailgates for pickup trucks are generally manufactured with an outer and an inner panel, which are joined together and both have Class A finishes visible on the vehicle. One challenge in tailgate manufacturing involves creating panel surfaces free of cracks or creases in the corners of the inner panel. Another challenge is ensuring that the inner and outer panels are adequately reinforced to prevent "minor sheet metal warping," a condition in which the paneling flexes when pressure is applied to either the inner or outer panel. A further challenge is providing durable mounting points for connecting hinges and latches. Tailgates for pickup trucks and possibilities for stiffening sheet metal are disclosed in the generic prior art US 6 199 930 B1 as well as in US 2005 / 0 057 064 A1, JP 2002 - 37 136 A and CN 2 01 545 081 U.

[0004] The object underlying the invention is therefore to provide tailgates for pickup trucks with stable yet visually appealing paneling.

[0005] The problem is solved by the subject matter of the independent claims. Advantageous embodiments are specified in the dependent claims. SUMMARY

[0006] According to an aspect of the present disclosure that is useful for understanding the invention but is not covered by the claims, a tailgate for a pickup truck is disclosed, comprising an outer panel and an inner panel having a bottom wall and two side walls at the right and left corners. A pair of hinges, each with a transverse leg and a vertical leg, are attached outside each of the corners and are connected to a pair of reinforcement brackets attached inside the corners. The reinforcement brackets each comprise a side wall flange and a bottom flange, which are connected by an intermediate section forming the hypotenuse of a triangle extending between the transverse and vertical legs of the hinges.

[0007] According to other aspects of the present disclosure that are useful for understanding the invention but are not covered by the claims, the intermediate flange of each of the reinforcement holders can be spaced apart from the respective right and left corners of the inner paneling. The reinforcement holders can include an upper rounded area between the side wall flange and the intermediate section, and between the lower flange and the intermediate section. The rounded surfaces act to accommodate part variations and the accumulation of tolerances in the inner paneling and the hinges. The tailgate can further comprise several press-fit nuts attached to each of the side wall flanges and the lower flanges, designed to receive a threaded fastening element for attaching the hinges to the inner paneling.The transverse leg, the bottom wall, and the lower flange can be joined in a surface-to-surface orientation, and the vertical leg, the side wall, and the side wall flange are joined in a surface-to-surface orientation. The reinforcing brackets, the inner sheathing, and the outer sheathing are preferably made of aluminum, and the hinge is preferably made of steel.

[0008] According to the invention, a tailgate for a pickup truck is provided, comprising an outer panel and an inner panel attached to the outer panel. A transversely extending reinforcement is provided, which has a U-shaped body with a rounded surface between an upper leg having an upper flange and a lower leg having a lower flange. The rounded surface is bonded to an inner surface of the outer panel with a structural adhesive. The upper and lower flanges are connected to the inner panel by fasteners.

[0009] A locking bracket is provided, which is connected to the upper leg of the transversely extending reinforcement and extends upwards from it, supporting a locking mechanism for locking the tailgate in a closed position. The locking mechanism can be mechanical or electronic. The tailgate further comprises a handle reinforcement, which is attached to the locking bracket at its lower end, extends to the outer paneling, and is attached to the outer paneling at its upper end. The tailgate also includes a transversely extending reinforcement, which is attached between the inner and outer paneling and located beneath the transversely extending reinforcement.

[0010] According to another aspect of the invention, a tailgate for a pickup truck is provided, comprising an outer panel and an inner panel defining an access opening. The access panel has an upper rebate formed on an upper flange and a lower rebate formed on a lower flange. The access panel defines several fastening element openings on the flanges, spaced apart from the rebates. Several fasteners are inserted into the fastening element openings to connect the access panel to the inner panel.

