Multi-position tailgate adjustment apparatus and method

A method and apparatus for adjusting the location of suspension for a tailgate is disclosed. The method may include selecting a vehicle comprising a first side, a second side, a tailgate, a tailgate support, and an adjustor. The tailgate may be connected to pivot with respect to the first and second sides through a range of motion. The adjustor may include a base and a traveler configured to move with respect to the base. The base may be positioned on, and fixed with respect to, one of the tailgate and a first side of the vehicle. When the base is positioned on the tailgate, the tailgate support may extend to connect the traveler to the first side of the vehicle. Alternatively, when the base is position on the first side of the vehicle, the tailgate support may extend to connect the traveler to the tailgate. In either configuration, by manipulating the position of the traveler with respect to the base, the location of suspension for the tailgate may be adjusted.

BACKGROUND

1. Field of Invention

This invention relates to motor vehicles and utility trailers and, more particularly, to apparatus and methods for a multi-position tailgate adjustment mechanism facilitating suspension of a tailgate in multiple positions that each retain the tailgate's external appearance and full load-carrying capacity.

2. Prior Art

In certain situations, it may be desirable to have a low loading height on a vehicle. In the past, attempts to lower vehicle loading height have focused in two primary areas. First, attempts have been made to lower the bed height of certain vehicles. While this may work well for trailers and special purpose vehicles, it is problematic for multi-use vehicles like pickup trucks, which have certain structural limitations and clearance requirements. Second, attempts have been made to add hoists to vehicles. While hoists neutralize the need for a lower loading height by simply lifting the load for the user, they are typically large, heavy, and expensive. Thus, neither of these two areas of improvement is particularly helpful for the average pickup truck user.

Currently, many vehicles, including pickup trucks, have tailgates. However, a typical tailgate is of no assistance in raising or lowering vehicle loading height. Conventional tailgates pivot between a closed position and an open position. The open position is typically ninety degrees of rotation from the closed position. Accordingly, a typical tailgate in the open position forms an extension to the bed of the vehicle. Thus, the loading height of a vehicle with a tailgate is typically the height of the bed.

In view of the foregoing, what is needed is an inexpensive and unobtrusive apparatus and method for either raising or lowering the loading height of a vehicle like a common, everyday, pickup truck. Additionally, what is needed is a tailgate that retains its full load-bearing capacity in a partially open position, which position may provide increased retention of loads extending longer than the cargo area of the pickup truck.

SUMMARY

The present invention relates in selected embodiments to vehicles with tailgates such as, without limitation, pick-up trucks having tailgates that rotate about a horizontal pivot axis positioned proximate a lower edge of the tailgate. Certain devices in accordance with the present invention may provide an easy to use quick change, multi-position tailgate support and adjustor system. A tailgate support and adjustor system in accordance with the present invention may allow the tailgate to be used (e.g., loaded with weight) in multiple suspended positions. For example, in one embodiment, the tailgate may be suspended and used in a conventional open position, one or more open positions above the conventional open position, one or more positions below the conventional open position, or some combination thereof.

In selected embodiments, an adjustor may form an interface between a tailgate support and a vehicle. As such, an adjustor may be viewed as part of a tailgate support, as part of the vehicle (e.g., tailgate, side wall, etc.), or as an independent component separable from both the tailgate support and the vehicle. One or more adjustors (e.g., one for each tailgate support) in accordance with the present invention may be installed on a vehicle in an initial manufacturing process or in an aftermarket installation or modification.

An adjustor may include a traveler and a base. A traveler may be configured to move between various positions or locations on or with respect to a base. A base may, in turn, be formed in, mounted on, or fixed with respect to a portion of the vehicle. For example, a base may be formed in, mounted on, or otherwise fixed with respect to the tailgate. A first end of a tailgate support may engage the side wall of the vehicle, while a second end of the tailgate support engages the traveler. Accordingly, by manipulating the position of the traveler with respect to the base, the location of suspension for the tailgate may be adjusted.

Alternatively, a base may be formed in, mounted on, or fixed with respect to the side wall of a vehicle. In such embodiments, a first end of a tailgate support may be connected to the traveler, while a second end of the tailgate support engages the tailgate. In still other embodiments, adjustors may be positioned at each end of a tailgate support (i.e., one adjustor on the side wall and another on the tailgate). In such embodiments, a first end of a tailgate support may be connected to the traveler of one adjustor, while a second end of the tailgate support engages the traveler of the other adjustor.

In all such embodiments, by manipulating the position of the traveler or travelers with respect to the respective base or bases, the location of suspension for the tailgate may be adjusted. This may be done by freeing the traveler with respect to the base, moving the traveler with respect to the base from a first location to a second location, and then fixing the traveler with respect to the base.

