Torsion bar anchor for a vehicle tailgate assembly

Abstract

A tailgate assembly includes a frame subassembly for a tailgate. The frame subassembly has a first strut positioned adjacent to a second strut to provide a connecting member with a hollow structural part. The assembly further includes a torsion bar and a torsion bar anchor. The torsion bar is located at least partially within the hollow structural part. The torsion bar anchor has a bar receiving opening that receives an end section of the torsion bar to anchor it.

Description

FIELD OF TECHNOLOGY

[0001] This disclosure relates generally to a tailgate assembly and, more particularly, to a tailgate torsion bar anchor. GENERAL STATE OF THE ART

[0002] Many motor vehicles typically include cargo spaces for carrying various types of cargo. A pickup truck, for example, includes a bed that defines the pickup's cargo area. A tailgate typically closes one end of the bed. The tailgate can be moved between a closed and an open position to provide access to the bed. SUMMARY

[0003] In some aspects, the techniques described herein relate to a tailgate assembly including: a frame subassembly for a tailgate, the frame subassembly having a first strut positioned adjacent a second strut to provide a connecting beam with a hollow structural member; a torsion bar disposed at least partially within the hollow structural member; and a torsion bar anchor having a bar receiving opening that receives an end portion of the torsion bar to anchor the end portion of the torsion bar.

[0004] In some aspects, the techniques described herein relate to a tailgate assembly further including: a bed access opening between a driver side portion and a passenger side portion of the frame subassembly, the hollow structural portion extending between the driver side portion and the passenger side portion; and a door subassembly pivotally coupled to the frame subassembly, the door subassembly pivotable relative to the frame subassembly between an open door position and a closed door position, the door subassembly closing the bed access opening when the door subassembly is in the closed door position.

[0005] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the connecting beam extends along a bottom surface of the bed access opening.

[0006] In some aspects, the techniques described in this document relate to a liftgate assembly wherein the torsion bar is preloaded to assist pivotal movement of the frame subassembly and the door subassembly from an open liftgate position to a closed liftgate position.

[0007] In some aspects, the techniques described in this document relate to a liftgate assembly, wherein the frame subassembly and the door subassembly pivot together about a horizontally extending axis between an open liftgate position and a closed liftgate position, wherein the door subassembly pivots relative to the frame subassembly about a vertically extending axis between an open door position and a closed door position.

[0008] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the first strut and the second strut each have a C-shaped cross-sectional profile.

[0009] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the first strut and the second strut overlap each other when placed adjacent to each other to provide the connecting beam to the hollow structural member.

[0010] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the torsion bar anchor provides an entire circumferential perimeter of the bar receiving opening.

[0011] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the torsion bar anchor includes no more than one piece.

[0012] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the torsion bar anchor is completely contained within the hollow structural member.

[0013] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the rod receiving opening includes a planar side aligned with a planar portion within the end portion of the torsion bar.

[0014] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the torsion bar anchor is a polymer-based material.

[0015] In some aspects, the techniques described in this document relate to a tailgate assembly further including a set screw engaging the torsion bar anchor and extending partially into the bar receiving opening to secure the end portion of the torsion bar within the bar receiving opening.

[0016] In some aspects, the techniques described in this document relate to a tailgate assembly further including an anchoring fastener that directly secures the torsion bar anchor to the connecting beam.

[0017] In some aspects, the techniques described in this document relate to a tailgate assembly wherein the connecting bracket includes an access opening to provide access to the anchor fastener.

[0018] In some aspects, the techniques described in this document relate to a method of torsion bar anchoring for a tailgate, including: positioning a torsion bar anchor within a hollow structural member provided by a connecting beam of a tailgate; and receiving an end portion of a torsion bar within a bar receiving opening of the torsion bar anchor to anchor the end portion of the torsion bar.

[0019] In some aspects, the techniques described in this document relate to a method of torsion bar anchoring for a liftgate, further including securing the torsion bar anchor directly to the connecting beam.

[0020] In some aspects, the techniques described in this document relate to a method of torsion bar anchoring for a tailgate, further including assisting pivoting of the tailgate using the torsion bar.