[0011] The access panel can extend transversely across the inner paneling from a right side wall to a left side wall. The access cover can be removed to provide access to a locking mechanism and a handle for assembly and servicing. The tailgate can also include several vertically extending cutouts or recessed grooves formed in a central area of ​​the access paneling to increase its rigidity. Furthermore, the tailgate can include several vertically extending cutouts or recessed grooves formed in a central area of ​​the inner paneling to increase its rigidity.Furthermore, the tailgate may also include several horizontally extending recesses or recessed grooves formed in the inner paneling on opposite lateral sides of the central upper area of ​​the inner paneling to increase the rigidity of the inner paneling.

[0012] The above aspects are described below with reference to the attached drawing figures. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a perspective view of a pickup truck from the rear right with the tailgate in an open position; Fig. Figure 2 is a perspective interior view of a tailgate assembly; Fig. 3 is a stretched perspective view of the in Fig. 2 tailgate arrangement shown; Fig. Figure 4 is a cross-sectional view along line 4-4 in Fig. 2; Fig. Figure 5 is a cross-sectional view along line 5-5 in Fig. 2; and Fig. Figure 6 is a cross-sectional view along line 6-6 in Fig. 2. DETAILED DESCRIPTION

[0013] The embodiments shown are disclosed with reference to the drawings. It is understood, however, that the disclosed embodiments are merely examples that can be implemented in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of certain components. The specific structural and functional details disclosed here are not to be interpreted as limiting, but rather as a representative basis for teaching a person skilled in the art how to implement the disclosed concepts.

[0014] On Fig. Figure 1 shows a pickup truck 10 with a tailgate 12 in an open position. The tailgate 12 includes an inner panel 16 and an access panel 18, which is attached to the inner panel 16. The inner panel 16 and the access panel 18 have several vertical recesses 20 and horizontal recesses 22. The vertical recesses 20 and the horizontal recesses 22 stiffen the inner panel 16 and the access panel 18. The recesses 20 and 22 also facilitate loading and unloading the pickup truck 10. Several vertical recesses 20 are provided in the central area 24 of the tailgate 12. When referring to the vertical recesses 20, the term "vertical" refers to the orientation of the recesses when the tailgate 12 is closed. When the tailgate 12 is open, the vertical recesses 20 actually extend in a horizontal plane.

[0015] On the Fig. 2 and Fig. 3 With reference to, a tailgate is generally specified by the reference number 12 and includes the interior paneling 16 and the access paneling 18, as above with reference to Fig. 1 described. The outer sheathing 28 is separated from the inner sheathing 16 in the drawing, and the access sheathing 18 is also separated from the inner sheathing 16. A transverse reinforcement 30 or upper brace is shown between the inner sheathing 16 and the outer sheathing 28. A transverse lower reinforcement 32 or lower brace is shown below the transverse reinforcement 30.

[0016] Two hinge reinforcement brackets 36 are in Fig. 2 shown. Although in Fig. Since only one hinge reinforcement bracket 36 is shown, it should be obvious that a mirror image of the hinge reinforcement bracket 36 and the hinge plate 38 would be provided on the opposite side of the tailgate 12. A hinge plate 38 is attached to the hinge reinforcement bracket 36 by the inner panel 16.

[0017] The interior paneling 16 includes a floor wall 40 and a right side wall 42 on the right side of the tailgate 12. References to the right and left side herein refer to the right and left sides of the vehicle in the direction of travel. The left side wall 44 is formed as part of the interior paneling 16. The floor wall 40 extends between the right side wall 42 and the left side wall 44.

[0018] A locking bracket 48 is attached to the transversely extending reinforcement 30. A locking assembly 50 is shown schematically and is attached to the locking bracket 48 in the illustration. The locking assembly 50 can be a mechanical lock containing connecting elements extending to the right side wall 42 and the left side wall 44. Alternatively, the locking assembly 50 can be an electronic locking assembly electrically connected to locking solenoids associated with the right side wall 42 and the left side wall 44. A handle reinforcement 52 extends upwards from the locking bracket 48 and is provided to reinforce the area of ​​the outer paneling 28 where a handle (not shown) is attached to the tailgate 12.