By supporting or suspending a tailgate in an open position that is more than ninety degrees from the closed position, a tailgate support and adjustor system may lower the loading height of the corresponding vehicle. A lower loading height may reduce the incline angle of loading ramps commonly used to load items such as motorcycles, ATVs, small tractors, and the like. Reducing the incline of such ramps may make it easier and safer to load and unload such items. Additionally, a tailgate with a lower leading edge may support loading of items with low ground clearance (e.g., riding lawn mowers), which would normally hang on the leading edge of a conventional tailgate at the location where the ramps rest.

By supporting or suspending a tailgate in an open position that is less than ninety degrees from the closed position, a tailgate support and adjustor system may resist rearward movement of cargo that is longer than the cargo area of the corresponding vehicle. Additionally, a tailgate with a higher leading edge may facilitate transfer of items between a cargo area and surfaces higher than the cargo area (e.g., loading docks).

Selected embodiments in accordance with the present invention may comprise systems or packages including a new bumper or bumper relocation kit. These new bumpers or bumper relocation kits may accommodate a lower tailgate position than conventional bumpers. Such bumpers and bumper relocation kits may support greater lowering by a tailgate support and adjustor system in accordance with the present invention.

KEY FOR REFERENCE NUMERALS CONTAINED IN DRAWINGS

DETAILED DESCRIPTION OF SELECTED EMBODIMENTS

Referring toFIG. 1, in selected embodiments, a cargo area15or bed15of a vehicle such as a pickup truck may include a tailgate10, two bed sides17or side walls17, two tailgate supports20(e.g., cables20, linkages20, etc.), and a bed floor16. A tailgate10may be pivotable about a tailgate pivot11and have a pivot edge12and a leading or top edge13. The tailgate10may be supported or suspended in the open position by the tailgate supports20. One end of each tailgate support20may be attached to a stud24located on the side walls17or bed sides17of the cargo area15. The other end of each tailgate support20may be connected to a tailgate side14. The tailgate10may be pivotable about a tailgate pivot11between a generally vertical closed position and an open position.

Referring toFIGS. 2 through 7, in selected embodiments, a tailgate support20may include hardware that is identical or nearly identical to that found on existing, common, or conventional tailgate systems. For example, a first end21of a tailgate support20may be sized and shaped to engage and retain a stud24extending from the side wall17of a vehicle. A second end22of a tailgate support20may be attached the tailgate side14by a fastener29(e.g., bolt29). In selected embodiments, a second end22may include an aperture for receiving the fastener29therethrough.

A vehicle in accordance with the present invention may include one or more adjustors30. An adjustor30may form an interface between a tailgate support20and a vehicle. As such, an adjustor30may be viewed as part of a tailgate support20, as part of the vehicle (e.g., tailgate10, side wall17, etc.), or as an independent component separable from both the tailgate support20and the vehicle. One or more adjustors30(e.g., one or perhaps two for each tailgate support20) in accordance with the present invention may be installed on a vehicle in an initial manufacturing process or in an aftermarket installation or modification.

In selected embodiments, an adjustor30may include a traveler40and a base41. A traveler40may be configured to move between various positions or locations on or with respect to a base41. A base41may, in turn, be formed in, mounted on, or fixed with respect to a portion of the vehicle. For example, as in the illustrated embodiment, a base41may be formed in, mounted on, or otherwise fixed with respect to the tailgate10. A first end21of a tailgate support20may engage the side wall17of the vehicle, while a second end22of the tailgate support20engages the traveler40. Accordingly, by manipulating the position of the traveler40with respect to the base41, the location of suspension for the tailgate10may be adjusted.

Alternatively, a base41may be formed in, mounted on, or fixed with respect to the side wall17of a vehicle. In such embodiments, a first end21of a tailgate support20may be connected to the traveler40, while a second end22of the tailgate support20engages the tailgate10. In still other embodiments, adjustors30may be positioned at each end of a tailgate support20(i.e., one adjustor30on the side wall17and another on the tailgate10). In such embodiments, a first end21of a tailgate support20may be connected to the traveler40of one adjustor30, while a second end22of the tailgate support20engages the traveler40of the other adjustor30.

In all such embodiments, by manipulating the position of the traveler40or travelers40with respect to the respective base41or bases41, the location of suspension for the tailgate10may be adjusted. This may be done by freeing the traveler40with respect to the base41, moving the traveler40with respect to the base41from a first location to a second location, and then fixing the traveler40with respect to the base41(e.g., to preclude substantially all relative motion therebetween).