[0021] In some aspects, the techniques described in this document relate to a method of torsion bar anchoring for a tailgate, wherein the torsion bar is at least partially disposed within the hollow structural member.

[0022] The embodiments, examples, and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be considered independently of one another or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are inconsistent. SHORT DESCRIPTION OF THE CHARACTERS

[0023] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The figures accompanying the detailed description may be briefly described as follows: Fig. 1 is a rear perspective view of a motor vehicle equipped with a cargo space and a tailgate assembly positioned in a closed tailgate position relative to the cargo space. Fig. 2 illustrates the tailgate assembly from Fig. 1 in an open position of the tailgate. Fig. 3 illustrates a door subassembly of the tailgate assembly of Fig. 1 in an open door position. Fig. 4 is a rear and top view of the tailgate assembly and door subassembly of Fig. 3. Fig. 5 is a view of a frame subassembly from the tailgate assembly Fig. 1, with selected sections removed. Fig. 6 illustrates a perspective view of a connecting beam from the tailgate assembly Fig. 1 with a torsion bar and a torsion bar anchor in a non-installed position. Fig. Figure 7 illustrates a sectional view along line 7-7 in Fig. 6. Fig. Figure 8 illustrates a perspective view of the connecting beam from the tailgate assembly Fig. 1 with the built-in torsion bar and torsion bar anchor. Fig. Figure 9 illustrates a sectional view taken along line 9-9 in Fig. 8. Fig. 10 illustrates a perspective view of an end portion of the torsion bar received within a bar receiving opening of the torsion bar anchor. Fig. Figure 11 illustrates a perspective view of the torsion bar anchor. DETAILED DESCRIPTION

[0024] This disclosure describes in detail exemplary liftgate assemblies that include torsion bars, and particularly anchors for these torsion bars. The liftgate assemblies may include a frame subassembly and a door subassembly that pivot together about a horizontal liftgate axis. The door subassembly may also pivot relative to the frame assembly about a vertical door axis.

[0025] Fig. 1-4 illustrate selected portions of a motor vehicle 10 including a cargo space for storing and / or transporting cargo. In the illustrated embodiment, the vehicle 10 is a pickup truck, and the cargo space is formed by a bed 14 of the pickup truck. Although this specification specifically depicts and refers to a pickup truck with a bed, other vehicles having other types of cargo spaces could also benefit from the teachings of this disclosure. The vehicle 10 could be a conventional vehicle powered by an internal combustion engine, an electric or hybrid vehicle powered by a traction battery, an autonomous vehicle (i.e., a driverless vehicle), etc.

[0026] Although a specific relationship of components is illustrated in the figures of this disclosure, the illustrations are not intended to be limiting of this disclosure. The placement and orientation of the various components of the vehicle 10 are shown schematically and could vary within the scope of this disclosure. Additionally, the various figures accompanying this disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to emphasize certain details of a particular component.

[0027] The cargo bed 14 is generally located behind a passenger compartment (not shown) of the vehicle 10 and includes a floor 18 extending between a pair of longitudinally extending side walls 22, a transversely extending bulkhead 26, and a tailgate assembly 30. The overall size, shape, and configuration of the cargo bed 14 are not intended to limit this disclosure.

[0028] The liftgate assembly 30 may be considered a multi-axis liftgate that includes, among other things, a frame subassembly 34 and a door subassembly 38. The frame subassembly 34, in the exemplary embodiment, includes a driver-side portion 42, a passenger-side portion 46, and a connecting bracket 50 connecting the driver-side portion 42 and the passenger-side portion 46. The door subassembly 38 may sometimes be referred to as a "swing door subassembly." The door subassembly 38 is pivotally coupled to the passenger-side portion 46 and is locked to the driver-side portion 42 when closed. At least one hinge assembly 54 is used to pivotally connect the door subassembly 38 to the passenger-side portion 46. In another example, the door subassembly 38 is pivotally coupled to the driver side panel 42 and is locked to the passenger side panel 46.