[0019] On Fig. With reference to Figure 4, a lower corner 54 of the inner sheathing 16 is shown in cross-section to illustrate the reinforcement structure for the hinge. The hinge plate 38 includes a transverse leg 56 and a vertical leg 58. The transverse leg 56 is attached to the bottom wall 40 of the inner sheathing 16. The vertical leg 58 is attached to the left side wall 44 of the inner sheathing 16. The hinge reinforcement bracket 36 includes a side wall flange 60, which is attached within the inner sheathing 16 and is connected in an area-to-area relationship to the left side wall 44 of the inner sheathing 16 and the vertical leg 58 of the hinge plate 38. The hinge reinforcement holder 36 further includes a lower flange 62, which is attached inside the left side wall 44 of the inner paneling 16 and the cross leg 56 of the hinge plate 38.The lower flange 62, the bottom wall 40, and the transverse leg 56 are joined in a surface-to-surface relationship. An intermediate section 64 of the hinge reinforcement holder 36 extends diagonally between the side wall flange 60 and the lower flange 62 of the hinge reinforcement holder 36. The intermediate section 64 forms the hypotenuse of a triangular area formed by the transverse leg 56 and the vertical leg 58 of the hinge plate 38. The intermediate section 64 defines a clearance with respect to the lower corner 54 of the inner panel 16. A clearance is also defined between the lower corner 54 and the hinge plate 38 on the outside of the inner panel 16. These clearances allow for tolerance accumulation and variation in the shape of the lower corner 54 during the drawing process and can accommodate any springback that occurs after the formation of the inner panel 16.

[0020] An upper rounded area 68 is provided between the intermediate part 64 and the side wall flange 60. A lower rounded area 70 is provided between the intermediate part 64 and the lower flange 62. The rounded areas 68 and 70 also facilitate assembly by allowing a limited degree of play when the hinge reinforcement holder 36 is attached within the lower corner 54 of the inner panel 16. Press-fit nuts 72 are attached to the side wall flange 60 and the lower flange 62 and are designed to receive fasteners 74, which are inserted through holes formed in the hinge plate 38, the bottom wall 40, and the left side wall 44 of the inner panel 16. Holes are also provided in the side wall flange 60 and the lower flange 62.The fasteners 74 attach the hinge reinforcement bracket 36 to the inside of the inner panel 16 at the lower corner 54, while the hinge plate 38 is attached to the lower corner 54 of the inner panel 16 to partially enclose the outer surface of the lower corner 54. The hinge plate 38 is preferably made of steel or another durable alloy, while the hinge reinforcement bracket 36 and the inner panel 16 are made of an aluminum alloy to reduce the vehicle weight. The other main components of the tailgate 12 are also made of aluminum, including the transverse reinforcement 30 and the lower transverse reinforcement 32.

[0021] With reference to Fig. Figure 5 shows the transverse reinforcement 30 in its attached state between the inner sheathing 16 and the outer sheathing 28. The transverse reinforcement 30 is formed with a U-shaped body 76, which has a rounded surface 78 designed for adhesive bonding with the outer sheathing 28. An upper leg 80 and an upper flange 82 extend from the outer sheathing 28 to the inner sheathing 16 on the upper side of the transversely extending reinforcement 30. A lower leg 84 and a lower flange 86 extend from the outer sheathing 28 to the inner sheathing 16 below the upper leg 80. The upper flange 82 and the lower flange 86 are fastened by rivets 88 that extend through the inner sheathing 16 and into the upper flange 82 and the lower flange 86. Although in Fig. The five rivets 88 shown are understood to represent other single-sided fasteners, or the fasteners may be conventional threaded fasteners that are inserted into press-fit nuts or the like to hold the transversely extending reinforcement 30 in engagement with the inner sheathing 16. A structural adhesive 90 is applied between the rounded surface 78 of the U-shaped body 76 and the outer sheathing 28. The structural adhesive 90 is used to attach the outer sheathing to the reinforcement 30 without forming a visible fastener or mark on the outer surface of the outer sheathing 28.