Changes in the location of suspension of a tailgate10may be reflected in the angle35from vertical to the tailgate10. Actuating or manipulating an adjustor30may adjust the angle35of a tailgate10between various distinct values. One such value36may correspond to a tailgate10supported or suspended in a conventional open position, which is about ninety degrees of rotation from the closed position. Another such value37may correspond to a tailgate10supported or suspended with its leading or top edge13lower than it is in the convention open position. Yet another such value38may correspond to a tailgate10supported or suspended with its leading or top edge13higher than it is in the convention open position.

An adjustor30in accordance with the present invention may be configured with a guard to protect the adjustor30from the weather and from damage that may be caused by inadvertent impact. This guard may reduce or eliminate any adverse effects from weather or use on the adjustor30.

Referring toFIGS. 8 through 13, in selected embodiments, a tailgate support20may include a length of cable23. Additionally, a first end21of a tailgate support20in accordance with the present invention may include an aperture25sized and shaped to engage and retain a stud24extending from the side wall17of a vehicle. At the other end22, a tailgate support20may have an aperture27formed therein for receiving a fastener29therethrough. The fastener29may then connect the second end22of the tailgate support20to the adjustor30(e.g., traveler40). The adjustor30may be located on the tailgate side14or elsewhere, as noted above.

In certain embodiments, a base41may be formed as a rail41or track41. In such embodiments, a traveler40may be configured to slide along or within the rail41or track41. In selected embodiments, an adjustor30may include a lock45. A lock45in accordance with the present invention may have any configuration suitable for selectively fixing a traveler40with respect to a base41.

A lock45may selectively fix a traveler40with respect to a base41at multiple locations. In certain embodiments, a traveler40may include an array of apertures31a,31b,31c, a base41may include a locking aperture26, and a lock45may comprise a locking pin46. When an aperture31bof the traveler40is aligned with the locking aperture26of a base41, the apertures31b,26may collectively form a composite aperture. The locking pin46may be inserted within this composite aperture and effectively lock or fix the traveler40with respect to the base41.

Removal of the locking pin46may permit a traveler40to again slide (e.g., translate, exclusively translate, etc.) along or within a base41. Accordingly, a user may slide a traveler40along or within a base41, aligning another aperture31a,31cof the traveler40with a the locking aperture26in the base41. Once this alignment is achieved, the locking pin46may be inserted within the new composite aperture, thereby securing the traveler40in a new location or position with respect to the base41.

Each aperture31a,31b,31cof a traveler40may correspond to a different opening angle35and, therefore, a different suspended position of a tailgate10. In selected embodiments, an intermediate aperture31bmay correspond to a tailgate10supported or suspended in a conventional open position, which is about ninety degrees of rotation from the closed position. Apertures31con one side of that intermediate aperture31bmay correspond to a tailgate10supported or suspended with its leading or top edge13lower than it is in the convention open position. Apertures31aon the other side of that intermediate aperture31bmay correspond to a tailgate10supported or suspended with its leading or top edge13higher than it is in the convention open position. The number of apertures31on each side of an intermediate aperture31bneed not be balanced. For example, in selected embodiments, a traveler40may have only two apertures31as shown inFIG. 7and, therefore, support a tailgate10in the convention open position and only one other open position (e.g., an open position lower than the conventional open position).

In selected embodiments, a traveler40may include an aperture34(e.g., threaded aperture34) to receive the fastener29securing an end22of a tailgate support20thereto. In certain embodiments, a traveler40may also include a rotation stop33. The rotation stop33of a traveler40may act in cooperation with one or more rotation stops28of a tailgate support20to ensure that the tailgate support20flexes or bends in the proper direction as the tailgate10moves toward closure.

In certain embodiments, a traveler40may include a mount32or attachment stud32. A biasing member50(e.g., coil spring50) may attach at one end to the mount32. The other end of the biasing member50may attach to a mount52or attachment stud52located on the inside of the tailgate10. In certain embodiments, a base41may include a slot43. The mount32or attachment stud32extending from a traveler40may extend through, and be free to slide within, the slot43throughout the range of motion of the traveler40. The biasing member50may bias the traveler40toward one end (e.g., the open end) of a base41.

In such embodiments, when the lock45is disengaged and the tailgate10pivots toward the closed position, the biasing member50may move the traveler40toward one end of the base41. Conversely, when the lock45is disengaged and the tailgate10is pivoted away from the closed position, the biasing member50may permit a traveler40to move toward a stop42formed in the base41, thereby storing energy within the biasing member50.