[0029] The tailgate assembly 30 is pivotable about a first axis A1 relative to the loading area 14 between a Fig. 1 shown closed tailgate position and one in Fig. 2. The tailgate assembly 30 is pivotable from the closed tailgate position to the open tailgate position, for example, in response to grasping operation of a first handle 58 of the tailgate assembly 30. The tailgate assembly 30 is vertically oriented when in the closed tailgate position, thus generally closing off an end of the load bed 14 opposite the bulkhead 26, and the tailgate assembly 30 is horizontally oriented when in the open tailgate position, thus generally providing access to the load bed 14. Vertical and horizontal, for the purposes of this disclosure, refer to the ground in the usual orientation of the vehicle 10 during operation.

[0030] The door subassembly 38 of the tailgate assembly 30 is in a door closed position and is locked to the frame subassembly 34 when the frame subassembly 34 and the door subassembly 38 pivot between the tailgate closed position and the tailgate open position. Thus, the frame subassembly 34 and the door subassembly 38 pivot together as a unit when the tailgate assembly 30 is reciprocated between the tailgate closed position and the tailgate open position.

[0031] In the closed tailgate position, the door subassembly 38 is pivoted relative to the frame subassembly 34 about a second axis A2 between the Fig. 1 shown closed door position and one in Fig. 3. In one embodiment, the first axis A1 is a horizontally extending axis and the second axis A2 is transverse to the first axis A1 and is a vertically extending axis. The door subassembly 38 can be moved between the closed door position and the open door position, for example, by a second handle 62 (see Fig. 1) of the tailgate assembly 30 is gripped and operated.

[0032] The door subassembly 38 provides a bed access opening O when moved to the open door position. The bed access opening is located between the driver side portion 42 and the passenger side portion 46 of the frame subassembly.

[0033] In one embodiment, the loading area access opening O extends vertically downwards at least to the floor 18 of the loading area 14. A user 66 (see Fig. 4) can access the load bed 14 through the load bed access opening O when the door subassembly 38 is in the open door position. Placing the door subassembly 38 in the open door position allows the user 66 to move closer to the load bed 14 than when, for example, the tailgate assembly 30 is in the open tailgate position. Fig. 2. The loading area access opening O may also provide a space for the user 66 to enter the loading area 14 in order to either load or remove a cargo item (see Fig. 4).

[0034] Now with reference to Fig. 5-11 and with continued reference to Fig. 1-4, the frame subassembly 34 includes a first strut 70 positioned adjacent to a second strut 74 to provide a connecting beam 78 having a hollow structural portion. The first strut 70 and the second strut 74 each have a C-shaped cross-sectional profile.

[0035] In this example, the first strut 70 and the second strut 74 overlap slightly when placed adjacent to each other to provide the hollow structural portion. The first strut 70 and the second strut 74 may be joined together, for example, using welds.

[0036] The frame subassembly 34 further includes a driver side support 82 of the driver side portion 42 and a passenger side support 86 of the passenger side portion 46. The driver side support 82 and the passenger side support 86 extend from opposite ends of the connecting beam 78.

[0037] The bottom surface of the bed access opening O is a vertical bottom surface when the tailgate assembly 30 is in a closed position. The connecting bracket 78 extends along a bottom surface of the bed access opening O to connect the driver-side portion 42 of the frame subassembly 34 to the passenger-side portion 46 of the frame subassembly 34.

[0038] The connecting beam 78 houses a torsion bar 86 that is preloaded to assist the pivoting movement of the door subassembly 24 and the frame subassembly 22 about the axis A1. The torsion bar 86 is at least partially received within the connecting beam 78 and is preloaded to assist the pivoting movement.

[0039] During assembly, an end portion 90 of the torsion bar 86 is moved through an open end 94 of the connecting beam 78 into the hollow structural portion and then into a bar-receiving opening 98 of a torsion bar anchor 102. The torsion bar anchor 102 may be a polymer-based material.

[0040] The torsion bar anchor 102 is positioned within the hollow structural member when receiving the end portion 90 of the torsion bar 86. The bar receiving opening 98 that receives the end portion 90 of the torsion bar 86 may have tapered edges to guide the end portion 90 of the torsion bar 86 into the bar receiving opening 98.