[0022] With reference to Fig.Figure 6 shows the access panel 18 separated from the inner panel 16. An access opening 94 is defined by the inner panel 16 and covered by the access panel 18 when the access panel 18 is attached to the inner panel 16. The access panel includes an upper rebate 96 formed in an upper flange 98 of the access panel 18. A lower rebate 100 is formed on the lower flange 102 of the access panel 18. Fastener openings 104 are formed in the upper flange 98 and in the lower flange 102, which are offset inwards on the access panel 18 with respect to the upper rebate 96 and the lower rebate 100. The fastening element openings 104 are aligned with holes 106 formed in the inner paneling 16, and press-fit nuts 108 are provided within the inner paneling 16 in alignment with the fastening element openings 104 and the holes 106.Fastening elements 110 are inserted through the access panel 18 and the inner panel 16 and tightened in the press-fit nuts 108 to attach the access panel 18 to the inner panel 16 after the tailgate has been assembled with the locking assembly 50 and other internal components of the tailgate 12 have been attached. The access panel 18 can be removed to provide access for maintenance of internal components of the tailgate 12.

Claims

[1] Tailgate (12) for a pickup truck (10), comprising: an external cladding (28); an inner paneling (16) which is attached to the outer paneling (28); a reinforcement extending in a transverse direction (30) comprising a U-shaped body (76) with a rounded surface (78) between an upper leg (80) having an upper flange (82) and a lower leg (84) having a lower flange (86), a lower reinforcement (32) extending in a transverse direction, which is attached between the inner and outer sheathing (16, 28) and arranged under the reinforcement (30) extending in a transverse direction; a locking retainer (48) which is connected to the upper leg (80) of the reinforcement (30) and extends upwards from it and is designed to support a locking arrangement (50) for locking the tailgate (12) in a closed position; and a handle reinforcement (52) which is attached at a lower end of the handle reinforcement (52) to the locking holder (48), extends to the outer paneling (28) and is attached at an upper end of the handle reinforcement (52) to the outer paneling (28), characterized by , that the rounded surface (78) is connected to an inner surface of the outer sheathing (28) with a structural adhesive (90) and the upper and lower flanges (82, 86) are connected to the inner sheathing (16) by fasteners (88). [2] Tailgate according to claim 1, wherein the locking arrangement (50) is a mechanical locking arrangement. [3] Tailgate according to claim 1, wherein the locking arrangement (50) is an electronic locking arrangement. [4] Tailgate (12) for a pickup truck (10), comprising: an external cladding (28) and an interior paneling (16) defining an access opening (94); characterized by an access panel (18) having an upper rebate (96) formed on an upper flange (98) and a lower rebate (100) formed on a lower flange (102), wherein the access panel (18) defines several fastening element openings (104) on the flanges (98, 102), the fastening element openings (104) being offset inwards with respect to the upper rebate (96) and the lower rebate (100); and several fastening elements (110) inserted into the fastening element openings (104) to connect the access paneling (18) to the inner paneling (16). [5] Tailgate (12) according to claim 4, wherein the access paneling (18) extends in a transverse direction over the inner paneling (16) from a right side wall (42) to a left side wall (44). [6] Tailgate (12) according to claim 4, wherein the access panel (18) can be removed to provide access to a locking arrangement (50) and a handle arrangement for assembly and servicing. [7] Tailgate (12) according to claim 4, further comprising several vertically extending recesses (20) formed in the access panel (18) in a central area (24) of the tailgate (12) to increase the stiffness of the access panel (18). [8] Tailgate according to claim 4, further comprising several vertically extending recesses (20) formed in the inner paneling (16) in a central area (24) of the tailgate (12) to increase the stiffness of the inner paneling (16). [9] Tailgate (12) according to claim 8, further comprising several horizontally extending recesses (22) formed in the inner paneling (16) on opposite lateral sides of the central area (24) of the tailgate (12) to increase the stiffness of the inner paneling (16).

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