A stop42formed as part of a base41may prevent a traveler40from inadvertently sliding off or out of a base41. In selected embodiments, the other end of a base41(i.e., the end opposite a stop42) may be open to facilitate installation of the traveler40. In such embodiments, the length of the slot43may define a portion (e.g., one end) of the range of motion of a traveler40along or within a base41.

In certain embodiments, a lock45may include a locking pin46, a pin boss47, a solenoid48, and a solenoid frame49. A pin boss47may be mounted on the inside of the tailgate10opposite a base41to provide reinforcement and help guide a locking pin46into and out of engagement. In selected embodiments, a solenoid48may be spring biased towards the engaged position and may retract the locking pin46when activated. The solenoid48may be secured in place by a solenoid frame49.

Any suitable actuation devices may be used to selectively fix and free a traveler40with respect to a base41. While the embodiments described hereinabove have focused on electrical actuation devices (i.e., solenoids48), other technologies may be used in place of electrical actuation devices. For example, in selected embodiments, mechanical linkages may be incorporated into systems in accordance with the present invention.

The components of an adjustor30in accordance with the present invention may be formed of any suitable material or combination of materials. Suitable materials may be selected based on cost, formability, strength, durability, corrosion resistance, and the like. In selected embodiments, the components of an adjustor30may be formed of metal, metal alloys, or combinations thereof.

Referring toFIG. 14, a system in accordance with the present invention may include an actuator44for disengaging (e.g., simultaneously disengaging) the locks45of the various adjustors30located on a vehicle. For example, in selected embodiments, a system may include an actuator44mounted on a tailgate10adjacent a tailgate release handle39. The actuator44may be an electric button44connected to the various solenoids48of the various adjustors30. Depression of the actuator44may activate the solenoids48, causing them to withdraw the locking pins46from corresponding apertures31and, thereby, freeing the corresponding travelers40.

To adjust the position in which a tailgate10is supported or suspended, a user may first disengage the various locks45(e.g., depress an actuator44to withdraw the locking pins46) to free the corresponding travelers40. The user may then pivot the tailgate10up or down slightly and release the actuator44. This pivoting may ensure that the apertures31of the travelers40have moved out of alignment with the locking pins46. The release of the actuator44may free the corresponding locking pins46to act as biased. The user may then continue to pivot the tailgate10until different locking apertures31of the various travelers40align with the locking apertures26of the corresponding bases41to form new composite apertures. Once new composite apertures are formed, the various locks45may automatically insert the corresponding locking pins46into the new composite apertures, thereby fixing the travelers40in their new locations.

Referring toFIGS. 15 through 17, in certain alternative embodiments, an adjustor30may include a traveler40comprising a pin55and a base41comprising an array of apertures56or sockets56shaped to receive the pin55therewithin. In such embodiments, a traveler40may include a rotation stop33secured to the pin55by a retaining ring51. The rotation stop33may have a first extension configured to engage one or more rotation stops28of a tailgate support20and a second extension configured to engage (e.g., be received within) an aperture53formed in the base41. This second extension may prevent a rotation stop33from rotating with respect to a base41about the pin55. In selected embodiments, each socket56a,56bof a base41may have a corresponding aperture53a,53bsuch that the rotation stop33of a traveler40may be secured regardless of the socket56into which the pin55is inserted.

Each socket56a,56b,56cof a traveler40may correspond to a different opening angle35and, therefore, a different suspended position of a tailgate10. In selected embodiments, an intermediate socket56bmay correspond to a tailgate10supported or suspended in a conventional open position, which is about ninety degrees of rotation from the closed position. Sockets56con one side of that intermediate socket56bmay correspond to a tailgate10supported or suspended with its leading or top edge13lower than it is in the convention open position. Sockets56aon the other side of that intermediate socket56bmay correspond to a tailgate10supported or suspended with its leading or top edge13higher than it is in the convention open position. The number of sockets56on each side of an intermediate socket56bneed not be balanced.

In such embodiments, a lock45may comprise a detent mechanism54and a detent release button57. For example, when the pin55of a traveler40is inserted within the socket56of a base41, a detent mechanism54on the pin55may engage a groove58formed within the socket56. To move the traveler40with respect to the base41, a user may depress the detent release button57to disengage the lock45, withdraw the pin55from the socket56, move the pin55to a new socket56, and then insert the pin55into the new socket56until the detent mechanism54engages the groove58in the new socket56. Accordingly, a detent release button57may be considered an actuator44in accordance with the present invention.