[0041] The torsion bar anchor 102 can be moved into the hollow structural portion through an access opening 106, which in this example is provided within the second strut 74. A positioning feature 110 can be integrated into the torsion bar anchor 102 to facilitate proper positioning within the hollow structural portion. In this example, the positioning feature 110 is an angled surface of the torsion bar anchor 102 that, when properly positioned within the hollow structural portion, interfaces with a corner portion of the connecting beam 50.

[0042] In this example, the entire torsion bar anchor 102 is positioned within the hollow structural member. Specifically, the torsion bar anchor 102 is entirely contained within the hollow structural member. In another example, a portion of the torsion bar anchor 102 could extend outside the hollow structural member.

[0043] The exemplary torsion bar anchor 102 provides an entire circumferential perimeter of the bar-receiving opening 98 with a single piece. That is, two pieces are not joined together to provide the bar-receiving opening 98 with a portion of the bar-receiving opening 98 formed by one piece and the remaining portion formed by the other piece.

[0044] To circumferentially align the torsion bar 86 within the bar-receiving opening 98, a planar portion 114 within the end portion 90 of the torsion bar 86 is circumferentially aligned with a planar side 118 of the bar-receiving opening 98. In this example, the end portion 90 cannot be received within the bar-receiving opening 98 if the planar portion 114 of the torsion bar 86 is not circumferentially aligned with the planar side 118 of the bar-receiving opening 98. Furthermore, once the end portion 90 is inserted into the bar-receiving opening 98, the planar side 118 prevents rotation of the end portion 90 of the torsion bar 86 within the bar-receiving opening 98 relative to the torsion bar anchor 102.

[0045] In this example, a set screw 122 engages the torsion bar anchor 102 and extends partially into the bar receiving opening 98 to secure the end portion 90 of the torsion bar 86 within the bar receiving opening 98 to the torsion bar anchor 102. The set screw 122 can be accessed through the access opening 106 during assembly. The set screw 122 can help prevent the end portion 90 of the torsion bar 86 from retracting from the bar receiving opening 98 and can help prevent rotation of the end portion 90 of the torsion bar 86 within the bar receiving opening 98 relative to the torsion bar anchor 102.

[0046] In this example, an anchoring fastener 126, here a bolt, secures the torsion bar anchor 102 directly to the connecting beam 50 when the torsion bar anchor 102 is installed. The anchoring fastener 126 extends through an opening 128 in the first strut 70 or the second strut 74 to engage the torsion bar anchor 102. The anchoring fastener 126 can be accessed through the access opening 106 during assembly.

[0047] In some examples, a locating feature, such as a locating pin, may extend from the torsion bar anchor 102 into an opening provided by the first strut 70, the second strut 74, or both. The locating feature may, among other things, assist in properly aligning the torsion bar anchor 102 within the hollow structural member during assembly. The locating feature may, among other things, assist in preventing movement (e.g., rotation) of the torsion bar anchor 102 within the hollow structural member when the anchoring fastener 126 is tightened to secure the torsion bar anchor 102 directly to the connecting beam 50.

[0048] When the torsion bar anchor 102 is secured to the connecting bracket 78 and the end portion 90 of the torsion bar 86 is prevented from rotating relative to the torsion bar anchor 102, the end portion 90 of the torsion bar 86 rotates along with the connecting bracket 78 when the tailgate assembly 30 is moved between the open tailgate position and the closed tailgate position.

[0049] Within the hollow structural portion of the connecting beam 78, the torsion bar 86 may be spaced from the inner surfaces 130 of the first strut 70 and the second strut 74 by at least one insulator (not shown). The insulator may maintain a distance between the torsion bar 86 and the inner surfaces 130 of the connecting beam 78. The insulator may be rubber.

[0050] While not required, the exemplary liftgate assembly 30 includes an actuator system that pivots the liftgate assembly 30 (i.e., the door subassembly 38 and the frame subassembly 34) about the first axis A1 between the Fig. 1 shown closed tailgate position and the one in Fig. 2 shown open tailgate position. To pivot the tailgate assembly 30, the actuator system rotates relative to a pivot rod 134 ( Fig. 5), which is rotatably fixed to the side wall 22.

[0051] The actuator system may include a clutch 138 and an electric motor 142. The electric motor 142 is energized to drive the pivot rod 134 through the clutch 138. Rotation may force the pivoting movement of the tailgate assembly 30.

[0052] Features of some of the disclosed examples include a torsion bar and a torsion bar anchor, which may be incorporated within a connecting bar having a hollow structural portion. Previous tailgates that do not house a torsion bar within a connecting member have utilized multi-piece torsion bar anchors. Such multi-piece designs present assembly challenges when used with a connecting beam having a hollow structural portion. For example, the bolt heads could potentially interfere with the pivoting of the door subassembly, the pivoting of the tailgate assembly, or both.

[0053] The foregoing description is exemplary and not restrictive in nature. Variations and modifications of the disclosed examples may occur to those skilled in the art without necessarily departing from the spirit of this disclosure. Accordingly, the scope of protection afforded by this disclosure can only be determined by reading the following claims.

Claims

[1] Tailgate assembly comprising: a frame subassembly for a tailgate, the frame subassembly having a first strut positioned adjacent to a second strut to provide a connecting beam with a hollow structural member; a torsion bar disposed at least partially within the hollow structural member; and a torsion bar anchor having a bar receiving opening that receives an end portion of the torsion bar to anchor the end portion of the torsion bar. [2] The chopping flap assembly of claim 1, further comprising: a bed access opening between a driver side portion and a passenger side portion of the frame subassembly, the hollow structural portion extending between the driver side portion and the passenger side portion; and a door subassembly pivotally coupled to the frame subassembly, the door subassembly pivotable relative to the frame subassembly between an open door position and a closed door position, the door subassembly closing the bed access opening when the door subassembly is in the closed door position, and the connecting bracket optionally extending along a bottom surface of the bed access opening. [3] The tailgate assembly of claim 2, wherein the torsion bar is biased to assist pivotal movement of the frame subassembly and the door subassembly from an open tailgate position to a closed tailgate position. [4] The tailgate assembly of claim 2, wherein the frame subassembly and the door subassembly pivot together about a horizontally extending axis between an open tailgate position and a closed tailgate position, the door subassembly pivoting relative to the frame subassembly about a vertically extending axis between an open door position and a closed door position. [5] A tailgate assembly according to claim 2, wherein the first strut and the second strut each have a C-shaped cross-sectional profile and wherein the first strut and the second strut optionally overlap each other when placed adjacent to each other to provide the connecting beam to the hollow structural member. [6] The tailgate assembly of claim 1, wherein the torsion bar anchor provides an entire circumferential perimeter of the bar receiving opening. [7] The tailgate assembly of claim 1, wherein the torsion bar anchor includes no more than one piece. [8] The tailgate assembly of claim 1, wherein the torsion bar anchor is completely received within the hollow structural member. [9] The tailgate assembly of claim 1, wherein the rod receiving opening includes a flat side aligned with a flat portion within the end portion of the torsion bar. [10] The tailgate assembly of claim 1, wherein the torsion bar anchor is a polymer-based material. [11] The tailgate assembly of claim 1, further comprising a set screw engaging the torsion bar anchor and extending partially into the bar receiving opening to secure the end portion of the torsion bar within the bar receiving opening, and optionally further comprising an anchoring fastener securing the torsion bar anchor directly to the connecting beam. [12] The tailgate assembly of claim 11, wherein the connecting bracket includes an access opening to provide access to the anchoring fastener. [13] A method for torsion bar anchoring for a tailgate, comprising: Positioning a torsion bar anchor within a hollow structural member provided by a tailgate connecting beam; and Receiving an end portion of a torsion bar within a bar receiving opening of the torsion bar anchor to anchor the end portion of the torsion bar. [14] A method of torsion bar anchoring for a tailgate according to claim 13, further comprising assisting pivoting of the tailgate using the torsion bar. [15] A method of torsion bar anchoring for a tailgate according to claim 13, wherein the torsion bar is at least partially disposed within the hollow structural member, and optionally further comprising securing the torsion bar anchor directly to the connecting beam.

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