Referring toFIGS. 18 through 20, in certain alternative embodiments, a tailgate support20may extend to connect the traveler40of one adjustor30ato the traveler40of another adjustor30b. For example, one adjustor30bmay be configured as described with respect toFIGS. 15 through 17. The other adjustor30amay comprise one or more bases41a,41bformed in, mounted on, or fixed with respect to the side wall17of a vehicle. Such embodiments may increase the number and range of tailgate positions. For example, another adjustor30amay enable a tailgate support20to support or suspend a tailgate10in higher positions than those provided by the primary adjustor30bacting alone.

Referring toFIGS. 21 through 28, in certain alternative embodiments, an adjustor30may comprise a traveler40configured to rotate with respect to a corresponding base41. In such embodiments, a fastener29may pivotably connect a traveler40to a receiver65(e.g., threaded boss65) formed as part of a base41. The fastener29may pass through a bushing61, enabling the traveler40to rotate thereabout. The traveler40may include an aperture64for pivotable receiving a post60extending from an end22of a tailgate support20. A retaining ring67may secure the post60within the aperture64.

In selected embodiments, a biasing member50may extend between a traveler40and the base41(or tailgate14or side wall17of the vehicle). The ends of the biasing member50may be formed as tabs63or extensions63. Corresponding apertures62in the base41(or tailgate14or side wall17of the vehicle) may receive the tabs63or extensions63therewithin. Accordingly, the biasing member50may bias the traveler40such that when the lock45is disengaged and the tailgate10is pivoted toward the closed position, the traveler40may rotate, maintaining tension in the tailgate support20until the next aperture31is aligned with the locking pin46. When the lock45is disengaged and the tailgate10is pivoted away from the closed position, the traveler40may rotate, loading the biasing member50with energy until the next aperture31is aligned with the locking pin46.

Each aperture31of a traveler40configured to rotate with respect to a corresponding base41may support or produce a different angle35of a tailgate10. In selected embodiments, an intermediate aperture31bmay correspond to a tailgate10supported or suspended in a conventional open position, which is about ninety degrees of rotation from the closed position. Apertures31con one side of that intermediate aperture31bmay correspond to a tailgate10supported or suspended with its leading or top edge13lower than it is in the convention open position. Apertures31aon the other side of that intermediate aperture31bmay correspond to a tailgate10supported or suspended with its leading or top edge13higher than it is in the convention open position. The number of apertures31on each side of an intermediate aperture31bneed not be balanced. For example, in selected embodiments, a traveler40may have only two apertures31as shown inFIGS. 26 through 28and, therefore, support a tailgate10in the convention open position and only one other open position (e.g., an open position lower than the conventional open position).

Referring toFIG. 29, while the embodiments described hereinabove include tailgate supports20comprising apertures25, other attachment mechanisms may be used or substituted in the embodiments described. Accordingly, the first end21of a tailgate support20may be configured to fit existing, common, or conventional tailgate systems. For example, in the illustrated embodiment, the first end21of a tailgate support20has been configured to fit an alternative embodiment of a stud24extending from the vehicle (e.g., from the side wall17of a truck bed).

Referring toFIGS. 30 and 31, by allowing a tailgate10to open more than ninety degrees, embodiments in accordance with the present invention lower the leading or top edge13of the tailgate10. This may result in a reduction in the incline of loading ramps93used when loading items such as motorcycles, ATV's94, small tractors, or the like into the bed of a vehicle. By reducing the loading ramp angle92of the loading ramps93, it may be easier and safer to load and unload such items.

Referring toFIGS. 32 through 35, a tailgate10with a lower leading edge13may facilitate loading of items with low ground clearance (e.g., riding lawn mowers95). Such items would normally hang on the leading edge13of a conventional tailgate10at the location where the loading ramps93rest. However, in embodiments in accordance with the present invention, when the leading edge13of the tailgate10is lowered below the plane of the bed floor16, both the incline of the loading ramps93and the break-over angle91are reduced.

The break-over angle91may be defined as the angle between the plane of the tailgate10extended rearward and the angle of the loading ramp(s)93. The angle that a tailgate10rotates down from the conventional open position to a fully open position in accordance with the present invention may be referred to as the tailgate decline angle90. Accordingly, between the tailgate decline angle90and the reduced break-over angle91, embodiments in accordance with the present invention may provide a more gradual transition from ground to bed floor16.

Referring toFIGS. 36 through 38, additionally, embodiments in accordance with the present invention allow the height of the leading edge13of the tailgate10to be easily adjusted to facilitate moving cargo between the pickup bed floor16and loading docks98of various heights. They may also facilitate securement of cargo96(e.g., motorcycles97or lumber) that is longer than the vehicle bed15.